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Ground Improvement
Sustainable, economic solutions
A sustainable and economic solution
“PolyCom changes the quality and workability of the soil to increase it’s load bearing capacity and resistance to
displacement and weathering”
Case Study examples
The following are case studies of sub-grade and pavement stabilisation in variable or hard to manage soils using PolyCom Stabilising Aid
Significant improvements to project outcomes delivered major benefits to the contractor and/or project owner
Contact SEALS for more details
Utilising available ground - Black soil Stabilised for temporary or low volume roads
ChinchillaSEALS &
Ostwald Construction
Virgin ground -1. Scarify to 150mm on a 9 metre profile 2. This gains sufficient material for 7 metre road and establishes drainage area3. Standard wet mix installing PolyCom4. Mix and compact with pad foot until roller walks out5. Trim and wheel roll
Mow grass and scarify Wet mix profile and compact 5 days later - haulage completed
2 weeks later and constant traffic
1 2 3
4Major project benefits:
✓Economic stabilisation and faster construction
✓Durable and water resistant temporary or low volume road
Utilising available ground - Black soilStabilised + 75mm gravel wear course
Mt Tyson SEALS & Toowoomba RC
Virgin ground -1. Scarify to 150mm on a 9 metre profile 2. This gains sufficient material for 7 metre road and establishes drainage area3. Wet mix with PolyCom and compact using pad foot rollers 4. Leave pad foot finish to key gravel 5. Place, profile and roll reduced thickness gravel layer
Black soil sub-grade Grader crew stabilise with PolyCom Profiled & Compacted
Reduced gravel thickness 75 mm wear course placed over improved sub-grade
Standard solution for this constructionmeant a gravel cart of more than40 klm and placement of 300mm gravel sheet
Major project benefits:
✓Cost saving of 40% on standard construction option
✓Increased sub-grade strength and water resistance means less gravel (saving resources)
“Stabilisation eliminates the need to ‘remove and replace’ variable, hard to manage soils”
Utilising available ground - Sandy loamAdding workability to difficult ground
Sandy loamdifficult to manage - normally cut to spoil
Strengthened sandy loam sub-grade is now useful allowing thinner pavement designs
Alpha Coal Project 28 klm Access RoadSEALS & Shadforths Civil
1. Scarify to 150mm, wet mix with PolyCom and compact sub-grade to 8 metre road profile2. Proof roll and place gravel - 150mm
Alternate solution was to remove and replace sub-grade to
300mm
Major project benefits:
✓Improved sub-grade strength & stiffness removed the need for alternate solution ✓Faster, more economical solution
Road train haul road prepped for 150mm gravel sheet
“Improving sub-grade structural strength and stiffness means less chance of road displacement or deformation”
Utilising available material - Sandy clay loamSub-grade stabilisation - road rebuild
Problem sub-grade is wet and unstable
PolyCom + compaction
Stabilised, trimmed and proof rolled - same day
= Desired result
Boundary St - ToowoombaRoad rebuild
SEALS & Toowoomba RC
1. Scarify area to increase exposed surface area2. Dry spread PolyCom over wet ground3. Mix area to 200mm depth with stabilising machine4. Compact and trim
Major project benefits:
✓More economical and much faster than remove and replace option
✓Improved sub-grade structural strength and stiffness means less chance of road deformation
Reconstruction required remove and replace of in-situ sub-grade material or stabilisation. PolyCom stabilising aid was selected after considering cost, environment and speed of works.
Utilising available material - Dispersive clayHigh sodic level soil remediated
Highly dispersive soilRemediated by stabilisation with PolyCom
Strengthened,water resistant
Condamine Gas PlantSEALS, Ostwald Bros & Watpac
Construction
Remediate dispersive soil
1. 210,000m² - scarifyarea to 150mm2. Wet mix with PolyCom, compact and trim
Major project benefits:
✓Economic remediation of dispersive soil eliminated the need for capping layer
✓Increasing sub-grade strength allowed engineers to reduce design pavement thickness
“Stabilised sub-grades become part of the overall pavement structure and as such improve the integrity of all layers placed above”
R.O. & Ponds
Gas Plant area
Utilising available material - In-situ ground Upgrade with PolyCom and competent soil blending
300 Ton all up - 7 m wide bitumenShoulder up-grade using available roadside soil
Blend black soil, sand and gravelStabilise with PolyCom
Strengthened, water proof shoulderSix months and two metres of rain
after the works
Boonal Haul RoadUpgrade
SEALS & Alexanderson Civil
Major project benefits:
✓Safer road for haulers and light vehicles
✓No imported gravel - substantial cost savings
✓27.2 Klm of shoulder stabilisation work was completed with a grader crew only making this work a very economical solution
Utilising available material - Permian claySub-grade capping
Newcastle Freeway Construction SEALS & Thiess Construction
Final inspectionRip and re-compact to line and level with PolyCom
Major project benefits:✓Stabilising/capping in cut to fill operation reduced traffic and weather damage
✓Significant savings are realised with less re-work
Sub-grade material is reactive Permian clay.Construction method for access roads, construction and plant areas was cut and fill. This meant that areas brought to level exposed vulnerable low strength reactive sub-grade to weather and traffic damage during the construction phase leading to expensive re-work in damaged areas.
Bohemia Downs Rd 35 klm x 6m
PolyCom wear course up-grade SEALS & Emerald Shire
1. PolyCom stabilisation was completed during a standard rip and re-compact 2. Road was reshaped and drainage was also repaired during this service
Pre work: Natural ground softens during rain event Feb 2010
Stabilisation + 7 months: No ill effects after 2 metres of rain 2010 - 2011
Major project benefits:
✓Improved user safety
✓Increased density delivers decreased permeability
Utilising available material - Natural groundAdding water resistance and strength
Utilising available material - Natural ground - silt loamIn-situ stabilisation
Auburn Rd: 2 Klm x 6mSEALS & Chinchilla Shire
Low strength natural ground road meant constant and continual maintenance to keep this road at a usable standard
PolyCom stabilisation has strengthened this ground and reduced the frequency of ongoing service to the area
Major project benefits:
✓Improved natural ground strength & weather resistance
✓Significant ongoing maintenance savings - remote area works
Low strength natural ground
Grader mix, shape and compact
Consistent, strengthened and weather resistant
Utilising available material - Loamy sand Stabilised and durable
Stanthorpe 5klm x 5mSEALS & Stanthorpe Shire
1. Scarify and dry spread PolyCom2. Add water to approx 60% OMC3. Compact and trim
Major project benefits:
✓100mm stabilisation with grader crew
✓Higher densities with less water
12 months after stabilisation80% sand + 5% clay
Tight surface matrix
Utilising available material - Tertiary clayIn-situ ground can be useful if managed correctly
Mine road wear course improvement utilising in-situ mine spoil - Tertiary Clay
Hard wearing - water resistant - easily managedCat 789 and 793 are using this road
Major project benefits:
✓All weather surface
✓Less future road maintenance and water for dust control
✓Economic stabilisation by on site grader crew
Haul Road ‘A’45,000 m²
SEALS & Jellinbah Mine
PolyCom stabilisation negates the need for gravel
sheeting in some cases
Utilising available material - Mud stoneCompetent blending and stabilising = results
1. Mud stone haul road2. Mud stone + Basalt + PolyCom
Competent blending3. All weather road
80% less water
4. Seven months on and no maintenance
High volume coal circuit
Haul Road StabilisationSouthern & Northern Haul
Roads & Access Roads180,000 m ²
SEALS & Minerva Mine
Major project benefits:
✓Reduced haul road maintenance
✓Less downtime after rain ✓Improved tyre wear
Stabilising gravelsRe-sheet improvement
Re-sheet completed in February 2011 with
PolyCom stabilised gravel
PolyCom stabilised re-sheet March 2011 January 2012
Biloela Rd: Re-sheet - 15 Klm x 6m: SEALS and CHRC - Duaringa office
Standard 150mm re-sheet with the gravel being stabilised at site during placement
Ten months after the works and there has been several substantial rain events and seasonal heavy traffic (grain and cattle trucks)
Major project benefits:
✓Increased service life of road
✓Safer, smoother more weather resistant surface
Visual inspection:Minimal lose of material and no corrugations or general road deformation is evident.Minor rutting at 6 Klm - 6.5 Klm, this rutting is due to road shape at this point - area needs re shaping.Shoulder area is eroded at the ten Klm point and needs material adding.
Stabilising gravelsRehabilitate in-situ gravel
End of life road rehabilitated2 Klm x 6m in-situ stabilised
to 100mm in Aug 2006
Road condition- July 2009: good shape has been retained
little material losstight surface matrix
Beerburum Rd: Stabilisation - 2 Klm x 6m: SEALS and Forestry Queensland
Standard 100mm stabilisation of existing gravel using grader crew.Road carries local traffic and heavy seasonal logging traffic.Three years after the works and only three minor maintenance trimsthis road is in excellent condition as evidenced
Major project benefits:
✓Rehabilitation has delivered substantial cost savings - alternate was re-sheet
✓Durable surface with reduced maintenance
Stabilising gravelsImproving crushed rock hard stand
BMA - Crinum Mine3 hectare lay down areaSEALS & Garwoods Earth Moving
Class three road base wear course stabilised with PolyCom to provide weather immunity, improve strength & flexibility
Stabilised to 100mm with PolyComusing standard grader crew
Very tight surface
Major project benefits:
✓Cost effective improvement
✓Durable surface with less dust
✓Reduced ongoing maintenance
Stabilising gravelsRehabilitate in-situ pavement
End of life road rehabilitated with PolyCom
1 Klm x 6m in-situ pavement stabilised with PolyCom to 200mm in May 2007
Visual inspection Feb 2011Seal in in good condition with no signs
of embedment or bleedingNo other signs of wear are evident
Cooyar Rd: Pavement rehabilitation - 1 Klm x 6m x .2m:
SEALS, Main Roads Qld & Kingaroy Shire
Works were completed using a stabilisation machine and standard grader crew. Old pavement was recycled (including bitumen) and PolyCom was used to stabilise.
Major project benefits:
✓Rehabilitation has delivered substantial cost savings - alternate solution was rebuild
✓Considerable savings in time for pavement stabilisation and preparation for seal plus construction water
Stabilising gravelsRehabilitate in-situ pavement
‘End of life’ road due for rebuildalternate option:
In-situ pavement stabilisation using PolyCom Works completed
Mar 2007
May 2011No visual signs of wear
this road is in top condition
Proston Rd: Pavement rehabilitation - 1.5 Klm x 6m x .15m:
SEALS, Main Roads Qld & Wondai Shire
Stabilisation works were completed using a standard grader crew. Old bitumen was removed, pavement was recycled to 150mm depthand prepped for a seal.
Major project benefits:
✓The use of PolyCom and a grader crew only for the stabilisation works realises significant cost savings for this project
✓Stabilising thin layers (as little as 100mm) is possible without fatigue or stress problems normally encountered with conventional stabilisation of thin layers
Simple insuranceAdding weather immunity to soils and gravel
Water crossed this road for a six hour period Road shoulders and table drains have washed away
PolyCom stabilised pavement is still in place
Gingi grain storage access - Emerald, Qld - SEALS & CHRC
Installation methodsStabilising machine
Cunningham Hwy, Warwick, Qld
SEALS, Main Roads Qld & CMC Construction
Installation with stabilising machine No bulk bags or spreader trucks
Strengthened flexible
&water resistant
Stabiliser Installation:
✓No cure time constraints
✓No block or shrinkage cracking
Installation methodsGrader crew
Standard grader crew wet mixGrader, water cart & rollers
Standard compaction techniquesLoaded scraper works well
Jellinbah CoalHaul road ‘A’ - 45,000 m²
SEALS & Jellinbah works crew
Grader Installation:
✓Conventional, standard work method
✓No extra plant or man power
Installation methodsDry spread
1. Grading and spreading 2. Council maintenance utility
3. SEALS Group support utility 4. Contractor power rake
1. Australian Rail And track - Site access road
2. Bendigo Council, VictoriaWear course upgrade
3. Main Roads, QueenslandHighway truck parking bays
4. Calder Highway, VictoriaHighway patching crew
Engineering benefits
Reliable, cost effective treatment for sub-grades, gravels and crushed rock
Adding workability to variable ground allows more certainty and consistency to design and construction
Long term improved performance of roads
Works crew benefits
Consistent work methods
Added workability means easier use of variable or hard to manage soils and gravels
Minimum machinery and plant requirement
Cost benefits
Guaranteed cost savings through thinner pavement requirements, less cartage and less onsite plant
Faster construction and less labour to achieve the same results
Increased pavement life with reduced ongoing maintenance
Contractor quoting advantage
Environmental benefits
Saving of resources (gravel and water)
Stabilised roads produce less dust and sediment
Less CO2 production during construction and maintenance
Zero environmental or OH&S concerns
SEALS Group - Specialist sub-contractor
SEALS Group 143-157 Harrison RdCedar Vale, Qld, 4285
AustraliaP. 61 7 5543 1053 - Ops Manager 0414 185 493
[email protected] www.sealsgroup.com
“It’s all about improving and preserving the dry strength of the available material”
