5.

Construction of pneumatic caissons

5.1 Preparation
Pneumatic caissons are usually constructed above ground level. Prior to the actual
construction, sand bodies are applied upon the ground level and should then be
stabilised. The sand bodies form the counter mould of the work chambers. Formwork
is put into the sand body on the place of the future entrance to
the work chamber to initiate excavation later on. A blinding (werkvloer) with starter
bars (stekeinden) is cast on top of the sand body. The starter bars should lateron
connect the fill concrete with the structural concrete of the caisson. They should also
prevent that parts of the blinding let off during subsidence.
5.2 Caisson construction
The cutting edges (eventually prefabricated) and the bottom plate are cast as a whole.
Together they form the 'work chamber'. After hardening of the work chamber, the
walls and eventually the roof can be cast. This can either be done in one cast.
Otherwise the inner walls can be cast before the outer walls and the roof
depending on the cooling mechanism used. If freshly cast concrete has been cooled,
impermissible shrinkage cracks should not occur in structural parts that are cast onto
already hardened parts.
To prevent air leakage, joints of timber caissons, which were used in the past, were
packed with oakum (uitgeplozen touw). Also the joints of former steel caissons,
subjected to air pressure, must be well caulked (waterdicht gemaakt). Nowadays
reinforced concrete is commonly used for caissons because it is considered to be the
best material for caissons and also to be the most economical. Reinforced concrete
caissons, however, also need precautions because the material frequently is not proof
against loss of air pressure through the concrete. This can be accomplished by
painting the inner surfaces with bituminous or other suitable paint. Special attention
should be paid to joints, the number of which should be limited as much as possible.
5.3 Subsidence
When the caisson itself is ready, soil can be dug from within this work chamber which
causes the caisson to subside into the ground. Nowadays the soil is often removed
after it has been mixed with water. In this way it can be removed by suction through a
high-pressure tube. Excavation was traditionally done by hand, but nowadays
preferably by water canons or sand pumps. Sometimes the air pressure can be used to
blow out mud and wet soil through a pipe. The excavated soil is removed by a
hydraulic transport system. There should be a basin close to the site where the
removed sand-water mixture can be deposited.
The caisson is subsided under its weight. This is usually done by gradually building
up, which is especially favourable if there will be ballast on top of the caisson anyway
in its final stage (like a pier, for example) (see Figure 5-1). Ballast can alternatively be
applied inside the caisson.
It should be given thought that a heavy dead weight can cause a caisson to subside
even before excavation starts, leading to fill of the working chamber (and possibly
even the shafts) with soil. If this will happen, bothersome delay is inevitable. It
should for this reason be avoided that the caisson is too heavy.
 Figure 5-1 Measures to improve subsidence of a pneumatic caisson
The air in the work chamber has to be kept under compression to prevent ground
water from intruding. Compressed air, on the other hand, also functions as an air bag
that lifts the caisson. By varying the air pressure, the pressure on the cutting edges can
be regulated in order to influence the subsidence and position of the caisson. The
pressure in the working chamber is adjusted to balance, or slightly exceed the water
pressure at the depth of the cutting edge. To boost sinking, the air pressure is
often reduced more considerably when works men are out of the working chamber.
The cutting edge must be sufficiently below the inside soil surface to prevent serious
loss of air through the soil. The height of the cutting edges can therefore measure up
to two metres. If air pressure and excavation near the cutting edges do not sufficiently
regulate the subsiding process, a sliding plane of bentonitecan be applied between the
caisson wall and soil. An other measure to better control the subsidence process isto
project the edges of the work chamber slightly outside the profiles of the structure
(this should be considered in advance).
Excavation generally occurs aloof of the cutting edges to leave them embedded in soil
and thus avoid loss of air. If, however, the subsidence needs correction because the
caisson is not kept level, excavation should occur close to the cutting edges where
greater subsidence is desired. Eventual obstacles that come across during excavation,
like remainders of old structures, can be removed through the air lock. Large obstacles
like boulders (zwerfkeien) can be subsided along with the caisson by washingaway
the soil beneath them.
When the caisson has reached its final depth, it isgenerally sealed with concrete,
which means that the work chamber is completely filled up or injected completely
with concrete. To prevent the caisson from sinking lower than the desired level before
the concrete seal is fulfilling function, the caisson can be propped (gesteund) well
from the soil up to the roof. In that case, the caisson roof has to be sufficiently strong.
Otherwise, the props will need to be placed under the ribs in the roof. In some cases
the caisson is subsided onto previously applied foundation piles to assure fixation.
The subsequent stages of pneumatic caisson subsidence are depicted in Figure 5-2.
This example comes from the steel caisson which has been used for the river pier of
Lambeth Bridge in London.
The application of pneumatic is limited to depths up to about 30 m below the free-
water surface, because of the high water pressure at these depths. This limitation may
sometimes be overcome where it is possible to lower the groundwater level by
pumping. This can only be done in case of suitable surface and subsoil
conditions. Lowering of the groundwater level can even be accomplished in river or
estuary beds if the caisson is surrounded by a cofferdam and an impermeable lay er
separates the river bed from the artesian water.