German University in Cairo

Faculty of Engineering and Material Science

Civil Engineering Program
Heavy Civil Construction
Winter 2015 / 16

CIG 704: Heavy Civil Construction

Make-up Exam [150]

1. How do you see the profession of a civil engineer? Present a small vision on tasks and
responsibilities. [12]

Civil engineers are entrusted by society to create a sustainable world and enhance the global
quality of life, civil engineers serve competently, collaboratively and ethically as master:
 planners, designers, constructors and operators of society’s economic and social
engine, the built environment;
 stewards of the natural environment and its resources;
 innovators and integrators of ideas and technology across the public, private and
academic sectors;
 managers of risk and uncertainty caused by natural events, accidents and other
threats;
 leaders in discussions and decisions shaping public environmental and infrastructure
policy.
As used in the vision, “master” means one who possesses widely recognized and valued
knowledge, skills and attitudes acquired as a result of education, experience and
achievement. Individuals within a profession who have these characteristics are willing and
able to serve society by orchestrating solutions to society’s most pressing current needs while
helping to create a more viable future.
(From: ASCE Civil Engineering Body of Knowledge for the 21st Century ,Vision 2025)

Prof. Dr.-Ing. Mahmoud El Khafif Make-up Exam WS 2015 / 16, Page [2]
 German University in Cairo
Faculty of Engineering and Material Science
Civil Engineering Program
Heavy Civil Construction
Winter 2015 / 16

2. Safety in Construction [14]

a. A trench for a sewer line (width / depth = 2m / 3.5m) has to be excavated in sandy soil at close
distance to a road. Explain how the trench shall be secured against collapse to provide a safe
working space and explain your choice. Make a suitable 3D sketch and name the components
of the chosen method to secure the trench.

 The trench will be secured using the shoring method,

Shoring is the provision of a support system for trench faces used to prevent movement of soil,
underground utilities, roadways, and foundations towards the empty excavation pit. Shoring or
shielding is used when the location or depth of the cut makes sloping back to the maximum
allowable slope impractical.

Prof. Dr.-Ing. Mahmoud El Khafif Make-up Exam WS 2015 / 16, Page [3]
 German University in Cairo
Faculty of Engineering and Material Science
Civil Engineering Program
Heavy Civil Construction
Winter 2015 / 16

3. Make a sketch of a formwork for a box girder super- structure, name its components and
the order of casting concrete. [8+4+4=16]

 The main elements of a box girder formwork are:

a. Bottom slab formwork
b. Web formwork outside
c. Cantilever slab formwork
d. Inner formwork for web and deck
e. Bulkheads to close the formwork at the front and end of the segment.
f. Supporting scaffolding mechanism that allows quick dismantling

 The order of concrete casting is normally:

a. Bottom slab
b. Webs & deck and cantilevers

or

a. Bottom slab
b. Webs
c. Deck and cantilevers

Front and back ends of the formwork are closed by bulk heads.

Prof. Dr.-Ing. Mahmoud El Khafif Make-up Exam WS 2015 / 16, Page [4]
 German University in Cairo
Faculty of Engineering and Material Science
Civil Engineering Program
Heavy Civil Construction
Winter 2015 / 16

4. A small passenger bridge shall be built over a roadway using the composite construction
method. Demonstrate with a sketch the principle structure and its components. [12]

Prof. Dr.-Ing. Mahmoud El Khafif Make-up Exam WS 2015 / 16, Page [5]
 German University in Cairo
Faculty of Engineering and Material Science
Civil Engineering Program
Heavy Civil Construction
Winter 2015 / 16

5. Name two different methods of building bridge superstructures using pre-cast elements.
Make a suitable sketch for each method. [7+7=14]

I-Beam Superstructures

Segmental Superstructures

Full-span Element Superstructures

Prof. Dr.-Ing. Mahmoud El Khafif Make-up Exam WS 2015 / 16, Page [6]
 German University in Cairo
Faculty of Engineering and Material Science
Civil Engineering Program
Heavy Civil Construction
Winter 2015 / 16

6. A cut-and-cover tunnel shall be built for a subway in a downtown area with traffic around
the construction site. Describe with the help of suitable sketches the construction process.
The soil is light with sand gravel mix and a high ground water level.
What are the advantages of using top-down approach in basement construction?
[12+6=18]

Dewatering Deep wells

Existing Ground
Water Level Lowered Ground
Water Level

Existing Condition Install Diaphragm Walls,

Dewatering

Excavate and Install Props Construct Floor Slab

Construct Tunnel Structure Backfill and Remove Props

Prof. Dr.-Ing. Mahmoud El Khafif Make-up Exam WS 2015 / 16, Page [7]
 German University in Cairo
Faculty of Engineering and Material Science
Civil Engineering Program
Heavy Civil Construction
Winter 2015 / 16

The main advantages of top-down approach can be listed as follows:

(i) The structures above ground can be carried out simultaneously with the structures
below ground. This greatly reduces the time for construction.
(ii) By using this approach, settlement can be reduced.
(iii) Since the permanent columns and slabs can be utilized to support loadings during
construction, it saves the cost of formwork.

Prof. Dr.-Ing. Mahmoud El Khafif Make-up Exam WS 2015 / 16, Page [8]
 German University in Cairo
Faculty of Engineering and Material Science
Civil Engineering Program
Heavy Civil Construction
Winter 2015 / 16

7. What are the limiting factors of the CFA piling method in terms of length and diameter of
the pile (compare to the bored pile method)?
Compare the accuracy of CFA piles to the accuracy of a bored pile and explain the
difference.
What is the main advantage of CFA piling and what is its main use? [14]

The CFA piling method is based on intruding a steel helix of the diameter of the pile through
rotation into the ground until reaching the foundation depth. That means that a soil column
of the pile volume (length and diameter of the pile) needs to be rotated which requires
substantial torque which needs to be provided by the drilling equipment. Through economic
limits of the equipment size and available torque, this limits the size (length and diameter) of
the CFA pile.
The bored pile method, on the other side is confined to excavation at the very bottom of the
bore hole through a garb or a short helical drilling tool. While casing requires large torques,
depending on the length of the casing, the torque required for excavation of the bored pile is
limited.
The CFA method usually does not reach the accuracy of a bored pile, especially as the
reinforcement cage is inserted after pouring the concrete which challenges the exact
centricity of the cage and the concrete cover on the rebar. Also, the exact verticality of bored
piles can hardly be reached with the CFA method.
CFA piling is a very fast and rather cost efficient piling method, mostly used for the
foundation of mid-size buildings.

Prof. Dr.-Ing. Mahmoud El Khafif Make-up Exam WS 2015 / 16, Page [9]
 German University in Cairo
Faculty of Engineering and Material Science
Civil Engineering Program
Heavy Civil Construction
Winter 2015 / 16

8. Why has traffic management around construction sites significant importance? Explain the
problematic of construction operations in traffic areas and name the main requirements.
[12]
 Significance: Traffic management has to allow for safe and efficient travel during the
construction works. This concerns the areas around the construction site which are
under traffic, the construction site itself and the interface between both (deliveries to
the site, in & out traffic etc.).
o Therefore, detours, like all temporary works, have to be engineered and
properly executed as per applicable temporary works standard and regulation.
o For driver orientation, detours have to be equipped with clear signage, traffic
lanes need to be marked and as per needs, detours might require a lighting
system for night times.

 Requirements:
o Constructing detours / alternative routes
o Temporary works construction to be considered in the project’s schedule
o Detour traffic capacity has to consider the actual traffic flows,
o Speed limits have to be considered
o Avoidance of critical works during traffic peak hours

Prof. Dr.-Ing. Mahmoud El Khafif Make-up Exam WS 2015 / 16, Page [10]
 German University in Cairo
Faculty of Engineering and Material Science
Civil Engineering Program
Heavy Civil Construction
Winter 2015 / 16

9. A retaining wall shall be constructed (see figure below). The retaining wall is divided into
20 segments, each 8 m long. [26]
You are required to make the following:
a. Establish a Work Breakdown Structure (WBS) reaching the activity level.
b. Based on the activities above, establish a Logic Diagram.
c. Estimate the duration of the construction of 1 segment of the retaining wall.
Information given:
a. Assume a steel reinforcement content of 175kg/m3 concrete. The width of backfilling
behind the retaining wall can be assumed with 10m. After construction of the
retaining wall an insulation layer shall be applied. The filter package shall be installed
together with the backfilling (see below figure).
b. Consider that :
i. Ideal productivity of 1 crew of shuttering formwork is 5 m 2/h (efficiency factor
0.75)
ii. Ideal productivity of 1 crew of reinforcement steel fixing is 3 t/h (efficiency factor
0.75)
iii. Ideal productivity of 1 crew of pouring concrete is 5 m3/h (efficiency factor 0.75)
iv. Ideal productivity of excavation including leveling and compaction is 12 m3/h.
(efficiency factor 0.7)
v. Ideal productivity of backfilling in layers and compaction: 25 m 3/h (efficiency
factor 0.7)
vi. Ideal productivity of insulation is 8 m2/h (efficiency factor 0.7)
Make reasonable assumptions for missing information (if required with a short justification).

Prof. Dr.-Ing. Mahmoud El Khafif Make-up Exam WS 2015 / 16, Page [11]
 German University in Cairo
Faculty of Engineering and Material Science
Civil Engineering Program
Heavy Civil Construction
Winter 2015 / 16

Prof. Dr.-Ing. Mahmoud El Khafif Make-up Exam WS 2015 / 16, Page [12]
 German University in Cairo
Faculty of Engineering and Material Science
Civil Engineering Program
Heavy Civil Construction
Winter 2015 / 16

a. Establish a Work Breakdown Structure (WBS) reaching the activity level.

Prof. Dr.-Ing. Mahmoud El Khafif Make-up Exam WS 2015 / 16, Page [13]
 German University in Cairo
Faculty of Engineering and Material Science
Civil Engineering Program
Heavy Civil Construction
Winter 2015 / 16

c. Based on the activities above, establish a Logic Diagram.

Site preparation  SP
Sub-Structure  Sub-S
Super –Structure  Super-S
Backfilling  BF

SP F.S Sub- F.S Super- F.S BF

1 S1 S1 1
F.S F.S F.S F.S

F.S Sub- F.S Super- F.S BF

SP
1 S2 S2 2

And all the inner relations are also Finish to start.

Prof. Dr.-Ing. Mahmoud El Khafif Make-up Exam WS 2015 / 16, Page [14]
 German University in Cairo
Faculty of Engineering and Material Science
Civil Engineering Program
Heavy Civil Construction
Winter 2015 / 16

d. Estimate the duration of the construction of 1 segment of the retaining wall.

1. Earthworks:
a. Excavation:
Quantity = (4 *2*8)+(.5*2*2*2*8) = 96 m3

Duration =

b. Backfilling:
Quantity = (96-(4*2*8))+(12*8*6) = 608 m3

Duration =

2. Concrete works:
a. Shuttering formwork:
Quantity = (2*7*8)+((4-1.2)*8)+(1*2*8) = 150.4 m2

Duration =

b. Steel Reinforcement:
Quantity = 79.5 * 175 = 13,930 Kg = 13.93 tons

Duration =

c. Pouring Concrete:
Quantity = (0.5*7*8)+(0.5*7*0.7*8)+(1*4*8) = 79.6 m3

Duration =

d. Insulation:
Quantity = (7+1.4+1+1+1.4+1) *8 =102.4 m2

Duration =

Total Duration of 1 segment = 2 + 5 + 6 + 1 + 3 + 3 = 20days

Prof. Dr.-Ing. Mahmoud El Khafif Make-up Exam WS 2015 / 16, Page [15]
 German University in Cairo
Faculty of Engineering and Material Science
Civil Engineering Program
Heavy Civil Construction
Winter 2015 / 16

10. Explain the special pre-cautions when planning the concrete pouring of mass concrete structures
of a concrete dam. [12]

The pouring of mass concrete structures such as concrete dams poses special risks regarding the heat
evolution during the hydration process of the concrete which can lead to cracks or even disintegration
of the structural elements.
The heat evolution is mainly correlated to the speed cement is hardening. Therefore, due
consideration is required regarding the concrete mix using low hydration heat cements which harden
slowly.
The concrete mix might require the use of ice flakes as part of the water content.
The pouring process itself needs to be planned in a way that avoids unnecessary heat evolution, with
limited pouring speed, pouring heights etc.
Further, the size of sections where concrete is poured needs to be limited which involves working
joints between sections. This often calls for due shear formations.
In the extreme case, cooling pipes with circulating chilled water that run through the concrete
sections are used to cool down the hardening concrete and avoid cracks.

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