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Underground Construction Methods: A Comprehensive Guide

1. Open-Cut Excavation (Mass Excavation)

Description:
Open-cut excavation involves digging without internal support or bracing structures, allowing for large-scale excavation equipment and efficient construction of the main structure. This method is fast and cost-effective, suitable for sites with low groundwater levels and ample space.

Advantages:

  • No retaining or bracing structures required (except for high-permeability strata, where water cutoff structures are necessary).

  • Easy excavation and quick soil removal.

  • Convenient for internal civil structure construction.

  • Lower construction costs.

Disadvantages:

  • Higher soil removal volume; backfilling may increase costs if no stockpile area is available.

  • Limited excavation depth (generally ≤10m).

  • Requires low groundwater levels or dewatering measures if no water cutoff structure is used.

  • Needs open space with no nearby protected structures.

  • Slope protection measures may increase costs during rainy seasons or long construction periods.


2. Gravity Cement-Soil Wall Method (Shallow Trench Support)

Description:
This method is environmentally friendly, producing no pollution, noise, or vibration. It is cost-effective and allows for unobstructed excavation and construction inside the pit.

Advantages:

  • No internal bracing required.

  • Lower construction costs.

Disadvantages:

  • Low strength of cement-soil mixing piles (typically 0.8 MPa).

  • Significant environmental impact during construction.

  • Requires trapezoidal overlapping construction.

  • High cement consumption (13–15%).

  • The large construction site is needed.

  • Significant wall deformation.


3. High-Pressure Jet Grouting Pile Method

Description:
This technique forms piles of various diameters (single, double, or triple-fluid systems) and can bypass underground utilities. It serves as a water cutoff curtain and can create self-supporting walls, eliminating the need for internal bracing.

Applications:

  • Suitable for soft soils, clay, silt, sand, loess, and gravel.

  • Not ideal for soils with large boulders, hard clay, or organic content.

  • Used in foundation reinforcement, deep excavation waterproofing, slope stability, and underground pipeline reinforcement.

Advantages:

  • Functions as a gravity retaining wall or water cutoff structure.

  • Higher strength than cement-soil mixing piles (1.2–2.0 MPa).

  • Less environmental impact.

  • Flexible obstacle avoidance.

  • Larger diameters (0.6–2.5m).

Disadvantages:

  • Higher cost than cement-soil mixing piles.

  • High cement consumption (20%).


4. Soil Nailing Wall Method

Description:
Best for low-water-table cohesive soils, this method uses soil-wall interaction for stability, offering fast construction and minimal environmental impact.

Applications:

  • Temporary/permanent retaining structures.

  • Slope stabilization, foundation underpinning.

Advantages:

  • Fast construction, no internal bracing.

  • Lower deformation than gravity walls.

  • Cost-effective.

Disadvantages:

  • Requires layered excavation.

  • Waterproof curtains are needed in high-water-table soft soils.

  • Difficult quality control; low nail load capacity.


5. Caisson Method

Description:
Minimal footprint, no additional retaining structures, and low impact on surroundings.

Types:

  • Wet Caisson: Uses slurry or compressed air.

  • Dry Caisson: Workers excavate inside.

Advantages:

  • Cost-effective, structurally robust.

Disadvantages:

  • Difficult to correct large caisson deviations.

  • Challenging soil removal in wet conditions.

  • Significant ground settlement.


6. Deep Excavation Methods

6.1 Diaphragm Walls

Types:

  • By construction: Pile, panel, composite.

  • By material: Reinforced concrete, plastic concrete, steel.

Applications:

  • Depths >10m.

  • Permanent structural walls with high waterproofing needs.

  • Top-down construction.

6.2 Sheet Piles

  • Used for shallow slopes/excavations.

  • Low noise/vibration alternatives are available.

6.3 Soldier Pile Walls

  • Composed of drilled/bored piles.

  • Requires capping beams for stability.

6.4 External Anchoring (Ground Anchors)

  • Installed in pre-drilled holes for tension resistance.

  • Ideal for unobstructed excavation.


Conclusion

Choosing the right underground construction method depends on soil conditions, depth, groundwater, and project requirements. Each technique offers unique benefits, from cost-effective open-cut excavation to robust diaphragm walls for deep projects. Proper selection ensures safety, efficiency, and cost control.

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