SMW

Soil Mixing Wall System

03/2012

The SMW-System
Mixing self-hardening slurry in-situ with
native soil (SMW) is a cost-effective
technique for the construction of
walls for groundwater control (cut-off
walls), walls for excavation support
(retaining walls) as well as for ground
improvement.
For walls with shallow depths (typically
6 to 15 m) the Bauer Soil Mixing Wall
Method (SMW) has been developed.
The soil is loosened and immediately
mixed with a self-hardening suspension by three adjacent slightly overlapping augers and mixing paddles.
By loosening, conveying and mixing of
the soil, minimum friction between rods
and mixed soil is ensured. Therefore, it
is possible to construct walls effectively
rigs with medium power supply.
At the same time a very homogeneous
soil-cement mixture can be ensured in
order to achieve a good quality of the
wall.
Main advantages of the method are:

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Small to medium size rigs can be

used
The in-situ soil is used as a construction material
Very little generation of spoil (important factor in contaminated
areas)
No vibrations induced during construction (SMW can be used in
immediate vicinity to buildings)

BAUER Maschinen GmbH, 2012

Construction sequence

Step 1:

Excavation of a guide trench for collecting surplus slurry (trench width corresponding to diameter of mixing
tool, depth approx. 50 cm) and align mixing tool with centreline of wall.

Step 2:

Drill mixing tool into the ground in a continuous operation and concurrently inject self-hardening slurry. The
two outer mixing paddles are rotated in opposite direction. The rate of penetration of the mixing tool and the
volume of slurry delivered by the pump are controlled in such a way that no surplus slurry appears on the surface.

Step 3:

After reaching the predetermined design depth, the mixing tool is withdrawn whilst the mixing paddles continue to be rotated. The volume of slurry injected during the withdrawal phase is equal to the displacement volume of the mixing tool.

Step 4:

During the construction of a continuous wall, individual wall panels are installed in an alternating sequence of
primary and secondary panels.

Step 5:

Reinforcing elements required for structural purposes can be inserted into the completed soil mixing wall.
a) Insertion of sheet pile wall elements or steel stanchions into the not fully hardened wall. The spacing between individual stanchions is dependent on the characteristic strength of the hardened wall (arching effect)
and the intensity of static loading.
b) Alternative: Installation of cast-in-situ bored piles in the hardened wall. The spacing between individual piles
is dependent on the characteristic strength of the hardened wall (arching effect).

Sequence of wall construction

Primr / Primary

500 mm 700 mm

Primr / Primary

Primr / Primary

370 mm 550 mm
1.000 mm 1.400 mm

1.000 mm 1400 mm

Sekundr / Secondary

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A continuous wall is formed in a series of

overlapping primary and secondary panels.
Overcutting into fresh adjacent panels is
called fresh-in-fresh method.
The width of the secondary SMW panels
results from the width of the used mixing
tools.

Sekundr / Secondary

BAUER Maschinen GmbH, 2012

Productivity factors
favourable conditions

Unfavourable conditions

Soil structure

uniform soil structure

layered soil structure

Soil type

loose to medium dense gravelly sand,

silty sand

dense to very dense soil, cobbles and boulders embedded in soil, stiff or hard soil, cohesive or organic
soil (reduction of the final strength)

Site geometry

long, straight wall sections

irregular wall layout

Wall depth

wall depth > 6 - 10 m

wall depth < 5 m (influence of non-productive periods

such as moving, setting-up)

The SMW process is a technique with wide-ranging applications. In order to avoid economical and technical problems
during the construction of the wall and also quality-related problems on the completed wall, the following process-specific
limitations should be taken into account:

Capacity to drill in rocky types of soil or in soils containing cobbles and boulders

Reduction in the strength of the completed wall in cohesive or organic soils.

Rate of production
Recommended rates of production

favourable conditions:
20 - 24 m per hour
unfavourable conditions
12 - 15 m per hour
(Net production per m of completed wall including overlaps and in-situ mixing)
When determining the theoretical total production it is recommended to apply a utilization rate ranging from 65 80 %

Personnel

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1 operator SMW-rig
1 mixing plant operator
1 foreman
(1 helper)

03/2012

BAUER Maschinen GmbH, 2012

Slurry
Components
The slurry mix used in the construction of SMW panels consists normally of:
Cement
OPC or blast furnace cement CEM III/B 32,5 (typical)
Bentonite
Standard bentonite
Additives
(plasticizer, retarder or polymer additions) optional
Admixtures (fly ash) optional

Mix proportions and consumption values

The mix design is governed by various factors:
Application:

Cut-off wall (permeability, strength, plasticity, erosion stability)

Retaining wall (strength, permeability, plasticity of fresh mix - as precondition for the installation of reinforcement)

Soil properties:
Particle size distribution, grain size, fines content, organic content, relative density, porosity, groundwater level, groundwater chemistry
The mix design should always - especially in unknown conditions - be determined by suitability tests prior to the start of
construction.
The following tables give values for an initial design of the mix proportions. They should be used for reference only. They
have to be confirmed by suitability tests.

Binder slurry (typical predesign values)

Cut-off wall

Retaining wall

250 - 450 kg/m slurry

750 1.200 kg/m slurry

Bentonite

30 50 kg/m slurry

15 30 kg/m slurry

w/c ratio

2,0 - 4,0

0,5 - 1,0

Cut-off wall

Retaining wall

0,5 - 2 MPa

5 - 15 MPa

Cement

Wall characteristics (typical predesign values)

Compressive strength qu
Permeability kf
Cement content in soil

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ca. 1 x 10-8 m/sec

100 - 200 kg/m soil

200 - 450 kg/m soil

BAUER Maschinen GmbH, 2012

SMW-Mixing units
The SMW mixing units are available in two dimensions: (SMW 370 and SMW 550).
Wall thickness of 370 mm or 550 mm can be reached.

SMW 550

1455

1845

3355

5165

SMW 370

1000

1400

Technical data:

Rotary drives:

Technical data:

Rotary drives:

Type
Manufacturer

SMW 370
EURODRILL

Type
Manufacturer

SMW 550
EURODRILL

2 Rotary drives (outer)

Speed (max.)
Torque (max.)

50 rpm
23.6 kNm

2 Rotary drives (outer)

Speed (max.)
Torque (max.)

25 rpm
51 kNm

1 Rotary drive (central)

Speed (max.)
64 rpm
Torque (max.)
19 kNm

1 Rotary drive (central)

Speed (max.)
68 rpm
Torque (max.)
14 kNm

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BAUER Maschinen GmbH, 2012

In the SMW method the soil is loosened and mixed with self hardening slurry with three slightly overlapping augers and
mixing paddles.
A SMW-mixing unit consists of four sections:

Section 4:
The rods end with a simple tube extension. This ensures the required depth of the panel,
without the building up of friction.

Section 3:

The mixing area is located right above the augers (Section 2). Counter-rotating and overlapping of the paddles ensures a homogeneous mixing over the whole panel area.

Section 2:
Short augers above the central pilots are moving the loosened soil and the slurry upwards, to
ease the loosening process. The auger flights of the outer strings are smaller in the starter
area of the inner auger to prevent collision of the three augers.

Section 1:
The soil is loosened at the bottom of each auger with two cutting edges and a central pilot bit.
The outer augers are rotating in opposite direction. The starter of the central auger is placed
at a slightly higher position. While cutting the soil, slurry is pumped into the soil through radial
nozzles at the bottom of the augers.

2
1

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Base carrier (BG-series)

25415

20900

BG 18 / BG 20

BG 24 / BG 28

SMW 370

SMW 370 / SMW 550

13 m - 14,5 m

15,5 m - 18 m

Installed power

186 kW - 205 kW

261 kW - 313 kW

Crowd pull

200 kN - 260 kN

330 kN

Overall height

19,1 m - 20,9 m

21,8 m - 25,4 m

53 t - 60 t

60 t - 90 t

SMW-unit (recommended)
Panel depth (approx.)

Operating weight (approx.)

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Base carrier (RG-series)

27400

17000

RG 14 T

RG 16 T

RG 19 T

SMW 370

SMW 370 / SMW 550

SMW 370 / SMW 550

Panel depth (approx.)

10,6 m

11,5 m

14,6 m

Installed power

311 kW

570 kW

570 kW

Crowd pull

170 kN

200 kN

200 kN

Overall height

18,3 m

21,5 m

24,7 m

Operating weight (approx.)

48,5 t

60 t

70 t

RG 21 T

RG 18 S / RG 22 S

RG 25 S

SMW 370 / SMW 550

SMW 370 / SMW 550

SMW 370 / SMW 550

Panel depth (approx.)

17,1 m

17,5 20,0 m

20,0 m

Installed power

570 kW

570 kW

570 kW

Crowd pull

260 kN

400 kN

530 kN

Overall height

27,6 m

22,1 26,03 m

29,4 m

Operating weight (approx.)

82,7 t

79 80 t

98 t

SMW-unit (recommended)

SMW-unit (recommended)

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BAUER Maschinen GmbH, 2012

Additional equipment
kW
(ca.)
Slurry mixing station

minimum capacity 20 m/h (e.g. batch mixer MAT SCC 20 or bigger)

30

Delivery pump

frequency controlled slurry pump with remote control, capacity depends on

volume of panel and speed of mixing.(typically: 200 - 400 l/min, 12 15 bar,
for instance EP 12-400 or EP 12-600)

Agitator tank

approx.3 - 5 m (as buffer for cement slurry)

Silos

for cement and bentonite with screw conveyors

Hydraulic backhoe

for excavation of guide trench, maintenance of working platform, handling

of backflow

Hoses

for conveying cement or bentonite slurry from the agitator to the rig. Typically 1,5 or 2 rubber hose (length to suit site requirements)

Service crane and

vibrator

for inserting universal beams into the panel of retaining wall. Size of crane
depends on length and weight of beams and vibrator use

18,5
2,2
2x5

Steel plates or excavator support mats if working platform is not able to

support the weight of the rig

50

60

optional
recommended

Schematic site installation

Guide trench

Delivery
pump

Agitator
tank

SMW-panel

Cement
Silo

SMW-rig

Mixer

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10

Bentonite
Silo

BAUER Maschinen GmbH, 2012

Quality control
Pumpen
quantity
Pumpmengen
bervs.
dieDepth
Tiefe

Prior to construction:
Suitability test to determine mix design.
Material testing in accordance with QA
plan.

General
Allgemeine
Data
Daten

0,56
2,5
10,0

During construction:

0,0
-1,0
-2,0
-3,0
-4,0

Geometric checks of individual panel

positions

-5,0
-6,0

Equipment
Gerte
Data
daten

-7,0
-8,0
-9,0

Slurry tests in accordance with QA plan

-10,0

Control of production parameters displayed on the monitor of the rig operator:

Depth

Volume

Slurry pressure

Pumped volume v. time

Pumped volume v. depth

Inclination

Speed of mixing tool

Inclinometer readings
Neigungsmessung
der
On outerBohrstangen
drill pipes
usseren

Documentation:
All production parameters are monitored recorded and stored inside the rig throughout the construction process and can be
printed out in the form of a quality assurance record for each individual panel.

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BAUER Maschinen GmbH, 2012

Site examples

Retaining wall with RG, Sydney, Australia

Cut-off wall with BG, Oberhausen, Germany

Excavated SMW retaining wall, Sydney, Australia

Exposed test shaft, Sydney, Australia

BAUER Maschinen GmbH

BAUER-Strae 1
D-86529 Schrobenhausen
Tel. +49 (0)8252/97-0
Fax +49 (0)8252/97-1135
e-mail: [email protected]
www.bauer.de
Design developments and process improvements may require the
specification and materials to be updated and changed without
prior notice or liability. Illustrations may include optional equipment
and not show all possible configurations. These and the technical
data are provided as indicative information only, with any errors and
misprints reserved.

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