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Caisson (engineering)

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In geotechnical engineering, a caisson is a watertight retaining structure. These heavy-duty tools allow engineers to perform construction in difficult environments. They are essential for building bridge piers and concrete dams. They are also used for repairing ships.

Caisson Schematic 2
Caisson Schematic 2

By creating a controlled workspace, caissons enable builders to reach stable ground deep beneath water or soft soil. This process ensures that massive structures have a solid foundation to rest upon.

The installation process depends on the type of caisson used. Generally, a caisson is brought down through soft mud. It continues to sink until it reaches a suitable foundation material. While bedrock is the preferred stopping point, engineers sometimes use stable, hard mud if the bedrock is too deep. This movement is achieved through various methods. Some caissons sink by their own weight. Others use concrete or water ballast placed on top. In some cases, engineers use hydraulic jacks to push the structure down into the earth.

There are four primary types of caissons: box, open, pneumatic, and monolithic. A box caisson is a prefabricated structure with sides and a bottom, but it is open at the top. It is typically placed on a prepared, flat base. Because hollow concrete is often less dense than water, engineers must secure box caissons to prevent them from drifting. They may use elaborate anchoring systems or GPS surveys for pinpoint accuracy. Once positioned, the box is filled with ballast to become a permanent part of the foundation.

An open caisson is similar to a box caisson, but it lacks a bottom face. This design is ideal for soft clays found in riverbeds. However, they are not suitable for areas with large underground obstructions. These structures can also be used to install deep manholes or pump stations. To help the caisson sink vertically, the leading edge, or cutting shoe, is sloped at a sharp angle. This shoe is usually made of steel and is wider than the caisson to reduce friction.

FMIB 49991 Fixed Apparatus, supplied with Compressed Air
FMIB 49991 Fixed Apparatus, supplied with Compressed Air

Sometimes, pressurized bentonite slurry is supplied to the edge to fill voids and stabilize the settlement.

A pneumatic caisson, also called a pressurized caisson, is a bottomless box sealed at the top. This top seal allows the interior to be filled with compressed air. This air pressure keeps water and mud from entering the workspace at great depths. Workers inside these chambers are known in American English as sandhogs. They move debris, called muck, from the workspace into a water-filled tube called a muck tube. A crane at the surface then removes the soil using a clamshell bucket.

Caisson Schematic 2
Caisson Schematic 2

Pneumatic caissons offer the advantage of dry working conditions, which is better for placing concrete. However, this method carries significant health risks. Workers must decompress slowly when leaving the pressurized environment. If they do not, they may suffer from decompression sickness, once known as caisson disease. This condition involves the release of inert gases in body tissues. It can cause barotrauma to the ears, sinuses, and lungs, or lead to dysbaric osteonecrosis. During the construction of the Brooklyn Bridge, many workers were killed or permanently injured by this disease.

History shows the growing importance of caisson engineering throughout the 19th century. The Royal Albert Bridge was completed in 1859. The Eads Bridge followed in 1874. The Brooklyn Bridge was finished in 1883. These projects demonstrated how caissons could conquer challenging waterways. Beyond bridges, caissons have various other roles in modern technology. They are used to install single-stage ram hydraulic elevators below ground level. During World War II, caissons codenamed Phoenix were used in the Mulberry harbours during the invasion of Normandy.

The term caisson is also used in other engineering contexts. In canal systems, it refers to the moving trough in a caisson lock that lifts ships between elevations. In ventilation, a caisson is an airtight housing for filters in facilities handling hazardous materials. It may contain multiple compartments for pre-filters and high-efficiency filters. Finally, in structural engineering, the term is sometimes used colloquially for any reinforced concrete pillar formed by pouring concrete into a hollow shape below grade.

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File:Caisson Schematic 2.svg
Caisson Schematic 2.svg
File:FMIB 49991 Fixed Apparatus, supplied with Compressed Air.jpeg
FMIB 49991 Fixed Apparatus, supplied with...
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