Hand-dug caissons have been widely used in Malaysia over the last 10 years for the construction of foundations, retaining structures, excavation shafts and have also functioned as an investigative tool. Adapting from the construction practice in Hong Kong, as adopted until recently, hand-dug caissons are especially popular for steep hillside sites and urban developments where access for heavy piling equipment is difficult. Two main examples of sites which are conducive to the application of hand-dug caisson technique, are in Penang Island and popular hillside resorts. The construction stages and design process are briefly described in this paper. The results of various load tests carried out in different soil and rock conditions including granite, weathered sedimentary rocks and limestone are also presented. The paper aims to provide guidance on the issues and pitfalls that a designer should be aware of when designing caisson foundations. This is followed by a discussion of the construction, health and safety issues.
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