Title: Continuous Flight Auger CFA Pile Foundations for Highway Projects
1Continuous Flight Auger (CFA) Pile Foundations
for Highway Projects A Market-Ready Technology
2FHWA NATIONAL GEOTECHNICAL PROGRAMWhat Can we
do for you?
- www.fhwa.dot.gov/engineering/geotech
3(No Transcript)
4Course Update.
- NHI 132012
- Soils and Foundations Workshop
5132012 Soils and Foundations
- Recently completed a major update of the manual
and course slides for the Soils and Foundations
Workshop - Publication finalized in December, 2006 and the
pilot for the course was successfully completed
during the week of December 11, 2006 (Baton
Rouge, LA) - Still to complete Final course slides and
Instructors Manual - Materials completely overhauled!
6NEW ADDITIONS
- Chapter 2 Stress and Strain in Soils
- Introduce basic phase (weight-volume)
relationships - Effect of size/shape of particles
- Effect of water on physical states
- Principle of effective stress
- Vertical stress distribution under load and DOSI
- Load deformation process
- Lateral stresses in soil
- Shear strength of soil
- Lateral earth pressure
7NEW ADDITIONS
- Chapter 10 Earth Retaining Structures
- Classification and wall selection
- Lateral earth pressures
- Calculation of
- Effect of water
- Effect of surcharge loads
- Design of walls (step-by-step procedure)
- Surface/subsurface drainage
8PRESENTATION CHANGES
- Construction Inspection/Monitoring
- Previously a stand-alone chapter that focused
solely on pile driving, pile load testing and
embankment instrumentation. - Updated to include construction inspection
information on all geotechnical aspects covered
in manual. - Included with respective chapter as a part of the
discussion of that feature.
9MAJOR UPDATES
- Chapter 3 - Subsurface Explorations
- Expanded discussion on landforms
- Inclusion of CPT as a primary exploration tool
- Section on geophysical testing
- Chapter 4 Engineering Characteristics
- Expanded discussion on description,
classification and characteristics of rock
10MAJOR UPDATES
- Chapter 5 Laboratory Testing
- Section added on Quality Assurance
- Inclusion of correlations for common parameters
- Permeability testing
- Volume change (swell potential/collapse/frost
action) - Compaction of soils
- Laboratory vs. field
- Engineering characteristics
- Laboratory testing of rock
- Elastic properties of soils and rock
- Guidelines for laboratory testing
11MAJOR UPDATES
- Chapter 6 Slope Stability
- Infinite slope analysis
- Recommended stability methods and safety factor
discussion - Use of stability charts
- Preliminary design of RSS (improving embankment
stability) - Chapter 7 Approach Roadway Deformation
- Better discussion on internal vs. external
deformation - Discussion on secondary compression
- Better discussion on lateral squeeze
12MAJOR UPDATES
- Chapter 8 Shallow Foundations
- Inclusion of a discussion on general approaches
to foundation design - Foundation alternatives and cost evaluation
- Loads and limit states
- Bearing capacity sections re-written to better
align with AASHTO 2006 Interims - Recommendation of Schmertmanns modified method
for immediate settlement - Improved section for spread footings on compacted
structural fills - Spread footings on IGMs and rock
- Effect of deformation on bridges
- Tolerable movements/Construction point concept
13MAJOR UPDATES
- Chapter 9 Deep Foundations
- Expanded section on drilled shafts and better
balance with driven piles - Driven piles section re-written to better align
with updated Driven Pile Manual - Inclusion of screen shots for discussion on use
of DRIVEN computer program - Expanded sections on static load testing, O-Cell
and Statnamic testing.
14What did we lose?
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16CFA PILES - INTRODUCTION AND TECHNOLOGY OVERVIEW
17Why Continuous Flight Auger (CFA) Pile
Foundations?
- FHWA Interest is due to
- An increase in successful projects in the U.S.
private sector and in other countries - Cost effective and more efficient in many
circumstances - Fits with Agency Priorities
18New Highway Bill
- Safe, Accountable, Flexible, Efficient
Transportation Equity Act A Legacy for Users
(SAFETEA-LU) signed into law in August, 2005 - Includes funding for Highways for L.I.F.E.
Pilot Program - Long Lasting Highways using
- Innovative Technologies and Practices to
Accomplish - Fast Construction of
- Efficient and Safe Pavements and Bridges
19Infrastructure Research and Development
- The Bridge of the Future
- 100-year service life with minimal maintenance
- A fraction of the current construction time
- Immunity to flooding, earthquakes, fire, wind,
fracture, corrosion, overloads and vessel
collision - Entire bridge from foundations to parapet
designed and constructed as a system - Constructability as important as durability
- Expand to include rehabilitation and methods
- Emphasize minimize impact on traveling public
20Current FHWA Activities with CFA Piles
- Publications
- Geotechnical Engineering Circular No. 8 on Design
and Construction of Continuous Flight Auger Piles - 2004 TRB Session Proceedings Recent
Experiences Advancements in the US and Abroad
on the Use of Auger Cast-in-Place Piles.
FHWA-RC-BAL-04-003 - Future TRB Sessions to Launch GEC 8
- 2002 International Scan Tour Follow-up
- Promoted by FHWA Office of Infrastructure as a
Market-Ready Technology
21FHWA Implementation Activities
- Technology Deployment
- Column Supported Embankments
- Structure Foundations
- Sound Wall Foundations
- Lateral Earth Support
- Research
- Design Methodologies
- QA/QC
- Technology Transfer
- Project Based Training
22What is a CFA pile?
23A Continuous Flight Auger (CFA) Pile is
- Any foundation element formed by rotating a
hollow-stem auger to a desired depth, or until
refusal criteria is met - At depth, grout or concrete is pumped under
continuous pressure through the hollow stem as
the auger is steadily withdrawn - Reinforcing steel is placed in the hole once the
auger has been withdrawn - This includes traditional continuous flight auger
piles, drilled displacement piles and partial or
intermediate displacement piles
24Courtesy of Bauer
Schematic of CFA Pile Construction
25(No Transcript)
26History of Augered Piles
- Development of Auger Cast-in-Place (ACIP) piles
in US dates to 1940s - First patents applied for in 1951 granted in
1956 - 1950s saw development of grout pumps capable of
pumping coarse sands and hydraulic powered
systems - Led to increases from original maximum depths
(20 ft) and diameters (12 in) - Today, piles have been installed to depths of
more than 130 ft at diameters of 36 to 48 in.
27Transportation Applications
- Bridge Foundations Including Abutments
- Retaining Structures (Secant or Tangent Pile
Walls) - Column Supported Embankments over Soft Ground
- Sound Walls
28Bridge Foundations including Abutments
29Retaining Structures (Secant or Tangent Walls)
30Column Supported Embankements
31Sound Walls
32Advantages
- Economy and speed
- Does not produce excessive noise or vibration
- Can operate in restricted space and low headroom
areas - High production rates typically on the order of
1000 1500 ft/day in private applications (500
ft/day expected for transportation applications)
33Limitations
- With US systems, success is highly operator
dependant - Drilling resistance does not provide a direct
indication of soil strength or stiffness
(research being done in this area) - Mining and soil decompression can occur in some
soil types - Difficult to advance through cobbles or boulders
34Geotechnical Conditions Affecting CFA Pile Use
- Favorable Conditions
- Medium to very stiff clays
- Cemented sands and weak limestone
- Residual soils
- Medium dense to dense silty sands and well-graded
sands - Unfavorable Conditions
- Very soft soils
- Loose sands or very clean sands below groundwater
table - Karst terrains or highly variable conditions
- Hard/stiff soils overlain by soft soils/loose
granular soils - Rock or very hard strata
- Deep scour or liquefiable sand layers
35There Must Be Technical Concerns or Issues!
36Some Concerns We Are Addressing
- There is no nationally accepted design protocol
for ACIP/CFA piles - There is no national guideline specification
which addresses the materials and methods of
construction - Quality control and assurance measures must be
enhanced - Specifications should give clear guidance for
pile acceptance and rejection criteria
37Some Technical Issues We Are Addressing
- Cage Installation and Minimum Cover
- Installation Control (soil mining)
- Inspection
- Frequency of Load/Integrity Testing
- Grout/Concrete Strength
- Soft Ground Installation
- Seismic Design
- Structural Design
38Cage Installation (Minimum Cover)
39Cage Installation (Full Depth)
40Installation Control (Soil Mining)
41Installation Control (Pile Finishing)
42Installation Control (Pile Finishing)
43FHWA Development of Guidance on CFA Piles
- Geotechnical Engineering Circular (GEC) 8 is
complete! - Development fostered by several issues and
concerns identified regarding design and
construction of CFA piles for highway projects
including - Minimum equipment requirements
- Penetration rates and control during drilling
- Specific recommendations for problem resolution
- Guidance for verification testing of piles
- Difficulties in contracting/development of
specifications
44GEC 8 Whats In It?
- Construction Techniques and Materials
- Guidance on Design Process
- Initial design considerations
- Pile design and constructibility
- Preparation of plans and specifications
- Quality Control/Quality Assurance Procedures
- Construction monitoring
- Verification testing
- Load testing
- Integrity testing
- Contracting Methods
- Appendix
- Design examples
- Evaluation of static capacity methods
45PILE TYPES, EQUIPMENT AND BASIC MECHANISMS
46CFA Pile Types
- Auger Cast-in-Place (ACIP)
- Continuous Flight Auger (CFA)
- Drilled Displacement (DD)
- Berkel Displacement Pile (Berkel US)
- DeWaal Pile (Morris-Shea Bridge Company US)
- Omega Pile (L.G. Barcus Sons US)
- Fundex/Tubex (IHC Holland)
- Atlas Screw Pile (Franki/Keller Austrailia)
- Starsol Pile (Soletanche Bachy France)
47ACIP Piles
- Predominantly US system/terminology
- Consists of crane supported swinging or fixed
leads - Generally fastest installation time
- Typical pile diameters range from 12-24 inches
and depths up to 100 feet - Typical design loads of up to 150 tons in private
sector applications
48Typical ACIP Pile Rig
49Typical ACIP Pile Rigs
50CFA Piles
- Predominantly European terminology
- Mast driven equipment (similar to drilled shaft
rigs) - Equipment provides higher torque at lower rpm
than ACIP equipment (better control) - Concrete typically used as opposed to grout
- Can install to larger diameters than ACIP piles
typically 24 to 36 inches (specialty piles up to
54 inches)
51Typical CFA Pile Rig
52Drilled Displacement Piles
- Displace soils laterally produce minimal spoils
- Less decompression of soil due to pile
installation - Comparable load capacities with shorter, smaller
diameter piles in certain soil conditions - Many different types of equipment available (full
and partial displacement) worldwide to develop
displacement piles
53- Crawler mounted fixed mast drill rig
- Minimum torque of 150,000 ft-lbs
- Minimum crowd of 25 tons
- Grout pumping similar to crane-mounted ACIP pile
Drilled Displacement Pile Rig (Berkel)
54Partial Displacement
Full Displacement
Drilled Displacement Pile Rigs (Berkel)
55Drilled Displacement Pile Rig (DeWaal)
56Drilled Displacement Pile Rig (Omega Screw)
57Drilled Displacement Pile Rig (Fundex/Tubex)
58Drilled Displacement Pile Rig (Atlas Screw)
59Drilled Displacement Pile Rig (Screwsol)
60Drilled Displacement Pile Rig (Menard CMC)
61Drilling Tools and Equipment
62Augers and Drilling Tools
63Auger Cleaning
64Auger Plug
- Generally made of steel or other hard material.
If the discharge point of auger is off-center,
plug may be cork or plastic - Can be attached or reusable
- Primary purpose is to prevent soil from entering
auger stem prior to grout or concrete placement - In some cases (stiff clays, difficult drilling),
compressed air has been used in lieu of a plug to
facilitate auger penetration
65Plug at Bottom of Auger
66Disposable Plugs for Bottom of Auger
67Pumping Equipment
- Positive displacement pump capable of delivering
up to 350 psi of pressure - Typically, grout pumps operate with reciprocating
pistons (up to 1 cf per stroke) - Most important to select pumps for the size of
pile being constructed (delivers volume per
stroke of approximately 4 inches of pile length)
68Grout/Concrete Pumps
69Grout/Concrete Pumps
70Finishing the Top of Pile
- Critical item for completion of an acceptable
pile - Once concreting is complete and the auger is
withdrawn, laborers must work to clean the top
of the pile and protect the pile from fall in of
surrounding soil - Typically, contractors will use some type of form
to case the top of the pile once the excess grout
and soil have been removed - Laborer will then scoop the pile to remove
contamination in the uppermost portion of the pile
71Finishing the Pile Top
72Grout and Concrete
- Both have been successfully used for the
construction of CFA piles. For CFA piles, grout
is similar to concrete except that the mix does
not have coarse aggregate, only sand - Mixes typically contain Portland cement, fly ash,
water, and aggregate/fine aggregate - May see water reducers, fluidifiers, or retarders
for various purposes - Use of grout or concrete in CFA pile construction
has generally been personal preference
73Grout vs. Concrete
- Advantages of grout relative to concrete
- Tends to be more fluid and have better
workability - Tends to be easier to pump (especially with
certain equipment - Easier insertion of reinforcing steel
- Disadvantages of grout relative to concrete
- Generally more expensive unit cost
- Will tend to have a slightly lower elastic
modulus - Will be less stable in the hole (especially in
soft soils) - More susceptible to small variations in water
content (leading to segregation or excessive
bleed water)
74Reinforcing Steel
- Typically similar to what would be specified for
drilled shaft construction (ASTM A615 Grade 60
steel) - Occasionally may see steel pipe (large bending
stresses), or high-strength threaded bars (large
tensile loads) - Cages normally specified with 3-inch cover. If
single bars are used, centralizers are normally
used for centering - If splicing is required, mechanical is preferred
- Key is working quickly to place steel once auger
is withdrawn from hole
75Reinforcing Steel Installation
76Reinforcing Steel Installation (Splice)
77Reinforcing Steel Installation
78STATIC CAPACITY OF CFA PILES
79FHWA GUIDANCE
- Based on evaluation of comparative studies of
numerous methods identified in literature - Method of installation supports assumption that
static capacity of a well constructed CFA pile
lies between drilled shafts and driven piles - Reasonable to estimate static capacity using
methods developed specifically for each since
load-settlement behavior is similar - Design in practice has used both driven pile and
drilled shaft approaches - Drilled shaft approaches favored by most
practitioners
80FHWA Guidance
- Recommended design guidance based on Allowable
Stress Design (ASD) for geotechnical conditions.
Structural pile design is in accordance with LFD - Recommended that CFA piles be designed with a
factor of safety of at least 2.5. A factor of
safety of 2.0 may be used provided the following
conditions - At least one static load test to failure
- Automated monitoring is used on production piles
- Relatively consistent geology, stratigraphy and
soil properties - Suitable site conditions for construction
81Development of Axial Resistance
- Total Axial Compressive Resistance
- RT RS RB
- Total Side Resistance
- RS S fs,i p Di Li
- Total End Bearing
- RB qp p D2/4
82Development of Axial Resistance
- Side shear component is mobilized with relatively
small vertical displacement (less than 0.4
inches) - End bearing component is mobilized at larger
displacements (load at 5 displacement of pile
diameter defined as ultimate) - Load-settlement curves will typically appear
softer than for a driven pile (considered when
evaluating load test data) - Refer to Reese and ONeill (1988) for assessing
mobilized side and end bearing resistance under
load
83Comparison of Static Methods
- Several comparative studies have evaluated the
ratio of measured to predicted total capacity
using different methods - Prediction methods compared to one another using
mean and standard deviation of capacity ratio - Failure defined as load at a displacement of
either 5 or 10 of the pile diameter - Recommended design procedures appear to provide
good overall correlation to CFA pile capacity for
generalized soil types in US Practice - Alternate methods are discussed for special
conditions and prediction using in-situ tests
84Recommended Design Methodology Cohesive
Qult (pDL)fs (p/4)D2qp
Side Shear fs a Su
a 0.55 Su /Pa lt 1.5
a varies linearly from 0.55 0.45 1.5 lt Su /Pa
lt 2.5
End Bearing qp Nc Su
Nc 9 2 tsf lt Su lt 2.6 tsf, and L gt 3D
Nc adjusted for Su lt 2 tsf and L lt 3D
85Recommended Design Methodology Cohesionless
Qult (pDL)fs (p/4)D2qp
Side Shear fs K sv tan f b K tan f Limited
to 0.25 lt b lt 1.2
b 1.5 0.135 Z 0.5 N60 gt 15 bpf
b (N60 /15)(1.5 0.135 Z 0.5) N60 lt 15 bpf
End Bearing qp (tsf) 0.6 N60 for 0
lt N lt 75 qp 45 tsf for N gt 75
86Recommended Design Methodology DD Piles
- Based on evaluation of load test database from 19
sites around the US (NeSmith, 2002) - Failure defined as displacement of 1 inch of tip
movement or a loading curve displacement rate of
0.02 in/ton - Drilled displacement pile correlations should be
used with caution since these rely heavily on the
experience of the contractor and must be verified
for the specific site and equipment
87Recommended Design Methodology DD Piles
Qult (pDL)fs (p/4)D2qp
Side Shear fs 0.01 qc Ws for qc lt
200tsf fs 0.05 N60 Ws for N60 lt 50 Ws
0 fs lt 1.7 tsf for uniform rounded sands, lt40
fines Ws 0.5 tsf fs lt 2.2 tsf for well-graded
angular sands, lt10 fines
88Recommended Design Methodology DD Piles
Qult (pDL)fs (p/4)D2qp
End Bearing qp 0.01 qc WT for qc lt 200tsf
qp 0.05 N60 WT for N60 lt 50 WT 0 fs lt
75 tsf for uniform rounded sands, lt40 fines WT
0.5 tsf fs lt 85 tsf for well-graded angular
sands, lt10 fines
89Additional Information on Design Methodologies
- Guidance for static capacity of end bearing piles
on rock and in intermediate geomaterials - Guidance for laterally loaded piles
- Guidance for pile groups
- Design for uplift and piles in tension
- Structural design of piles
- Design for settlement
90Typical Ultimate Axial Compression Loads
91Typical Ultimate Lateral CFA Pile Capacity
92Typical Capacity and Cost Estimation
- Rule of Thumb (CFA Piles in US)
- Capacity Estimation
- Qall (Pile Area)(1 ksi) - For 4000 psi
strength grout - 16 inch pile 100 tons
- Cost Estimation
- Cost 1/inch of pile diameter (per linear foot)
- 16 inch pile 16/l.f.
93Quality Control/Quality Assurance
94FHWA Guidance
- CFA piles have been under-utilized in
transportation projects due to perceived
difficulties in quality control - In addition, the variety in available equipment
and proprietary systems do not fit easily into
traditional design-bid-build contracting - FHWA has developed a performance based
specification to allow contractors to find the
most cost-effective solution for project
requirements - QC/QA requirements developed with necessary
performance based measures as the end product
95Why Performance Specifications for CFA Piles?
- Ease in facilitating deployment and
implementation of new technologies in
transportation projects - Provide a contracting method that can incorporate
the different equipment and proprietary systems - In the bigger picture, public works projects are
moving toward more innovative contracting methods
for development of projects - Has precedence for successful implementation
described in FHWA Publication No. FHWA-SA-97-070
96Types of Piles and Installation Methods
97Performance-Based Specifications
- Contractor responsible for pile design (final
determination of pile length) - Performance criteria must be established by the
owner and met by the contractor - Criteria need to be quantifiable and must be
measured to provide a reliable indication of
performance
98Test Pile Program
- Testing
- Pre-production test pile program
- Automated monitoring required
- Integrity Testing
- Verification testing
99- Pre-production test pile program sets criteria
for production piles - Establish target drilling penetration rates
- Establish pressure/volume relationships for
grouting - For DD piles, establish targets for torque and
crowd - Establish/verify mix design parameters
- Evaluate static design correlations
100Conformance Testing
- Integrity testing
- Load testing
- Materials testing
Access Tubes for CSL Testing
Testing with Statnamic (Rapid Load Test) Device
Sonic Echo Testing
101Inspection Responsibilities During Construction
- Pile location/elevation/tolerances
- Grout/concrete monitoring
- Subsidence or lost grout
- Pile completion (screening etc.)
- Reinforcement placement
- Grout/concrete return depth
- Grout Volume
102Monitoring During Drilling
- Monitoring of drilling phase of installation to
ensure - No excessive flighting of soil occurs
- Appropriate level of soil displacement occurs
with DD piles - Penetration rates are in accordance with test
program installation rates - General Guidelines for Penetration Rate for CFA
Piles
103Monitoring During Drilling
- Private practice has typically monitored
penetration rate manually by direct observation
of the auger leads and stopwatch time - This is not sufficiently accurate for
transportation work and should not be used as the
primary means of monitoring drilling - Automated monitoring systems should include a
depth encoder and revolution counter such that
the rate of penetration can be displayed to the
operator - In mixed profiles, higher penetration rates
should control drilling to reduce possibility of
excessive flighting of soils
104Effects of Over-Excavation During Drilling
105Difficult Drilling Conditions for CFA Piles
106Monitoring During Grouting/Concreting
- The Deep Foundations Institute Augered
Cast-In-Place Piles Manual (2003) Section 1.3 -
The grout volume placed for each increment of
depth is the single most important installation
control used during ACIP pile construction. - Grout volume is the most important and most
difficult inspection item
107Use of Automated Monitoring Equipment
- Manual inspection of grout volume is difficult
- Grout volume usually measured by counting pump
strokes - Stroke volume calibrated with 55 gallon drum
- Hard to accurately determine grout pumped versus
depth increment, and in many cases this results
in measurement of overall volume only - Lifting speed and depth of the auger are
controlled by feel and observation auger height
in the leads - The pump does not always maintain a repeatable
volume per pump stroke - Well conditioned pumps operating well during
construction will have up 10 missed or bad
strokes - Lead to gross overestimations of grout/concrete
take
108From PIR-A pressure - 229 good strokes (plus 20
bad) Inspector counted 246 strokes (7 high)
109B
A
110Monitoring During Grouting/Concreting
- Recommended that the following elements of the
grouting/ concreting operation be monitored by
automated system - Position of the auger tip (depth encoder)
- Volume of grout (in-line flow meter)
- Grout/concrete pressure (pressure gauge)
- Rotation of the auger
- Lifting speed (operator controlled based on above
controls)
111Automated Monitoring Equipment
- European industry requirements for QA/QC have led
to the development of sophisticated computer
based monitoring systems - The systems now record every detail of the
augering and concreting operations of each pile - US systems not as sophisticated yet. Designed for
adaptability to existing ACIP equipment
112- Measures
- Location of auger tip
- Auger torque
- Grout volume (magnetic flow meter)
- Display of actual vs. target
Developed by Pile Dynamics, Inc.
113Typical PIR Readout From Pile Dynamics, Inc.
114Developed by Jean Lutz, SA
- The system controls
- Auger rotation speed
- Advancing speed
- Speed/torque settings on the rotary table
- Pressure and the delivery of the concrete
- Extraction speed
115Finishing the Pile
- Completion of the pile top and installation of
reinforcing steel are not activities that will be
monitored by automated systems - Inspection responsibilities for finishing the
pile top include - Noting the point at which grout first appears at
the surface - Ensuring that volume of grout remains consistent
once grout is vented at the surface - Observe screening or dipping of the top of the
pile to ensure removal of any contamination
116Additional Inspection Issues
- Reinforcing Steel
- Inspection should concerned with size and
dimensions of steel, final depth of reinforcement
and cover - Sampling and Testing of Grout/Concrete
- Inspection should be concerned with strength and
workability of the grout or concrete
117Verification Testing
- Integrity Testing
- LS (PIT) Light Hammer Impact
- HS (PDA) Heavy Ram Impact
- CSL Cross-Hole Ultrasound w/ 2 or more tubes
- SHSL Ultrasound single tube
- Load Testing
- Dynamic Heavy Ram Impact (WR 1-2 of Load)
- Rapid Statnamic Pseudostatic (5-10)
- Static Top Loaded (100)
118SPECIFICATIONS FOR CFA PILES
119FHWA CFA Pile Guideline Specification
- Performance based to address several issues
identified earlier in this presentation - Owner develops design loading criteria and
performance requirements for foundation elements - Contractor provides individual pile design and
selects means and methods for installing piles
120FHWA CFA Pile Guideline Specification
- Highlights of the specification include
- Design and construction submittals
- Materials and mix design (grout or concrete)
- Protection of adjacent structures
- Grout or concrete sampling and testing
- CFA pile equipment and installation
- Acceptance and rejection criteria
- Inspection records
- Verification testing
121Design and Construction Submittals
- Prior to construction, contractor will provide
(not all-inclusive) - Design calculations
- Design criteria and parameters
- Safety factors
- Design calculation sheets
- Any design notes
- Working drawings
- Plan, elevations and cross sections
- Pile locations and spacing
- Typical pile sections
- Construction sequencing
- Details, dimensions and schedules for piles
- Details for verification testing
122Design and Construction Submittals
- Prior to construction, contractor will provide
the following construction submittals - Pile Installation Plan
- List and sizes of proposed equipment
- Step by step installation procedures
- Target drilling and grouting parameter
- Mix designs, AME procedures, contigency plans
- Conformance testing plan
- Preproduction tests
- Production load testing
- Integrity testing
123Grout or Concrete Mix Design
- Grout
- Workability test for fluid consistency using
modified flow cone test - Shall not exhibit shrinkage in excess of 0.15 in
vertical direction (ASTM C 1090) - Must achieve minimum compressive strength
- Mix design will include viscosity loss vs. time
curves - Mixes with flyash, silica fume or slag will
include strength development vs. time curves - Samples should be 2-inch cubes and subjected to
10 increase in required compressive strength
than cylinders
124Grout or Concrete Mix Design
- Concrete
- Workability slump testing in accordance with
ASTM C 143 - Must achieve minimum compressive strength
- Mix design will include viscosity loss vs. time
curves - Mixes with flyash, silica fume or slag will
include strength development vs. time curves - Samples should be 6 in by 12 in cylinders, or
sized appropriately for the maximum aggregate
size (ASTM C 39)
125Auger Equipment
- Auger flights shall be continuous from the top of
the auger to the bottom tip of the cutting face - Gaps at joints between auger sections shall be
less than 1 inch - Auger flighting diameter shall be uniform and
outside diameter shall be at least 97 of the
design pile diameter - Injection port shall be fitted with a means of
sealing against ingress during drilling - Leads should be clearly marked along length to
facilitate inspection during drilling and grouting
126Drilling
- Adjacent piles within 6 diameters shall not be
installed until grout in first pile has set and
will not be compromised - Auger shall be advanced into the ground at a
continuous rate and such that excess soil is not
flighted to the ground surface - Pile termination (and/or refusal) criteria shall
be established during test pile program. Once
reached, rotation of the auger should be stopped
127Grout/Concrete Placement
- Placement of grout or concrete should commence
within 5 minutes of auger reaching planned depth - At start of pumping, auger shall be raised 6 to
12 inches to facilitate removal of plug. Once
grouting has started, auger shall be re- inserted
to original depth - Auger pull shall be at a smooth, steady rate
while continuously pumping. If any rotation of
the auger occurs, it shall be in the same
direction as drilling - Volume measurements will occur as a function of
depth and will be recorded at intervals of not
more than 2 feet
128Grout/Concrete Placement
- Auger withdrawal and pumping will be coordinated
to maintain positive pressure at the auger tip - Typical grout volume factors will range from 1.15
to 1.2. Factors greater than 1.5 may indicate a
problem - Volume factor for any pile should be within 7.5
of the target volume factor - If grouting is suspended for any reason, the pile
is deemed unacceptable and will need to be
re-drilled
129Testing
- FHWA is currently recommending the following
- Verification testing on a minimum of 2 of
production piles, or as required by the Engineer - Integrity testing on a minimum of 20 of
production piles
130Rejection Criteria
- Conditions for unacceptable piles
- Failed integrity testing
- Failed load test
- Automated monitoring or project inspection
indicates an inadequate pile (does not meet test
program criteria) - Pile out of tolerance (plan or elevation)
- Grout/concrete strength or volume factor
inadequate - Reinforcing steel not inserted as designed
- Visual evidence of contamination, excessive
settlement, structural damage, honeycombing
131Thank You!Silas Nichols, P.E.Geotechnical
EngineerFHWA Resource Center61 Forsyth Street,
SWSuite 17T26Atlanta, GA 30303Phone
404-562-3930Email silas.nichols_at_fhwa.dot.gov