02-baquerizo

1The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012

Part 2: Installation Processes/EquipmentAndres Baquerizo, P.E., HJ Foundation Company

The Deep Foundations Institutes Cast-in-Place Piling Seminar- KC '09

Process Summary Drill to required depth using continuous-flight,

hollow-stem auger Begin pumping grout (expel cork) Build up target grout head on auger Withdraw auger at constant rate to produce a

target over-supply per length of pile Continue pumping grout until auger tip reaches

ground surface Insert Reinforcing bar or cage

2Caissons/Shafts or Barretes/ LBE

Augered PileAugered Pile

The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012

Vs Shaft/Caisson

The Deep Foundations Institutes Cast-in-Place Piling Seminar- KC '09

Equipment

Hollow Stem Auger Drill Bits Leads/Torque Arm Hydraulic Gearbox Hydraulic Power Unit Grout Pump Crawler Crane

3Typical Equipment


GEAR BOX

PILE LEADS

TORQUE ARM

HYDRAULIC POWER UNIT

CRANE

STICKERS

CRANE

MAST

BOOM


4Hollow Stem Auger

Continuous flight auger 3 inch inside diameter pipe Auger diameters: 12, 14, 16, 18, 20, 22,

24, 30, 36, 42 and 48 inches Auger section lengths: 4, 5, 10, and 20 ft Weight ranges from about 70 lbs per ft

for 12 inch, to 120 lbs per ft for 24 inch, and 200 lbs per ft for 36 inch


AUGER CONNECTORS

Torque Resistant

Fluid Tight

Ease of assembly disassembly

Bayonet Connector

API Connector

Hex Connector

5Drill Bits Basic Bit - Pengo bit Basic Rock Bit - fitted with carbide teeth Clay Flight Bit - for clay soils


Cutting Head for IGM Application

Leads/Torque Arm Leads provide the guide for the gearbox to

travel up and down on during drilling Leads can either be fixed to the crane boom

or hung from a cable Torque Arm - steel pipe designed to absorb

torque from drilling operation - optional Hydraulic Spotter - used for tiebacks and

battered piles Traveling Guide-maintain stability of auger



Gearbox Hydraulically operated top head drive Travels up and down the leads Torques range from about 15,000 ft-lbs to

90,000 ft-lbs or more Weighs 2,000 to 10,000 lbs

(down force in addition to the auger weight) Rotational speed ranges from 30 to 60 rpm


7SWIVEL


Hydraulic Power Unit

Provides the hydraulic power to turn the gearbox and auger

Typically mounted on the back of a crawler crane to aid in mobility

The higher the hp rating, the greater the torque and rotational speed for drilling

Horsepower ratings range from about 200 hp to 750 hp



Grout Pump Hydraulically operated, positive displacement piston-ball valve

pump Pump pressures typically around 350 psi at pump outlet Stroke displacements range from about 0.4 to 1.7 cubic feet per

stroke Grout hoses typically 2 to 3 inch diameter Can pump grout several hundred feet Grout typically delivered by ready mix trucks Pump Calibration-Usually performed by counting the number

of pump strokes required to fill a 55 gal (7.35 cu ft) barrelNote: All 55 gallon barrels are not created equal-measure barrel,

calculate volume



Stroke displacements range

from 0.4 to 1.7 cft per stroke

(40 to 170 cyds/hour)

Crawler Crane

Capacity and boom lengths vary with project conditions

40 to 100 ton cranes most typical 40 ton crane - 40 ft of up to 18 inch auger 60 ton crane - 60 ft of up to 18 inch auger 100 ton crane - 100 ft of up to 18 inch auger 150 ton crane - 100 ft of up to 24 inch auger


10

40 60 60 90 69 80100 155 85 120

155 120 130100 100 200220

335 440440 440

700 700 700

1,200

2200

0

400

800

1200

1600

2000

2400

1980 1983 1988 1994 2010 1996 2000 2004 2002 2004 2005 2006 2014

Cap

aciti

es (t

ons)

/ Le

ngth

s (ft

)

Years

Typical Pile Lengths (ft)

14-inch 16-inch 18-inch

30-inch

24-inch

36-inch

Future 42-inch

Reference Evolution of the Foundation Industry Met Miami Development Miami, Florida, Carlos Ortiz, P.E. & Matthew Meyer, P.E. Langan Engineering and Environmental Services, Inc. presented in DFI referencing O-cell Tests on Augered Cast-in-Place Piles, Edwin W. Hickey and Andres M. Baquerizo of HJ Foundation, and John Hayes of Loadtest, presented in DFIs Augered Cast-in-Place Pile Committee Specialty Seminar: Augered Cast-in-Place Piles on June 22, 2007 in Coral Gables, FL.

Augered cast-in-place milestones

201218-inch145 ft

201236-inch 152 ft


Use of full length reinforcing as Tension Reinforcement & instant quality control for Augered cast-in-place piles.

Augercast piles are not comonly designed with full length reinforcing. The questions is Can & Has it been done?

18-inch 145 Ft

36-inch 122 Ft

30-inch 130 FtYES


11

36-inch 152 Ft30-inch 155 Ft



Batter Piles - Typically Inclined 1: 6 or less

12

Full length reinforcing instant quality control method?


Pile Cut Off When Required


13

5200 ton O-cell

Load Test: Top Down, O-cell & Statnamic Testing

3000 ton Top Down

1500 ton Top Down

4500 ton Statnamic


Installation Close to Structures


14

Install Augered Piles Close to Utilities?



15

2.2 Low Head Room/Limited Access (LHR-APG) Piles


(LHR) Limited Head Room Installation

Used where overhead clearances are at least 8.5 ft Track-mounted or forklift mounted drilling

equipment Piles are drilled with auger sections typically 3 ft

to 10 ft in length Installation time much longer than with crane-

mounted equipment


16

Typical Limited Headroom (LHR) Rig


Low Headroom Pile Installation


17


Power Pack, Grout Pump


18

Restricted Access Piles


30Ft 50Ft

4Ft

19

Drilled displacement type pile - (pro's/con's)

Augered cast-In-Place Pile

Drilled Displacement

Limestone cannot be Displaced

DISPLACEMENT EQUIPMENT LIMITATIONS - (pro's/con's)

Variable top of limestone elevations iterbeded with

soft layers

20

Numbering Print


21

Submittals & Pile Cap Detail



Part 3: Pile MaterialsAndres Baquerizo, P.E., HJ Foundation Company

22

PILE MATERIALS

Ready-Mix Grout Steel Reinforcing


3.2 Grout

Portland cement Flyash Sand (fine to coarse) Grout aid

(fluidifier, non-shrink additive) Water


23

Typical Grout Mix (cubic yard proportions)

752 lbs cement 225 lbs fly ash 2400 lbs sand 3 lbs grout aid W/C ratio: 0.45 to .50 Compressive strength: 4,000 psi (28 day)


Compressive strengths are typically referenced to 2 X 2 cubes. Compressive strength tests on cylindrical (L=2D) specimens will produce about 0.85 of those on cubes (see ASTM C780-06, p482)

Compressive strengths in the range of 3000 psi to 5000 psi are common. Maximum available compressive strength is dependent upon available materials and varies regionally. Compressive strengths of 9000 psi have been used (South Florida)

Grout Strengths


24

Importance of Testing Samples

Quality Control Fresh tests Cured tests

Represents the pile

Evaluates the material Predict future material behavior

Compressive strength Proportions in the mix

Determines compliance Specifications

4

Part 1: Field Sampling & Testing


ASTM C172 Standard Practice for Sampling

4

Proper Sampling Techniques

Important Factors Qualified Field Testing Technicians Area for testing/storing

No disturbances, vibrations Level surface

Frequency of sampling SpecificationsTime

25

4

Size

Strength test specimens min 1ft3 Flow cone & temperature

specimens may be smaller Representative of the condition of

the grout

Revolving Drum Mixer

Specimens obtained from discharge stream

Specimens obtained from auger tip (DFI)

Collect after All water and admixtures added

Proper Sampling Techniques


Temperature Thermometer capable to measure 30F-120F Sensor embedded in >3 in of grout Make sure no voids Leave in 2-5min Report to nearest 1F

5

Field Tests: Temperature ASTM C1064

Standard Test Method for Temperature of Freshly Mixed Hydraulic-Cement Concrete


26

Flow Cone Test Fluidity Measures the time of outflow of the grout Recommended 70-78F

Flow Cone Test 1 min before introducing grout drain cone with

water Close the outlet, introduce grout up to point gage Start stop watch, remove stopper Stop watch at first break in continuous flow

Flow Cone Test Recommends at least 2 tests with times within 2 s Flow time 15-25 seconds

5

ASTM C939

Standard Test Method for Flow of Grout for Preplaced-Aggregate Concrete (Flow Cone Method)

*If light not visible, not acceptable

inchdiameter

Field Tests: Flow Cone


ASTM C109 Standard Test Method for Compressive

Strength of Hydraulic Cement Mortars

5

Field Sampling: Strength Samples

Sampling Cubes 2 in x 2 in x 2 in cube molds No more than 3 compartments Separable in 2 sections Coat with release agent

Sampling Cubes: Mixing the Grout

Following flow cone test: Return batch to mixing bowl Scrape sides of bowl Mix for 15 seconds at medium speed Allow to stand 90 seconds with no cover Repeat


27


Strength of Hydraulic Cement Mortars

5

Sampling Cubes: Molding

Pour molds < 2 min 30 seconds after mixing Fill each mold halfway ( ASTM C1107) Puddle each mold with gloved finger five

times to consolidate Fill all compartments to top and puddle Smooth off tops of cubes

Trowel at 90 3 samples per composite sample for each

period of test (7, 14, 28 day)




Strength of Cylindrical Concrete Specimens

5

Sampling Cylinders

Length 2x diameter Coat with release agent Place grout in layers Tamp according to diameter

Into layer below ~1 Tap outsides 10-15 times Remove excess grout



28

Water content Hydration of cement

Cement/water glue As hydration continues, strength bonding

increases

5

Field Tests: Water Content

Unhydrated particles

Partially hydrated particles

Hydrated cementThe Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012

Water content Hydration of cement

Cement/water glue As hydration continues, strength bonding

increases Development of strength

Pores between cement filled Denser, stronger, less-permeable grout Depends on initial volume of pores (w/c)

Water/cement ratio (Weight of the water)/(weight of cement) 45%-60%

Want to Minimize pore space Provide sufficient water for hydration

Check batch ticket

5

Low w/c High w/c

Low porosity High porosity

Cementsuspended

in water

Fullyhydratedcement

Field Tests: Water Content

29

5

Extreme Temperature Influences

High temperatures ACI 305.1 Rapid rate of hydration, early setting Chemical admixtures

Reduce water demand Improve workability

Cement, water, aggregate temperatures Water is easiest to cool

Low Temperatures ACI 306R Slow rate of hydration, late setting Insulation

Other influences Evaporation due to

Wind Dry weather Direct sunlight


Proper Storage: Initial Curing Immediately move to initial curing area Level surface, free from vibrations/disturbances Stored up to 48 hours

60-80F Environment preventing moisture loss

Proper Storage: Final Curing Keep in moist room for 20-72h

73.5+5.5F For 1 day compressive strength samples

Strip molds at 24 + 1 hr Strip remaining molds at 72 + 1 hr

5

Proper Storage/CuringASTM C31

Standard Practice for Making and Curing Concrete Test Specimens in the Field


30

Cubes vs. Cylinders Cylinders

Lower strength results (~15-20%) Geometry

Cubes High strength results More confinement More consistent performance

5

Compressive Strength Testing


6

ASTM C109

Standard Test Method for Compressive Strength of Hydraulic Cement Mortars

Determination of Strength Place specimen in testing machine Apply load rate between upper and lower

plates to 200-400 lbs/s Specimens made from same batch

Average and report to nearest 10 psiDetermination of Strength

Specimens must be surface-dry Smooth and parallel No loading on uneven surfaces Uneven surface area (lbs/in2) Discard specimens (grinding >few thousandth

of an inch)

Test Age Permissible Tolerance

24 h + h

3 days + 1 h

7 days + 3 h

28 days + 12 h



31

Capping Methods Compressive forces evenly distributed Consistent and accurate results Different capping methods affect strength

Sulfur-mortar Neoprene pads & metal retaining rings

ASTM C617

Standard Practice for Capping Cylindrical Concrete Specimen



Other Roles of Grout in APG Piles

The injection of grout under pressure is considered to improve the soil in the pile area.

Grout acts to stabilize the hole until it hardens and becomes a pile.

The fresh grout column must be capable of accepting reinforcing steel.

In order to properly serve these purposes, the grout must be in a fluid state.

(DFI manual States a Flow Cone Rate of 10 to 25 seconds through a opening in the Flow Cone)


32

3.3 Steel Reinforcement

Cages Single center bar High strength (150 ksi) thread bar Combination of cages and center

bars Pipes All elements should be fitted with

centralizers to properly position them in the pile


Reinforcing Cage Placement


33

Reinforcing Cage with Wheels


Centralizers for Center Bars/Pipes

Football for typical Center Bar Centralizer for Pipe Reinforcement


34

Note 1: The length and configuration of the reinforcing steel cage can greatly impact the successful insertion of pile reinforcement into the grout. The addition of steel surface area (closely spaced circular ties with seismic hooks for example) has a significant impact on deep placement.

Note 2: High static pressures in the fresh grout column forces fluid from the grout into permeable soils, making steel placement difficult. At the bottom of a 50 column of fresh grout, the pressure is about 3.6 tons per square foot.

Local codes and pile loads dictate pile reinforcement design, but consideration must be made as to the constructability of installing massive post-set pile reinforcement elements. Consult a piling professional to discuss constructability issues and alternatives such as spiral cages, pipes, etc.

Pile Reinforcement Placement Issues



Break

02-baquerizo

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