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By Piotr Kozlowski, Stanley L. Worst, Matthew J. Niermann

The Waterman Hospital in Tavares, Florida was undergoing an expansion and required a below-grade excavation immediately adjacent to the Emergency Department. This wing of the hospital was under high traffic and required uninterrupted access for ambulances as well as helicopter landings. The below-grade expansion was also next to a part of the hospital which did not have a basement. Tiedback soldier beams and wood lagging were used as the earth retention system where the shoring line was not immediately adjacent to the existing structure. Structural jet grout underpinning was used to support the existing building and to serve as the earth retention system in the more sensitive area. Jet grout underpinning was chosen to minimize movements, loss of ground and settlement of the structure which was bearing on clean sand deposits. This paper will discuss the design, quality control and construction of jet grouting and its application to this project. INTRODUCTION Project Background The expansion of the Waterman Hospital included an addition to the Emergency Department. This addition was located adjacent to the existing hospital building in a congested area with limited access. The north side of the addition was bordered by the ambulance drop-off area. The south side of the addition was bordered by the helipad landing area. Both areas had to remain open and fully accessible 24 hours a day, 7 days a week.

Jan 1, 2019

By Paul M. Schuman, Alessandro Bertero, Giuliana A. Zelada, Sharon G. Cranston

Many jet grouted columns were recently installed to create a jet grout-treated soil foundation for an earthen embankment used in a large shoreline stabilization project in the Mystic River in Charlestown, MA. A physical test program was used to determine whether the jet grouting parameters the Contractor selected would meet the design requirements given the local soil variability, including soft river sediments and organic soils. The presence of hydrocarbons encountered in the marine sediments during the test program caused concern that the design strength could not be achieved. The published literature discusses the environmental aspects of jet grouting with hydrocarbons. The literature did not include many studies of the effect on jet grout-treated soil strength for the types and concentration of hydrocarbons encountered on this project. The grout mix, air pressure, and number of passes of jet grouting were varied in a second field test program to determine jet grouting parameters needed to achieve the design strength of columns with hydrocarbons. A geo-probe study was performed to identify the type and concentration of hydrocarbons on the site. With few exceptions, the quality control core samples from the production columns met the design requirements with many strength values far exceeding the design strength. This paper presents the data, and reviews the lessons learned. PROJECT BACKGROUND The Charlestown Bus Garage, located in Cambridge, Massachusetts, is a Massachusetts Bay Transportation Authority (MBTA) bus maintenance facility located on the Mystic River. The site was home to a coal gasification facility before it was developed by the MBTA as a bus garage in 1978. A deadman-anchored steel sheet pile bulkhead wall installed along the Mystic river on the east side of the site supports the site grade at about El. 11 ft (NAVD 1988) (Figure 1).

Jan 1, 2019

By Seth H. Hamblin, Leo J. Hart, John E. Regan

The Route 6 /10 10 Interchange Design/Build project, located in Providence, Rhode Island, involves the design and construction of five (5) new elevated bridge structures to replace and reconfigure the existing interchange and to provide a link between Route 10 northbound and Route 6 westbound. Due to site logistics, headroom restrictions, and depth to bedrock, 50 ton drilled micropiles installed in the deep medium dense sand strata were initially proposed as the deep foundation solution. Post project award, Geosciences Testing and Research, Inc. (GTR) performed various analyses and developed an alternate driven pile solution using steel Tapertube. The results of these analyses indicated that driven steel taper tube and steel pipe piles could develop greater capacities than the drilled micropiles in the granular soil layer, thereby reducing the number of foundation elements, decreasing construction schedule and providing a more cost effective foundation alternative. A comprehensive driven pile load test program was subsequently executed by GTR and the Design Build Team led by Barletta Heavy Division of Canton, Massachusetts, to assess the performance of Tapertube and steel pipe piles, including pile drivability, load-deformation characteristics under static and dynamic loading, and to develop site-specific design parameters in two (2) distinct test areas. The test pile program included dynamic, static compression, tension and lateral load tests on each test pile. Load test measurements were automated with embedded Vibrating Wire Strain Gages (VWSG) to measure load transfer with depth. The execution and results of the successful pile load test program are presented and offer unique case study and valuable data for the use of Tapertube piles on deep foundation projects in the New England region INTRODUCTION The Rhode Island Department of Transportation (RIDOT) Route 6 / Route 10 Interchange is located west of downtown Providence. Originally constructed in the 1950’s as a highway bypass around the historic Olneyville neighborhood, the interchange consists of a series of nine (9) bridges and ramps that serve as a vital east-west link between Interstate 295, 95 and 195. Based on recent bridge rating assessments, seven of the nine bridge structures are rated “structurally deficient”. With many bridge structures shored with temporary supports as many as 15 years ago, the interchange is in critical need of replacement. In 2018, RIDOT awarded the Route 6/10 Reconstruction Design-Build Project to 6/10 Constructors, Joint Venture. Led by Barletta Heavy Division of Canton, Massachusetts, the Design Build team includes O&G Industries, DW White Construction, Aetna Bridge Co. and AECOM. The scope of work includes the replacement of the bridges and ramps, and will provide direct access from Route 10 northbound to Route 6 westbound. Valued at over $400M (US), this is currently the largest project awarded in RIDOT history.

Jan 1, 2019

By Tai Luu, Maxim C. Schisler, Yaser Taheri

The Stevens Gateway Project is an expansion of the Stevens Institute campus overlooking the Hudson River in Hoboken, NJ. The plans call for 90,000 ft2 (8360 m2) of new classroom, research, and student life facilities in new, 4-story buildings. The excavations for the building footprints were bounded by city streets and existing buildings, including the historic Carnegie Laboratory of Engineering, built in 1902. Pit underpinning was originally specified for the Carnegie building. However, given the depth of cut, construction time required for the 13 ft (4.9 m) deep pits would be substantial. The geotechnical contractor retained for the support of excavation work therefore offered an innovative active soil nail wall design that would meet project requirements in a shorter timeframe. Unlike the passive soil nail systems common in the industry that are chiefly used for soil slope stabilization, active soil nail walls contain pre-stressed anchor components to resist soil movement and limit settlement of soil and structures being contained. In addition to a discussion of the overall design approach of the active soil nail wall system, this paper will include a detailed description of its constructability and effectiveness. This project’s use of a conventional slope stabilization technique for an unconventional purpose may have positive implications going forward. INTRODUCTION Stevens Institute of Technology is a private university in Hoboken, New Jersey that sits on the cliffs of the City of Hoboken overlooking the Hudson River and Manhattan Island to the east of the campus. In recent years, the university has executed numerous plans to expand and upgrade its campus academic, student life, and residential facilities. One such project is the Academic Gateway Complex. The plan adds 90,000 ft2 (8360 m2) of new classroom, research, and residential facilities while also enhancing community connections by building a park to serve as a green corridor for the city. The proposed construction took place on the north and south side of 6th Street between Hudson Street and River Street. The project included the demolition of an existing university building followed by the construction of two, 4-story buildings on the north and south property lots. The north and south buildings will be connected by a second floor bridge spanning 6th Street. The buildings each contain a full basement extending from the proposed ground floor at approximately El. 41ft (12.5 m) to the basement subgrade at El. 26 ft (7.9 m). Each building will be constructed on respective mat foundations. Figure 1 presents an overview of the project area.

Jan 1, 2019

By Jason Herron, Joseph Brown

The common couplings for joining sections of helical piles with an outside diameter of 6.625 inches and 8.625 inches are square on square, flange to flange, external pipe sleeve, internal pipe sleeve, and welded joint. Each coupling type has advantages and disadvantages in efficiency, capacity, installation, and economics of the installed pile. All these coupling types have been used in the helical pile market in North America for various applications and designs. Many of these applications require on-site testing, but test records are not typically shared with the helical pile industry. Due to the lack of information available for square on square and flange to flange couplings, testing was done to compare the efficiency of installation, load to deflection response, and torque to capacity ratios of external pipe sleeve, square on square, and flange to flange couplings. Field installations and tension tests were performed in non-cohesive (sand type) soil near Caseyville, IL and in cohesive (clay type) soil in Centralia, MO. The data collected during these tests included rotations per foot during installation, installation torque, applied pressure, and deflection. The results of this testing are analyzed and discussed within this paper. The results indicate that the square to square coupling is the most efficient of the designs tested, but this conclusion cannot be fully justified without further testing due to the variability in the data gathered and the small number of piles tested. INTRODUCTION A helical pile is typically assumed to be a medium-displacement pile when its outside diameter is between 4.5 inches and 8 inches and a high-displacement pile when its outside diameter is greater than 8 inches. A helical pile designer has multiple options when selecting a coupling type for medium- to high-displacement helical piles. Each type of coupling has advantages and disadvantages and must be analyzed on the bases of efficiency, capacity, installation, and economics of a project. Typical couplings that are chosen by designers include square on square, flange to flange, external pipe sleeve, internal pipe sleeve, and welded joint. A helical pile must transfer axial, lateral, bending moment, and torsional loads, and the coupling must be designed to effectively and efficiently transfer each type of load. During the installation of a helical pile, the rate of penetration and the disturbance of soil layers play a critical role in the efficiency and torque to capacity ratio (Kt) of the pile. It is common for a coupling to protrude beyond the outside diameter of the pipe section being used. This is necessary for the function of certain coupling types and can facilitate the connection of couplings. However, it causes increased soil disturbance and reduce the rate of penetration due to soil bearing against the protruding portion of the coupling. A helical pile designer typically will work to minimize the coupling protrusion and create a pile with optimal installation efficiency but may choose a design with lower installation efficiency if it offers sufficient economic advantage.

Jan 1, 2019

By Babak Mamaqani, Pirooz Barar

The Moanalua trestle spanned over Moanalua Stream, Honolulu, HI and was designed to accommodate construction of five 10 feet diameter cast in drilled hole (CIDH) piers as a part of Honolulu Authority for Rapid Transportation (HART) project. Due to the proximity of piers to the existing bridge, the trestle was elevated 20 feet above grade. Stratigraphy of the site consisted of shallow depth of fill and 150 feet of loose to very loose recent alluvium (soft clay) underlain with stiff to hard old alluvium (stiff clay). CIDH casings were installed by a rotator or oscillator depending on the diameter of the piers. The challenge was to design the trestle, not only for heavy gravity loads, but also to resist significant lateral loads from rotator and oscillator with minimal deflection. Series of piles, called reaction piles, were integrated into the trestle at each CIDH pier location to provide adequate lateral support for the rotator/oscillator. Due to the lack of information regarding soil Young’s modulus (E), a methodology was developed to calibrate and calculate E with two methods. Extensive analyses using LPILE and finite element analysis program, PLAXIS, were performed to model reaction piles and calculate lateral deflection. PROJECT SPECIFICATIONS The Honolulu Rail Transit includes 20-mile route and 21 stations to be built from East Kapolei to Ala Moana Center, with $1.55 billion construction budget. The project is divided into two phases as shown in Fig. 1: Phase 1 which connects East Kapolei to Aloha Stadium with expected operation in late 2020, and Phase 2 which connects Aloha Stadium to Ala Moana Center with expected operation in 2025.

Jan 1, 2019

By Patrick J. Hannigan, Alex Ryberg, Rozbeh B. Moghaddam

Driven piles are widely used for foundation support. In the vast majority of cases, an increase in pile capacity occurs with time which is referred to as “set-up.” However, in a very limited number of cases, a decrease in capacity with time can occur. This phenomenon is referred to as “relaxation.” This paper will provide a brief review of the relaxation phenomenon, as well as pile driving information and dynamic test data on cases where relaxation has occurred. The pile types in the presented relaxation cases include H-piles, open-end and closed-end pipe piles, prestressed concrete piles, and prestressed concrete piles with H-pile stingers. The soil conditions where relaxation occurred includes dense to very dense fine sands, heavily over consolidated clays, and weak laminated rocks. Relaxation information from 36 piles at 26 sites is assessed. The collected data will assist foundation designers by identifying the subsurface conditions where relaxation has occurred, as well as by documenting the corresponding relaxation magnitude. One method of addressing relaxation when it is encountered is to drive the foundation piles to a greater end of initial driving capacity than required long-term. Hence, the identification and quantification of the relaxation magnitude will be beneficial to foundation designers installing similar pile types in similar subsurface conditions. The paper will also present pertinent observations and recommendations on mitigating relaxation when encountered. INTRODUCTION One of the earliest observations of a decrease in redriving resistance following initial driving was reported by Miller (1937). He reported that piles driven into a saturated, coarse grained soil could lose 40 to 50% of their resistance when redriven 24 hours after initial driving. Yang (1956) similarly reported that after a break in driving, a decrease in driving resistance could be encountered for piles driven in dense fine sand, inorganic silt, or stiff fissured clay. Parsons (1966) in his paper that described piling difficulties in the New York City metropolitan area termed this phenomenon “relaxation”. In this time period, pile capacity was most often evaluated from a pile driving formula frequently checked by a static load test. Hence, the true magnitude of the capacity decrease on a given pile was often poorly quantified. Furthermore, dynamic measurements that could determine what influence driving system performance variation had on the observed redriving resistance were not yet readily available.

Jan 1, 2019

By B. Mirabile, B. Stables

Standing support is often used in conjunction with underground retreat mining. Knowledge of the load-displacement behavior of a standing support, and loading induced by the mine opening is critical to proper support selection. The NIOSH STOP database contains load-displacement laboratory test data for most commonly used standing supports. Hydraulic load cells currently used to measure in-situ loading of standing supports have exhibited leakage under load, producing irregularities within the dataset. An improved hydraulic load cell eliminates leakage and produces more consistent data. INTRODUCTION A hydraulic load cell, more commonly known by “flat jack” or JackPack, is a device installed to determine the loading characteristics of roof to floor supports. These standing or roof to floor supports include, but are not limited to: pumpable cribs, cans, wooden cribs (4-point, 9-point, etc.), metal props, wood timbers, concrete donut cribs, and other variations of these standing supports. Flat jack devices have been used previously to determine the loading of such roof to floor supports. The most commonly used load cell for standing supports is based on a design intended for pre-stressing standing supports, not load measurement. These load cells are produced in South Africa, and can be formed into several different shapes depending on the applications (Barczak). Flat Jacks are manufactured in various shapes and sizes depending on the application, common shapes are square and round that are 25.4 mm (1.0 inch) thick when collapsed as shown in Figure 1. The sheet metal that makes up the bladder is comprised of 19 gauge or 1.11125 mm (0.04375 inch) thickness, the top and bottom pieces of sheet metal are resistance seam welded around the perimeter. There are two different ports installed on one of the bladder skin corners of the flat jacks; these ports allow a fluid to fill the unit and the other port has a relief valve. The fill port is comprised of a check valve. The pressure relief valve is located in the second port; preset to 1724 kPa (250 psi), pressure relief valve will keep the load cell from bursting. Bursting of these load cells typically causes a small tear in the metal skin allowing the fluid to leak out without a large catastrophic failure. The effective inflation range of these load cells is between 25.4 mm (1.0 inch) to 254.0 mm (10.0 inches) thick. Different types of fluids can inflate these load cells but the most common and easily accessible fluid for testing applications is water. Water pressure from the mine supply line can inflate these load cells to the desired load. Depending on the pre-stressing requirements a pneumatic powered pump, hydraulic pump or hand pump may be required to inflate the load cells.

Jan 1, 2019

By J. Bilant, B. Carlson, N. Gow

High Pressure Grinding Roll (HPGR) technology has been evaluated to replace tertiary cone crushing at Coeur Rochester operations (Coeur Rochester, Inc.) as an opportunity to improve silver recovery. In 2016 and 2017, onsite and third-party pilot programs were initiated to evaluate the impact of metallurgical recovery and heap leach performance of crushed product generated by an HPGR. In 2018, Forte Dynamics evaluated the HPGR laboratory metallurgical data from Coeur Rochester and all third parties to develop field-scale leach curves based on new crushing scenarios. The laboratory recovery test work data was consolidated and scaled to field conditions to determine projected heap leach performance. Based on the metallurgical testing conducted, the replacement of current tertiary cone crushers with HPGR technology has the potential to increase Coeur Rochester’s silver recovery rate by 8%, from 61% to 69%, and shorten the overall timing of silver recoveries from 20 years to just over two years. INTRODUCTION The Rochester mine, and associated valley fill heap leach facilities is an open-pit silver and gold mine located in Pershing County, Nevada, approximately 26 miles northeast of the city of Lovelock. In 2017, Rochester produced approximately 4.7M troy oz silver (Ag) and 51k troy oz gold (Au). Ore mined at Rochester is either fed directly to the primary X-Pit crusher, crushed at an in-pit crusher system, or placed directly onto a heap leach pad as run-of-mine (ROM). Both crushing circuits are comprised of three stages of crushing to produce a nominal 3/8” ore. Primary crushing consists of jaw crushing while secondary and tertiary crushing are composed of varying cone crushers. Historical recovery rates of crushed Rochester ore average 61.4% Ag and 95.9% Au over a period of 20 years [1]. These rates were derived from third party verification of in-house metallurgical test results, crusher production and heap leach production results from 1986 through 2004 in a private report for Rochester produced by KD Engineering Co., Inc. Recovery rates are regularly verified by compositing daily samples of ore delivered to each leach pad from the X-pit crusher, in-pit crusher, and/or ROM. A proportionate split of each sample is used to generate monthly composites for metallurgical analysis utilizing column leaching and bottle roll leaching. These tests are run in a manner analogous with production conditions and deliver test results that provide expected heap leach performance. As the Rochester oxide deposit has been mineralogically and metallurgically consistent, the gold and silver recovery trends have also been consistent over the life of the project. In 2016 and 2017, onsite and third-party pilot programs were initiated to evaluate the impact of HPGR technology to metallurgical recovery and heap leach performance of crushed product in an open circuit configuration, as a potential replacement for the currently in place tertiary cone crushers. During these years, HPGR was evaluated in three phases of test work.

Jan 1, 2019

By J. Perlacia

Introduction The Bulk Handling Technology has already started its transformation to the Industry 4.0. Having some of the harshest working and environmental conditions of the industry, the possibility of remote analysis and maintenance of the components seems a perfect target to focus on. The most important and expensive tools have been adapted to the digital era during last years, from remotely controlled haul trucks to monitored conveyor belts. However, these big parts of the installations rely in smaller parts that have been left aside for a while, mainly due to the difficulty to adapt them to IoT (Internet of Things). The paradigmatic example is the lack of monitored rollers whereas all the other components of the conveyor belt installations (the belt itself, motors, drums etc.) were monitored some time ago. The main problem is that a failure of a single roller can cause the stop of the whole conveyor, due to the possible damages to the belt, thus the implementation of an integral monitoring system of all the components of the conveyor is a must. The R&D Department of ULMA Conveyor Components, has been working since early 2012 on the development of Monitored Rollers, facing all the problems until its final installation in very different demanding conveyors, from the Australian extreme heat to the freezing cold Norway. All the tests done under actual working conditions, in real installations, have given a valuable knowledge in the identification of problems, their solution and the final advantages of a roller monitoring system. Background and Current State The malfunction of a single roller in certain conveyor belts can suppose the standstill of the whole installation until its replacement, due to the risk of greater and more expensive failures like the rip of the belt. In the case of a bulk handling installation where a continuous supply of material is necessary, an unexpected stop of one hour could entail huge economical losses. What’s more, many conveyor belts are several kilometers long or the access to some parts of them is very complicated. Due to these difficulties the inspection and maintenance operations can become expensive and hard going, with staff going over the whole area checking the correct condition of the conveyor and rollers, which means a dangerous activity. As in many other industry products, the condition of rollers can be recognized measuring key parameters like the temperature of the bearings, the vibration level etc. The traditional way is to use the characteristic noise of a failing bearing, but this method usually implies to change several rollers because the maintenance team is not able to identify a single source of the noise. In recent years different attempts to measure the temperature of the bearings have been made, but the result is not accurate enough due to the proximity of the rollers in the idlers

Jan 1, 2019

By M. Li, W. R. Reed, J. P. Rider, J. D. Potts

The National Institute for Occupational Safety and Health (NIOSH) has recently developed a series of validated models utilizing computational fluid dynamics (CFD) to study the effects of air-blocking shelves on airflows and respirable dust distribution associated with medium-sized surface blasthole drill shrouds as part of a dry dust collector system. Using validated CFD models, three different air-blocking shelves were included in this study: a 15.2-cm (6-in.) wide shelf; a 7.6-cm (3-in.) wide shelf; and a 7.6-cm (3-in.) wide shelf at four different shelf heights. In addition, the dust-collector-to-bailing airflow ratios of 1.75:1, 1.5:1, 1.25:1, and 1:1 were evaluated for the 15.2-cm (6-in.) wide air-blocking shelf. This paper describes the methodology used to develop the CFD models. The effects of air-blocking shelves and dust-collector-to-bailing airflow ratios were identified by the study, and problem regions were revealed under certain conditions. The simulation results could be used for future development of dust control methods, particularly to address respirable silica dust, for a surface mine blasthole drill shroud. INTRODUCTION Surface blasthole drilling can generate considerable amounts of respirable silica dust. These high dust concentrations can be exacerbated by the high silica content as drilling cuts through silica-bearing materials such as sandstone and shale, causing overexposures for miners to respirable silica dust. These overexposures can lead to silicosis, an occupational lung disease that has no cure and is often fatal. A review of the Mine Safety and Health Administration (MSHA) respirable silica dust sample database from 2010 to 2016 for metal/nonmetal mining shows the following overexposure rates for occupations related to blasthole drilling: • 14.1% of rotary air drillers were overexposed to respirable silica dust (22 out of 156 samples) • 5.8% of rotary drillers were overexposed to respirable silica dust (9 out of 155 samples) • 7.3% of drill helpers were overexposed to respirable silica dust (3 out of 41 samples) • 7.5% of blaster/shotfirer were overexposed to respirable silica dust (3 out of 40 samples) Of significant interest is an x-ray surveillance study recently completed under the NIOSH Enhanced Coal Workers’ Health Surveillance Program (ECWHSP). This program offered free chest radiographs to surface coal miners in 16 states. Pneumoconiosis was found among 2.0% of the 2,328 screened miners with at least 1 year of mining tenure. Twelve miners had radiographic changes consistent with progressive massive fibrosis, and 9 of these 12 miners reported no underground mining tenure. All but 1 of the 9 miners worked at occupations that were in the vicinity of blasthole drilling, either as a driller, blaster, or blast crew member [1].

Jan 1, 2019

By Mohsen Elsayed, Amr Sallam, Ahmad Mohamed, Xuebing Zheng, Mohamed Alrowaimi

The foundation is an essential component of the wind turbine that ensures continued operation under stable and safe conditions. Both shallow and deep foundations are utilized to support wind turbines including gravity spread foundation, anchor foundation, pier or drilled shaft foundation and pile and pile cap foundations. Conventional methods were typically utilized to design the wind turbine foundations. With the advances in numerical modeling in the geotechnical field, foundation designers may utilize numerical analysis to design wind turbine foundations. Geotechnical numerical packages allow modeling structural components and soil-structure interaction that is usually neglected in conventional methods. Furthermore, the subsoil conditions, geometries, stress-strain behavior, boundary conditions and load staging can be modeled, minimizing the assumptions and generalization. This results in better understanding of the stress strain behavior of the foundation leading to optimized foundation designs. This paper includes a brief review of current foundations used to support wind turbines with an emphasis on post tensioned single pier foundations. The current conventional foundation design methodologies and state-of-the-art foundation design utilizing numerical modeling of the single pier foundation will be discussed. Two case histories where the single pier foundation, designed using numerical modeling, were utilized to support the wind turbines will be presented. INTRODUCTION The foundation is an essential component of every wind turbine that ensures continued operation under stable and safe conditions. Turbine manufacturers provides load specifications for designers to be utilized for wind turbine foundations design. Loads include bending moments, torsional moments, lateral forces and vertical forces in both operational and extreme wind conditions. Essential specifications under seismic conditions might also be provided in seismic prone areas. Turbine manufacturers also include foundation design criteria including minimum rotational stiffness, minimum horizontal stiffness, maximum allowed inclination and maximum allowed lateral movement under both operational and extreme loads. Geotechnical explorations and evaluations are typically performed at early stages of the wind development projects. The field explorations usually include Standard Penetration Test (SPT) borings, Cone Penetration Test (CPT) Soundings, geophysical surveys, and laboratory tests to define soils stratification system and soil strength and compressibility characteristics. The most critical soil parameters for turbine foundation design are shear strength parameters (cohesion and friction), shear modulus, Poisson’s ratio, and unit weight. The depth to the groundwater table is also a crucial parameter in design. Advanced field explorations techniques such as Dilatometer Tests and Pressuremeter Tests may also be utilized. Laboratory tests for foundation design typically include index parameters, consolidation and triaxial tests.

Jan 1, 2019

By A. Rod Kern, Michael A. McNicholas, Yaser Taheri

Deep foundations were required for construction of an 18,000 ft2 (1,672 m2) 4-story office building and an adjacent 23,750 ft2 (2,206 m2) 5-story parking garage in Queens, New York due to an existing uncontrolled fill layer ranging from 15-20 ft (4.6 - 6.1 m) in thickness beneath the building footprint. The geotechnical engineers for the project initially selected auger cast-in-place (ACIP) piles over driven piles to limit the impact of noise and vibrations on the surrounding neighborhood. Ultimately, drilled displacement piles (DDP) were installed since this method offered a more economical solution that would generate the required pile capacity with shorter drill depths and would also mitigate spoils volume. During installation of test piles by the geotechnical contractor retained for the foundation work, multiple unanticipated soil conditions were encountered that would adversely affect the constructability of the piles. The existing fill contained significantly more natural and manmade obstructions than expected and the underlying glacial soil became too dense to penetrate at shallower depths than anticipated. This paper discusses how these issues were overcome through pre-drilling and the use of detailed instrumented test pile data coupled with in-house engineering capability to proactively re-evaluate minimum pile lengths at any given location and keep the project on track. INTRODUCTION Geotechnical work in the New York City market presents soil conditions that can be highly variable and challenging due to the presence of uncontrolled urban fill placed over the native soils. Construction in this area can therefore pose many unforeseen challenges, even with detailed geotechnical analysis being performed at project sites. A case in point is a construction site in Queens, New York. The proposed site development consisted of construction of a 4-story office building with a footprint of 18,000 ft2 (1672 m2) and a stand-alone 5-level parking garage with a footprint of 23,750 ft2 (2206 m2), together with associated new pavements and utilities. The site is bordered by a mix of commercial buildings and residential properties on all sides. Depth of the uncontrolled nature of the fill extended up to 20 ft (6.1 m) below street grade. Given the significant cost associated with removal and replacement, deep foundations were recommended to bypass the unsuitable soils and support the structures at depth where good bearing material existed.

Jan 1, 2019

By Mahdi Soudkhah, Akhter Hossain

Vertical micropiles are generally considered to be low in lateral resistance. Therefore, battered micropiles are often used when additional lateral load carrying capacity is required. However, battering of micropiles can sometimes be restricted due to existing adjacent structures or utilities, especially in highly urbanized areas. For example, presented in this paper are lateral load test data from a 43-story building project in New York City where vertical micropiles were used due to proximity to adjacent structures. Three static lateral load tests were conducted on micropiles consisting of 13.375-in-outside diameter and 25- to 51-ft-long casings, and socketed 10 to 12.6 ft into the bedrock (gneissic schist). The subsurface profile above the bedrock consists of loose to very dense, mostly sandy and silty soils. The design load for the three test piles was 14,000 lb and the maximum load applied during the tests was 200% of the design load. Lateral load- displacement behavior of the free pile heads from the load tests are compared with the results of p-y analyses based on a widely used p-y method for sandy soils and using a lower and an upper bound estimates of soil index properties and strength parameters. Since the existing p-y curves were formulated for larger diameter driven piles at a specific geographic location, major differences are observed between the results of the load tests and the p-y analyses. In general, the lateral displacements estimated based on the p-y analyses using upper bound soil parameters are relatively closer to the results of the field load testing. Modified p-y curves specific to the sandy and silty soils representative of the general subsurface conditions of New York City matched with the lateral load tests are presented in this paper. INTRODUCTION Micropiles generally are limited in lateral load carrying capacities due to their relatively higher slenderness ratios (ratio of depth to diameter) compared to more conventional deep foundation alternatives, such as driven piles and drilled shafts. So, micropiles are not typically considered as deep foundation solutions when significantly high lateral loads are expected on the substructures. Various means to increase the lateral resistance of micropiles include battering and installing an oversized casing in the top portion of the piles (FHWA 2005; and Richard and Rothbauer 2004). However, it is often not possible to install micropiles in a battered position in highly urbanized areas due to existing adjacent structures or utilities. Installation of oversized casing is often restricted by limited space availability and concerns of losing lateral capacities due to closely spaced group of piles. Thus, estimation of lateral resistance of vertical micropiles can become highly important for geotechnical engineering projects in urban areas when a small to moderate amount of lateral resistances are expected from the substructures, often to withstand seismic and wind loads.

Jan 1, 2019

By Ali Ebrahimi, Jeremy M. Gasser, Cuneyt Gokmen, Paul J. Sabatini, Roneet Das, William Tanner, Amir Ahmadipur

There are safety concerns related to operation of heavy equipment over coal combustion residual (CCR) impoundments during construction of the impoundment closure programs. As part of a pilot study prior to a full-scale closure construction, an access pathway and working platform were designed and constructed to facilitate equipment access for construction of deep soil mixing (DSM) zones on the ash delta of a CCR impoundment. The access pathway and working platform was constructed using shallow mass mixing with cement at the CCR surface to address safety concerns related to the geotechnical behavior of CCR. This paper describes the data from the instrumentation system which was implemented to monitor the geotechnical performance of the CCR during the pilot study. The instrumentation system included monitoring of the ground movement, vibration, and porewater pressure within the ash delta of the CCR impoundment during a pre-construction load testing, equipment mobilization over the access pathway, and DSM column installation over the working platform. INTRODUCTION A deep soil mixing (DSM) pilot study was conducted at a coal combustion residual (CCR) surface impoundment to evaluate mix designs and construction techniques for the regulatory closure. The DSM columns will create a wall which will separate and retain the CCR in a consolidated footprint separate from the closure by removal portion of the footprint and provide a barrier between the two areas of the surface impoundment. Historically, the surface impoundment received CCRs including fly ash, bottom ash, boiler slag, and gypsum, along with other byproducts produced from flue gas desulfurization (FGD). The predominant CCR in this impoundment were fly ash and bottom ash. The primary goals of the DSM pilot study were to assess the mix design strengths and to evaluate DSM construction techniques that could reach the design mixing depths of up to 90 ft. The DSM test columns were installed on the CCR delta approximately 500 ft from the nearest impoundment dikes. Another objective of the pilot study was to develop, construct, and monitor an access pathway for safe passage and movement of construction equipment on the CCR delta.

Jan 1, 2019

By Thomas D. Humbert, Christopher J. Ramsey

Construction of a new underground parking structure in State College, Pennsylvania, is situated on a site constrained by limited ROW and required excavations ranging in depth from 25 ft to 40 ft. Additional complications included busy surface streets, an active intersection, and numerous underground utilities that could not be disrupted by construction activities. To combat these challenges, an innovative approach for earth retention was designed that combined multiple types of retention systems. The overall system included alternating sections of soil nail walls and a hybrid system of soldier pile walls (consisting of micropiles) that were partially restrained by a soil nail wall in the lower portions of the excavation. Further, due to the limited space within the property limits that inhibited the length of the permanent nails, the wall design team collaborated with the project designers to develop a solution such that the completed wall became an integral part of the final design/construction of the underground parking structure. INTRODUCTION HERE at State College is a mixed-use, high-rise building in State College, Pennsylvania. The 12-strory building has up to 3 levels of below-grade parking, with the above-grade levels consisting of residential and commercial/retail space. The existing property was a parking lot bound by the streets Calder Way to the north, Garner Street to the east, East Beaver Avenue to the south, and Heister Street to the west. The overall property sloped approximately 20 ft in elevation from southeast to northwest. Excavation for the below-grade levels extended 21 ft to 36 ft (6.4 m to 11 m) below street level. During design-development phases of the project, it became evident that due to subsurface conditions and right-of- way limitations, conventional construction techniques would not be feasible. The full perimeter of the excavation would require earth retention including the weak shale bedrock along the bottom of the excavation. The project developer (CA Ventures) and general contractor (Brinkmann) coordinated with the specialty contractor and wall design engineer to find a solution. At this time, Coastal Drilling East (specialty contractor) and Wood Environment & Infrastructure Solutions (wall design engineer) became involved. The project developer and general contractor were aware they needed an earth retention system, but given the many variables the project faced, a single, straightforward solution would not work in this application.

Jan 1, 2019

By Chu E. Ho, Paul Napoli

This paper presents the performance of nineteen open-ended steel pipe piles driven through highly variable overburden soils into glacial till and schist bedrock. The piles were 16 inches in diameter and 0.656 inches thick, with yield strength of 50 ksi. The piles were designed for a service capacity of 250 kips and were driven to achieve an ultimate geotechnical capacity of at least 500 kips. Due to the large variation in the ground conditions, installed pile lengths ranged from 25 to 66 feet. Some piles were driven to refusal on the bedrock while others were terminated at final driving resistance of 2 to 7 blows/in. Two piles were suspected to be plugged during driving while others did not. Each pile was instrumented with strain gages and accelerometers near the pile top, and observed using a Pile Driving Analyzer (PDA) to provide preliminary guidance on pile capacity achieved at end of initial drive (EOID). The influence of plugged and unplugged pile toe conditions on the interpretation of pile capacity was investigated using Case Pile Wave Analysis Program (CAPWAP). Characteristics of driving energy, compressive and tensile stresses developed in the steel pipe piles, and the resulting pile deformation behavior are discussed. INTRODUCTION The Hunters Point South redevelopment in Long Island City, Queens is one of New York City’s major efforts to transform former manufacturing zones into mixed developments for the middle-income community. The site is located along the eastern shoreline of the East River and Newtown Creek. The development included low to high-rise residential buildings, a public school and retail structures. Open spaces were created along the East River and Newtown Creek waterfronts in the form of a continuous park providing for recreational and community related activities. Waterfront structures included small park buildings, walkways and viewing platforms with the shoreline protected by revetments as part of the City’s flood mitigation strategy. The project was implemented in two phases, with completion of construction for Phase 1 in 2013 and Phase 2 in 2019. Based on available historical information, extensive reclamation took place between 1855 and 1898. After 1951, changes to the shoreline were made along the East River, including the removal of reclaimed land along the northern portion of the project site to allow for docking facilities. By 1977, these facilities had been demolished and backfilled to form the current shoreline configuration. The present site was temporarily used as a parking lot with stockpiles of fill mixed with construction demolition rubble, rip-rap and boulders of varying heights across the site. The existing ground surface varied significantly up to approximately 25 feet difference in elevation. The stockpiles were removed and the site was re-graded during final development of the project. This paper discusses the foundation design challenges due to the loose overburden soils and potential obstructions within the fill material, in particular, the issues relating to installation of open-ended steel pipe piles through the ground conditions encountered on site.

Jan 1, 2019

By Yazen Khasawneh, Yao Zhang

Upgrading and maintenance programs were proposed at a power generating plant in Indiana. To perform construction activities associated with the proposed upgrading and maintenance, a LR11350 crawler crane with a dead load of 1,500 ton was required in the vicinity of existing plant structures. The contact pressure from the crane tracks for the heaviest lift, maximum reach and angle (worst loading condition) were estimated by the rigging engineer to be on the order of 84 psi. Several concerns were raised regarding the total and differential settlements while the crane is in operation and the induced stresses on existing underground utilities due to crane loads. Three-dimensional finite element simulations were conducted using hardening soil model for the subsurface soils and elastic model for the other structural elements (underground utilities and crane mats) to optimize the configuration of the proposed crane foundation. It was found 1-foot thick engineered steel mats underlain by a 1.5-foot thick crushed stone pad will provide enough support to the crane. It will also control the settlement to the allowable limit and maintain the stresses in the underground utilities within tolerance. INTRODUCTION A LR11350 heavy lift crawler crane was proposed as part of an upgrade program at an existing power plant in the state of Indiana. The proposed crane will be sitting on an open ground in the vicinity of existing plant facilities, with multiple underground utilities going beneath the proposed footprint of the new crane pad. The existing utilities are of diverse kinds, including sanitary sewer corrugated metal pipes, electrical conduits and variable steel water/oil drain pipes. The safety and functionality of these underground utilities are critical to maintain the proper operation of the power plant. Therefore, the design of the new crane pad foundation system is of essential to control the ground settlement and the imposed stresses to the existing utilities (Davie et al., 1998, Scott 2017). To ensure all utility locations and depths are identified, the proposed footprint was thoroughly surveyed. Information in regard to each identified utility was provided by the owner. Subsurface explorations were conducted using geotechnical soil borings and soundings to evaluate the ground conditions and generate soil profiles. Numerical simulation and analysis utilizing finite element method were performed to design the crane pad foundation system and evaluate the responses of the utilities. This paper summarizes project information, geotechnical conditions and then focuses on the finite element analysis in assisting the design of crane pad and the utilities evaluation.

Jan 1, 2019

By Zhang Wengang, L. John Endicott

The properties of many geological materials are variable. This is especially true for variations in elevation of the top of rock profile, strength of weathered rock, and conductivity of rock masses. Often the site investigation stage is completed by site specific ground investigation utilizing boring, sampling, and testing. Statistically this is a sampling procedure, but the borings are often widely spaced, and ground conditions between borings are deduced by interpolation. Often budgets are a limiting restraint and the information that is obtained may be less than desired. Sampling and testing is often biased. If claims for unforeseen ground conditions are to be avoided, the properties of the ground should be adequately identified. This paper describes how data can be used to evaluate the subsurface top of rock profiles, and can give insight into representative, maximum, and minimum strengths, and variation in conductivity relating to inflow of water into excavations, that can assist in planning the works and also in resolution, or avoidance, of disputes about unforeseen ground conditions. INTRODUCTION The mechanical properties of the ground are naturally variable. The work of Geologists, Engineering Geologists and Geotechnical Engineers is fundamentally investigative. Frequently, budgets for ground investigation are squeezed, resulting in widely spaced boreholes, with conditions between them determined by interpolation. Profiling can be adopted but the measurement, such as seismic velocity, is used as an indirect means of computing in-situ profiles and mass properties. Often a lot of test data are generated on large projects or by many projects in the same vicinity. Published data enlarge the database for a given project, and databases can be interrogated to gain insight into different categories of ground. Integration with geological studies can then lead to more reliable characterization of the ground in terms of identifying the materials present, their extent and their range of properties. This paper focuses on properties of rocks that are generally required for ground engineering, namely the top of rock profile, the unconfined strength of rock materials, and the mass conductivity. Data are obtained from Granodiorite and Granite in Hong Kong, and from Granite and the Jurong Series of weakly metamorphosed sedimentary rocks in Singapore. All four rock types have been tropically weathered, resulting in widely varying top of rock profiles, material strengths and mass conductivity. With a wide range in values for these parameters, project specific ground investigation conducted within a limited budget may run the risk of falling short of obtaining sufficiently reliable data sets, resulting in risk that unforeseen ground conditions may be encountered.

Jan 1, 2019

By Patrick J. Hannigan, Frank Rausche, Rozbeh B. Moghaddam

Large diameter open-end pipe piles are increasingly used as deep foundations to support heavy onshore and offshore structures. During the driving process, several factors such as subsurface conditions, hammer type, hammer efficiency, pile type, plug conditions, temporarily increased base resistance, and loss of shaft resistance have direct impact on the driveability of large diameter open-end pipe piles. In a uniform subsurface condition, the unit shaft resistance increases with depth. Consequently, more resistance is accumulated as piles penetrate to greater depths which results in higher driving resistance. However, according to the friction fatigue analysis, the greater the number of shearing cycles occurring on a soil segment along the pile shaft, the greater the reduction of its shear resistance. As a consequence, since upper soil layers are subjected to a greater number of blows than those at greater depths, they have a relatively lower resistance compared to what would be calculated with standard geotechnical analysis methods. As a result of this progressive and nonuniform loss of shaft resistance with driving, blowcounts tend to increase at a lower rate than expected from traditional analyses. This paper discusses one of the approaches to the driveability analysis with the geotechnical friction fatigue consideration. It also shows comparisons between predicted driveability obtained from wave equation analysis and field driving records. All analyses were performed for a 2.134 m (7.0 ft) diameter open-end pipe pile installed at a total depth of 192.90 m (554 ft). Two separate static resistance and wave equation analyses were completed for the case study presented in this paper: 1) Friction Fatigue analysis based on the recommendations of Alm and Hamre (2001), subsequently referred to as the FF model, and 2) Standard Driveability analysis based on soil set- up factors, hereafter referred to as the SD model in this paper. Results from analyses included the shaft resistance distributions compared to the result of the signal matching analyses determined from the pile dynamic measurement. Furthermore, predicted blowcounts were compared to observed blowcounts during the pile driving. The comparison analyses indicated a 54.4 percent resistance loss of the Static Resistance during Driving (SRD) due to the geotechnical friction fatigue corresponding to a 46 percent reduction in total resistance. The analyses also showed that average predicted blowcounts using the friction fatigue were 6.4 percent lower than measured blowcounts, whereas, the standard driveability approach showed 42.1 percent higher blowcounts compared to the blowcounts shown in the driving log values.

Jan 1, 2019