TH 53 Bridge, artistic rendering courtesy of MnDOT
The official groundbreaking for the Trunk Highway (TH) 53 Bridge and Relocation Project occurred last week at the project site in Virginia, Minnesota. The bridge, which is the main element of the project, will span the Rouchleau Iron Ore Mine Pit. The project is scheduled to be completed in a brisk two years in order to allow for mining where a section of TH 53 is currently located. Upon completion the 1,100-foot long bridge will be Minnesota’s highest, with the roadway sitting approximately 330 feet above the bottom of the floor of the Rouchleau Pit. Kiewit was selected as the general contractor for the project with Veit Specialty Contracting as the foundation contractor.
Foundation construction will start in late November or early December with the installation of 30-inch diameter micropile foundations for the western pier of the three span, steel plate girder bridge. Although the foundation work is just about to get started, DBA has been hard at work on the project for over a year. DBA first got involved as a consultant to MnDOT for the design-phase load test program conducted last fall. Since then, DBA was contracted as the geotechnical engineer of record for the project. Working with bridge designer Parsons, DBA designed the bridge foundations, an anchored abutment, and rockfall hazard mitigation systems for this geologically challenging site. DBA has also analyzed several soil and rock slopes to verify stability of the bridge and roadway.
Most recently, some of us were on site to inspect some of the rockfall protection elements on the east side of the mine pit. Last week we spent two days climbing and repelling a on a portion of the eastern highwall, which is currently covered in rockfall protection drapery. The drapery was installed for the protection of workers excavating rock for the eastern bridge pier. The drapery was installed by Pacific Blasting in association with Hoover Construction. Some pictures from our drapery inspection visit are below.
For more information about the project, click here, and for our previous blog posts on this project, click here.
John and Paul provide some scale to this picture as they work their way down the drapery.
John concentrating as he inspects the drapery seam as he decends.
The Transportation Research Board (TRB) has released a synthesis report prepared by Dan and Robert on large diameter piles: NCHRP Synthesis 478, Design and Load Testing of Large Diameter Open-Ended Driven Piles. The report is a summary of the state of practice with regard to Large Diameter Open-Ended Piles (LDOEPs) in the transportation industry. We conducted a survey of state DOTs as well as interviews with private practitioners to summarize current practices as well as recommend best practices with regard to the selection, design, installation, and testing of LDOEPs. Several state DOTs are using LDOEPs more regularly where large foundation loads may exist and/or the piles are subject to significant unsupported length due to scour, liquefaction, or very weak surficial soils. Marine construction conditions also favor the use of these piles, particularly where pile bents might be employed to eliminate footings.
You can download a PDF of the report or purchase a hard copy at the link below.
Last spring, DBA conducted a construction phase load test program for a U.S. Army Corps of Engineers floodwall improvement project along the Missouri River in Kansas City, Kansas. Located on property owned and maintained by the Kansas City Board of Public Utilities (BPU), the BPU floodwall was slated for structural improvements including a series of buttresses founded on 24-in drilled shafts. As part of the project contract a load test program performed under the direction of a qualified P.E. and D.GE was required. General contractor L.G. Barcus & Sons, Inc., secured our Paul Axtell, P.E., D.GE as the qualified load test expert. DBA teamed up with load testing subcontractor Applied Foundation Testing, Inc., to perform the static load tests.
The load test program requirements included three test shafts, a statically loaded axial test shaft, a statically loaded lateral test shaft, and a combined statically loaded axial and lateral test shaft. The required combined lateral and axial test shaft provided some unique challenges with respect to applying the loads and collecting data. As can be seen in the picture above, the axial load was applied using dead weights.
We have added selected pictures from this unique project to our web albums, which can be viewed here.
Cover Image of the Hastings Mississippi River Arch Bridge
The featured article in the July/August 2013 issue of Deep Foundations, the magazine of the Deep Foundations Institute, is coauthored by Dan, Paul, and Rich Lamb, P.E., of the Minnesota Department of Transportation (MnDOT). The article summarizes how load testing has been used successfully as part of the foundation design process by DBA and MnDOT on five major bridge projects along the Mississippi and St. Croix Rivers during the last 10 years and the lessons learned from these successive projects. The featured bridge projects include two major design-build projects, the emergency replacement of the I-35W St. Anthony Falls Bridge (2007) and the Hastings Mississippi River Arch Bridge (2011). The other traditional design-bid-build projects include the I-494 Wakota Mississippi River Bridge, the U.S. Hwy 52 Lafayette Mississippi River Bridge, and the St Croix River Bridge. As is often the case, each of these projects presented unique geological and hydrogeological challenges to foundation design – despite the projects all being within 30 miles of each other – including thick layers of highly organic compressible soils overlying bedrock, layers of cobbles and boulders, artesian groundwater conditions, and bedrock ranging from weak weathered sandstone to very hard dolostone. These varying conditions resulted in the use and testing of a variety of foundations. Load testing “with a purpose” has proven to be an integral part of the design and construction process on these projects, as the load tests were not simply for verification of a design but provided valuable information used to optimize the designs and provide quality assurance of the construction practices.
Please read the full article here or in a copy of Deep Foundations, a bi-monthly magazine published by the Deep Foundations Institute. DFI is an international technical association of firms and individuals involved in the deep foundations and related industry. More information about DFI and how to become a member can be found at www.dfi.org.
Also see our Projects Page for more about some of these projects and our other major projects.
Earlier this week, officials from the Minnesota and Wisconsin departments of transportation (MnDOT and WisDOT) met for an official groundbreaking ceremony on the projected $629 million bridge and highway project that will connect Oak Park Heights, Minnesota, to St. Joseph, Wisconsin, just south of Stillwater, Minnesota, as highlighted in yesterday’s edition of The Minneapolis St. Paul Business Journal. The new bridge will replace the 80-year-old Stillwater Lift Bridge and relieve traffic congestion in nearby Stillwater.
DBA has been retained by MnDOT as the lead geotechnical consultant and foundation designer for the extradosed river bridge. Last summer, DBA aided MnDOT in the design and oversight of a load test program described in my blog post, “DBA Wraps Up Load Test Program and Proceeds with Design on St. Croix Bridge.” Following final design, which took place over the fall and winter, construction of the foundations will begin next week with the installation of a technique shaft. DBA will participate in construction as well, providing construction observation and review of the technique shaft and at least one shaft at each of the five production piers. Edward Kraemer & Sons, Inc. of Plain, Wisconsin, has been selected as the general contractor for the foundation contract with sub-contractor Case Foundation Company of Chicago, Illinois, performing the drilling. The extradosed bridge will feature five main river towers, each resting on two footings supported by a 4-shaft group of 8.5-foot drilled shafts, socketed 25-feet or more into sandstone bedrock.
I hope to have some more updates soon with some pictures following my upcoming site visits to observe the construction operations. In the mean time, you can stay updated by visiting the MnDOT project page and watching the “action” live via the construction webcam.
In the course of digging throughout the internet for data and information for a couple of projects, I came across some (relatively) recent research reports geared toward improving design of driven piles based on field testing. A report from The Illinois Center for Transportation at the University of Illinois at Urbana-Champaign is focused on improving pile design through increased resistance factors and nominal bearing values. A project by the Institute for Transportation at Iowa State University focuses on developing LRFD design procedures for steel piles in Iowa. It was published in two volumes, with Volume I covering the development of LRFD calibrations and a load test database, and Volume II covering field load tests performed for the project.
I have not had time to dig into them yet, so I just offer the links and abstracts to pique your curiosity. Perhaps you may find something interesting in them, or maybe something applicable to a project. There is a lot of research going on out there for TRB and NHI, so I figure sharing interesting tidbits helps get things circulated.
Click on the name of each of the research centers above to find out what other things they are doing, available reports, etc.
Dynamic pile testing and one static load test was performed in accordance with ICT project R27-69, “Improved Design for Driven Piles Based on a Pile Load Test Program in Illinois.” The objectives of this project are to (1) increase the maximum nominal required bearing that designers can specify to reduce the number and/or weight of piles, (2) decrease the difference between estimated and driven pile lengths to reduce cutoffs and splice lengths by development of local bias factors for predictive methods used in design, (3) increase reliance of pile setup to increase the factored resistance available to designers, (4) reduce the risk of pile driving damage during construction, and (5) increase the resistance factor (decrease in factor of safety) based on increased data and confidence from load tests in and near Illinois. Project deliverables can be categorized as (1) better prediction methods for stresses during driving, (2) better prediction methods for pile capacities using resistance factors for driven piling based on local calibrations that consider the effects of pile setups, and (3) collections of static and dynamic load test data focused on Illinois soils and geology.
For well over 100 years, the Working Stress Design (WSD) approach has been the traditional basis for geotechnical design with regard to settlements or failure conditions. However, considerable effort has been put forth over the past couple of decades in relation to the adoption of the Load and Resistance Factor Design (LRFD) approach into geotechnical design. With the goal of producing engineered designs with consistent levels of reliability, the Federal Highway Administration (FHWA) issued a policy memorandum on June 28, 2000, requiring all new bridges initiated after October 1, 2007, to be designed according to the LRFD approach. Likewise, regionally calibrated LRFD resistance factors were permitted by the American Association of State Highway and Transportation Officials (AASHTO) to improve the economy of bridge foundation elements. Thus, projects TR-573, TR-583 and TR-584 were undertaken by a research team at Iowa State University’s Bridge Engineering Center with the goal of developing resistance factors for pile design using available pile static load test data. To accomplish this goal, the available data were first analyzed for reliability and then placed in a newly designed relational database management system termed PIle LOad Tests (PILOT), to which this first volume of the final report for project TR-573 is dedicated. PILOT is an amalgamated, electronic source of information consisting of both static and dynamic data for pile load tests conducted in the State of Iowa. The database, which includes historical data on pile load tests dating back to 1966, is intended for use in the establishment of LRFD resistance factors for design and construction control of driven pile foundations in Iowa. Although a considerable amount of geotechnical and pile load test data is available in literature as well as in various State Department of Transportation files, PILOT is one of the first regional databases to be exclusively used in the development of LRFD resistance factors for the design and construction control of driven pile foundations. Currently providing an electronically organized assimilation of geotechnical and pile load test data for 274 piles of various types (e.g., steel H-shaped, timber, pipe, Monotube, and concrete), PILOT (http://srg.cce.iastate.edu/lrfd/) is on par with such familiar national databases used in the calibration of LRFD resistance factors for pile foundations as the FHWA’s Deep Foundation Load Test Database. By narrowing geographical boundaries while maintaining a high number of pile load tests, PILOT exemplifies a model for effective regional LRFD calibration procedures.
In response to the mandate on Load and Resistance Factor Design (LRFD) implementations by the Federal Highway Administration (FHWA) on all new bridge projects initiated after October 1, 2007, the Iowa Highway Research Board (IHRB) sponsored these research projects to develop regional LRFD recommendations. The LRFD development was performed using the Iowa Department of Transportation (DOT) Pile Load Test database (PILOT). To increase the data points for LRFD development, develop LRFD recommendations for dynamic methods, and validate the results of LRFD calibration, 10 full-scale field tests on the most commonly used steel H-piles (e.g., HP 10 x 42) were conducted throughout Iowa. Detailed in situ soil investigations were carried out, push-in pressure cells were installed, and laboratory soil tests were performed. Pile responses during driving, at the end of driving (EOD), and at re-strikes were monitored using the Pile Driving Analyzer (PDA), following with the CAse Pile Wave Analysis Program (CAPWAP) analysis. The hammer blow counts were recorded for Wave Equation Analysis Program (WEAP) and dynamic formulas. Static load tests (SLTs) were performed and the pile capacities were determined based on the Davisson’s criteria. The extensive experimental research studies generated important data for analytical and computational investigations. The SLT measured loaddisplacements were compared with the simulated results obtained using a model of the TZPILE program and using the modified borehole shear test method. Two analytical pile setup quantification methods, in terms of soil properties, were developed and validated. A new calibration procedure was developed to incorporate pile setup into LRFD
Here is a blast from the past on pile groups: NCHRP Report 461 – Static and Dynamic Lateral Loading of Pile Groups. I had a request for this report recently, so I found it and figured we needed to post the links to it. Dan was the lead researcher on this report during his time at Auburn University, and had an all-star line up that included Dr. Mike O’Neill and Dr. Mike McVay, two of the heavy hitters in foundation engineering. The report introduction gives a good summary of the contents:
A key concern of bridge engineers is the design and performance of pile group foundations under lateral loading events,
such as ship or ice impacts and earthquakes. This report documents a research program in which the following were developed:
(1) a numerical model to simulate static and dynamic lateral loading of pile groups, including structural and soil hysteresis and energy dissipation through radiation; (2) an analytical soil model for nonlinear unit soil response against piles (i.e., p-y curves) for dynamic loading and simple factors (i.e., p-multipliers) to permit their use in modeling groups of piles; (3) experimental data obtained through static and dynamic testing of large-scale pile groups in various soil profiles; and (4) preliminary recommendations for expressions for p-y curves, damping factors, and p-multipliers for analysis of laterally loaded pile groups for design purposes. The report also describes experimental equipment for performing site-specific, static, and dynamic lateral load tests on pile groups.
Several full-scale field tests were conducted on pile groups of 6 to 12 piles, both bored and driven, in relatively soft cohesive and cohesionless soils. All of the groups were loaded laterally statically to relatively large deflections, and groups of instrumented pipe piles were also loaded dynamically to large deflections, equivalent to deflections that might be suffered in major ship impact and seismic events. Dynamic loading was provided by a series of impulses of increasing magnitude using a horizontally mounted Statnamic device.
For a relatively short (50 pages) report, there is a lot of information packed into it gleaned from a lot of full-scale field work.
Lateral Statnamic test, picture by David Graham of DBA, click here for a YouTube video
DBA has been selected by MnDOT as a geotechnical and load testing consultant for the design phase load test program and foundation design of a new bridge crossing the the St. Croix River near Oak Park Heights and Stillwater, Minnesota. The new bridge will carry State Highway 36 across the St. Croix River between Minnesota and Wisconsin. Currently, Highway 36 is carried on an 80-year old two-lane vertical lift bridge in downtown Stillwater. The new bridge will divert the heavy through traffic away from the historic downtown center and reduce travel time for commuters. The iconic lift bridge will be converted to a pedestrian and bicycle only structure.
Work began this summer on the load test program which consisted of one 8-foot test shaft, two 24-inch driven steel pipe piles, and two 42-inch driven steel pipe piles, all installed in the St. Croix River along the alignment of the new bridge. Local contractor Carl Bolander & Sons Co. was selected as the general contractor for the load testing program. Bolander self-performed the installation of the test piles and sub-contracted the construction of the test shaft to Case Foundation Company, of Chicago, Illinois. Axial load testing of the test shaft was performed by Loadtest, Inc., of Gainesville, Florida, using Osterberg Cells (O-cells). Dynamic testing of the driven piles using the pile driving analyzer (PDA) was performed by local geotechnical consultant Braun Intertec. Axial testing of the driven piles and lateral testing of the shaft and one of each size pile was performed using the Statnamic Device by Applied Foundation Testing, Inc. (AFT), of Jacksonville, Florida. DBA provided pre-test recommendations, assisted MnDOT in construction oversight, provided analysis and review of the test results, and made design recommendations based on the test results.
Following the successful load test program, DBA is working with MnDOT’s structural design consultants for the project, HDR, Inc. and Buckland & Taylor Ltd. to optimize the bridge design. Already, the design team has been able to lengthen the bridge spans and eliminate a river pier as a result of the load test results, as was recently reported by Minnesota Public Radio (MPR). Also, because the total number of drilled shafts required to support the main pier towers has been reduced, construction on the foundations will been moved up to 2013 rather than the original estimated start date in 2014, also reported by MPR.
The months of September and October will be busy for several DBA team members speaking at a variety of conferences and events. Dan Brown and John Turner will be speaking at the ADSC/DFIDrilled Shaft Seminar and Field Day in Denver September 12 and 13. Dan will be giving the 4th Annual Osterberg Memorial Lecture at the DFI Educational Trust dinner being held on the evening of the 12th. Dan and John will be speaking mostly on construction issues during the seminar.
Later in the month, Dan and Robert Thompson are both featured at the 2012 Midwest Geotechnical Conference hosted by Ohio DOT in Columbus, Ohio. Dan will be speaking on base grouted shafts while Robert will give his presentation on the ADSC SE Chapter rock socket load test research program.