drilled shaft foundations for the cr #85 bridge · main bridge contract $1,522,000 prestressed box...

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Anthony J. Anthony J. Borrelli Borrelli , PE Stephen C. , PE Stephen C. Catherman Catherman , PE , PE Bergmann Associates Bergmann Associates Steuben County DPW Steuben County DPW Presented By: Drilled Shaft Foundations for the CR #85 Bridge Drilled Shaft Foundations for the CR #85 Bridge

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Page 1: Drilled Shaft Foundations for the CR #85 Bridge · Main bridge contract $1,522,000 Prestressed box beams $164,000 Temporary bridge $342,000 ... 6/1/05 – Construction begins. Project

Anthony J. Anthony J. BorrelliBorrelli, PE Stephen C. , PE Stephen C. CathermanCatherman, PE, PEBergmann AssociatesBergmann Associates Steuben County DPWSteuben County DPW

Presented By:

Drilled Shaft Foundations for the CR #85 BridgeDrilled Shaft Foundations for the CR #85 Bridge

Page 2: Drilled Shaft Foundations for the CR #85 Bridge · Main bridge contract $1,522,000 Prestressed box beams $164,000 Temporary bridge $342,000 ... 6/1/05 – Construction begins. Project

Project Overview

Locally-Administered, Federal-Aid Project w/ NYSDOT Region 6

Owner: Steuben County Department of Public Works

Engineer: Bergmann Associates with:Tierney Geotechnical Engineering

SJB Drilling

Page 3: Drilled Shaft Foundations for the CR #85 Bridge · Main bridge contract $1,522,000 Prestressed box beams $164,000 Temporary bridge $342,000 ... 6/1/05 – Construction begins. Project

Project Overview (continued)

Contractor: The L.C. Whitford Company

Box Beam Supplier: Schuylkill Products

Construction Costs:

Main bridge contract $1,522,000Prestressed box beams $164,000Temporary bridge $342,000Total cost $2,028,000

Page 4: Drilled Shaft Foundations for the CR #85 Bridge · Main bridge contract $1,522,000 Prestressed box beams $164,000 Temporary bridge $342,000 ... 6/1/05 – Construction begins. Project

Site Overview

CR #85

NYS Rte 417

Tuscarora Creek Stats:121 sq mi drainage area18,000 cfs peak flow 14 fps max. velocity

Page 5: Drilled Shaft Foundations for the CR #85 Bridge · Main bridge contract $1,522,000 Prestressed box beams $164,000 Temporary bridge $342,000 ... 6/1/05 – Construction begins. Project

Page 6: Drilled Shaft Foundations for the CR #85 Bridge · Main bridge contract $1,522,000 Prestressed box beams $164,000 Temporary bridge $342,000 ... 6/1/05 – Construction begins. Project

Project Timeline

9/11/04 – Bridge closed, detour set up

Page 7: Drilled Shaft Foundations for the CR #85 Bridge · Main bridge contract $1,522,000 Prestressed box beams $164,000 Temporary bridge $342,000 ... 6/1/05 – Construction begins. Project

Project Timeline

12/12/04 – Temporary bridge opens

Page 8: Drilled Shaft Foundations for the CR #85 Bridge · Main bridge contract $1,522,000 Prestressed box beams $164,000 Temporary bridge $342,000 ... 6/1/05 – Construction begins. Project

Project Timeline

6/1/05 – Construction begins

Page 9: Drilled Shaft Foundations for the CR #85 Bridge · Main bridge contract $1,522,000 Prestressed box beams $164,000 Temporary bridge $342,000 ... 6/1/05 – Construction begins. Project

Page 10: Drilled Shaft Foundations for the CR #85 Bridge · Main bridge contract $1,522,000 Prestressed box beams $164,000 Temporary bridge $342,000 ... 6/1/05 – Construction begins. Project

Project Timeline

11/18/05 – New bridge opened

Page 11: Drilled Shaft Foundations for the CR #85 Bridge · Main bridge contract $1,522,000 Prestressed box beams $164,000 Temporary bridge $342,000 ... 6/1/05 – Construction begins. Project

Page 12: Drilled Shaft Foundations for the CR #85 Bridge · Main bridge contract $1,522,000 Prestressed box beams $164,000 Temporary bridge $342,000 ... 6/1/05 – Construction begins. Project

Shaft Foundation Challenges:Construction diligence and expertise Specialized equipment Engineering expertise

Shaft Foundation ChallengesShaft Foundation Challenges::Construction diligence and expertise Construction diligence and expertise Specialized equipment Specialized equipment Engineering expertiseEngineering expertise

Shaft Foundation Advantages:Minimized shaft cap footprint Adaptable to varying geologyHigh lateral / axial capacity

Shaft Foundation AdvantagesShaft Foundation Advantages::Minimized shaft cap footprint Minimized shaft cap footprint Adaptable to varying geologyAdaptable to varying geologyHigh lateral / axial capacityHigh lateral / axial capacity

Page 13: Drilled Shaft Foundations for the CR #85 Bridge · Main bridge contract $1,522,000 Prestressed box beams $164,000 Temporary bridge $342,000 ... 6/1/05 – Construction begins. Project

Page 14: Drilled Shaft Foundations for the CR #85 Bridge · Main bridge contract $1,522,000 Prestressed box beams $164,000 Temporary bridge $342,000 ... 6/1/05 – Construction begins. Project

Page 15: Drilled Shaft Foundations for the CR #85 Bridge · Main bridge contract $1,522,000 Prestressed box beams $164,000 Temporary bridge $342,000 ... 6/1/05 – Construction begins. Project

Page 16: Drilled Shaft Foundations for the CR #85 Bridge · Main bridge contract $1,522,000 Prestressed box beams $164,000 Temporary bridge $342,000 ... 6/1/05 – Construction begins. Project

Shaft Reinforcement

Rebar cages constructed on stands

Page 17: Drilled Shaft Foundations for the CR #85 Bridge · Main bridge contract $1,522,000 Prestressed box beams $164,000 Temporary bridge $342,000 ... 6/1/05 – Construction begins. Project

Page 18: Drilled Shaft Foundations for the CR #85 Bridge · Main bridge contract $1,522,000 Prestressed box beams $164,000 Temporary bridge $342,000 ... 6/1/05 – Construction begins. Project

Page 19: Drilled Shaft Foundations for the CR #85 Bridge · Main bridge contract $1,522,000 Prestressed box beams $164,000 Temporary bridge $342,000 ... 6/1/05 – Construction begins. Project

Hinged-Gate Details

Page 20: Drilled Shaft Foundations for the CR #85 Bridge · Main bridge contract $1,522,000 Prestressed box beams $164,000 Temporary bridge $342,000 ... 6/1/05 – Construction begins. Project

Shaft Concrete

Tremie tube

Page 21: Drilled Shaft Foundations for the CR #85 Bridge · Main bridge contract $1,522,000 Prestressed box beams $164,000 Temporary bridge $342,000 ... 6/1/05 – Construction begins. Project

Page 22: Drilled Shaft Foundations for the CR #85 Bridge · Main bridge contract $1,522,000 Prestressed box beams $164,000 Temporary bridge $342,000 ... 6/1/05 – Construction begins. Project

Page 23: Drilled Shaft Foundations for the CR #85 Bridge · Main bridge contract $1,522,000 Prestressed box beams $164,000 Temporary bridge $342,000 ... 6/1/05 – Construction begins. Project

Page 24: Drilled Shaft Foundations for the CR #85 Bridge · Main bridge contract $1,522,000 Prestressed box beams $164,000 Temporary bridge $342,000 ... 6/1/05 – Construction begins. Project

Page 25: Drilled Shaft Foundations for the CR #85 Bridge · Main bridge contract $1,522,000 Prestressed box beams $164,000 Temporary bridge $342,000 ... 6/1/05 – Construction begins. Project

Validation of CSL ResultsCSL testing should not be sole basis for shaft rejection – false results can occur

Inspector reports & drill logs

Compressive strength tests

Additional test methods:

Angled CSL testCross-hole tomographyCoring

Page 26: Drilled Shaft Foundations for the CR #85 Bridge · Main bridge contract $1,522,000 Prestressed box beams $164,000 Temporary bridge $342,000 ... 6/1/05 – Construction begins. Project

Page 27: Drilled Shaft Foundations for the CR #85 Bridge · Main bridge contract $1,522,000 Prestressed box beams $164,000 Temporary bridge $342,000 ... 6/1/05 – Construction begins. Project

Defect Remediation Options

Refined analysis

Full scale load test

Abandon shaft & install new adjacent shaft

Install other adjacent foundation system

Structural grouting

Page 28: Drilled Shaft Foundations for the CR #85 Bridge · Main bridge contract $1,522,000 Prestressed box beams $164,000 Temporary bridge $342,000 ... 6/1/05 – Construction begins. Project

Footing Construction1:1.5 Slope

Page 29: Drilled Shaft Foundations for the CR #85 Bridge · Main bridge contract $1,522,000 Prestressed box beams $164,000 Temporary bridge $342,000 ... 6/1/05 – Construction begins. Project

Footing Construction

Page 30: Drilled Shaft Foundations for the CR #85 Bridge · Main bridge contract $1,522,000 Prestressed box beams $164,000 Temporary bridge $342,000 ... 6/1/05 – Construction begins. Project

Footing Reinforcement

Page 31: Drilled Shaft Foundations for the CR #85 Bridge · Main bridge contract $1,522,000 Prestressed box beams $164,000 Temporary bridge $342,000 ... 6/1/05 – Construction begins. Project

AbutmentConstruction

Page 32: Drilled Shaft Foundations for the CR #85 Bridge · Main bridge contract $1,522,000 Prestressed box beams $164,000 Temporary bridge $342,000 ... 6/1/05 – Construction begins. Project

AbutmentConstruction

Page 33: Drilled Shaft Foundations for the CR #85 Bridge · Main bridge contract $1,522,000 Prestressed box beams $164,000 Temporary bridge $342,000 ... 6/1/05 – Construction begins. Project

Box Beam Installation

Page 34: Drilled Shaft Foundations for the CR #85 Bridge · Main bridge contract $1,522,000 Prestressed box beams $164,000 Temporary bridge $342,000 ... 6/1/05 – Construction begins. Project

Deck Placement

Page 35: Drilled Shaft Foundations for the CR #85 Bridge · Main bridge contract $1,522,000 Prestressed box beams $164,000 Temporary bridge $342,000 ... 6/1/05 – Construction begins. Project

Finished Elevation

Page 36: Drilled Shaft Foundations for the CR #85 Bridge · Main bridge contract $1,522,000 Prestressed box beams $164,000 Temporary bridge $342,000 ... 6/1/05 – Construction begins. Project

Completed Bridge

Before After

Page 37: Drilled Shaft Foundations for the CR #85 Bridge · Main bridge contract $1,522,000 Prestressed box beams $164,000 Temporary bridge $342,000 ... 6/1/05 – Construction begins. Project

Lessons LearnedThe more subsurface information, the better

Specify a test shaft or installation sequence

Design with construction in mind

Careful contractor attention required for tremies

Engineer, inspector, contractor and owner must all understand shaft construction practices

Let the contractor select methods and equipment

Page 38: Drilled Shaft Foundations for the CR #85 Bridge · Main bridge contract $1,522,000 Prestressed box beams $164,000 Temporary bridge $342,000 ... 6/1/05 – Construction begins. Project

Types of Shaft DefectsBulge or neck in shaft

Non-homogeneous section: Sand lensSidewall cave-inVoids (esp. outside rebar cage)Excessive waterForeign materials

“Soft Toe”

Over consolidation

Off-location / out-of-plumb

Page 39: Drilled Shaft Foundations for the CR #85 Bridge · Main bridge contract $1,522,000 Prestressed box beams $164,000 Temporary bridge $342,000 ... 6/1/05 – Construction begins. Project

Page 40: Drilled Shaft Foundations for the CR #85 Bridge · Main bridge contract $1,522,000 Prestressed box beams $164,000 Temporary bridge $342,000 ... 6/1/05 – Construction begins. Project

Correct flaws if present in >50% of the profiles

Correct defects if present in 2 or more profiles

False results:

Damaged / unbonded tubesGreen concreteTube alignment

Interpreting CSL Results

Page 41: Drilled Shaft Foundations for the CR #85 Bridge · Main bridge contract $1,522,000 Prestressed box beams $164,000 Temporary bridge $342,000 ... 6/1/05 – Construction begins. Project

Quality Control Measures

Tight specification with proper tolerances

Thorough review of contractor submittals

Trial or technique shafts (not part of final structure)

Test shaft (production shaft)

Knowledgeable personnel

Proper concrete placement practices

Integrity testing

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