CASE STUDY: DESIGN, INSTALLATION AND QUALITY ASSURANCE TESTING OF HIGH

CAPACITY SOCKETED PILES IN A COMPLEX GEOLOGIC ENVIRONMENT

Thomas M. Caruso, TRC Engineers, Inc., Mount Laurel, New Jersey, USA
Melissa L. Gillespie, TRC Engineers, Inc., Mount Laurel, New Jersey, USA
Craig H. Olson, TRC Engineers, Inc., Mount Laurel, New Jersey, USA

Construction of a new ship dock at a major Philadelphia area refinery required

geotechnical design and field consultation. The new dock, which consists of a system of
mooring dolphins and platforms, will be capable of docking the Stena V-MAX Oil Tanker
(V-MAX). The 1100 ft long V-MAX is currently the largest tanker to travel the Delaware
River and will induce significant lateral loads on the new ship dock. Lateral loads
induced on the dock will be resisted by over 200 pipe piles installed on a batter. The piles
used for support of the dock included 20 and 30 in. diameter reinforced, concrete filled
pipe piles. Complete construction of each pile included driving of the pile to the design
ultimate capacity, flushing the pipe pile casing clean of overburden materials followed by
drilling rock sockets into the underlying Wissahickon Formation. Variations in depth to
bedrock, rock quality and degree of weathering and presence of very hard quartzite
lenses created a complex geologic environment that presented challenges for the
pile/rock socket design and installation. The design of the pile system, installation
methods, QA/QC and testing (Pile Dynamic Analysis), as well as the challenges that
were encountered through the duration of the project are presented and discussed.

BACKGROUND batter angles so as to transmit these lateral

TRC Engineers, Inc. was retained as the
geotechnical consultant for the design of a New
Ship Dock at a refinery located on the Delaware
River in Trainer, PA. TRC also performed field
construction quality assurance activities for this
project [including construction oversight and Pile
Dynamic Analysis (PDA) for driven piles], and
TRC geotechnical design engineers provided
consultation services during the course of
construction.
The need for a New Ship Dock (NSD) was due
to the load demands of larger oil tankers that will
be docking at this refinery in the future.
Specifically, the NSD was designed to dock the
Stena V-MAX Oil Tanker (V-MAX), which is
currently the largest tanker to travel the
Delaware River.
The New Ship dock consists of a series of
mooring dolphins and breasting cells supported
on steel pipe piles with either drilled rock
sockets or H-pile stingers. The mooring
dolphins and breasting cells will be subjected to
very high lateral loads. The most prevalent
overburden material encountered at the site
consists of very soft river sediments (primarily
silt). Due to the fact that the river sediments
provide a relatively low resistance to deflection
under lateral loading, the piles were installed at
loads as axial loads (tension and compression).
In compression, piles readily obtain required toe
capacity from the underlying rock material. In
tension, however, the shaft resistance generated
from the river sediments is marginal. Therefore,
rock anchor installation below the tip of the pipe
piles, or driving of steel H-pile stinger section
into the underlying bedrock was required. This
paper includes a brief discussion of rock anchor
design. Its focus is on installation and QA/QC
procedures implemented during construction
and associated challenges resulting from site
geologic conditions.
REGIONAL GEOLOGY
The project site is located on the Atlantic
Coastal Plain Physiographic Province,
approximately 5 to 10 miles southeast of the Fall
Line, which is the physiographic / geologic
boundary between the crystalline rock
formations of the Piedmont Province and the
sediments of the Atlantic Coastal Plain Province.
The area in the project vicinity is underlain by
recent river deposits of sand, silt, clay, and
gravel which overly metamorphic rock of the
Wissahickon formation. Rock of the
Wissahickon formation is a heterogeneous
regional unit of schists, gneisses, and phyllites.
The general rock type found in the project area
is mica schist. Predominant mineralogy of this
mica schist consists of quartz, muscovite, biotite,
feldspar, and chlorite. Weathering profiles in the
mica schist tend to be highly irregular.
The site is also located near the contact of the
Wissahichon Formation with the Trenton Gravel
Formation. The Trenton Gravel formation is
generally a gray to pale reddish-brown, very
gravelly sand.
SITE SUBSURFACE CONDITIONS
A total of 26 test borings were drilled for this
project. Subsurface conditions encountered at
the site consisted primarily of alluvial deposits of
silts underlain by sand and gravel, residual soil
resulting from in-place weathering of the parent
rock (very dense portions referred to as
decomposed mica schist herein), and mica
schist bedrock varying from severely weathered
to slightly to moderately weathered, and with
occasional interbedded quartzite.
The presence, consistency and thickness of
alluvial and residual overburden materials were
highly variable across the site. Furthermore,
there was no identifiable trend associated with
the location or thicknesses of severely
weathered and slightly to moderately weathered
rock types. The severely weathered and slightly
to moderately weathered rock was found to be
inter-layered. Quartzite seams of variable
thickness, weathering and hardness were also
encountered within the mica schist at
approximately half of the test borings advanced
for this project. At two test boring locations,
approximately 10 to 12 ft of decomposed mica
schist was encountered below a 2 to 5 ft “ledge”
of weathered mica schist. This relatively wide
distribution of rock quality is not unusual for the
Wissahickon formation. Figures 1a and 1b
illustrate the variability in subsurface conditions
encountered at the project site. Figures 2, 3 and
4 illustrate the variability in rock recovery (REC),
rock quality designation (RQD) and unconfined
compressive strength (UC) with depth.
SUMMARY OF ROCK SOCKET DESIGN
As indicated above the large lateral loads to be
imposed on the NSD are to be resisted by
groups of battered piles. Maximum anticipated
pile compression and uplift loads are on the
order of 150 to 250 kips per pile. Anticipated
compression loads could be achieved in/on the
mica schist bedrock encountered at the site
using several pile alternatives. However, based
on consideration for the relatively large uplift
loads anticipated for this project and the extreme
variability in the presence and consistency of
overburden soils at the site, driven pipe piles
with rock anchors were selected for support of
the NSD.
From a geotechnical perspective, the rock
anchor design included consideration for the
length required to resist failure along the rock-
grout interface and the length required to
mobilize a sufficient mass of rock to support the
applied load. Multiple calculations were
performed for each component of the proposed
NSD based on the following items:
• The range of possible subsurface conditions
to be encountered based on available test
boring information.
• Anticipated pile loading conditions.
• Potential group effects based on anticipated
pile configurations.
Based on the results of analyses performed for
this project, total required rock anchor lengths
(severely and moderately to slightly weathered
rock) were on the order of 25 to 35 ft, with a
minimum of 15 to 25 ft being in moderately to
slightly weathered rock. In all cases, the length
of rock anchor required for mobilization of a
sufficient mass of rock to support the applied
load, including consideration for group effects,
was the controlling factor in the design.
SUMMARY OF CONSTRUCTION PHASE
ACTIVITIES
Construction of the NSD was performed in two
separate phases. Phase 1 rock anchor
construction generally encountered relatively
favorable rock conditions, consisting of
decomposed and weathered mica schist
throughout the length of the rock socket.
However, highly variable and often problematic
soil and rock conditions were encountered
during Phase 2 construction. Figure 5 presents
a schematic of the ship dock construction areas.
Because the intent of this paper is to discuss
complications related to complex geologic
conditions, the proceeding sections focus on
Phase 2 rock anchor construction.
Figure 1a and 1b – Generalized Subsurface Profile between Main Dock Structure and Bravo Dolphin (see
Figure 5)

1a – Borings Outshore of Mooring Dolphins

Mean Low Water – Elev. 0.0

Downriver Upriver

2
?
3
4 ?

1b – Borings Inshore of Mooring Dolphins

Mean Low Water – Elev. 0.0

Downriver Upriver

3
1a

2
3 4
4

Strata Definitions:
1 – Alluvial SILT
1a – Alluvial SAND and GRAVEL
2 – Decomposed MICA SCHIST
3 – Highly Weathered MICA SCHIST
4 – Slightly to Moderately Weathered MICA SCHIST with interbedded QUARTZITE
Figure 2 – Distribution of REC vs Depth from ROCK ANCHOR CONSTRUCTION
Test Boring Data
Prior to rock anchor construction, an open-end
REC 24 in. diameter, steel pipe pile with 0.5 in. wall
0 20 40 60 80 100
thickness was driven to the required capacity at
40
each of the rock anchor location using an ICE I-
50 46. Capacities of all piles driven were verified
using Pile Dynamic Analysis (PDA). It was
60
expected that the majority of the pipe piles were
Depth (ft)

70 installed through the dense decomposed rock to

80
the top of the intact, weathered rock surface.
However, some exceptions to this assumption,
90 determined through observations during rock
100 anchor construction, are discussed below.
110
Drilling of 15 in. and 17 in. diameter rock sockets
was performed using an alternative drilling
method to that generally used for this type of
Figure 3 – Distribution of RQD vs Depth from construction. Typically, rock sockets are
Test Boring Data advanced using conventional rotary drilling
equipment, whereby the drill string is assembled
RQD in segments as the drilling progresses. For this
0 20 40 60 80 100
project, individual drilling rod sections were
40
connected into one continuous 110 ft section
50 with a Hammerdrill XL 12 down-the-hole
hammer at the bottom of the rods. Torque was
60
applied to the hammer/drill rod system using an
Depth (ft)

70 ICE 35AT auto-torque top drive auger.

Compressed air, used to operate both the auto-
80
torque top drive auger and the down-the-hole
90 hammer, was injected through the top of the drill
rod. The 110 ft hammer/drill rod system traveled
100
up and down tracks inside swinging leads
110 through the permanent steel casings
constructed of 24 in. diameter pipe piles.

The majority of the overburden materials within

Figure 4 – Distribution of Unconfined the pipe pile casing were removed during
Compressive Strength (UC) vs Depth from advancement of the drill hammer through the
Laboratory Test Data pile. This was accomplished through
UC (tsf) continuously pumping water into the pile casing.
0 500 1000 1500 The drilling operations created turbulent
40 conditions within the casing, loosening the
overburden materials adhering to the pile walls.
50
As the pneumatic hammer was periodically lifted
60 from the rock surface, compressed air was
forced down through the drill bit and up through
Depth (ft)

70
the pile. This movement of compressed air
80 thrust water, overburden materials, and drill
cuttings from within the pipe pile casing and was
90 effective in removing most overburden materials
100
for both the 15 and 17 in. diameter rock sockets.
Additionally, upon completion of socket drilling
110 and immediately prior to rock socket grouting,
overburden materials that remained within the
Figure 5 – Schematic of Ship Dock Construction Areas
pipe pile or that had sloughed into the rock
socket were removed via a suction system
developed by the Contractor. After removal of
soil materials, a 2.5 in. diameter continuously
threaded steel bar and associated structural
components were installed through the entire
length of the uncased rock anchor and inner
diameter steel casing. The piles were then
tremie grouted using ready mix grout.
VERIFICATION OF ROCK CONDITIONS
Due to the variability of the quality of the rock
underlying the project site, accurate assessment
of rock conditions encountered during rock
anchor installation, namely determining the
extent of weathering/decomposition or
competency of the rock material through which
each rock anchor was installed, was a critical
part of the quality assurance process. Precise
methods of determining rock quality during
drilling were not available; therefore, field
representatives relied on the information
obtained from the test borings and observations
made during rock anchor drilling in order to
confirm that design requirements were satisfied
at each rock anchor location. The two most
important observations made in assessing rock
conditions encountered included observations of
hammer penetration rate during drilling and
observations of the characteristics of rock
cuttings expelled during drilling.
Penetration rates of the equipment were
monitored and recorded as the rock socket was
advanced through apparent decomposed,
weathered, and competent rock strata. This was
accomplished by marking the drill rod at five foot
intervals and measuring the elapsed time for
advancement of each of the intervals (or portion
of an interval). A decrease in hammer
penetration rate during drilling was generally
associated with an increase in rock quality.
The characteristics of the rock cuttings expelled
during drilling were also monitored for
assessment of rock quality. Cuttings expelled
during drilling through apparent decomposed
rock material were generally very soft. Although
the color and “fabric” of the material expelled
resembled that of the underlying parent bedrock,
the consistency of these materials was similar to
that of a “stiff” / “dense” soil (i.e., a lump of silty
and/or clayey sand) with only small quantities of
brittle rock fragments. Cuttings observed during
drilling through severely weathered rock were
generally stronger and harder than those
observed within decomposed rock; however, the
majority of the rock fragments could be broken
manually. Cuttings expelled during drilling
through more competent rock were primarily
hard, strong mica schist rock fragments that
could not be broken manually and also
appeared to indicate the presence of quartzitic
and gneissic rock materials. Generally, the size,
or equivalent diameter, of the cuttings appeared
to decrease with increasing rock quality.
Another “secondary” observation used to verify
rock quality included monitoring of the behavior
of the hammer during the course of rock socket
drilling. This included observations of the sound
of the rock hammer during drilling and the
frequency of blows from the pneumatic hammer
during drilling. During drilling through
decomposed and severely weathered rock, the
hammer produced a dull sound against the
underlying rock material, and there were
intervals where hammer firing stopped
momentarily. During drilling through higher
quality rock material, the hammer produced a
louder sound and continuous drilling. These
observations were especially useful in identifying
the transition zone between decomposed and
weathered rock material, and identifying
decomposed rock seams that existed within
higher quality rock material. However, these
“secondary” observations could not be used to
further distinguish between the severely
weathered and moderately to slightly weathered
rock. This was due to the fact that these
observations did not vary significantly within the
more intact weathered rock material.
Observations regarding hammer penetration
rates, hammer behavior and performance, and
characteristics of cuttings, as described above,
were compared with the test boring data in order
to establish criteria to be applied in assessing
rock quality throughout the project. For the
majority of the rock sockets drilled, observations
made during socket drilling remained relatively
consistent. The rock hammer generally began
to “fire” in the “dense to very dense” plug within
the lower portion of the pile casing. The
penetration rate of the drill was observed to vary
from less than 0.5 to 1.0 minute per ft through
this material. Observations of cuttings expelled
from within the pile during drilling through the
plug were indicative of decomposed rock
material. Penetration rates generally decreased
once the hammer reached the bottom of the pile,
and again at the transition from severely
weathered to moderately to slightly weathered
rock. After careful consideration of the above-
mentioned construction observations and data
from test borings closest to the drilling locations,
the following general criteria were established
for evaluation of rock quality for this project:
y Penetration rates ranging from less than 0.5
to 1 minute per ft, with soil-like cuttings are
indicative of decomposed rock.
y Penetration rates from 1 to 2 minutes per ft,
with rock fragments of varying strength and
hardness are indicative of decomposed to
severely weathered rock.
y Penetration rates of above 2 minutes per ft
are indicative of competent (slightly to
moderately weathered) rock, provided that
cuttings are primarily observed to be strong,
hard rock fragments.
Field personnel were in communication with
design engineers throughout the course of
construction. Decisions regarding the need for
modifications to minimum required rock socket
lengths were efficiently made on case-by-case
basis depending on actual conditions
encountered at each pile location.
COMPLICATIONS ENCOUNTERED DURING
CONSTRUCTION
Increased Penetration Rate
As indicated above, penetration rates, hammer
behavior and performance, and observations of
cuttings were carefully monitored through the
course of rock anchor drilling.
The above criteria were developed based on
initial observations during drilling, primarily
through mica schist bedrock. However, as
previously indicated, the rock formation contains
quartzite inclusions. Observed drilling
penetration rates were greatly affected by the
presence of the much harder quartzite rock.
This was first observed during drilling at the first
mooring dolphin upriver of the main dock
structure (see Figure 1). During initial drilling,
the penetration rates and cutting observations
appeared consistent with the criteria indicated
above. However, at varying depths below the
bottom of the pile, the penetration rate
decreased to approximately 10 minutes per ft to
up to 45 minutes per ft. Cuttings expelled during
drilling appeared to be white, coarse sand to fine
gravel sized, hard rock fragments, indicative of
quartzite. The quartzite at these locations
persisted for approximately 2 to 10 ft, with a total
drill time within the quartzite of up to 5 hours.
Similar observations were noted at several other
upriver mooring dolphin locations during drilling
within the quartzite zones. The increased
amount of time required for completion of the
rock anchors in this area became of significant
concern, especially when considering the overall
project schedule.
A minor enhancement was made to the drilling
equipment in an attempt to increase drill
penetration rates. This enhancement included
increasing air pressure of the compressor used
to drive the pneumatic hammer. The goal was
to increase the frequency of repetitions of the
rock hammer on the underlying rock material.
Increasing air pressure was not observed to
have any significant impact on drilling
penetration rates. After discussion with the
Contractor, project Geotechnical Engineers re-
evaluated the rock anchor design to determine if
a 15 in. diameter rock socket would be viable
from a geotechnical perspective. This was
thought to be a potentially viable solution
because a smaller hammer operating under the
same weight of drill rod and air pressure, would
exert a greater amount of energy and pressure
on a smaller rock surface area, thereby
increasing production drilling rates. Upon re-
evaluation, it was concluded that because the
design was not governed by the bond shear
strength along the rock-grout interface, a
reduction of rock socket diameter to 15 in. would
not compromise the rock anchor tension
capacity from a geotechnical perspective. At the
direction of the General Contractor, in
conjunction the Structural Engineer, the size of
the rock hammer was reduced to 15 in.
diameter. The reduction in socket diameter was
effective in increasing penetration rates,
especially during drilling through zones of
quartzite material. Penetration rates through
quartzite using the smaller diameter hammer
were observed at no greater than 10 minutes
per ft, as opposed to up to 45 minutes per ft
during drilling with the 17 in. diameter rock
hammer.
Socket Cave-In
As previously discussed, it was anticipated that
the 24 in. diameter pipe piles were driven though
alluvial river sediments and dense decomposed
rock to the top of the competent weathered rock
surface. Based on this assumption, the potential
for caving of overburden materials into the
socket zone at the location of the pile tip was
believed to be minimal due to the tight seal that
would be created by the decomposed rock
materials. However, during rock socket drilling
at the Bravo Dolphin, the rock hammer and drill
rod appeared to “jam” at a depth of 10 ft below
the bottom of the socket. Due to the observed
jamming, the Contractor attempted to lift the drill
rod and hammer from within the socket. Lifting
of the drill rod/hammer was observed to
encounter a substantial amount of resistance.
Once raised above the socket zone, the
Contractor attempted to set the drill rod/hammer
system back in the excavation; however, it could
not be lowered beyond the tip of the pile
(approximately 10 ft above the depth previously
drilled). Furthermore, large cobble to gravel
sized rocks were observed to be expelled from
within the pile during re-advancement of the
rod/hammer system. During the second attempt
at drilling, the drill rod/hammer again became
locked within the socket zone. The drilling rods
were subsequently detached from the crane
leads and the drill rod/hammer system removed
using a vibratory hammer. Rock anchor drilling
at this was temporarily abandoned and anchor
drilling continued at the next scheduled location.
The driven depth of the temporarily abandoned
pile location was evaluated with respect to the
information from the closest test borings. Due to
the fact that the pile was installed on batter
angles of 2V to 1H, the tip of the pipe pile
extended a horizontal distance of approximately
20 ft (in the inshore direction) from the top of the
pile. The borings located closest to the vertical
surface projection of the pile tip encountered an
approximately 5 ft thick layer of alluvial gravel
and cobbles with varying quantities of sand
(likely an intrusion of the Trenton Gravel
Formation, predominant on the New Jersey side
of the Delaware River). This gravel and cobble
layer was encountered at an approximate
elevation that corresponded with the tip
elevation of the pile of concern. It was
concluded that during driving of the pipe pile at
this location, the pile achieved the required
capacity within the gravel and cobble layer.
While this layer was able to provide adequate
bearing resistance, it did not provide the sealing
affect that was provided by penetration into
decomposed rock material. Once the socket
drill hammer was advanced past the pile tip, this
gravelly material was no longer confined and
was readily washed into the socket zone under
hydrostatic pressure. After discussion of
possible remediation schemes between TRC
and the General Contractor, the Contractor
attempted to stabilize the breached area by
pumping a flowable grout mixture through tremie
tubes advanced to a location near the tip of the
pipe pile. However, re-drilling at this location
was unsuccessful as the hammer continued to
become lodged at a depth of 5 ft below the tip of
the pile. At the direction of the General
Contractor, the pile was spliced with an
additional 15 ft section and re-driven to a depth
that corresponded to the depth of the weathered
rock surface indicated on the borings. Socket
drilling was then completed at this location
without further complications.
Pile Damage at Bravo Dolphin
As indicated, PDA testing was performed on all
piles driven during Phase 2 construction. PDA
provides close estimates of pile capacities,
determined in real-time (during driving). PDA is
also advantageous in monitoring stresses at the
top and bottom of the pile, evaluating hammer
efficiency, and detecting damage to the pile
during driving.
As mentioned above, the presence of the
quartzite was problematic across the project
site. During the initial driving operations for one
of the Bravo piles, the PDA recorded observable
signs of impedance changes in the pile at
approximately 3 feet from the pile toe. The pile
was removed and damage was verified at the
pile toe as illustrated in Photo 1.
Photo 1 - Pile Damage at Bravo Dolphin
The pile was re-driven without PDA monitoring
to a final driving resistance of 10 blows per inch
and was successfully drilled out for a rock
socket in subsequent construction operations. It
is the opinion of TRC that the pile encountered a
hard quartzite layer which created local stress
concentrations that caused the pile damage.
Pile Damage at the Main Dock Structure
During rock socket drilling at one of the Main
Dock Structure (MDS) piles, the drill hammer
was observed to encounter refusal to further
advancement at a depth that corresponded to
the tip of the pipe pile. Several attempts were
made at drilling past this depth, however, all
attempts were unsuccessful. Upon review of the
PDA data, indications of impedance change
were observed in several of the blow records at
approximately 2 ft above the pile toe. This
impedance change is illustrated in Figure 6.
Figure 6 – Impedance Change Observed in
Blow Record during PDA at the MDS
Impedance change at
2 feet from toe.
Upon recommendation, the pile was extracted
and the extent of the damage is shown in Photo
2.
Photo 2 - Pile Damage at MDS
Based on observations of the damage, TRC
concluded that pile damage was likely caused
by steel and timber obstructions that had been
part of the old ship dock.
In both cases, the occurrence of pile damage
was correctly predicted based on review of PDA
data; the piles were subsequently extracted and
successfully re-driven. In these cases, the use
of the PDA to obtain real time QA data helped
construction-phase personnel take a proactive
approach to identifying and mitigating potential
problems encountered during pile installation,
thereby preventing situations that could
potentially cause significant delays during rock
anchor drilling and also the potential for damage
of the drilling equipment. As a result, increased
PDA testing frequency was critical to keep the
project on schedule considering the problematic
nature of the highly variable rock formation
encountered at the site.
OBSERVATIONS AND CONCLUSIONS
Complex geologic conditions were encountered
at the site of a proposed new ship dock (NSD)
located along the Delaware River in Trainer,
Pennsylvania. The presence, consistency and
thickness of alluvial and residual overburden
materials were highly variable across the site, as
was the location and quality of site bedrock.
Bedrock encountered at the site, predominantly
mica schist of the Wissahickon Formation,
exhibited varying degrees of weathering and
hardness. There was no identifiable trend
associated with the location or thicknesses of
highly weathered zones, which were often inter-
layered with more intact rock. Additionally,
quartzite seams of variable thickness,
weathering and hardness were also
encountered within the mica schist. This
relatively wide distribution of rock quality is not
unusual for the Wissahickon Formation. These
complex geologic conditions encountered at the
site created challenges for design and
construction of foundation support systems for
the ship dock.
Based on consideration for the relatively large
uplift loads anticipated for this project and the
extreme variability in the subsurface conditions
encountered at the site, driven pipe piles with
rock anchors were selected for support of the
NSD. From a geotechnical perspective, the rock
anchor design included consideration for the
length required to resist failure along the rock-
grout interface and the length required to
mobilize a sufficient mass of rock to support the
applied load. Multiple calculations were required
to account for the range of possible subsurface
conditions that might be encountered across the
site; anticipated pile loading conditions for each
component of the NSD; and potential group
effects based on anticipated pile configurations
for each component of the NSD. Total required
rock anchor lengths (including severely and
moderately to slightly weathered rock) were on
the order of 25 to 35 ft, with a minimum of 15 to
25 ft required in moderately to slightly weathered
rock. In all cases, the length of rock anchor
required for mobilization of a sufficient mass of
rock to support the applied load, including
consideration for group effects, was the
controlling factor in the design.
Construction quality control is an essential
aspect of every project; however, the geologic
environment in which foundations for this project
were to be installed highlighted the importance
of quality control activities. Observations
regarding hammer penetration rates, hammer
behavior and performance and characteristics of
cuttings expelled as excavations for rock
anchors were advanced, were used in
conjunction with the test boring data to establish
general criteria to be applied in assessing rock
quality throughout the project. The rock hammer
generally began to “fire” in the “dense to very
dense” plug within the lower portion of the pile
casing. Penetration rates were slowest through
this material and generally increased once the
hammer reached the bottom of the pile, and
again at the transition from severely weathered
to moderately to slightly weathered rock. The
following general criteria to were established
and used to evaluate rock quality for this project:
y Penetration rates ranging from less than 0.5
to 1 minute per ft, with soil-like cuttings are
indicative of decomposed rock.
y Penetration rates from 1 to 2 minutes per ft,
with rock fragments of varying strength and
hardness are indicative of decomposed to
severely weathered rock.
y Penetration rates of above 2 minutes per ft
are indicative of competent (slightly to
moderately weathered) rock, provided that
cuttings are primarily observed to be strong,
hard rock fragments.
This information was also used to assess the
need for modifications to minimum required rock
socket lengths on a case-by-case basis
considering actual conditions encountered at
each pile location.
Construction of the NSD was performed in two
separate phases. The first phase of rock anchor
construction progressed without notable difficulty
or delays. However, highly variable and often
problematic soil and rock conditions were
encountered during the second phase of
construction. Complications included extremely
slow drilling penetration rates at times, cave-in
of alluvial overburden materials into the rock
socket zone, and pile damage that was
prohibitive of rock anchor construction.
Interaction and collaboration between field
inspection personnel, design engineers, and
contractor representatives allowed for exchange
of ideas and timely decision-making with regard
to approaches for remediation of problematic
conditions. This minimized disruption to the
overall project schedule and provided valuable
insight for consideration on future projects of a
similar nature.
Use of PDA as a QA tool was also beneficial on
this project because it allowed for prediction of
pile damage. This pile damage would not have
otherwise been realized until problems were
encountered during rock socket drilling
operations. Attempting to advance rock drilling
equipment through the damaged pile section
could also have resulted in damage to drilling
equipment. The additional time spent during
unsuccessful rock socket drilling and/or damage
to rock drilling equipment would have been very
costly and would have resulted in significant
impacts to the overall project schedule.