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Innovations in Geotechnical Engineering GSP 299 50

Highway Bridge Supported on ACIP Piles in Clay Soils: Instrumentation,


Monitoring and Performance of Service Piles

C. Vipulanandan1; K. Vembu2; and V. K. Gattu3


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1
Professor, Director of Center for Innovative Grouting Materials and Technology, and
Director of Texas Hurricane Center for Innovative Technology, Dept. of Civil and
Environmental Engineering, Univ. of Houston, Houston, TX 77204-4003. E-mail:
cvipulanandan@uh.edu
2
Project Engineer, Fugro Marine GeoServices, Inc., Houston, TX 77081. E-mail:
vkalaiarasi@gmail.com
3
Graduate Student, Center for Innovative Grouting Materials and Technology, Univ.
of Houston, Houston, TX 77204-4003. E-mail: vikhyathkumar.gattu@gmail.com

Abstract

In this study, supporting a state highway bridge with auger cast in-place
(ACIP) piles in clay soil replacing the drilled shafts that were used in the preliminary
design for supporting the bridge was investigated. Hence this study was a multi-phase
study where the design capacity of the ACIP pile had to be verified with many other
factors that control the rapid construction of the bridge. A full-scale load test was
performed to verify the constructability, axial capacity, and skin friction developed in
the ACIP pile supported in clay soil was investigated. The design load for the
760 mm (30 in.) pile was 1,150 kN (130 tons) but the test pile was loaded to 4,600 kN
(520 tons), four times the design load, and the settlement was 17 mm. In addition to
the full-scale load test, four (4) service piles were instrumented and monitored during
the initial 600 days in service. The load transfer in the service piles (skin friction and
tip resistance) were within the design relationships used in the design and was
compared to the load test data. The total load carried by the service piles increased
with time and varied from 523 to 754 kN (59–86 tons) and the range was 45–66% of
the design load of the ACIP pile. Vipulanandan models such as p-q model, pile
model, and three parameter correlation model were used to model the curing, the
performance of the test pile, skin resistance, tip resistance, and the time dependent
responses of the service piles.

INTRODUCTION

Based on the project type, loading conditions, geological features and available
resources, there are many options to select the supporting foundation systems. Non-
displacement augered cast-in-place (ACIP) piles are increasingly used for supporting
building, bridges, sound barrier walls and many other structures around the world

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(Neely, 1991; O’Neill, 1994; Vipulanandan, 2005). These piles have been used in the
private sector in the United States for over 50 years (O’Neill, 1999) and became very
popular in the early 1990’s because of the developments in the construction quality
control systems. Fast installation, low cost and minimum environmental impact are
some reasons for the tremendous growth in ACIP pile usage. ACIP piles can be
distinguished geotechnically from drilled shafts and driven piles by the magnitude of
effective stress changes they produce in the surrounding soil during the construction
(O’Neill, 1994). In an ACIP pile, depending on the soil type and rate of the auger
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advance, ground stresses are maintained near the value that existed before
construction by using a continuous flight auger, which is never withdrawn until the
cementitious material (fluid Portland cement grout) is placed by pumping the grout
beneath the withdrawing auger under pressure through the hollow stem of the auger
(Vipulanandan et al., 2005-2012). Therefore, considering the principle of effective
stress, the load-displacement behavior of the ACIP pile falls in between that of a
drilled shaft and a driven pile (O’Neill, 1999).
Load-displacement measured at the pile head provides the capacity of the pile but
gives no information on the load transfer mechanism which is shaft resistance
distribution and toe resistance separately. This information is needed in order to
design a safe and economical pile. Therefore, conventional pile load tests are being
instrumented more frequently to provide the load transfer along the pile.
Instrumenting the piles using vibrating wire strain gages is a preferred method
because of the durability and the accuracy of this type of gages. Vibrating wire strain
gages operate on the vibrating wire principle rather than the electric resistance
principle common to most strain gages (McRae and Simmonds, 1991). The vibrating
wire sister bars measures strain in a member by measuring the change in frequency of
a tensioned piano wire clamped in a fixture securely attached to the member. Strain
obtained from gages was then multiplied by the product of the equivalent elastic
modulus for the cross section and the nominal cross-sectional area to obtain load in
the pile at the depth of the strain gage. The load difference between levels gives the
amount of load carried in friction over the length at the pile-soil interface.
Instrumentation mainly provides the skin friction developments at each load
increment applied during a load test to verify the capacity of a pile. This information
can then be used to evaluate the design equations accuracy.

Every ACIP pile would become a “verified” pile (Brettmann, et. al. 2005),
since the construction quality was monitored using the automated monitoring system
where the volume of the grout pumped and the pressures are monitored with the
depth. One of the main concerns when using ACIP piles is the possibility of
decompression of the soil surrounding the pile during drilling. Controlling the rate of
penetration of the auger will avoid decompression of the ground, loosening of the in-
situ soil, and ground subsidence (Brown, 2005).

OBJECTIVES
The overall objective was to monitor the performance of newly constructed
ACIP piles in clay soils supporting a highway bridge. The specific objectives were as
follows:

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(i) Instrument and monitor the performance of four service piles supporting the
highway bridge along the length of the bridge for 600 days.

(ii) Compare the performance of the four service piles to the load tested pile on
site.

The four ACIP piles selected for monitoring along the bridge crossing the Cohino
Bayou is shown in Fig, 1.
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Highway Bridge
Cohino Bayou

Pile S

Pile R

Pile Q

Pile P

Figure 1. The Four ACIP Service Piles (P, Q, R & S) Along the Highway Bridge
Selected for Monitoring

SITE INFORMATION

In order to understand the behavior of substructures supporting transportation


facilities, it was critical to instrument and monitor there performance over a period of
600 days. This study was focused on verification the design capacity of ACIP piles
based on instrumentation and monitoring. The first phase of the study included a full-
scale load test not only to verify the constructability, axial capacity and skin friction
developed in the ACIP pile based on the construction method used in the clay soil but
the earliest time it could be loaded. The earliest time to carry the load by the ACIP
piles would also control the rapid construction of the bridge and the supporting
structures.

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Soil Borings

The bridge site consists of a mixed soil profile of generally soft to stiff clays
and loose sands. Two soil borings were performed to design the ACIP piles and the
typical soil profile with the Texas Cone Penetrometer (TCP) readings is shown in Fig.
2. In this borehole, the top 3 m (10 ft) layer consists of loose gravelly sand, under laid
by a very stiff clay layer. Stiff clay layer was observed below the depth of 8.5 m
(27.5 ft). Test pile was 12 m (39.1 ft) long with almost 5.5 m (18 ft) long part was
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socketed into this stiff clay layer. Figure 2 shows the schematic view of the
instrumentation and geotechnical profile.

LOAD TEST

The conventional load-deformation measured at the pile head during a full-


scale load test establishes the capacity of pile, but it does not give quantitative
information on the load-transfer behavior over the length of pile. Hence,
instrumentation and monitoring of the test pile plays an important role in
understanding the load transfer mechanisms and curing of the grout in the ACIP pile
so that it can be loaded. This paper discusses not only the instrumentation of 760 mm
(30 in.) diameter and 12 m (39 ft) long test ACIP pile supported on hard clay but also
eight reaction piles used to provide adequate reaction capacity. The test pile was
instrumented with a load cell at the top with head settlement gauges, in order to
measure the applied load and settlement during the load test. Also, vibrating-wire
sister bars with thermocouple were attached along the length of the test pile and
selected reaction piles. Also in the test pile vibrating-wire sister bars were placed
horizontally to quantify the lateral deformation of the pile during loading and
determine the curing of the grout in the middle of the pile. The load distribution
along the length of the test piles and reaction pile were determined from the strain
measured with the sister bars. Strain values were measured using the vibrating wire
gages at four levels along the test pile and three levels along the reaction piles. The
design load for the pile was 120 tons.

The test pile was instrumented with a top load cell and settlement gauges, in
order to measure the applied load and settlement during the load test. Before
installing the test pile, the reinforcing cage for the pile was instrumented with
vibrating wire sister bar. Vibrating wire sister bars with thermocouples are essentially
strain gauges that operate on the vibrating wire principle rather than the electric
resistance principle common to most strain gauges. The vibrating wire sister bars
measures strain in a member by measuring the change in frequency of a tensioned
piano wire clamped in a fixture securely attached to the member (McRae and
Simmonds, 1991). The gauges provide values of strain which was multiplied by the
cross sectional area and the elastic modulus of the pile to find the transferred load at
each level. Vibrating wire strain gage were attached at four levels (Figure 2) along
the length of the test piles and three levels along the reaction piles. In addition two
strain gages were installed in the lateral direction to quantify the lateral deformation
during loading and determine the curing of the grout in the middle of the pile.

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TCP
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Figure 2. Geotechnical Profile and Instrumentation of the Service Piles

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The full-scale axial load test was performed in general accordance with
ASTM D1143, “Standard Method of Testing Piles under Static Axial Compression
load” to better characterize the behavior of ACIP piles under axial loading. Eight
reaction piles (RP, 457 mm in diameter and 12 m long) were used for ACIP pile (Test
Pile, TP)load test to provide adequate reactive capacity. Figure 3 shows the
schematic view of load test set up.
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Figure 3. Schematic View of Load Test Set up

The test pile was loaded in 180 kN increments up to 4600 kN and unloaded in
four equal steps. The pile was loaded more than four times the design load of 1150
kN. The deflection at the design load was less than 2 mm and the maximum
deflection measured was 17 mm at the final load of 4600 kN and the residual
displacement after unloading was 9.7 mm after unloading. The load settlement curve
of the test pile is shown in Fig. 4. The ultimate capacity of the pile was estimated to
be 5916 kN (667 tons) based on the pile-displacement property correlation model in
Eqn. (1) (Vipulanandan, 2005).

Figure 4. Load-Settlement Relationship for the ACIP Test Pile

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(Q/Qult) = (ρ/d)/( (ρ50/d)+(ρ/d)) …….…………………………. (1)


………………………………………..

Where Q is the load and Qult is the ultimate load at very large settlement. The
settlement is  and 50 is the settlement at 50% of the ultimate load. The loading
model prediction using Eqn. (1) and the parameters summarized in Table 1 is shown
Fig. 4.
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Table 1. Summary of the Pile Load-Displacement Relationship Parameters

Description Qult(kN) d(mm) 50(mm) RMSE


Test Pile 5916 760 6.4 25.3

When unloading from test load Q* and settlement * the model used to predict the
relationship is as follows (Eqn. (2)):

(Q/Q*) = ((ρ-ρo)/ρ*)/A’-(B’(ρ-ρO)/ρ*) …………………………………(2)

The loading model prediction using Eqn. (1) and the parameters summarized in Table
2 is shown Fig. 4.

Table 2. Summary of the Pile Unloading Displacement Relationship Parameters

Description Q* (kN) ρO(mm) ρ*(mm) A’ B’


Test Pile 4610 9.7 17.0 1 1.28

BRIDGE CONSTRUCTION AND INSTRUMENTION

The highway bridge across the Cohino Bayou was supported on 24 ACIP piles
as shown in Fig. 5. The four service piles were selected along the bridge length based
on the accessibility to monitor, understand the edge effects in a bridge supporting
foundation system and effects due to changing environmental conditions. The four
service piles (identified as P, Q, R and S) were instrumented for monitoring the piles
during the first 600 days of service. The instrumentation consisted of vibrating wire
strain gages placed at three levels, vertically and one level in the middle, laterally
(Fig. 2). The lateral vibrating wire strain gage will not only give the lateral
deformation of the piles but also temperature in the middle of the pile during the
curing and during the monitoring time period. The curing of the services piles was
similar to the test pile.

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SERVICE PILES MONITORING

Curing and Environmental Effect


The four service piles were monitored during the initial 600 days of curing.
The patterns of the temperature variation within the four piles were very similar to the
test pile, where the average time to reach the maximum temperature was 9.4 hours.
Typical time-temperature relationship for the service pile is shown in Fig. 6. The
maximum average temperature measured was 63˚C. The maximum temperature
measured was over 45˚C higher than the surrounding ground temperature.
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Test Pile

Figure 5. The Layout Highway Bridge with the Supporting ACIP Piles

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Temperature with time was modeled using the Vipulanandan p-q curing
model using Eqn. (3) (Vipulanandan et al. 1990, 2015) and the prediction is compared
to the experimental results in Fig. 6. Integration of this curve with time will give the
maturity.
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Figure 6. Measured and Predicted Curing of the Pile

The p-q curing model is as follows:

 
 t 
 tp 
T  T
 ( pq)
 p
 t   p
 (3)
 t 
 q1  (1  p  q) t  p t  
 p  p 

where p, q are material parameters, Tp and tp represent the peak temperature and the
corresponding time respectively. In this case the parameter “q” was 0.8 and the
parameter p was 0.2.
In Fig. 7, the variation of temperature in the four service piles is compared to
the environmental temperature fluctuations. The minimum atmospheric temperature
fluctuated from 1.9oC to 23.3oC during the monitoring period. The maximum
atmospheric temperature fluctuated from 16.7oC to 36.1oC during the monitoring
period.

Performance of the Service Piles


As shown in Fig. 7, the temperature in the pile reached a stable value of 18oC
and remained unchanged during the time period of monitoring. The atmospheric
fluctuations in the temperature didn’t affect the temperature in the piles.

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Pile P: The variation of axial strain and lateral strain in the pile is shown in Fig. 8(a).
Of all the service piles monitored, Pile P had the highest axial strain at the top of the
pile. Hence Pile P carried the maximum axial load 754 kN (Fig. 9), 66% of the design
load of the ACIP pile. The variation of the pile load with time was predicted using the
two parameter Vipulanandan correlation model (1993, 2016) represented in Eqn. (4).
The lateral tensile strain increased with time and the maximum strain measured at the
middle of the pile was 36 microstrain.
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Pile Q: The variation of axial strain and lateral strain in the pile is shown in Fig. 8(b).
The axial strain at the top of the pile was about 40 macrostrain. Hence Pile Q carried
a maximum axial load of 541 kN (Fig. 9), 47% of the design load of the ACIP pile.
The variation of the pile load with time was predicted using the two parameter
Vipulanandan correlation model (1993, 2016) represented in Eqn. (4). The lateral
tensile strain increased with time and the maximum strain measured at the middle of
the pile was 22 microstrain.

Pile R: The variation of axial strain and lateral strain in the pile is shown in Fig. 8(c).
Of all the service piles monitored, Pile R showed the highest lateral strain of 57 micro
strain in the middle of the pile. Hence Pile R carried the maximum axial load of 648
kN (Fig. 9), 56% of the design load of the ACIP pile. The variation of the pile load
with time was predicted using the two parameter Vipulanandan correlation model
(1993, 2016) represented in Eqn. (4).

Pile S: The variation of axial strain and lateral strain in the pile is shown in Fig. 8(d).
Of all the service piles monitored, Pile S showed the lowest axial strain at the top of
the pile. Hence Pile S carried a maximum axial load of 523 kN (Fig. 9), 45% of the
design load of the ACIP pile. The variation of the pile load with time was predicted
using the two parameter Vipulanandan correlation model (1993, 2016) represented in
Eqn. (4).

Figure 7. Variation of Atmospheric Temperature and Curing Pile Temperature


with Time

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The loading variation with time was using the Vipulanandan two parameter
correlation model (Vipulanandan et al. 1993, 2016) and is represented as follows:

Q(t)= t/(A + Bt) ……………………………………(4)


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Figure 8. Axial and Lateral Strains Measured in the Service Piles (a) Pile P (b)
Pile Q (c) Pile R and (d) Pile S

Figure 9. Measured and Predicted Axial Load with Time

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Table 3. Summary of the Pile Loading Model Parameters


Pile Q(t) (kN) A (day/kN) B (1/kN)
P 754 0.22 0.00095
Q 541 0.05 0.0018
R 648 0.25 0.0011
S 523 0.25 0.0015
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The predictions are compared to the experimental results in Fig.9 and the model
parameters are summarized in Table 3.

SERVICE PILES PERFORMANCE COMPARED TO THE LOAD TEST PILE

The load transfers in the service piles were monitored and compared to the
load transfer in the test pile. In Fig. 10, load transfer after 589 days for the four
service piles are compared. The skin resistances developed in the service piles are
compared to the load test pile in Fig. 11 (a) and 11(b). The tip resistances developed
in the four service piles are compared to the test piles in Fig. 12 (a) and 12(b). The
total load carried by each service pile is compared to the load test pile in Fig. 13(a)
and 13(b).

Figure 10. Load transfer Along the Depth of the Service Piles

Table 4. Summary of the Performance of the Service Piles


Pile Highest Skin Tip % of the Pile Total Settlement
Resistance Resistance Loading (mm)
(kPa) (kPa)
P 22.6 750 45 1.1
Q 21.0 600 50 0.8
R 23.2 500 39 0.9
S 4.2 1100 95 0.7

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Pile P: As shown in Fig. 11 (b), Pile P developed the highest skin resistance of 22.6
kN/m2 compared to all the other piles at the top part of the pile. The lateral strain was
higher than the load test pile (Fig. 14) due to long-term loading in the pile resulting in
concrete creep in the pile. The tip loading was 750 kN/m2, representing 45% of the
pile loading. Based on the load-settlement relationship, the estimated total settlement
in the pile was 1.1 mm.

Pile Q: As shown in Fig. 11 (b), Pile Q developed a skin resistance of 21.0 kN/m2 in
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the bottom part of the pile. The lateral strain was higher than the load test pile (Fig.
14) due to long-term loading in the pile resulting in creep. The tip loading was 600
kN/m2, representing 50% of the pile loading. Based on the load-settlement
relationship, the estimated total settlement in the pile was 0.8 mm.

Figure 11. Measured and Predicted Skin Frictions Compared with Service Piles

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Pile R: As shown in Fig. 11 (b), Pile R developed the highest skin resistance of 23.2
kN/m2 in the bottom part of the pile. The lateral strain was higher than the load test
pile (Fig. 14) due to long-term sustained loading in the pile resulting in concrete
creep. The tip loading was 550 kN/m2, representing 39% of the pile loading. Based on
the load-settlement relationship, the estimated total settlement in the pile was 0.9 mm.

Pile S: As shown in Fig. 11 (b), Pile S developed 4.2 kN/m2 skin resistance on the top
part and compared to all the other piles had very low skin resistance in bottom part of
the pile. The tip loading was 1100 kN/m2, representing 95% of the pile loading.
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Based on the load-settlement relationship, the estimated total settlement in the pile
was 0.7 mm.

Figure 12. Measured and Predicted Tip Resistances Compared with Service Piles

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The skin friction (fs) variation with displacement () using the Vipulanandan
three parameter correlation model and is represented as follows:

(fs/fu) = (ρ/d)/(A + B(ρ/d)) ……………………………………….(5)

Where fu is the ultimate skin friction. The predictions are compared to the
experimental results in Fig.11 and the model parameters are summarized in Table 5.
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Table 5. Summary of the Pile Skin Friction Model Parameters

Pile fu(kN/m2) ρ50(mm) d(mm) A B R2 RMSE


Top 80 3.3 762 0.0028 1.0 0.98 5.8
Bottom 175 3.54 762 0.00475 1.0 0.99 8.2

The tip resistance (qt) variation with displacement () using the Vipulanandan
three parameter correlation model and is represented as follows:

(qb/qu) = (ρ/d)/(C + D(ρ/d)) …………………………………………....(6)

Where qu is the ultimate tip resistance. The predictions are compared to the
experimental results in Figs.12, 13 and 14 and the model parameters are summarized
in Table 6.

Table 6. Summary of the Pile Tip Resistance Model Parameters

Description qu(kN/m2) ρ50(mm) d(mm) C D R2 RMSE


Test Pile 3800 4.28 762 0.0081 1.0 0.99 91.4

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Figure 13. Measured and Predicted Load-Displacement Compared with Service Piles.

Figure 14. Measured Axial and Lateral Strains Compared with Service Piles.

CONCLUSIONS

Based on the instrumentation and monitoring of the full-scale load test and the
performance of the 760 mm diameter ACIP service piles for 600 days in clay soils
following conclusion are advanced:

1. Monitoring the curing of the grout not only helped in determining the quality
of the pile but also to decide on the earliest time the pile could be loaded. All
the ACIP piles that were monitored showed complete curing in 7 days.

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2. Based on the full-scale load test, it was determined that when the pile was
loaded to the design load of 1150 kN the settlement was about 2 mm. The
settlement was 17 mm at a load of 4600 kN, four times the design load. With
the instrumentation of the piles it was possible to quantify the skin and tip
load transfers in the test pile and service piles.
3. The service piles were loaded to a maximum of 66% of the design load. Long
term monitoring of the instrumented service piles showed that the load
transfer behavior were within the design relationships used in the design.
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4. The performance of all the ACIP service piles monitored during this study
was acceptable.
5. Vipulanandan models such as p-q model, pile model and property correlation
model were used to predict the curing, performance of the load tested pile,
skin friction, tip resistance and time dependent performance of the service
piles.

ACKNOWLEDGEMENT

This study was supported by the Center for Innovative Grouting Materials and
Technology (CIGMAT) with funding from the Texas Department of Transportation.
The sponsor is not responsible for any of the conclusions made in this study.

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