Spun Cast Piles in Florida

plantcitybusinessUrban and Civil

Nov 26, 2013 (3 years and 22 days ago)

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FLORIDA DEPARTMENT OF TRANSPORTATION

STATE CONSTRUCTION OFFICE

Industrial Concrete Products (ICP)
Spun Cast Piles in Florida

2011 FDOT/FTBA CONSTRUCTION CONFERENCE


Rodney Chamberlain, P.E.

Construction Structures Engineer

2011 FDOT/FTBA CONSTRUCTION CONFERENCE

ICP Piles


What Are They?


Spun

Cast

Cylinder

Piles



Prestressed

Sections



Weldable

Splice

Plate

Cast
-
In



Made

in

Malaysia



FLORIDA DEPARTMENT OF TRANSPORTATION
-

STATE CONSTRUCTION OFFICE

2011 FDOT/FTBA CONSTRUCTION CONFERENCE

ICP Piles versus Index 20654 Piles


Spun

cast

cylinder

piles



Pre
-
tensioned

Sections



Weldable

Splice

Plate

Cast
-
In



Sections

lengths

are

made

to

order



FLORIDA DEPARTMENT OF TRANSPORTATION
-

STATE CONSTRUCTION OFFICE

ICP

Piles

Index

20654

Piles


Vertically

cast

in

a

static

form



Reinforced

Concrete

Sections



Sections

are

spliced

by

post
-
tensioning



Generally

made

in

16
ft

sections



2011 FDOT/FTBA CONSTRUCTION CONFERENCE

ICP Piles


FDOT Approval


Component

acceptance

through

strength

testing



Meet

driveability

requirements

in

Section

455



Meet

domestically
-
produced

steel

requirements

(
23

CFR

635
.
410
)



Quality

Control

Plan

approved

by

the

State

Materials

Office



FLORIDA DEPARTMENT OF TRANSPORTATION
-

STATE CONSTRUCTION OFFICE

2010 FDOT/FTBA CONSTRUCTION CONFERENCE

FLORIDA DEPARTMENT OF TRANSPORTATION
-

STATE CONSTRUCTION OFFICE

ICP Pile Strength Testing


Testing

conducted

at

the

Structural

Research

Center

in

Tallahassee,

FL



Flexural

strength

testing

of

the

pile



Flexural

strength

testing

of

the

splice



Report

is

available

online

at

the

Structures

Design

Office

website



2010 FDOT/FTBA CONSTRUCTION CONFERENCE

FLORIDA DEPARTMENT OF TRANSPORTATION
-

STATE CONSTRUCTION OFFICE

ICP Pile Driving Demonstration

2011 FDOT/FTBA CONSTRUCTION CONFERENCE


State

Road

79

near

Vernon,

FL

in

District

3



Drive

one

out
-
of
-
position

pile



Drive

pile

in

two

49
ft

sections

to

test

constructability

of

splice



Drive

pile

to

practical

refusal
;

overstress

pile



FLORIDA DEPARTMENT OF TRANSPORTATION
-

STATE CONSTRUCTION OFFICE

ICP Pile Driving Demonstration

Details of the Test

2010 FDOT/FTBA CONSTRUCTION CONFERENCE

FLORIDA DEPARTMENT OF TRANSPORTATION
-

STATE CONSTRUCTION OFFICE

ICP Pile Driving Demonstration

Bottom Section of Test Pile

2010 FDOT/FTBA CONSTRUCTION CONFERENCE

FLORIDA DEPARTMENT OF TRANSPORTATION
-

STATE CONSTRUCTION OFFICE

ICP Pile Driving Demonstration

Splicing Top and Bottom Sections

2010 FDOT/FTBA CONSTRUCTION CONFERENCE

FLORIDA DEPARTMENT OF TRANSPORTATION
-

STATE CONSTRUCTION OFFICE

ICP Pile Driving Demonstration

Splicing Top and Bottom Sections

2010 FDOT/FTBA CONSTRUCTION CONFERENCE

FLORIDA DEPARTMENT OF TRANSPORTATION
-

STATE CONSTRUCTION OFFICE

ICP Pile Driving Demonstration

Splicing Top and Bottom Sections

2010 FDOT/FTBA CONSTRUCTION CONFERENCE

FLORIDA DEPARTMENT OF TRANSPORTATION
-

STATE CONSTRUCTION OFFICE

ICP Pile Driving Demonstration

Splicing Top and Bottom Sections

2010 FDOT/FTBA CONSTRUCTION CONFERENCE

FLORIDA DEPARTMENT OF TRANSPORTATION
-

STATE CONSTRUCTION OFFICE

ICP Pile Driving Demonstration

Overstressing the Pile During Driving

Real time monitoring of a fully
-
instrumented pile


2010 FDOT/FTBA CONSTRUCTION CONFERENCE

FLORIDA DEPARTMENT OF TRANSPORTATION
-

STATE CONSTRUCTION OFFICE

ICP Pile Driving Demonstration

Overstressing the Pile During Driving

2010 FDOT/FTBA CONSTRUCTION CONFERENCE

FLORIDA DEPARTMENT OF TRANSPORTATION
-

STATE CONSTRUCTION OFFICE

ICP Pile Driving Demonstration

Overstressing the Pile During Driving

Localized concrete spalling
at pile top

2010 FDOT/FTBA CONSTRUCTION CONFERENCE

FLORIDA DEPARTMENT OF TRANSPORTATION
-

STATE CONSTRUCTION OFFICE

ICP Pile Driving Demonstration

Overstressing the Pile During Driving

Loss of Pile Cushion

2011 FDOT/FTBA CONSTRUCTION CONFERENCE


Exceeded

maximum

allowable

compressive

stress

by

approx
.

28
%



Exceeded

maximum

allowable

tensile

stress

by

approx
.

200
%



Ultimate

static

pile

load

bearing

capacity

of

504

kips



Was

not

driven

to

practical

refusal
;

driven

beyond

allowable

limits



FLORIDA DEPARTMENT OF TRANSPORTATION
-

STATE CONSTRUCTION OFFICE

ICP Pile Driving Demonstration

Results and Conclusions

2011 FDOT/FTBA CONSTRUCTION CONFERENCE


Steel

plate

between

pile

and

pile

cushion



Vented

pile

helmet

to

reduce

water

hammer

effects



Increase

bevel

at

ends

of

piles

to

facilitate

welding



Alignment

pins

or

similar

to

assist

in

pile

alignment

during

splicing



FLORIDA DEPARTMENT OF TRANSPORTATION
-

STATE CONSTRUCTION OFFICE

ICP Pile Driving Demonstration

Recommendations

2011 FDOT/FTBA CONSTRUCTION CONFERENCE


Strength

testing

has

been

established



Pile

drivability

to

Specification

455

has

been

demonstrated



Quality

Control

plan

needs

to

be

approved

by

State

Materials

Office



Piles

need

to

be

produced

domestically

to

comply

with

Buy

America

Provisions



FLORIDA DEPARTMENT OF TRANSPORTATION
-

STATE CONSTRUCTION OFFICE

ICP Piles FDOT Approval

FLORIDA DEPARTMENT OF TRANSPORTATION

STATE CONSTRUCTION OFFICE

New Design Standards and
Construction Details

2011 FDOT/FTBA CONSTRUCTION CONFERENCE


Rodney Chamberlain, P.E.

Construction Structures Engineer

2011 FDOT/FTBA CONSTRUCTION CONFERENCE

Discussion Topics

New Design Standards and Construction Details
that Contractors should be aware of


New

Wind

Bracing

Standard



Elimination

of

End

Diaphragms



Squaring

of

Beam

Ends



New

Florida
-
I

Beam



FIB

84

and

FIB

96



FLORIDA DEPARTMENT OF TRANSPORTATION
-

STATE CONSTRUCTION OFFICE

2011 FDOT/FTBA CONSTRUCTION CONFERENCE

New Wind Bracing Standard

New tables in the Plans


Index

No
.

20005

in

the

2010

Interim

Design

Standards


Applicable

to

FIB’s,

Bulb
-
Tee’s

and

AASHTO

beams


Work

Standard

Index

with

tables

shown

in

the

plans
.

Contractor

must

either
:


Provide

certification

that

construction

loads

will

not

exceed

loads

specified

in

the

plans


Provide

signed

&

sealed

calculations

for

the

bracing

plans


Overhang

bracing

is

still

Contactor’s

responsibility



FLORIDA DEPARTMENT OF TRANSPORTATION
-

STATE CONSTRUCTION OFFICE

2011 FDOT/FTBA CONSTRUCTION CONFERENCE

New Wind Bracing Standard

Revisions to Section 5 of the Specifications

FLORIDA DEPARTMENT OF TRANSPORTATION
-

STATE CONSTRUCTION OFFICE

OLD

Contractor solely responsible for the design of
wind bracing system and ensuring the stability
of the beams throughout the duration of
construction (from placement on bearings to
casting of deck).

NEW

When temporary bracing requirements
are shown in the plans, the EOR takes
responsibility for the construction loads
shown in the tables, Contractor is
responsible for the design of the bracing
members and connections. Contractor
must certify that the construction loads do
not exceed the loads shown in the tables.

2011 FDOT/FTBA CONSTRUCTION CONFERENCE

Elimination of End Diaphragms

Reasons for the Change


Diaphragms

are

costly

and

difficult

to

form



Few

bearing

replacements

are

being

performed

and

fewer

expected



Beam

stability

can

be

provided

by

temporary

bracing



FLORIDA DEPARTMENT OF TRANSPORTATION
-

STATE CONSTRUCTION OFFICE

2011 FDOT/FTBA CONSTRUCTION CONFERENCE

Elimination of End Diaphragms

Thickened Slab End Details


Added

a

thickened

slab

end

at

deck

discontinuities



Details

are

shown

in

the

plans




FLORIDA DEPARTMENT OF TRANSPORTATION
-

STATE CONSTRUCTION OFFICE

2011 FDOT/FTBA CONSTRUCTION CONFERENCE

Elimination of End Diaphragms

Advantages


Less

Formwork
:

saves

time



Less

Concrete
:

saves

money


Faster

deck

casting

schedule
:

not

required

to

wait

48

hours

after

diaphragms

are

poured

before

casting

deck

as

per

Specification

400
-
7
.
13
.
7




FLORIDA DEPARTMENT OF TRANSPORTATION
-

STATE CONSTRUCTION OFFICE

2011 FDOT/FTBA CONSTRUCTION CONFERENCE

Elimination of End Diaphragms

Areas of Concern


Issue
:

Beam

ends

extend

to

expansion

joint
.

In

previous

practice,

a

portion

of

the

end

diaphragm

is

cast

in

front

of

beam

end,

allowing

for

casting

and

placement

tolerances
.


Solution
:



Monitor

casting

lengths

in

real

time


Pour

backwall

after

beams

have

been

set


Larger

expansion

joints

(up

to

3


for

joints

poured

with

backer

rod




FLORIDA DEPARTMENT OF TRANSPORTATION
-

STATE CONSTRUCTION OFFICE

2011 FDOT/FTBA CONSTRUCTION CONFERENCE

Squaring of Beam Ends

What’s Changed

FLORIDA DEPARTMENT OF TRANSPORTATION
-

STATE CONSTRUCTION OFFICE

PREVIOUS

CURRENT

2011 FDOT/FTBA CONSTRUCTION CONFERENCE

Squaring of Beam Ends

Advantages and Disadvantages


Simplified

casting

operations


Reduced

chances

of

spalling


Better

distribution

of

stresses

into

the

bearing

pad




FLORIDA DEPARTMENT OF TRANSPORTATION
-

STATE CONSTRUCTION OFFICE

Advantages

Disadvantages


May

require

a

larger

bent

cap


Gap

at

intermediate

joints

between

beam

ends




2011 FDOT/FTBA CONSTRUCTION CONFERENCE

Squaring of Beam Ends

Details


Details

will

be

shown

in

the

plans


Preferred

details

are

shown

in

the

Structures

Detailing

Manual,

Chapter

15


Includes

details

for

end

bent

and

intermediate

bents

with

and

without

expansion

joints


Beam

top

flange

is

required

to

be

clipped

at

end

bent

locations



FLORIDA DEPARTMENT OF TRANSPORTATION
-

STATE CONSTRUCTION OFFICE

Int
.

Bent

with

Exp
.

Joint

Int
.

Bent

without

Exp
.

Joint

2011 FDOT/FTBA CONSTRUCTION CONFERENCE

New Florida
-
I Beams

FIB 84 and FIB 96

FLORIDA DEPARTMENT OF TRANSPORTATION
-

STATE CONSTRUCTION OFFICE

FIB

96

FIB

84

2011 FDOT/FTBA CONSTRUCTION CONFERENCE

New Florida
-
I Beams

Maximum Span Lengths

FLORIDA DEPARTMENT OF TRANSPORTATION
-

STATE CONSTRUCTION OFFICE

191

Feet

6
ft

Beam

Spacing

8
.
5

ksi

concrete

208

Feet

6
ft

Beam

Spacing

8
.
5

ksi

concrete

153

Feet

14
ft

Beam

Spacing

8
.
5

ksi

concrete

170

Feet

14
ft

Beam

Spacing

8
.
5

ksi

concrete

FIB

84

FIB

96

2010 FDOT/FTBA CONSTRUCTION CONFERENCE

FLORIDA DEPARTMENT OF TRANSPORTATION
-

STATE CONSTRUCTION OFFICE

New Florida
-
I Beams

Florida
-
I Beams

2010 FDOT/FTBA CONSTRUCTION CONFERENCE

FLORIDA DEPARTMENT OF TRANSPORTATION
-

STATE CONSTRUCTION OFFICE

THANK YOU!