MLK CONNECTOR Presented by LARGE DIAMETER PILE REPAIR Brad Hessing & Heather Shoup Midwest Geotechnical Conference, September 17-19, 2019 1
PRESENTATION OVERVIEW • Installation of Large Diameter Open-Ended Pipe Piles (LDOEP) at the Piers for the New Martin Luther King Connector Bridge in East St. Louis. • Upon construction of Pier 3, one of its piles was damaged during driving. • Numerous solutions were considered to resolve the issue. • A repair plan was chosen, implemented, and the problem was resolved. Midwest Geotechnical Conference, September 17-19, 2019 2
PROJECT OVERVIEW • Total Replacement of existing ~60 year old Martin Luther King Bridge Approach (“MLK Connector”, Existing Structure Number 082-6003) in East St. Louis, Illinois. • The existing 15-Span structure consists of a 250’ long Steel Through Truss with multiple Curved Steel Girder Approach Spans. • The new structure will be a 1286’ long 5-Span 96” deep Plate Girder Bridge with Pile Bent Abutments supported by H-Piles to Rock and Open Pile Bent Piers made up by Large Diameter Open-Ended Pipe Piles (LDOEPs) to Rock. • New MLK Connector Bridge will carry traffic over relocated Illinois Route 3, Missouri Avenue, various R.R. tracks, and Interstates 55 and 64. Midwest Geotechnical Conference, September 17-19, 2019 3
PROJECT OVERVIEW • Proposed IDOT Structure Number: 082-0374 • Route: FAP 799 • Section 1BR-1-1 • County: St. Clair • Contract Number 76G39 Midwest Geotechnical Conference, September 17-19, 2019 4
MLK CONNECTOR SITE LOCATION City of East St. Louis (St. Louis Metro East Region) St. Clair County, Illinois IDOT District 8 Midwest geotechnical conference, September 17-19, 2019 5
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Midwest Geotechnical Conference, September 17-19, 2019 8
PROJECT OVERVIEW • Each Open Pile Bent Pier (Piers 1-4) comprised of 4 Large Diameter Open-Ended Pipe Piles (LDOEPs) driven to Rock. • All LDOEPs are 48-in Dia. with ¾-in wall thickness. • All piles to be driven to rock to a Nominal Required Bearing of 3006 kips with a Factored Resistance Available of 1954 kips. • All piles driven with Wave Equation (WEAP) with PDA Testing. Midwest Geotechnical Conference, September 17-19, 2019 9
PROJECT OVERVIEW • All piles are to be equipped with shoes. • Axial Capacity includes components of both Side Resistance and End Bearing. • No geotechnical losses were included in the design. • LDOEPs are to be filled with concrete to a minimum of 35 ft below ground elevation. Any material that may encroach above the proposed bottom of concrete inside the pipe shall be removed prior to filling. Midwest Geotechnical Conference, September 17-19, 2019 10
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PROJECT OVERVIEW WHY LDOEPs ? Midwest Geotechnical Conference, September 17-19, 2019 13
BACKGROUND-PIER FOUNDATION TREATMENTS FOUNDATION TREATMENTS CONSIDERED: • Driven Metal Shell (Friction) Piles • H-Piles Driven to Rock • Drilled Shafts with Rock Sockets • Large Diameter Open-Ended Pipe Piles (LDOEPs) Driven to Rock Midwest Geotechnical Conference, September 17-19, 2019 14
BACKGROUND-PIER FOUNDATION TREATMENTS METAL SHELL (FRICTION) PILES AND H-PILES DRIVEN TO ROCK • The required number of metal shells or H-Piles would be considerably greater than that required for either drilled shafts or LDOEPs since one drilled shaft or one LDOEP can be substituted for a number of piles. • Metal shells and H-Piles both would require footings; along with the number of piles required, this would create and require a much larger “footprint” than the other two treatment types. Midwest Geotechnical Conference, September 17-19, 2019 15
BACKGROUND-PIER FOUNDATION TREATMENTS METAL SHELL (FRICTION) PILES AND H-PILES DRIVEN TO ROCK (CONTD.) • Along with taking up more space, pile supported footings would also require temporary soil retention adjacent to IL-3 and the railroads. • Although metal shells and H-Piles are technically feasible, due to limited space, interferences with existing foundations, shoring requirements for IL-3 and the railroads, and additional utility and deep well conflicts, they were not considered favorable treatments for the interior bent locations. Midwest Geotechnical Conference, September 17-19, 2019 16
BACKGROUND-PIER FOUNDATION TREATMENTS DRILLED SHAFTS WITH ROCK SOCKETS • Drilled Shafts can be designed as an open pile bent and would not require a footing or soil retention. • Considerably less drilled shafts would be required than conventional piles. • However, shafts were less economical and would take longer and more effort to construct than LDOEPs. Midwest Geotechnical Conference, September 17-19, 2019 17
BACKGROUND-PIER FOUNDATION TREATMENTS LARGE DIAMETER OPEN-ENDED PIPE PILES (LDOEP S ) • LDOEPs can be designed as an open pile bent and would not require a footing or soil retention. • Considerably less LDOEPs would be required than conventional piles. • Construction issues common to drilled shafts can be avoided since they are driven and not drilled. • They are more economical and faster and easier to construct than drilled shafts. Midwest Geotechnical Conference, September 17-19, 2019 18
BACKGROUND-FINAL SELECTION OF LDOEP S FINAL SELECTION OF LDOEP S WAS BASED ON: • Its advantages over the other treatments as previously discussed above • Being the most economical and efficient foundation design • Overall Constructability • Heavily favored by IDOT District 8 (recently used on nearby structure) Midwest Geotechnical Conference, September 17-19, 2019 19
BACKGROUND-SUBSURFACE DATA • The subsurface at Pier 3 generally consists of a sequence of sandy fill, clay, sand, and cobbles and gravel overlying sandstone and limestone bedrock. • The top of rock is on average approximately 120 feet below ground surface. • Boring data for Pier 3 is supplied by Boring BB-304. Midwest Geotechnical Conference, September 17-19, 2019 20
#1 #2 WEST EAST #3 ABUTMENT #4 ABUTMENT 5 Midwest Geotechnical Conference, September 17-19, 2019 21
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PROJECT OVERVIEW (CONTD.) • Project was let in June of 2018 and is currently under construction. • During Pile Driving at Pier 3, Pile 4 was crushed at its toe (OUCH!!!). • As a result, the axial capacity of Pile 4 was compromised. • Consequently, this problem needed to be resolved in a timely manner! LET’S NOW TALK CONSTRUCTION AND THE FIX……… Midwest Geotechnical Conference, September 17-19, 2019 24
CONSTRUCTION … Midwest Geotechnical Conference, September 17-19, 2019 25
THE PILES ASTM A252 Grade 3 steel 50 ksi min. yield strength 45 ksi max allowable driving stress (90%) 48-in OD 0.75 inch wall thickness Drive shoes 2 planned splices Midwest Geotechnical Conference, September 17-19, 2019 26
THE HAMMER: Hammer: APE D160-42 Single acting diesel 397 kip-ft rated energy max at fuel setting, 35.28 kip ram weight 11.25 ft max rated hammer stroke Midwest Geotechnical Conference, September 17-19, 2019 27
WEAP ANALYSIS SUMMARY Drivability Analysis: Boring used BB-301 (W. Abut & Pier 1) Assesses Driving Conditions with depth Limestone bedrock assumed 2,500 ksf Assessed both with and without soil plug unit end bearing Bearing Graph Analysis Full soil plug not expected Did not use API method because of Partial plug simulated by increasing experience with the adjacent MLK end area linearly from no plug at top to Connector LDOEPs 50% plug at bottom in dense granular layer just above the bedrock surface. Max fuel setting 4 modeled Hammer modeled with 80% efficiency Midwest Geotechnical Conference, September 17-19, 2019 28
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WEAP DRIVABILITY ANALYSIS SUMMARY Max 10 bpi (IDOT spec.) Average Transfer Efficiency is 39% (COV = 26) for diesel hammers 11 bpi at 9.7 ft stroke (no plug) (Appendix B3 of the 2010 version GLRWEAP manual) 19 bpi at 9.4 ft stroke (partial plug) 8 bpi at 9.8 ft stroke (Bearing Graph Analysis) 31 – 35 ksi estimated driving stresses Midwest Geotechnical Conference, September 17-19, 2019 32
PDA TESTING TIMELINE FOR DRIVING PIER 3 ON 11/27/18 1 2 3 4 10:44 5:25 pm 4:46 pm 3:07 pm am Midwest Geotechnical Conference, September 17-19, 2019 33
Pier 3, Pile 1, EOID Midwest Geotechnical Conference, September 17-19, 2019 34
Pier 3, Pile 4, EOID Midwest Geotechnical Conference, September 17-19, 2019 35
PLAY BACK OF PDA RECORD FOR PIER 3, PILE 4 Midwest Geotechnical Conference, September 17-19, 2019 36
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DRIVE TIMELINE VIEWED IN PDA RECORD Midwest Geotechnical Conference, September 17-19, 2019 38
Blow 339: Just prior to stopping the hammer 3:15:54 pm Midwest Geotechnical Conference, September 17-19, 2019 39
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