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By Gisele R. Passalacqua, Taylor Malangone, Subhash Mahali

New York City is a busy metropolis with 8 million people. New York has the largest public transportation system with 6 million riders a day throughout the subway system. Keeping this infrastructure in service is vital to the overall economy of the region. Hurricane Sandy proved to have a devastating impact on infrastructure in Metropolitan New York. New York City Transit is on the forefront to provide resiliency and maintain its facilities with the use of flood protection systems. This paper presents flood protection structures utilized at Hammels Wye substation site in Far Rockaway, Queens, New York. The site is in close proximity and surrounded by water. The subsurface conditions consist of loose silts overlain by medium dense glacial sand. The high groundwater level combined with limited access to the site presented challenges. A flood protection system consisting of flood walls was recommended for this site. In certain areas the flood walls consisted of retaining walls supported on micropiles. For other areas, the flood walls consisted of steel sheet piles with jet grout columns to reduce seepage below the walls. The effect of driving sheet piles with vibratory hammers on nearby existing structures is always a concern. Recently, hydraulic hammers with variable moment/frequency are being considered as a mean to reduce vibration effects during driving. In this project, an instrumentation testing program was performed to measure peak particle velocity during sheet pile driving utilizing the variable moment vibratory hammer. Plots of peak particle velocity versus frequency were generated. This paper will present the design aspects of the flood walls and construction challenges during installation. This will prove beneficial to engineers in both design and construction fields.

Sep 8, 2021

By Gordon Chen

As part of a value engineering envisioned by East Coast Slurry, Weidlinger Associates, Inc. designed a unique elliptical slurry wall cofferdam for construction of the 65 ft. deep MWRA North Dorchester Pump Station. A conventional rectangle cofferdam with multiple levels of bracing would have been time consuming and costly and imposed a significant obstruction to the pump station construction. A circular slurry wall, while eliminating the bracings, conflicted with adjacent structures and required excessive backfilling around the final pump station structure. The ellipse shaped cofferdam fit the needs of the project well; however, it created a significant design challenge without the use of bracings. Unlike a circular cofferdam which primarily only has hoop stresses, the ellipse still has to be designed for horizontal bending moments in each panel because of the non-axial symmetric conditions. The more eccentric the cofferdam shape; the higher the horizontal bending. The challenge was to develop a three dimensional finite element model that could analyze both the hoop stresses and horizontal bending stresses above and below the bottom of excavation induced by soil and water pressure and unbalanced construction surcharge loads. This paper discusses the techniques used to model the soils and structure interactions and results of stresses on this challenging unbraced configuration.

Jan 1, 2010

By Gisele R. Passalacqua, Aly Mohammad, Joanna Smith

The $13 billion John F. Kennedy (JFK) airport construction redevelopment program includes new terminals and buildings that are supported on piles to meet the airport expansion demand due to increased travel. This paper presents a case history for JFK airport with main focus on construction activities and lessons learned. Challenges include limited head room, presence of underground utilities, and hard driving. Video inspection of pile proved very beneficial. In general, soil conditions at JFK Airport consists of sandy fill followed by a 5-foot thick organic soft layer. Below the organic layer, glacial sands occasionally mixed with gravel were encountered for great depth with increases in density with depth. The tapertube pile is an ideal choice for foundations with high capacity achieved through skin friction along the taper section. The piles are easy to splice to accommodate low head room. Pile Driving Analyzers (PDA), and Static Compression Load Tests were performed. The results of these tests are presented in this paper to illustrate the high pile capacity achieved. More detailed discussion and analysis of the test results will be presented in another paper related to the same project. Lessons learned from this project are shared to help the engineering community with future design and construction of similar projects.

By Cassandra A. Wetzel

"Rock socketed mini-piles are a desirable foundation alternative when design capacity is more than 40 tons and there is limited access. In this case history mini-piles were designed to support between 75 and 200 kips at 12 locations adjacent to a perimeter wall, a party wall and at cast iron column piers. Limited geotechnical information, low overhead clearance, and active building population tested the creativity of the team to get the piles installed. The key geotechnical concern during installation of the mini-piles was the presence of a glacial till layer above the bedrock surface that restricted the seating of the casing into bedrock with a track mounted drill rig. Soil loss during the advancement of the rock socket using an air hammer was excessive and increased the risk of subsidence. Over a three week period the engineer worked with the contractor to modify the design, means, methods, and materials to install piles with adequate load capacity. This paper will present the changes in design and construction methods that were required.INTRODUCTIONRock-socketed mini-piles are a common and desirable deep foundation alternative to support loads more than 40 tons in New York City. Limited vertical clearance, accessibility, vibration control, and load capacity make this pile type attractive; it also does not require a static axial load test when socketed into rock. This added benefit makes this alternative all the more feasible.The installation of a drilled pipe extending to bedrock through a glacial till deposit presented challenges to the contractor and engineers to confirm the casing is seated sufficiently into the rock prior to drilling the rock socket. The loss of soil between the steel pipe and the till/bedrock interface can compromise the performance of the pile and soil loss can result in settlement of the ground surface.This paper presents the design and construction method changes made on one project during the installation of ten limited access rock socketed mini-piles."

Jan 1, 2017

By Daniel Ruffing, Charlie Krug

In recent years, the chain-style trencher has been proven a valuable tool for installing vertical walls on challenging sites where conventional methods may be less desirable. Like many tools, trenchers are most effective when used with the right application. Trenchers are commonly used for applications that could also be completed with conventional slurry trenching; low-permeability cutoff walls, collection trenches and permeable reactive barriers (PRBs). Drawing from a wealth of experience with conventional slurry trenching and the trencher, this paper compares and contrasts the technical considerations, treatability, installation, performance, and lessons learned for recent projects.

By John S. Civetta, Seth Martin, Marc J. Gallagher, Arthur J. Alzamora, Ronald Peralta

The Crown Building, built circa 1921, is a 26-story iconic building located at West 57th Street and Fifth Avenue in the heart of Manhattan. The paper highlights collaboration between the geotechnical engineer and foundation contractor to develop economical and practical solutions to foundation design and construction challenges associated with this complex redevelopment project. The project includes both below-grade and above-grade expansion of the occupied building, and required undermining the existing foundations, and essentially doubling the foundation loads. The below-grade expansion required surgical foundation work including drilling minicaissons, shoring columns, underpinning, and excavating 20 feet of rock.

By Lori A. Simpson, Linda H. Liang

A high-rise building, consisting of two tower structures occupying the entire site, is in construction in San Francisco. The North Tower will consist of 12 and 35 stories above a one-level basement. The South Tower will consist of 9 and 22 stories over one partially below-grade level of common space; a portion of the South Tower will have a three-level basement. The towers will be supported on mat foundations bearing on native very dense sand in the footprint of the threelevel basement and on ground improved with soil-cement mixed (SCM) panels that extend through loose sand and marsh deposits into very dense sand. Shoring systems for the basement excavations include cantilevered and tiedback soldier-beam-and-lagging systems and SCM cutoff walls. Subsurface conditions include loose fill and Dune Sand and loose and soft marsh deposits overlying very dense sand of the Colma formation. Groundwater is approximately 15 to 22 feet deep; the three-level basement extends below groundwater. The site is on Market Street in San Francisco, with SF Municipal Railway (MUNI) and Bay Area Rapid Transit (BART) tunnels running below Market Street approximately 45 and 36 feet north of the site, respectively. Both tunnels are 16.5 feet in diameter. The top of MUNI and BART tunnels are 25 feet and 63.5 feet below street grade, respectively. BART has stringent requirements regarding construction adjacent to their facilities, including disallowing adding pressure to their tunnel, lowering groundwater by more than two feet, and vibrations from construction activities. Design of the shoring and the foundations within the BART zone of influence were subject to their design requirements. The project was also subject to a peer review, as required by the San Francisco Department of Building Inspection. We used FLAC to evaluate stresses at the BART and MUNI tunnels and on the SCM panels. This paper will present the mitigations needed to address seismic hazards and BART restrictions and to provide adequate foundation support for a tall building with high seismic loads.

Jan 1, 2017

By Lori A. Simpson

A high-rise building, consisting of two tower structures occupying the entire site, is in construction in San Francisco. The North Tower will consist of 12 and 35 stories above a one-level basement. The South Tower will consist of 9 and 22 stories over one partially below-grade level of common space; a portion of the South Tower will have a three-level basement. The towers will be supported on mat foundations bearing on native very dense sand in the footprint of the three-level basement and on ground improved with soil-cement mixed (SCM) panels that extend through loose sand and marsh deposits into very dense sand. Shoring systems for the basement excavations include cantilevered and tied-back soldier-beam-and-lagging systems and SCM cutoff walls. Subsurface conditions include loose fill and Dune Sand and loose and soft marsh deposits overlying very dense sand of the Colma formation. Groundwater is approximately 15 to 22 feet deep; the three-level basement extends below groundwater. The site is on Market Street in San Francisco, with SF Municipal Railway (MUNI) and Bay Area Rapid Transit (BART) tunnels running below Market Street approximately 45 and 36 feet north of the site, respectively. Both tunnels are 16.5 feet in diameter. The top of MUNI and BART tunnels are 25 feet and 63.5 feet below street grade, respectively. BART has stringent requirements regarding construction adjacent to their facilities, including disallowing adding pressure to their tunnel, lowering groundwater by more than two feet, and vibrations from construction activities. Design of the shoring and the foundations within the BART zone of influence were subject to their design requirements. The project was also subject to a peer review, as required by the San Francisco Department of Building Inspection. We used FLAC to evaluate stresses at the BART and MUNI tunnels and on the SCM panels. This paper will present the mitigations needed to address seismic hazards and BART restrictions and to provide adequate foundation support for a tall building with high seismic loads.

By Dan A. Brown

The foundations at the Huey P. Long Bridge in New Orleans presented special challenges for construction due to the requirements for very deep drilled shafts in the Mississippi River beneath the existing bridge structure. Drilled shafts were constructed to depths of approximately 200ft in alluvial soils using a rotator system with full-length segmental casing, and base grouted to improve axial resistance. This paper describes the design and construction of the work platform to provide access to the restricted-access site beneath the existing bridge, the approach used to construct the drilled shafts, and the results of a load test program to verify the axial resistance.

Jan 1, 2010

By Derrick Dasenbrock, Mary C. Nodine, Benjamin Rivers

Up to 50 percent of major infrastructure projects suffer impacts to schedule or cost due to geotechnical issues, many of which correspond to risks related directly or indirectly to the scope and quality of site characterization work. The Federal Highway Administration (FHWA) in coordination with industry organizations seeks to address this issue through Every Day Counts (EDC), a program that identifies and deploys proven, yet underutilized innovations at the project level to save time, money and resources. The A-GaME (Advanced Geotechnical Methods in Exploration) is one of the innovations supported under EDC.

By Benjamin Jennings, Jason Herron

In the summer of 2016 Xcel Energy experienced a storm event that resulted in the collapse of approximately 8.5 miles of a 345 KV transmission line near Rogers, Minnesota. In design of the new transmission line, Xcel Energy determined that ten tower locations would be replaced with steel H-frame structures supported by helical piles instead of wood H-frame structures supported by driven wooden piles. A steel foundation was proposed for the towers due to time constraints and site conditions unfavorable to large pile driving equipment. Xcel Energy contacted the helical pile manufacturer Hubbell Power Systems, Inc. (HPS) for aid in the design of a complete steel foundation for the structure legs. With the shear, moment, and axial loads provided, the manufacturer used pile group modeling and axial capacity software to design a four helical pile group; and used 3D modeling and finite element software to design a moment resistant grillage to connect to the tower base. The steel grillage utilizes a new moment resistant connection and clamp system to transfer loads from the piles to the grillage. This connection provides a true fixed head condition and reduces lateral deflection issues typical to smaller diameter piles in pinned head connections. The clamp is designed to deform the helical pipe pile shaft and transfer the full axial load of the structure through the mechanical and friction connection. The helical piles and the moment resistant grillage were manufactured with shorter than average lead times and a helical pile installation contractor performed the installation. An expedient plan of install was developed by the contractor that resulted in an average installation rate of one complete set of tower foundations per day. The design of the moment resistant grillage, clamping system, and excellent foundation construction by the contractor provided an expedient and efficient foundation system to be discussed in this paper.

Jan 1, 2017

By Christian Hoyme, Jochen Maurer, Hans Regler

Up to today, it has been very difficult to obtain qualitative and quantitative information about the status and production process of a construction site. It is becoming more and more important to be able to analyze this process so as to notice bottlenecks and interruptions on the site early on. The high costs of each shift in special foundation industry mean that making the wrong decision and/or interruptions can put the financial result at risk. Previously, keeping reliable data meant manual process documentation. This was done either by an additional staff member (incurring high additional costs for training, education, etc.) or by the equipment operators. The latter is critical, because they have to initiate every process step change, leaving no time to log data separately. Studies have shown that there are considerable deviations from the actual process steps. In this paper, a seamless, automated method will be introduced to analyze the construction process. This method recognizes each process step from the equipment data. The main purpose of the data recorded by the piling rig is the need of quality reports and now basis for the presented analysis. Here, a method was successfully transferred from theoretical computer science (compiler construction field) to find application for process recognition. Because the execution of works in special foundation construction can always be defined sequentially and therefore also practiced sequentially, recognition can occur step-by-step. Our method always recognizes the next step, so it does not have to monitor as much data at the same time. Individual trigger points are easier to define. Unlike solutions that are based on a global approach and allocate suitable process steps to data patterns, thereby also creating gaps, the presented method is always seamless. Furthermore, this method can be applied regardless of time or location provided that the necessary machine data is available, which is normally the case with production data logging. This means that construction sites even from the past can also be analyzed and the results used for comparisons. The first results from the analysis of a complete continuous flight augering (CFA piles) installation process of a construction site will be presented.

Sep 8, 2021

By Brenton Cook, Daniel Mageau, Larry Applegate, Aaron McCain

"Ground freezing was successfully used to create an impermeable barrier wall along 3,000 feet of the downtown Seattle waterfront as part of the Seattle Seawall Replacement Project. This $360 million re-development involved removing the original 1930-era seawall and replacing it with a new, seismically resistant concrete wall supported on fill soil improved by jet-grout. The replacement wall was one of the largest construction projects in the state of Washington at the time. Ground freezing is typically used as both a structural shoring wall and groundwater cutoff. However, at this project it was used primarily as a cutoff wall to stop groundwater seepage into the 16-foot deep excavation from the landside areas.The project was divided into ten boxes (sections), each typically 200 to 600 feet in length. Only a few boxes were under construction at one time to reduce the impact on tourist-dependent local businesses. Soil conditions in the freeze zone consisted of sand, gravel and silt fill with abundant wood and debris. Tidally influenced groundwater, much of it contaminated, was difficult and expensive to control using wells during initial stages of construction. For all subsequent stages, a frozen soil wall extending to about 35 feet in depth was used to stop groundwater seepage into the excavation. An additional benefit of ground freezing included elimination of potential settlement beneath nearby buildings, utilities, and the Alaskan Way Viaduct that would likely have occurred with the use of conventional dewatering wells. The frozen soil wall crossed more than 130 buried utility locations (including water, sewer, storm, electrical, fiber optic, phone, gas, steam) with no damage. The frozen soil wall was very successful and limited groundwater influx from the landside to the seawall excavation to a negligible amount so that pumping, storage and treatment of contaminated groundwater was essentially eliminated."

Jan 1, 2016

By Justin Lukens, Di Stasim Jeffrey, Frank Di Salvo

Columbia University’s Manhattanville Campus expansion includes the construction of two new business school buildings. The new buildings require development of an entire city block bound by 12th Avenue, W 131st Street, W 130th Street and Broadway in Upper Manhattan. A support of excavation (SOE) package was first released, followed by a foundation package. The SOE package consisted of approximately 100 soldier piles and 280 anchors, up to 215’ long, to support a cut anywhere from 30’- 50’ below street level. The foundation package alone included approximately 1600 drilled micropiles. Given the breadth of the work scope, Hayward Baker Inc and Moretrench joint ventured on these two projects to bring sufficient knowledge and work resources to complete the work in an efficient and timely manner. This included working with the Owner/Engineer to propose different means and methods for construction to significantly reduce the schedule while meeting the design intent, such as large diameter (36” diameter) augercast piles in place of conventionally drilled soldier piles and large hollow-bar micropiles (103/51 bars) in lieu of pressure-grouted micropiles. The anchors, ranging from 3 to 22 strands, were used for earth retention through both soldier pile and lagging walls and existing slurry walls. These anchors were complicated based not only on their size and length, but also the need to drill some of them under the historic Studebaker building. The overall magnitude of the project with considerations to resource management and material lead times will be addressed, highlighting critical strengths provided by the Contractor to ensure project success. The scope of work discussed in this paper was executed under two separate competitive bid contracts. The first contract included the support of excavation work and the second contract included the foundation package. The support of excavation comprised of drilled soldier piles (performed by Case Foundation as a subcontractor to the JV), driven soldier piles, driven sheet piles, hollow bar tiebacks, multi-strand tieback anchors and micropile soldier piles. The foundation package consisted of drilled micropiles. Due to the large scope of work and critical schedule requirements of the project, the JV had to think outside the box and present value engineered alternates to expedite installation durations.

Jan 1, 2019

By Daniel W. Mageau, Larry W. Applegate, Aaron K. McCain

"An innovative method of ground freezing was successfully tested to create a “dry” excavation condition for a new building foundation at a site in downtown, Miami, Florida. The subsurface conditions in Miami generally consist of very porous, weak limestone and sand with groundwater near the surface. Water flow through these materials can be very high. Dewatering is extremely restricted in Miami so deep below-grade structures are rare and expensive. A new, innovative method to allow deep excavations in dry conditions without dewatering involves the creation of a thick, temporary, frozen soil plug below the planned excavation depth across the entire site to cut off vertical groundwater flow during construction. Frozen soil is impermeable and very strong and has long been used for temporary structural and water-tight shored walls. Using the same proven principals, frozen soil plugs are very effective at cutting off water from the bottom of the excavation as well as resisting upward buoyant forces. This new freezing method can be used for fairly deep excavations in new building construction supported on deep foundations. The building piles act as temporary anchors for the frozen plug to resist very high upward buoyant pressures until the permanent structural slab is completed.IntroductionUnlike other Cities, below grade basements are rare in Miami. The few basement foundations constructed have utilized a cumbersome and expensive method of excavation and shoring involving underwater excavation, tremie slabs, and commercial divers. The key issue for underground construction in this area of the country is the vertical flow of groundwater through the base of the excavation. To deal with this issue in the past, the contractor first installed all of the building piles and the perimeter shoring walls. Then, interior sheet pile walls are installed to create small manageable excavation pits. Each pit is then excavated through standing water “in-the-blind” and around the buildings support piles. The final excavation, interior struts, and inspection is performed by commercial divers. Finally a thick foundation tremie slab is poured under water. This method could be successful but proved to be time consuming and expensive. In addition, some building piles were occasionally damaged during the under-water construction process."

Jan 1, 2015

By V. Tang

In this paper, Chinese economic situation are estimated and prospective developments predicted to assist those US firms who have been trying to do business in China, or are considering to pursue the China market.

Jan 1, 2010

By David Coleman

This paper presents a case history involving the installation of drilled in piles with rock sockets for the Bicycle and Pedestrian Path project located west of the Henry Hudson Parkway within the Riverside Park between 83rd Street and 91st Street at the Hudson River in New York, NY. The paper specifically addresses access and construction procedures for a marine installation when working in an urban and environmentally sensitive setting.

By Norm Kirk, Robert Bittner

"The addition of a new powerhouse at the existing Tulloch Hydroelectric site on the Stanislaus River in the western foothills of the Sierras Nevada Mountains of central California required a deep excavation in rock on the downstream face of the dam. A cofferdam (water exclusion device) was necessary to isolate the powerhouse construction site excavation from the existing Goodwin Reservoir and the turbulent discharge from the existing powerhouse. The cofferdam was positioned on a steeply sloping fractured rock surface exceeding 50 degrees.This paper describes the challenges encountered during design and construction of the cofferdam and describes the unique design features used to address these challenges including:•,The use of flat-sheet-piles to form cellular walls on the steeply sloping rock surface.•,The use of 5-ft deep tremie concrete plugs in the bottom of the sheet pocket cells to create the bottom seal of the cellular cofferdam walls against the sloping rock surface.•,The use of vertical post-tensioned rock anchors to provide shear resistance at the contact point between the base of the cellular-wall and the sloping rocksurface.INTRODUCTIONModification or expansion of existing hydroelectric power plants often require downstream cofferdams or water exclusion devices to temporarily separate new construction from turbulent downstream discharge of the existing dam. Most dams are positioned on solid rock in the narrowest and therefore the steepest section of the river. This combination of steeply slopingrock and the need for an exclusion barrier creates a challenge for the design engineer trying to maintain a safe dewatered construction site. Typical cofferdam solutions for hydroelectric dams usually use large granular filled circular sheet pile cells that perform as gravity structures. However, this type of structures is not well suited to steeply-sloping highly irregular rock surfaces in a confined area."

Jan 1, 2017

By D. Cantali

This paper will be presented in two parts. The first part will present the latest advancements in pile installation techniques using state-of-the-art press-in piling technology by Giken. By pressing in sheet piles and large modulus contiguous steel tube pile walls – as opposed to the more traditional installation methods using percussive hammers or vibrators – retaining structures can be constructed effectively noise and vibration free. For over water and coastal projects with limited access, this provides significant environmental benefits in the form of minimising the construction foot print and the impact to surrounding communities and the marine natural habitat. Typical noise and vibration data will also be presented. The second part of this paper will review the current manufacturing techniques for sheet piles and introduce innovative new materials used in the current piling market for embedded sheet pile walls. Materials include long service life non – ferrous materials such as new age plastics and fibre reinforced polymer piles. Their excellent long term performance and durability make them an effective solution in the marine environment. For steel piles, a number of steel grades with reduced corrosion characteristics will also be discussed including a newly developed steel to combat corrossion in the low water zone, an area often exhibiting the highest moments in a retaining wall. A number of project case studies will also be presented to reinforce their relevance in today’s changing construction landscape.

Nov 1, 2022

By D. E. Sherwood

Twelve toe grouted, and eleven ungrouted piles, founded in very dense sands have been analysed to establish how toe grouting enhances pile performance. It is shown that pile stiffness is greatly increased, and that pile bases work effectively. This is in contrast to ungrouted piles, where some milli­meters of base movement may be required before the base is mobilised. Grouting appears to recover most of the disturbance caused during construc­tion, but in general does not enhance the ultimate bearing capacity of undisturbed ground.

Jan 1, 1989