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By Andy Boeckmann

In early 2021, DFI formed a Foundation Reuse Task Force due to concurrent and coincidental discussions of this topic during meetings of the Subsurface Char- acterization for Deep Foundations and Testing and Evaluation committees. Interested members from both commit- tees, as well as of the Sustainability Com- mittee, joined forces to form the task force. The task force mission is to promote foundation reuse by leveraging experi- ence among DFI members and collabo- rating across pertinent committees. General goals of the task force are to identify, assess and reduce risks associated with reuse; to educate owners and decision-makers about reuse; and to improve the investigation, design, construction and testing practices associated with reuse. One of the first orders of business for the task force was to organize a roundtable discussion of foundation reuse for DFI's 46th Annual Conference on Deep Foundations in Las Vegas. Last fall's discussion was framed as a continuation of the successful "Horses for Courses" session of SuperPile '21, which also focused on foundation reuse. However, whereas the SuperPile session focused on technical content, the annual conference panel on October 13, 2021, was envisioned as a less technical conversation that emphasized audience participation while addressing approaches to decisions about foundation reuse issues. The roundtable consisted of five panelists: • • • Bryan Hartnagel, Ph.D., state bridge engineer, Missouri DOT (MODOT) Tom Bradley, project director, Stanhope, London Hilary Shields, senior geotechnical engineer, Arup, London Jim Mackey, vice president/chief marketing officer, McGee Group, London Susan White, attorney, Benesch, Cleveland The roundtable was moderated by Andy Boeckmann, Ph.D., P.E., a senior engineer who works in Dan Brown and Associates' Missouri and Illinois offices, and is an article co-author.

Feb 1, 2022

By Bengt H. Fellenius

.1.1 Prior to commencement of pile installation operation, submit to [Engineer] for [approval] [review], details of equipment for installation of piles. SPEC NOTE: The information requested in 3.1 .1.2 is necessary as input to a detailed wave equation analysis of the pile driving. .1.2 For impact hammers, give manufacturer's name, type, maximum rated energy and rated energy per blow at normal working rate during easy and at termination driving, mass of striking parts of hammer, mass of driving cap, and type and elastic properties of hammer cushion. .1.3 For non-impact methods of installation, such as drilling, jacking, jetting, use of vibratory hammers, or other means, give full details of characteristics necessary to evaluate performance. .2 Impact Hammer SPEC NOTE: Do not exclude a hammer type unless for very specific reason. .2.1 [Drop hammers will not be permitted.] [Diesel hammers will not be permitted.] For final driving of [TYPE] piles, provide a hammer capable of delivering to the pile a non-erratic impact stress not smaller than [VALUE] Pascal and transferring a non-erratic energy not smaller than [VALUE] Joules per blow to the pile head at normal working rate.

Jan 1, 1991

By Filippo Maria Leoni, George Filz, Wesley Schmutzler, Matteo Bertoni

"The US Army Corps of Engineers selected the Deep Mixing Method (DMM) for the required stabilization at the LPV 111 Project (New Orleans, USA). DMM was used for ground improvement/foundation strengthening and consequently to stabilize and support the burden of the new levee. Two different technologies were used: Trevi Turbo Mix (TTM) and Contrivance Innovation Cement Mixing Columns (CI-CMC). LPV 111 is the largest soil mixing project to date in the USA with its more than 18,000 elements installed to a depth of up to 67 feet for a total of 1.7 million cubic yards of treated soil. The preparation and execution of the project presented many challenges from various points of view. The little time available to complete the job led to the simultaneous utilization of eight deep mixing rigs and batch plants which worked 24 hours per day, 5.5 days per week on a stretch of land approximately 5.3 miles long. Given the imposing geographical extent of the project, a four phase laboratory programme and five field validation test programmes, conducted in as many different areas of the project, were completed to design and optimize the grout mixes and the installation parameters. The massive quality control/quality assurance testing programme produced over 500 drilled core holes and over 5,000 tested specimens in order to determine unconfined compressive strength (UCS) and uniformity of the DMM elements. This paper has the purposes of describing the tremendous challenges encountered and providing valuableinformation that may be useful for other future projects, including details not previously published.INTRODUCTIONReach LPV-111 is part of the Lake Pontchartrain and Vicinity Hurricane Protection System designed to protect the city of New Orleans and the surrounding areas from the surge that would accompany a 100 year hurricane event. LPV-111 measures approximately 8.5 km (5.3 miles) long, of which 7.2 (4.5 miles) extend along the north bank of the Gulf Intracoastal Waterway (GIWW) and the remaining 1.3 (0.8 miles) run north and terminates at the CSX Railroad Gate. The Bayou Sauvage National Wildlife Refuge borders the levee on both sides (Fig. 1)."

Jan 1, 2015

By Richard Shea

Morris-Shea, an Alabama-based deep foundation contractor, is installing foundation piles at the sites of North America's two largest liquefied natural gas (LNG) terminals currently under construction. The contractor has crews working at Venture Global's LNG lique- faction plant in Plaquemines Parish, Louisiana, as well as constructing foundations for the Cheniere Energy Stage 3 Liquefaction Project in Corpus Christi, Texas. This work includes installing ap- proximately 27,000 DeWaal drilled, full displacement, cast-in-place concrete piles to support seven new midscale LNG trains at Cheniere's Texas ter- minal. Deep foundation installation began at Venture Global's Plaquemines facility, located approximately 30 mi (50 km) south of New Orleans, with an initial phase of 24,000 piles. Plans for the Plaquemines LNG terminal include three loading berths on the Mississippi River and four LNG containment tanks. The facility will utilize new pretreatment com- pressors, liquefaction trains and on- site gas turbine power plants to maintain an annual LNG export capacity of nearly 20 million tons (18 million tonnes) per annum. The site's LNG trains are configured in 18 blocks. The contractor is installing piles through an initial 6-20 ft (1.8-6 m) of cement mixed improved soils, which provide a safe work plat- form for equipment to operate on the extremely weak native soils. Drilling continues through soft clay in the subsurface and tips into a stiff clay or dense sand layer. Production piles are drilled to depths up to 124 ft (38 m) below ground surface. The firm is working with engi- neering, procurement and construction contractor KZJV, a Kellogg Brown & Root and Zachry joint venture, at the Louisi- ana location. The foundation team mobilized at the Plaquemines site in May 2022, to install 16, 18 and 24 in (400, 450 and 600 mm) diameter test piles to depths of 90 and 120 ft (27 and 36 m). The piling contractor returned in September 2022, to start Phase 1 of the deep foundation project, beginning installation of production piles.

Apr 1, 2023

By John S. Pack

The application of square shaft helical piers in expansive soils is a standard of practice in many areas of the United States. Over 20 years of performance monitoring show exceptional performance and economy will result if proper design procedures, specification requirements and installation procedures are followed. This is true for new foundations and the repair of existing foundations, including lightly loaded wood-frame structures on expansive soils. Proper design includes: 1) site geotechnical characterization, 2) pier layout such that each pier is loaded to its maximum design capacity, 3) maximize spans between piers, 4) minimize the number of piers, 5) isolate the structure from the expansive soil with an appropriate void zone below all grade beams, slabs or other components that would otherwise be in soil contact and 6) utilize only single helix piers. Proper specification employs a performance specification that specifies: 1) the design load on each pier with a suitable safety factor, 2) the minimum installation torque, typically 4,000 ft-lbs (5.4 kN-m), or refusal, 3) a minimum pier shaft steel Fy = 70 to 90 ksi (483 to 621 Mpa) and pier helix steel Fy = 80 ksi (552 Mpa), 4) 1.5 to 1.75 inch (38.1 to 44.5 mm) square shafts, 5) smooth shaft surface, 6) the ICC Evaluation Report (ER) number of the manufacturer and 7) the manufacturer ISO 9001 certification for material quality control. Proper installation requires: 1) equipment with sufficient axial compression force (crowd) on the pier shaft so the helix engages the soil and advances to the specified minimum installation torque or refusal, 2) additional specialized techniques for expansive soils and 3) qualified specialty helical pier installation contractors experienced in expansive soils who submit and utilize pier configurations, techniques and equipment that will most effectively and economically meet the specified performance.

Jan 1, 2007

By Schmitz Stefan, Stephan Jee-Sun

"Due to the reunion of Western and Eastern Germany in the late 80’s, a multitude of infrastructure projects had to be executed. A good portion of these projects required improvement of the motorway system. In the southern region of Leipzig, in the eastern part of Germany, it was required to connect two existing motorways. Parts of the new motorway pass old strip mining areas. These strip mining areas consist of up to 70m thick backfill material. Especially the upper 20m are very inhomogeneous soil material with a very low bearing capacity. In order to increase the bearing capacity, to decrease the differential settlements and to homogenize the soil parameters, soil improvement using sand-gravel columns was required. Bauer Spezialtiefbau GmbH executed the installation of approx. 711,000 linear meters of columns with a length from 5 m to 25 m. For the project, 11 rigs with frame leads up to 40m were used to install the 43,000 columns with a diameter of 0.8m in 27 weeks.1. INTRODUCTION1.1 Site LocationThe construction site is located in the south-eastern part of Germany, in the south west of the city Leipzig.The area to be treated had a size of approx. 500,000 m² to allow the construction of dam/embankments and a highway bridge.1.2 Required WorkIn addition to the general earthworks and the installation of geogrids and fibre mats, a total amount of more than 710,000 linm of Gravel-Sand Columns with different lengths due to the given soil conditions had to be installed:•nos. 4,206 Columns length 5m ? 21,030 linm•nos. 4,581 Columns length 10m ? 45,810 linm•nos. 10,820 Columns length 15m ? 162,300 linm•nos. 19,634 Columns length 20m ? 392,680 linm•nos. 3,574 Columns length 25m ? 89,350 linmFor the installation of the columns Gravel-Sand with the grain size of 0/32mm was used. The total amount of Material was 580,000mt"

Jan 1, 2015

4.5.1 General The provisions of the article shall apply to the design of axially and laterally loaded driven piles in soil or extending through soil to rock. 4.5.1.1 APPLICATION (Revised Article 4.3.1.1) Piling may be considered when footings cannot be founded on rock, or on granular or stiff cohesive soils within a reasonable depth. At loca-tions where soil conditions would normally permit the use of spread footings but the potential for scour exists, piles may be used as a protection against scour. Piles may also be used where an unacceptable amount of settlement of spread footings may occur. 4.5.1.2 MATERIALS Piles may be structural steel sections, steel pipe, precast concrete, cast-in-place concrete, prestressed concrete, timber, or a combination of materials. In every case, materials shall be supplied in accordance with the provisions of this Article.

Jan 1, 1989

By Jeff Wilkinson, Brandon Walter

"A&N Electrical Cooperative provides electrical service to the counties of Accomack and Northampton along Virginia’s Eastern Shore and to Smith Island in Somerset County, Md.A&N recently worked to improve the efficiency of power distribution to a small island community and marina on Tangier Island in the Chesapeake Bay. This improvement consisted of upgrading the existing distribution substation with a new 25 kV 2-bay box distribution structure. Earth Contact Products (ECP) collaborated with PowerServices, Inc. (PSI) to design and install a helical foundation support system as part of the substation upgrade. Feasibility EvaluationThroughout the design process, A&Nworked with its partners PSI (design) andT&D Solutions (installation) to identifycost-effective alternatives. Foundationsystems considered included cast-in-placereinforced concrete caissons, precastconcrete foundations, driven steel piles and helical piles. In evaluating all of theoptions, the greatest concern was gettingthe material onto the island, followedclosely by the availability of the equipmentto install the foundations. Clearly, cost,more specifically the installed cost, was asignificant consideration and decisionfactor throughout the process.There were several limiting factors that had to be considered during the design process, the most significant of which was that all of the material had to be barged to the site. With traditional reinforced concrete deep foundations in mind, the cost for installing these piles was projected to be nearly $2,000/cu yd ($262/cu m) of installed concrete. Given that approximately 5 to 6 cu yd (3.8 to 4.6 cu m) of concrete would be required for this structure, the cost was significantly high for this project. What’s more, because the components of the concrete mix would have to be barged and then hand mixed on site, there was concern regarding both the time required to complete the piles and the quality of the installed concrete. For the driven pile alternative, the availability, or lack thereof, of equipment and material cost resulted in a total cost estimate that was more expensive than that of the concrete piling alternative. The high material cost for the piles, which was more than double than the cost of concrete, was due to the number and size of piles needed to resist the overturning moment. Ultimately, the team selected the helical pile alternative. The decision to a use helical pile foundation system was based on many factors, not the least of which was the remote location of the project site and the difficulties associated with getting material, equipment and construction personnel to the project site."

Jan 1, 2017

By K. E. Darnell

Drilled pier foundations have long been a favored foundation type for heavily loaded structures. Drilled piers derive their load-bearing capacity from end-bearing, and/or sidewall friction. This type of foundation is used in many geologic settings, including those areas underlain by hard carbonate rock, such as limestones and dolomites. When properly designed and constructed, drilled piers provide high load-carrying capacity in both compression and uplift. However, carbonate rock is often subject to intense differential weathering resulting in the formation of an irregular bedrock surface, sinkholes and caves; consequently, the investigation for, and the design of, drilled pier foundations is often complex. Further, the construction may be difficult and costly. This paper discusses geotechnical investigative procedures which can be employed to develop foundation design criteria and reduce the frequency of changed conditions. Finally, state-of-the-art construction practices and quality control techniques are discussed.

Jan 1, 2010

By James N. Mure

The paper describes the design development and construction of bored piles at Pindersfield Hospital, Wakefield, U.K. The piles were of monopile type. Monopile is the term used to describe piles which are constructed without pile caps so that the superstructure columns bear directly on the pile top. Pile geotechnical design was developed from the Site Investigation data and testing of two preliminary piles. Final design philosophy is described. Pile structural design was developed from the loadings applied by the superstructure, and the requirements, tolerances and limitations of monopile construction techniques. Construction was closely controlled in order to achieve a ?right first time? result. The conclusion gives a critique of the system and its value.

Jan 1, 2008

By Frank Haehnig

Ground freezing is a technique which is used more and more in tunnelling under complex ground conditions. This paper will present three case studies which highlight different aspects of the ground freezing technique when applied in urban environment. The first project is the City-Tunnel in Leipzig, Germany, which is being built beneath the central station and which is the largest ground freezing project currently under construction in Germany. The second case study is part of the North-South-Line project in Amsterdam, Netherlands where ground freezing will be carried out to al-low the TBM drive through old wooden foundation piles. The freeze tubes for this project will be driven using Horizontal Directional Drilling (HDD). The last project is the Hallandsas Tunnel Sweden where the ground freezing equipment has to be installed against high water pressure. The paper illustrates that ground freezing can be implemented in difficult ground conditions such as soft ground, highly fractured rock and high water pressure. The case studies highlight the importance of good workmanship. With the increasing numbers of large tunnels being constructed in difficult ground conditions the paper concludes that the complex case studies presented will be-come more representative for future tunnel projects in urban environments.

Jan 1, 2008

By Sam X. Yao

In construction of drilled shafts under water, placing concrete in the shafts is technically demanding and involves complex construction logistics. Past construction experience has demonstrated that high quality concrete can be placed in drilled shafts under water with a proper concrete mix and proper placement techniques. However, a significant number of failures have occurred which have resulted in excessive cost overruns and delays. These problems may have occurred because proper underwater concrete construction techniques have not been widely disseminated within the industry. This is a technical area where competent design and sound construction planning can achieve a significant reduction in both risk and cost. This paper will discuss some key technical issues in the concrete mix design, concrete production and placement for the drilled shaft construction. The paper also describes two lesson-learned case histories from drilled shaft construction projects.

Jan 1, 2013

By James S. Graham

Marine design and construction methods are presented on the caisson foundations for the tower piers at the Brooklyn, Ben Franklin, Delaware Memorial 1st, Tappan Zee, Walt Whitman, Throgs Neck, Verrazano Narrows, Delaware Memorial 2nd, and Newport Bridges. All of the bridges are founded on caissons, bearing on bedrock, soil, or piling. Caissons at the Tappan Zee Bridge are partially supported by piling and partially by buoyant forces. General subsurface conditions for each are provided. The purpose of this paper is inform engineers how bridge foundations using caissons were built over major waterways in the Northeastern USA in the past, anticipating a surge of new bridge construction in the near future.

Jan 1, 2013

By Theodore W. Vogelpohl

Augered cast-in-place piles have proven to be effective, adaptable and economical for projects throughout the Ohio River Valley. Specifically, they have been used extensively for high-rise structures, sports stadia and large commercial developments along the Cincinnati, Ohio and Northern Kentucky Riverfront. They have been designed and utilized as relatively short toe resistance piles in bedrock, and intermediate to long toe and shaft resistance piles in granular outwash deposits above the bedrock. They have been designed for large axial compression loads as well as moderate axial tension loads and lateral loads. This paper presents a few load test results that demonstrate the range of capabilities of augered cast-in-place piles in the variable subsurface profile along the Cincinnati, Ohio/Northern Kentucky Riverfront.

Jan 1, 2005

By G. W. Plant

This paper describes the design philosophy and construction details of piles between 25m and 32m deep to support 160m high and 110m base diameter cooling rowers for a major power station. It is sited on deep expansive soil where a vast plantation of Eucalypts had been felled. The depressed water table is expected to rise, leading to swell of the soil and uplift forces on the piles. These forces, combined with the complex loading from the cooling towers, led to design tensile loads up to 20MN (2 000 tons) per pile. When competent stable material was present hand excavated underreams 3m in diameter were constructed for the piles sup-porting the shells. However, in some areas it was not possible to form an effective underream and an innovative solution was sought. This comprised unstressed dowels in the underlying sandstone which were formed by percussion drilling through void formers cast into the piles.

Jan 1, 2010

By Dan Brown

Deep foundation contracting for transportation projects in the United States has typically followed the design-bid-build model in which contractors bid on a specific work product according to relatively inflexible prescriptive specifications. With continuous flight auger piling and the many types of proprietary drilled displacement auger piling, there appear to be advantages to contracting this work according to a different model. This paper provides a discussion of the use of a performance specification for this work in which the contractor has greater freedom to choose the most appropriate foundation system and also greater responsibility for the performance of the completed foundation. With public agencies subject to open bidding, this type of contractual arrangement presents opportunities to encourage innovation. There are also challenges for implementation in public works projects, notably the selection of qualified contractors and the verification of performance requirements on production foundations.

Jan 1, 2006

By Michael T. Lambert

The purpose of the this paper is to demonstrate the benefits of using additional instrumentation during load tests of auger-cast-in-place piles. Traditionally, only load and butt displacement are determined during load tests. The results from and methods used to instrument 15 auger-cast-in-place (ACEP) piles as part of six projects are included herein. By instrumenting the piles, the distribution of load along the pile length and load transfer can be determined, allowing the pile capacity to be adjusted or the length/diameter of the pile to be adjusted for the a given required load. The majority of the piles tested were designed as end bearing piles on either shale or limestone bedrock. No discussion of Geotechnical Instrumentation can be started without acknowledgement of the "Red Book." The actual title of the book is Geotechnical Instrumentation for Monitoring Field Performance, by Mr. John Dunnicliff, John Wiley and Sons, 1993. Anyone undertaking an instrumentation program should thoroughly review the Red Book, paying particular attention to Chapters 3 and 4. Instrumentation should not be done just because it can be done. There must be an unanswered question or questions that can be answered with measured data before instrumentation should be considered.

Jan 1, 2000

By J. G. La Fonta

The rapid development of real-time monitoring technology for the construction of large underground structures in urban areas can be attributed to: the zero-risk objective, the need for transparency between all parties involved and the control of real cost within the budget. Real-time monitoring can be an integral part of the construction contract (for example when compensation grouting is required) or independent, in particular when measurements of existing structures and buildings bordering the project are to be taken before construction starts. Three examples of extensive field instrumentation schemes are described: a large road tunnel in the Moscow suburbs, a new metro line in Amsterdam and major redevelopment works at a busy Central London rail interchange.

Jan 1, 2006

By Roderic A. Ellman

The new Woodrow Wilson Bridge (WWB) will replace the existing bridge over the Potomac River to connect Alexandria, Virginia to Prince Georges County, Maryland. The new WWB will extend approximately 1.1 miles across the river, with a 367-ft long bascule span in the main river channel where the water depth is about 36 ft. The bridge is primarily comprised of fixed spans in relatively shallow water and a bascule span over the navigation channel. The subsurface soil profile was quite variable along the bridge alignment. In Virginia, there was fill over soft Alluvial deposits underlain by dense Terrace deposits, as well as remnant foundations from a former ship yard. At the bascule span, there was up to 50 ft of a soft organic silty clay layer underlain by a deep deposit of stiff Cretaceous clay. Along the Maryland approach, there were Alluvial deposits over dense Terrace deposits over stiff Cretaceous clays and dense Cretaceous sands. The variation in subsurface conditions led to the selection of alternative deep foundations that suited the specific conditions and were based on the design phase testing program, from which ultimate design capacities were determined. During construction, there were instances of unexpected pile performance, notably different than that experienced during the design phase testing, requiring changes to the contract installation criteria and re-design. This paper will present the types of deep foundations used for the project, the performance criteria assumed during the design, the measured performance and difficulties encountered during construction, and the resulting remedial actions, i.e., changes to contract installation criteria and/or re-design due to the unanticipated field conditions.

Jan 1, 2009

By Matthew Janes

The RC Harris Filtration Plant, which treats the majority of the fresh water for over 2.5 million Torontonians, is a Canadian Architectural Heritage site demonstrating a classic example of Art Deco Architecture. The facility is undergoing an expansion to install an underground sludge treatment capability. Perched atop a bluff on the North shore of Lake Ontario the structure enjoys a commanding presence on the Lake Ontario shoreline. A series of underground tanks were proposed for the hillside below the structure, which when covered would preserve the building?s architectural presence. However, the plan required two, stepped excavations 12 m and 10m deep into compact, wet sands over stiff clays and clayey silts. Concerns regarding the original structure influenced designers to set the lateral deflection limit for the front footing of the existing structure at 4 mm, (0.03% excavation depth). The design-build team indicated at the time of tender that the movement criteria was unattainable using the tender design. Analysis indicated installation effects and overall elastic movement of the soil mass beneath the building would result in movements of 7 to 9 mm at the structure. Through extensive FLAC analysis and a novel construction geometry the design-build team crafted an alternative that produced significant savings over the original concept. Based upon the analysis the design-build team negotiated a new deflection criteria dictating a maximum of 2.0 mm of movement across the critical expansion joint between the Filter Building front footing and the tank slab beyond. The contractor invested in additional pre tender soils investigation to support the refined design process. The FLAC analyses indicated the Filter Building movements would be elastic and distributed up to 50 m back beneath the front footing of the structure. An extensive precision monitoring program proved construction related movements of 6 to 10 mm horizontal at the front footing. Extensometers placed at two locations over the critical interior tank expansion joint showed no measurable movements. The overall monitoring program, including inclinometers, tilt meters, tie back extensometers (smart cables) and tie back load cells indicated a good match between recorded movements and loads and those predicted by FLAC Analysis.

Jan 1, 2006