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The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
Part 2: Installation Processes/Equipment
Andres Baquerizo, P.E., HJ Foundation Company
The Deep Foundations Institutes Cast-in-Place Piling Seminar- KC '09
Process Summary
Drill to required depth using continuous-flight,
hollow-stem auger
Begin pumping grout (expel cork)
Build up target grout head on auger
Withdraw auger at constant rate to produce a
target over-supply per length of pile
Continue pumping grout until auger tip reaches
ground surface
Insert Reinforcing bar or cage
2
Caissons/Shafts or Barretes/
LBE
Augered Pile
Augered Pile
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
Vs Shaft/Caisson
The Deep Foundations Institutes Cast-in-Place Piling Seminar- KC '09
Equipment
Hollow Stem Auger
Drill Bits
Leads/Torque Arm
Hydraulic Gearbox
Hydraulic Power Unit
Grout Pump
Crawler Crane
3
Typical Equipment
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
GEAR BOX
PILE LEADS
TORQUE ARM
HYDRAULIC POWER UNIT
CRANE
STICKERS
CRANE
MAST
BOOM
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
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Hollow Stem Auger
Continuous flight auger
3 inch inside diameter pipe
Auger diameters: 12, 14, 16, 18, 20, 22,
24, 30, 36, 42 and 48 inches
Auger section lengths: 4, 5, 10, and 20 ft
Weight ranges from about 70 lbs per ft
for 12 inch, to 120 lbs per ft for 24 inch,
and 200 lbs per ft for 36 inch
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
AUGER CONNECTORS
Torque Resistant
Fluid Tight
Ease of assembly disassembly
Bayonet Connector
API Connector
Hex Connector
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Drill Bits
Basic Bit - Pengo bit
Basic Rock Bit - fitted with carbide teeth
Clay Flight Bit - for clay soils
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
Cutting Head for IGM Application
Leads/Torque Arm
Leads provide the guide for the gearbox to
travel up and down on during drilling
Leads can either be fixed to the crane boom
or hung from a cable
Torque Arm - steel pipe designed to absorb
torque from drilling operation - optional
Hydraulic Spotter - used for tiebacks and
battered piles
Traveling Guide-maintain stability of auger
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
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The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
Gearbox
Hydraulically operated top head drive
Travels up and down the leads
Torques range from about 15,000 ft-lbs to
90,000 ft-lbs or more
Weighs 2,000 to 10,000 lbs
(down force in addition to the auger weight)
Rotational speed ranges from 30 to 60 rpm
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
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SWIVEL
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
Hydraulic Power Unit
Provides the hydraulic power to turn the
gearbox and auger
Typically mounted on the back of a crawler
crane to aid in mobility
The higher the hp rating, the greater the
torque and rotational speed for drilling
Horsepower ratings range from about
200 hp to 750 hp
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
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The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
Grout Pump
Hydraulically operated, positive displacement piston-ball valve
pump
Pump pressures typically around 350 psi at pump outlet
Stroke displacements range from about 0.4 to 1.7 cubic feet per
stroke
Grout hoses typically 2 to 3 inch diameter
Can pump grout several hundred feet
Grout typically delivered by ready mix trucks
Pump Calibration-Usually performed by counting the number
of pump strokes required to fill a 55 gal (7.35 cu ft) barrel
Note: All 55 gallon barrels are not created equal-measure barrel,
calculate volume
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
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The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
Stroke displacements range
from 0.4 to 1.7 cft per stroke
(40 to 170 cyds/hour)
Crawler Crane
Capacity and boom lengths vary with
project conditions
40 to 100 ton cranes most typical
40 ton crane - 40 ft of up to 18 inch auger
60 ton crane - 60 ft of up to 18 inch auger
100 ton crane - 100 ft of up to 18 inch auger
150 ton crane - 100 ft of up to 24 inch auger
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
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40 60 60
90
69 80
100 155
85
120
155
120 130 100 100
200
220
335 440
440 440
700 700 700
1,200
2200
0
400
800
1200
1600
2000
2400
1980 1983 1988 1994 2010 1996 2000 2004 2002 2004 2005 2006 2014
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Years
Typical Pile Lengths (ft)
14-inch 16-inch 18-inch
30-inch
24-inch
36-inch
Future 42-inch
Reference Evolution of theFoundation Industry Met Miami Development Miami, Florida, Carlos Ortiz, P.E. & Matthew Meyer, P.E. Langan
Engineeringand Environmental Services, Inc. presentedin DFI referencingO-cell Tests on Augered Cast-in-PlacePiles, Edwin W. Hickey and
Andres M. Baquerizo of HJ Foundation, and J ohn Hayes of Loadtest, presented in DFIs Augered Cast-in-PlacePileCommitteeSpecialty Seminar:
Augered Cast-in-PlacePiles on J une22, 2007 in Coral Gables, FL.
Augered cast-in-place milestones
2012
18-inch
145 ft
2012
36-inch 152 ft
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
Use of full length reinforcing as Tension Reinforcement & instant
quality control for Augered cast-in-place piles.
Augercast piles are not comonly designed with full
length reinforcing. The questions is Can & Has it
been done?
18-inch 145 Ft
36-inch 122 Ft
30-inch 130 Ft
YES
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
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36-inch 152 Ft 30-inch 155 Ft
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
Batter Piles - Typically Inclined 1: 6 or less
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Full length reinforcing instant quality control method?
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
Pile Cut Off When Required
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
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5200 ton
O-cell
Load Test: Top Down, O-cell & Statnamic Testing
3000 ton Top Down
1500 ton Top Down
4500 ton
Statnamic
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
Installation Close to Structures
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
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Install Augered Piles Close to Utilities?
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
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2.2 Low Head Room/Limited Access
(LHR-APG) Piles
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
(LHR) Limited Head Room Installation
Used where overhead clearances are at least 8.5 ft
Track-mounted or forklift mounted drilling
equipment
Piles are drilled with auger sections typically 3 ft
to 10 ft in length
Installation time much longer than with crane-
mounted equipment
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
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Typical Limited Headroom (LHR) Rig
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
Low Headroom Pile Installation
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
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The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
Power Pack, Grout Pump
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
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Restricted Access Piles
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
30Ft 50Ft
4Ft
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Drilled displacement type pile - (pro's/con's)
Augered cast-
In-Place Pile
Drilled
Displacement
Limestone
cannot be
Displaced
DISPLACEMENT EQUIPMENT LIMITATIONS - (pro's/con's)
Variable top of limestone
elevations iterbeded with
soft layers
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Numbering Print
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
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Submittals & Pile Cap Detail
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
Part 3: Pile Materials
Andres Baquerizo, P.E., HJ Foundation Company
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PILE MATERIALS
Ready-Mix Grout Steel Reinforcing
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
3.2 Grout
Portland cement
Flyash
Sand (fine to coarse)
Grout aid
(fluidifier, non-shrink additive)
Water
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
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Typical Grout Mix (cubic yard proportions)
752 lbs cement
225 lbs fly ash
2400 lbs sand
3 lbs grout aid
W/C ratio: 0.45 to .50
Compressive strength: 4,000 psi (28 day)
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
Compressive strengths are
typically referenced to 2 X 2
cubes. Compressive strength
tests on cylindrical (L=2D)
specimens will produce about
0.85 of those on cubes (see
ASTM C780-06, p482)
Compressive strengths in the range of 3000 psi to 5000
psi are common. Maximum available compressive
strength is dependent upon available materials and varies
regionally. Compressive strengths of 9000 psi have been
used (South Florida)
Grout Strengths
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
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Importance of Testing Samples
Quality Control
Fresh tests
Cured tests
Represents the pile
Evaluates the material
Predict future material behavior
Compressive strength
Proportions in the mix
Determines compliance
Specifications
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Part 1: Field Sampling & Testing
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
ASTM C172
Standard Practice for Sampling
4
Proper Sampling Techniques
Important Factors
Qualified Field Testing Technicians
Area for testing/storing
No disturbances, vibrations
Level surface
Frequency of sampling Specifications
Time
<15 min obtain first & final portions
of composite sample
Flow cone & temperature within 5 min
Strength test specimens within 15 min
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
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4
Size
Strength test specimens min 1ft
3
Flow cone & temperature
specimens may be smaller
Representative of the condition of
the grout
Revolving Drum Mixer
Specimens obtained from
discharge stream
Specimens obtained from auger
tip (DFI)
Collect after All water and
admixtures added
Proper Sampling Techniques
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
Temperature
Thermometer capable to measure 30F-120F
Sensor embedded in >3 in of grout
Make sure no voids
Leave in 2-5min
Report to nearest 1F
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Field Tests: Temperature
ASTM C1064
Standard Test Method for
Temperature of Freshly Mixed
Hydraulic-Cement Concrete
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
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Flow Cone Test
Fluidity
Measures the time of outflow of the grout
Recommended 70-78F
Flow Cone Test
1 min before introducing grout drain cone with
water
Close the outlet, introduce grout up to point gage
Start stop watch, remove stopper
Stop watch at first break in continuous flow
Flow Cone Test
Recommends at least 2 tests with times within 2 s
Flow time 15-25 seconds
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ASTM C939
Standard Test Method for Flow
of Grout for Preplaced-
Aggregate Concrete (Flow Cone
Method)
*If light not visible, not acceptable
inchdiameter
Field Tests: Flow Cone
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
ASTM C109
Standard Test Method for Compressive
Strength of Hydraulic Cement Mortars
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Field Sampling: Strength Samples
Sampling Cubes
2 in x 2 in x 2 in cube molds
No more than 3 compartments
Separable in 2 sections
Coat with release agent
Sampling Cubes: Mixing the Grout
Following flow cone test:
Return batch to mixing bowl
Scrape sides of bowl
Mix for 15 seconds at medium speed
Allow to stand 90 seconds with no cover
Repeat
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
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ASTM C109
Standard Test Method for Compressive
Strength of Hydraulic Cement Mortars
5
Sampling Cubes: Molding
Pour molds < 2 min 30 seconds after mixing
Fill each mold halfway ( ASTM C1107)
Puddle each mold with gloved finger five
times to consolidate
Fill all compartments to top and puddle
Smooth off tops of cubes
Trowel at 90
3 samples per composite sample for each
period of test (7, 14, 28 day)
Field Sampling: Strength Samples
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
ASTM C39
Standard Test Method for Compressive
Strength of Cylindrical Concrete
Specimens
5
Sampling Cylinders
Length 2x diameter
Coat with release agent
Place grout in layers
Tamp according to diameter
Into layer below ~1
Tap outsides 10-15 times
Remove excess grout
Field Sampling: Strength Samples
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
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Water content
Hydration of cement
Cement/water glue
As hydration continues, strength bonding
increases
5
Field Tests: Water Content
Unhydrated particles
Partially hydrated particles
Hydrated cement
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
Water content
Hydration of cement
Cement/water glue
As hydration continues, strength bonding
increases
Development of strength
Pores between cement filled
Denser, stronger, less-permeable grout
Depends on initial volume of pores (w/c)
Water/cement ratio
(Weight of the water)/(weight of cement)
45%-60%
Want to
Minimize pore space
Provide sufficient water for hydration
Check batch ticket
5
Low w/c Highw/c
Low porosity High porosity
Cement
suspended
inwater
Fully
hydrated
cement
Field Tests: Water Content
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5
Extreme Temperature Influences
High temperatures ACI 305.1
Rapid rate of hydration, early setting
Chemical admixtures
Reduce water demand
Improve workability
Cement, water, aggregate temperatures
Water is easiest to cool
Low Temperatures ACI 306R
Slow rate of hydration, late setting
Insulation
Other influences
Evaporation due to
Wind
Dry weather
Direct sunlight
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
Proper Storage: Initial Curing
Immediately move to initial curing area
Level surface, free from vibrations/disturbances
Stored up to48 hours
60-80F
Environment preventing moisture loss
Proper Storage: Final Curing
Keep in moist room for 20-72h
73.5+5.5F
For 1 day compressive strength samples
Strip molds at 24 +1 hr
Strip remaining molds at 72 +1 hr
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Proper Storage/Curing
ASTM C31
Standard Practice for Making
and Curing Concrete Test
Specimens in the Field
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
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Cubes vs. Cylinders
Cylinders
Lower strength results (~15-20%)
Geometry
Cubes
High strength results
More confinement
More consistent performance
5
Compressive Strength Testing
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
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ASTM C109
Standard Test Method for
Compressive Strength of
Hydraulic Cement Mortars
Determination of Strength
Place specimen in testing machine
Apply load rate between upper and lower
plates to 200-400 lbs/s
Specimens made from same batch
Average and report to nearest 10 psi
Determination of Strength
Specimens must be surface-dry
Smooth and parallel
No loading on uneven surfaces
Uneven surface area (lbs/in
2
)
Discard specimens (grinding >few thousandth
of an inch)
Test Age Permissible Tolerance
24 h + h
3 days + 1 h
7 days + 3 h
28 days + 12 h
Compressive Strength Testing
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
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Capping Methods
Compressive forces evenly distributed
Consistent and accurate results
Different capping methods affect strength
Sulfur-mortar
Neoprene pads & metal retaining rings
ASTM C617
Standard Practice for Capping
Cylindrical Concrete Specimen
Compressive Strength Testing
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
Other Roles of Grout
in APG Piles
The injection of grout under
pressure is considered to improve
the soil in the pile area.
Grout acts to stabilize the hole until
it hardens and becomes a pile.
The fresh grout column must be
capable of accepting reinforcing
steel.
In order to properly serve these purposes,
the grout must be in a fluid state.
(DFI manual States a Flow Cone Rate of 10 to 25 seconds through a opening in the Flow Cone)
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
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3.3 Steel Reinforcement
Cages
Single center bar
High strength (150 ksi) thread bar
Combination of cages and center
bars
Pipes
All elements should be fitted with
centralizers to properly position
them in the pile
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
Reinforcing Cage Placement
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
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Reinforcing Cage with Wheels
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
Centralizers for Center Bars/Pipes
Football for typical Center Bar Centralizer for Pipe Reinforcement
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
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Note 1: The length and configuration of the reinforcing steel cage
can greatly impact the successful insertion of pile reinforcement
into the grout. The addition of steel surface area (closely spaced
circular ties with seismic hooks for example) has a significant
impact on deep placement.
Note 2: High static pressures in the fresh grout column forces fluid
from the grout into permeable soils, making steel placement
difficult. At the bottom of a 50 column of fresh grout, the pressure
is about 3.6 tons per square foot.
Local codes and pile loads dictate pile reinforcement
design, but consideration must be made as to the
constructability of installing massive post-set pile
reinforcement elements. Consult a piling professional
to discuss constructability issues and alternatives such
as spiral cages, pipes, etc.
Pile Reinforcement Placement Issues
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
The Deep Foundations Institutes Augered Cast-in-Place Pile Short Course Houston 2012
Break