@ USS. Department of Transportation Publication No. FHWA NHI-03-018 Federal Highway Administration December 2002 NHI Course No. 132070 Drilled Shaft Foundation Inspection PARTICIPANT WORKBOOK BP "| National Highway Institute NIENOTICE The contents of this report reflect the views of the authors, who are responsible for the facts and the accuracy of the data presented herein. The contents do not necessarily reflect policy of the Department of Transportation. This report does not constitute a standard, specification, or regulation. The United States Government does not endorse products or manufacturers. Trade or manufacturer's names appear herein only because they are considered essential to the objective of this document. Version 1:12-02Version 1: 12-02 7 REPORT FHWA-NHI-03-18 2, GOVERNMENT. Technical Report Documentation Page 3, RECIPIENT'S CATALOG NO, ACCESSION NO. 4. TITLE AND SUBTITLE Participant Workbook ~ Drilled Shaft Foundation Inspection T AUTHORS) Ronald Williams, P.E.; Darrel Burnett, P-E.; and James Savidge 9. PERFORMING ORGANIZATION NAME AND ADDRESS Ryan R. Berg & Associates, Inc. 2190 Leyland Alcove Woodbury, MN_ 55125 "5. REPORT DATE December 2002_ 6. PERFORMING ORGANIZATION CODE 8, PERFORMING ORGANIZATION REPORT NO, 10, WORK UNIT NO, 11, CONTRACT OR GRANTNO. DTFHG61-01-T-25071 1 12, SPONSORING AGENCY NA National Highway Institute Federal Highway Administration U.S. Department of Transportation _ Washington, D.C. IND ADDRESS, Is. SUPPLEMENTARY NOTES FHWA Technical Consultant: Peter Osborn, P.E. COTR - Larry Jones, Christopher Newman This course is an extension of similar course prepared by Will Florida Department of Transportation. 16, ABSTRACT This manual is the Participant’s Workbook for FHWA NHI course No. 132070 Drilled Shaft Foundation Inspection, This manual contains contains copies of each slide, room for student note taking, and some reference notes. A copy of this workbook is provided to each participant. 13, TYPE OF REPORT & PERIOD COVERED 114, SPONSORING AGENCY CODE Miams Earth Sciences (by the first three authors) for the 17-KEY WORDS Drilled shafts; equipment; drilling tools; construction inspection; earthwork; wet shafts; dry shafts; casing; reinforeing cage; concreting 20, SECURITY CLASSI. || Unclassified 19, SECURITY CLASSI. Unclassified 1-1 If, DISTRIBUTION STATEMENT No restrictions, 21, NO. OF PAGES 22. PRICE, 776 Participant WorkbookParticipant Workbook Drilled Shaft Foundation Inspection December 2002 TABLE OF CONTENTS LESSON NO. CONTENTS. PAGE 1 Welcome and Introduction 11 2 Course Overview 24 a. Course Background 26 b. Inspector's Role 2-40 3 Dry Shaft Construction 34 a. When Used 37 b, Dry Shaft Construction Process 31 . Typical Problems 349 4, Wet Shaft Construction At a. When Used aT b, Wet Shaft Construction Process 415 c. Slurry 4-29 d. Typical Problems 4-48 5 Casing Construction Method 5-1 a, When Used 56 b, Casing Construction Process 5-11 c. Typical Problems 5-26 6 Auger Rigs & Equipment 64 a, Terminology 66 b. Rigs 69 c. Bits & Tools 6-26 7 Soils & Rock Identification TH a, Why Subsurface Investigations 7-6 b. Soil/Rock Investigation, %REC and RAD 78 . Soil & Rock Identification 7-20 d. Soil Boring Log 7-33 8 Construction Documents 84 a. Plans and Specifications 86 b, Sample Plan Set 818 6. Drilled Shaft Installation Plan 8-34 d. Plan Set Governing Order 8-49 Version 1: 12-02 1-2 Participant WorkbookParticipant Workbook Drilled Shaft Foundation Inspection December 2002 TABLE OF CONTENTS (Continued) LESSON NO. CONTENTS PAGE 9 Assembling Your “Tool Box" ot a, Sample Inspector Tools Checklist 99 b, Review Plans 9-10 c. Typical Inspection Forms 417 d, Sample Drilled Shaft Inspection Checklist 919 10. Contractor & Equipment Arrive on-Site 10-4 a. Sample Drilled Shaft Inspection Checklist Questions 10-10 (Numbered 1-18. M Shaft Excavation & Cleaning 144 a. Trial Shaft 11-9 ‘Sample Drilled Shaft Inspection Checklist Questions (Numbered 19-22). b. Production Shafts 11-14 ‘Sample Drilled Shaft Inspection Checklist Questions (Numbered 23-40). 12 Reinforcing Cage 124 Sample Drilled Shaft Inspection Checklist Questions 12-7 (Numbered 41-47) 13, Conereting Operations 13-1 a. Concrete for Drilled Shafts, Slumps 13-7 b. Concrete Placement 13-47 c, Sample Drilled Shaft Inspection Checklist Questions 13-22 (Numbered 48-55) d. Possible Problems 13-30 e. Concrete Forms, Calculations and Volume Curves 13-37 Version 1: 12-02 1-3 Participant WorkbookParticipant Workbook Drilled Shaft Foundation Inspection December 2002 TABLE OF CONTENTS (Continued) LESSON NO. CONTENTS PAGE 14, Post Installation & Integrity Testing 14-1 a. Post Installation Load Tests 14-6 1. Load Tests 14-7 2. Integrity Tests 14-18 b, Sample Drilled Shaft Inspection Checklist Questions 14-39 (Numbered 56-61). c. Pay Items 14-48 15. Safety 15-4 Appendix A- Glossary of Terminology Appendix B- Inspector Math Tip Sheets Appendix C- Sample Forms, Checklists, and Charts Appendix D- List of Resources ‘Appendix E- Chapter 15, FHWA Guide Specifications Appendix F- Chapter 4, FHWA Subsurface Investigation Reference Manual & Modified Unified Description ‘Appendix G- Sample Drilled Shaft installation Plan Version 1: 12-02 1-4 Participant WorkbookLesson 1- Welcome and Introduction LESSON 1 WELCOME AND INTRODUCTION DRILLED SHAFT FOUNDATION INSPECTION DECEMBER 2002 fersion 4: 12-02 1-5 Participant WorkbookLesson 1- Welcome and Introduction FOUNDATION INSPECTION COURSE @ Highway Administration NHI Course 132070 Welcome to the Drilled Shaft Foundation Inspection course. Version 1: 12-02 1-6 Participant WorkbookLesson 1- Welcome and Introduction FHWA GEOTECHNICAL PROGRAMe» 9/20/2002 f Version 1: 12-02 ae Participant WorkbookLesson 1- Welcome and introduction National Geotechnical — | INSPECTOR QUALIFICATION Version 1: 12-02 1-8 Participant WorkbookLesson 1- Welcome and Introduction Objective The development of a nationally accepted qualification program that will serve to improve quality, ensure uniformity and establish a minimum standard of construction for geotechnical work. 7 Version 1: 12-02 1-9 Participant WorkbookVersion 1: 12-02 Lesson 1- Welcome and Introduction » NATIONAL State/Industry/FHWA initiative (Office of Infrastructure/NHI) > Driven Piling, Drilled Shafts, Subsurface Investigations, MSEW and RSS, Soil Nail Walls! Anchored Walls, Earth Embankments > Coordinated with National Regional Certification Groups 1-10 Participant WorkbookLesson 1- Welcome and Introduction Current Status | » Endorsed by AASHTO Subcommittees (Bridges, Materials, Construction) > Task Group has developed a Strategic Plan for the ea development of 6 modules. > Development undenway for Drilled Shafts and Driven Piles Implementation Jan 2003 Version 1: 12-02 1-11 Participant WorkbookLesson 1- Welcome and Introduction Modules 1 a2 Drilled Shafts & Driven Piles > To be modeled after Florida Program | | > Will include inspection of Drilled Shaft and Driven Pile Construction > Training modules to be administered by the Regional Certification Groups Version 1: 12-02 1-12 Participant WorkbookLesson 1- Welcome and Introduction Task Group Representatives of Regional Certification Groups: > Midwest, Missouri DOT, Mike Fritz > MidAtlantic, Virginia DOT, Ashton Lawler > New England, Vermont AOT, Chris Benda | > Southeast, Florida DOT, Sastry Putcha > Western, Oregon DOT, Jan Six | > Western, Idaho DOT, Garth Newman FHWA: > Peter Osborn, RI Division > Sam Mansukhani, MRC > Charles Luedders, WRC Version 1: 12-02 4-13 Participant WorkbookLesson 1- Welcome and introduction Industry Technical Support »>ADSC, James Cahill > PDCA, George Goble > DFI, Geordie Compton Version 1: 12-02 4-14 Participant WorkbookLesson 1- Welcome and Introduction Bridge Website | www.fhwa.dot.gov/bridge Version 1: 12-02 1-15 Participant WorkbookLesson 1- Welcome and Introduction LESSON 1 | WELCOME & INTRODUCTION This indicates the start of a new lesson, Lesson 1 Welcome. Version 1: 12-02 1-16 Participant WorkbookVersion 1: 12-02 Lesson 1- Welcome and Introduction LEARNING OBJECTIVES | + Describe the NHI active learning approach + Identify who is involved, what are their backgrounds, and why are we here 1-17 Participant WorkbookLesson 1- Welcome and Introduction HOUSEKEEPING Please- No Smoking in the facility- Please smoke only in designated areas. Please turn off cell phones and pagers to avoid interruptions to your fellow classmates. : Make sure you have signed in at the registration desk, where you can also get information on any CEUs. Agenda 3 Days + 8:00 AM to 5:00 PM, Day 1 & 2 + Homework Assignments + Day 3, Morning Review Session: Exam in late morning- Exam is 50 questions with a two hour time allocation. Version 1: 12-02 1-18 Participant WorkbookLesson 1- Welcome and Introduction | Your Instructors | po fm Lead Instructor- Asst. Instructor- Version 1: 12-02 1-19 Participant WorkbookLesson 1- Welcome and Introduction Now, please tell us who you are. Version 1: 12-02 1-20 Participant WorkbookLesson 1- Welcome and Introduction RESOURCES | + The Participant Workbook | * Drilled Shafts: Construction Procedures & Design Methods FHWA Publication No. FHWA-IF-99-025 + Drilled Shaft Inspector's Manual www. dfiorg www. adsc-iafd.com + Your Experienced Inspectors and State DOT Resources + Math refresher CD under development | 7 Po The primary course material is contained within the Participant Manual, which is the manual in front of you. The FHWA Guide Specifications were utilized as the “specifications” for the course. These guide specifications can be found in FHWA Publication No. FHWA-IF-99- 025, Drilled Shaft Construction Procedures & Design Methods, Chapter 15. There are many additional resources available to you from a variety of organizations and agencies including: Deep Foundations Institute (DF!) 420 Charlotte Place, Third Floor Englewood Cliffs, N.J. 07632 Phone: (201) 567-4232 Fax: (201) 567-4436 Association of Drilled Shaft Contractors P.O. Box 550399 Dallas, TX 75355-0339 Phone: (214) 343-2091 Fax: (214) 343-2384 In addition, many State Departments of Transportation may have related material Version 1: 12-02 4-21 Participant WorkbookLesson 1- Welcome and Introduction COURSE KEYS Your Manual WE CAN'T HELP IF | |_ You DON'T ASK COMPLETE THE THE EVALUATION \ Top of the page eueen is the slide currently on the screen. Follow along with the instructor. — Bottom of page may, or may not, contain notes, tips, specifications, etc. The dumbest question is the question not asked. If you have a question, ask it, because there are probably 3 or 4 other participants with the same question in mind. Remember, our goal is to assist you in gaining the information necessary to pass the Qualification examination. Many times, we, the course developers, believe we have developed the course in an easy to understand and comprehensive fashion. However, it is your perception that counts, so, please complete the Evaluation sheets for the course. The majority of the time, changes for the better in courses do not come from the designers, but from the participants. Your manual is setup for ease in following the course. The top of the page contains the slide that is currently being displayed on the screen. The bottom contains tips, comments, illustrations, or specifications that in general are related to the slide subject matter and the Instructor's commentary. Version 1: 12-02 4-22 Participant WorkbookLesson 1- Welcome and Introduction [Backgroun Information Version 1: 12-02 1-23 Participant WorkbookLesson 1- Welcome and Introduction COURSE CONTENT 4. Welcome and Introduction 2. Course Overview 3. Dry Shaft Construction 4, Wet Shaft Construction 5. Cased Shaft Construction 124 Version 1: 12-02 1-24 Participant WorkbookVersion 1: 12-02 Lesson 1- Welcome and Introduction COURSE CONTENT CONTINUED Auger Rigs & Equipment Soils & Rock Identification Construction Documents Assemble your “Tool Box” ). Contractor and Equipment arrive on Site 1-25 Participant WorkbookVersion 1: 12-02 Lesson 1- Welcome and Introduction COURSE CONTENT CONTINUED, 11. Shaft Excavation and Cleaning 12. Reinforcing Cage 13, Concrete Operations 14, Post Installation & Integrity Testing 15. Safety Concerns 128 1-26 Participant WorkbookLesson 1- Welcome and Introduction WHY A QUALIFICATION COURSE? To comply with Code of Federal Regulations (CFR 637) and provide instruction to qualify personnel for Drilled Shaft Construction Inspection | | This regulation states: | “Each State shall have Quality Assurance | | Procedures...” | |All sampling and testing data to be used in the | |acceptance decision... shall be executed by qualified | | sampling and testing personnel.” This type of qualification training is occurring across the nation. Virtually every state has some sort of training program that they initiated to comply with the Code of Federal Regulations. CFR 637 requires that personnel conducting sampling and testing on transportation projects shall be Qualified. The process for accomplishing this goal was left up to the individual states and therefore, some have their own Programs, while others have formed “consortiums” consisting of several states, utilizing a common Program. Version 1: 12-02 1-27 Participant WorkbookVersion 1: 12-02 Lesson 1- Welcome and introduction LEARNING OBJECTIVES + Describe the NHI active learning approach + Identify who is involved, what are their backgrounds, and why are we here 1-28 Participant WorkbookLesson 1- Welcome and Introduction | DMY QUESTIONS? THE ROAD BEING A CERTIFIED DRILLED Do you have a question in mind? Ask it!! Version 1: 12-02 1-29 Participant WorkbookNOTES Version 1: 12-02 1-30 Participant WorkbookLesson 2- Course Overview LESSON 2 COURSE OVERVIEW DRILLED SHAFT FOUNDATION INSPECTION | DECEMBER 2002 Version 1: 12-02 241 Participant WorkbookLesson 2- Course Overview LESSON 2 COURSE OVERVIEW NOTES Version 1: 12-02 2-2 Participant WorkbookLesson 2- Course Overview LESSON 2 COURSE OVERVIEW | Lesson 2- Course Overview Version 1: 12-02 2-3 Participant WorkbookLesson 2- Course Overview + Communication & Coordination Background Information During this Course Overview lesson, we will: Explain the general role, duties and importance of the Inspector. Explain the coordination and communication with the Engineer and Contractor required of the inspector. Identify the drilled shaft construction methods, process and the equipment and tools utilized Version 1: 12-02 2-4 Participant WorkbookLesson 2- Course Overview LEARNING OBJECTIVES | + Explain the general role, duties and importance of the Inspector. + Explain the coordination and communication with the Engineer and Contractor required of the Inspector. | Version 1: 12-02 2-5 Participant WorkbookLesson 2- Course Overview THE COURSE BASIC COURSE REQUIREMENTS + Must be taught for the novice Inspector + Must cover the “Specifications” (Chapter 15: Guide Drilled Shaft Construction Specifications; FHWA Publication No. FHWA-IF-99-025) | This course was developed for the beginning to intermediate Inspector. The overall goal of the course is to provide the participant a solid base of information on which to build their inspection skills and knowledge. Drilled Shaft Inspection is based upon inspecting items for verification to a set of "specifications". As this is a nationwide course, the Federal Highway Administrations Guideline Specifications for Drilled Shaft Construction were selected as the “specifications” for the course. Version 1: 12-02 26 Participant WorkbookLesson 2- Course Overview PSYCHOLOGY & LOGIC + First Impressions + Logical Sequence Background Information Construction Process Equipment Nomenclature The Inspector’s Role Two significant parts of developing the course were the need to address the “Psychology” part of being a Drilled Shaft Inspector and secondly to present the course in a logical sequence. Version 1: 12-02 27 Participant WorkbookVersion 1: 12-02 Lesson 2- Course Overview PSYCHOLOGY. FIRST IMPRESSIONS + “Inspect”- to look closely at or over; or view closely or critically + In pile driving, hammer blows give the Inspector a certain degree of “comfort” + The Drilled Shaft Inspector is unable to see what is happening underground- not much “comfort” 2-8 Participant WorkbookLesson 2- Course Overview Version 1: 12-02 29 Participant WorkbookLesson 2- Course Overview THE INSPECTOR’S ROLE, DUTIES & RESPONSIBILITIES Version 1: 12-02 2-10 Participant WorkbookLesson 2- Course Overview DRILLED SHAFT INSPECTOR’S ROLE “Serve as a representative of the State | Ensure the work is performed in accordance) | with the approved plans and OVERVIEW The purpose for a Drilled Shaft Inspector is to serve as a representative of the State to assure that the State gets what it is paying for. Every job is constructed with a set of guidelines called the Project Plans & Specifications. Part of the Inspector's duty is to monitor the job according to the Specifications. If any part of the work is done outside of the Specifications, then it becomes imperative that it be "fixed" as quickly, inexpensively, and as safely as possible. Therefore, the drilled shaft Inspector serves as the eyes, the ears, and the reporter for the job. Version 1: 12-02 244 Participant WorkbookLesson 2- Course Overview DRILLED SHAFT INSPECTOR’S ROLE | + Remember who you represent + Do not delay or interfere with the Contractor unnecessarily + Remember the Goal- Constructing a project in accordance with the approved documents | Le a tee ae Remember who you represent: the State- perform you job in a professional manner. Use common sense- do not delay the Contractor unnecessarily or interfere with his operations. You and the Contractor have a common goal- see that a project is constructed- the Contractor needs to build it and You are there to monitor and assure that the construction is in general accordance with the approved plans and specifications. Version 1: 12-02 2-12 Participant WorkbookLesson 2- Course Overview DRILLED SHAFT INSPECTOR’S DUTIES | + Bea “Recorder” + Be a “Reporter” Version 1: 12-02 2413 Participant WorkbookLesson 2- Course Overview DRILLED SHAFT INSPECTOR’S DUTIES + Make accurate, unbiased observations + Be a “Recorder” + Document events: consistent + Perform your duties promptly omplete & + Complete reports & forms + Be a “Reporter” accurately + Keep forms and diary up-to-date + Keep Project Engineer informed INSPECTOR ATTITUDE The Inspector should concern himself with making accurate, unbiased observations of all important drilled shaft construction events. This is very important if construction proceeds other than anticipated. If this is the case, the Inspector should not assume faulty operation on the part of the Contractor; the cause may be unanticipated site conditions, errors or omissions on the part of the designer, or equipment malfunction. The record kept by the Inspector is the only form of tangible data to make an engineering judgment whenever installation problems arise. Elimination of potential causes can best be made on the basis of accurate and complete data observations. The Inspector should always be aware that prompt performance of these duties is required 80 that follow-up work can be performed expeditiously, Job progress photographs should be made. Completeness is as important as accuracy. Hence the saying, “Document, Document, Document’ and be consistent with your documentation. Version 1; 12-02 2-14 Participant WorkbookLesson 2- Course Overview DRILLED SHAFT INSPECTOR’S RESPONSIBILITES PLANS KNOW THE SPECIFICATIONS The Designer knows this project by heart, they have lived it for probably a few years. The Contractor knows each detail of constructing the shafts. They went through the plans and specs with a fine tooth comb during the bidding process. The Inspector is brought in almost at the last moment so it is imperative that you become familiar with the details of the project as quickly as possible. The Inspector should receive, in advance of the project starting, the approved plans and Drilled Shaft Installation Plan. Review these documents for items that effect you Version 1: 12-02 2415 Participant WorkbookLesson 2- Course Overview DRILLED SHAFT INSPECTOR’S RESPONSIBILITES | Keep the Project Engineer Informed Notify the Project Engineer soon| enough to make a difference +Reduces the impact to the! | project schedule, cost or quality | ee Itis too late to close the gate after the horses are out. Well, the same Is true in performing inspection on construction projects. If you observe that something is going to be performed outside of the approved plans and specifications, notify the Contractor and immediately notify the Engineer. If you observed that the reinforcing cage construction does not appear to be in accordance with the approved plans & specifications, don't wait until the cage is in the ground, or worse yet the conerete is being placed, to say something. Hence- DOCUMENT AND REPORT AS SOON AS POSSIBLE Version 1; 12-02 2-16 Participant WorkbookLesson 2- Course Overview eee eeeeeee oO I LEARNING OBJECTIVE #1 | Explain the general role, duties and | importance of the Inspector. | What is the Inspector's Role? As a “Recorder” and “Reporter”, the Inspector’s duties include what? | Version 1: 12-02 2417 Participant WorkbookLesson 2- Course Overview LEARNING OBJECTIVE #1 Explain the general role, duties and importance of the Inspector. What two types of observations do Inspectors make? | | What is the overall goal to be achieved? Version 1: 12-02 218 Participant WorkbookVersion 1: 12-02 Lesson 2- Course Overview | | chain | iF COORDINATION & COMMUNICATION | CRUTHORITY 2-419 Participant WorkbookLesson 2- Course Overview COORDINATION & COMMUNICATION | {When to Contact the Engineer + If interpretation of specifications is required + If work is performed outside of the plans or specifications + Work or items requiring Approval Your communication and coordination with the Contractor and Engineer is a significant factor in a drilled shaft project running smoothly If the Inspector and the Contractor aren't communicating and coordinating with each other, work will be performed that is not inspected, thereby necessitating possible unpaid re-do by the Contractor. No one likes that situation. Your initial communication should begin at the Pre-Construction meeting and, if held, a Pre-Construction Inspector’s meeting conducted by the Project Engineer or his representative. If your review of the plans and specifications reveals something that might be a problem, bring it to the Engineers attention. If a specification clarification or applicability decision is needed, contact the Engineer. It is not the Inspector's responsibility to make these decisions. The Inspector monitors for conformance. Notify the Engineer and document out of conformance work. Notify the Contractor of the condition outside the specifications. Generally the Inspector does not approve a change in process, procedure or equipment, This is the Engineer's responsibility. Most Project Engineers would welcome getting a brief update at the end of the day on where the project stands and having the opportunity to discuss significant events that ‘occurred during the day. Remember the Chain of Authority- the Project Engineer has someone above them to report to also. Version 1: 12-02 2-20 Participant WorkbookLesson 2- Course Overview | | COORDINATION & COMMUNICATION + Remember, you are a team with a goal of constructing a drilled shaft | + If you observe potential non-conformance, notify the Contractor, prior, to avoid the situation occurring | + Avoid delaying Contractor 221 The Contractor's goal and the Inspector's goal are the same- build the project, Communicate possible conflicts or out of tolerance work as soon as possible~ youl find that in some cases, the Contractor will begin to appreciate the heads up. If something appears to be out of conformance, tell the Contractor right away. Don't wait until the damage is done, With proper coordination and communication, you can avoid falling into situations that can cause possible delays. For example, if you think they will be placing the cage tomorrow that you saw them constructing today, ask if so. Then make sure to get to the site early enough to do the inspection so the cage is good to go or modified, if required, in time to be ready. Version 1: 12-02 2-21 Participant WorkbookLesson 2- Course Overview | PRE-CONSTRUCTION MEETING + Review the approved Drilled Shaft Installation Plan, and have any questions answered + Discuss applicable Special Provisions + Discuss administrative issues It is essential that a Pre-Construction meeting be held and attended by the Resident Engineer, Shaft Designer, Geotechnical Engineer and the Inspector. This is in addition to the general pre-bid meeting. This will allow for going over the Contractor's Installation Plan submitted to see if there are any concerns. Itwill alert the Inspector as to potential problem areas that could affect the installation. The Designer should point out the operation or equipment that are critical for acceptance of the shaft This meeting will open up the communication between the team and enhance communication. Version 1: 12-02 2.22 Participant WorkbookVersion 1: 12-02 Lesson 2- Course Overview PRE-CONSTRUCTION MEETING + Discuss and resolve any conflicts. + Discuss any special site considerations + Document Meetings 2-23 Participant WorkbookVersion 1: 12-02 Lesson 2- Course Overview LEARNING OBJECTIVE # 2 | Explain the coordination and communication with the Engineer and Contractor required of the Inspector. When should the Inspector contact the Engineer 2 In situations requiring interpretation of the specifications or approvals, the Inspector should contact who? 224 2-24 Participant WorkbookVersion 1: 12-02 Lesson 2- Course Overview LEARNING OBJECTIVE # 2 “| Explain the coordination and communication with the Engineer and Contractor required of the Inspector. Should the Inspector only contact the Engineer when there is a problem or clarification needed? By attending what, may the Inspector start their rapport and communication with the Engineer? 2-25 Participant WorkbookVersion 1: 12-02 Lesson 2- Course Overview LEARNING OBJECTIVES + Explain the general role, duties and importance of the Inspector. | + Explain the coordination and communication with the Engineer and Contractor required of the Inspector. 2-26 Participant WorkbookLesson 2- Course Overview DRILLED | QUALIFIED ; | SHAFT ee i | | INSPECTOR) Version 1: 12-02 2-27 Participant WorkbookLesson 2- Course Overview NOTES Version 1: 12-02 2-28 Participant WorkbookLesson 3- Dry Shaft Construction LESSON 3 DRY SHAFT CONSTRUCTION DRILLED SHAFT FOUNDATION INSPECTION DECEMBER 2002 Version 1: 12-02 3-1 Participant WorkbookLesson 3- Dry Shaft Construction LESSON 3 DRY SHAFT CONSTRUCTION NOTES Version 1: 12-02 3-2 Participant WorkbookLesson 3- Dry Shaft Construction LESSON 3 DRY SHAFT CONSTRUCTION fe ; es Version 1: 12-02 3-3 Participant WorkbookLesson 3- Dry Shaft Construction Where Are We? (+ Dry Method cc Construction Process Version 1: 12-02 3-4 Participant WorkbookLesson 3- Dry Shaft Construction | LEARNING OBJECTIVES | « Describe the dry shaft construction | process. | * Describe typical/potential construction problems associated with dry shafts Version 1: 12-02 3-5 Participant WorkbookVersion 1: 12-02 Lesson 3- Dry Shaft Construction WHAT IS A DRY SHAFT? A shaft excavation that can be excavated to its designed depth without the need for slurry or casing. 36 3-6 Participant WorkbookLesson 3- Dry Shaft Construction WHEN USED + Inplace Soil/rock will keep the hole walls from collapsing. + Construction of the | shaft can be in relatively dry conditions. FHWA Publication IF-99-025 xxx.31 DRY CONSTRUCTION METHOD: The dry construction method shall be used only at sites where the ground water level and soil and rock conditions are suitable to permit construction of the shaft in a relatively dry excavation, and where the sides and bottom of the shaft may be visually inspected by the Engineer prior to placing the concrete. The dry method consists of drilling the shaft excavation, removing accumulated water and loose material from the excavation, placing the reinforcement cage, and concreting the shaft in a relatively dry excavation, Commentary The dry method is by far the least expensive method for drilled shaft construction Given the choice of drilling methods, Contractors will try the dry method even in soil or rock of dubious quality. In fact, one reason for constructing a trial shaft is to determine whether dry construction will be possible or whether more expensive methods (casing and/or wet methods) may be required. During the construction of trial shaft the Engineer should insure that the sides and bottom of the drilled hole do not degrade prior to completion of concreting, and the drilled shaft inspector must continue to observe the same during construction of production shafts. For that reason a trial shaft is recommended before the Contractor is permitted to use the dry method on production shafts. Version 1: 12-02 3-7 Participant WorkbookLesson 3- Dry Shaft Construction | STABLE VS. UNSTABLE SOILS ‘Unstable Stable Caving _ Non-Cavin Soils Soils Cohesive Cohesive] ] soils Soils Se Water table 2} | Unstable caving soils Stable non~ caving prevent maintaining soils maintain | hole stability hole stability Version 1: 12-02 3-8 Participant WorkbookWATER TABLE AT OR BELOW Lesson 3- Dry Shaft Construction THE SHAFT TIP ELEVATION Generally, soils cave hole stability Water table Water table Set at the water table preventing Stable Non-Caving Soils Cohesive Soils S| Water table below shaft tip does not impact hole stability 39 Version 1: 12-02 Participant WorkbookLesson 3- Dry Shaft Construction CONSTRUCTION IN RELATIVELY DRY CONDITIONS Dry construction defined _ by amount of water | accumulation permitted | | | over a specified time period." "> | Water] FHWA Publication IF-99-025 xxx,31 DRY CONSTRUCTION METHOD: Commentary ‘Approval of the dry method should be based on the following criteria: The dry construction method shall only be approved by the Engineer when the trial shaft excavation demonstrates that less than 12 inches (0.305 m) of water accumulates above the base over a one hour period when no pumping is permitted; the sides and bottom of the hole remain stable without detrimental caving, sloughing or swelling over a four-hour period immediately following completion of excavation; and any loose material and water can satisfactorily removed prior to inspection and prior to concrete placement. The Contractor shall use the wet construction method or the casing construction method for shafts that do not meet the above requirements for the dry construction method. Version 1; 12-02 3-10 Participant WorkbookLesson 3- Dry Shaft Construction “CONSTRUCTION PROCESS Drill the shaft excavation Cleanfshaft by removing the cuttings & seepage water Position the reinforcing cage Place the concrete n ‘osition Np ‘Competent, Th Non-Caving Soils. —— ( \ Water wie (ll This procedure consists of drilling the shaft excavation, removing the cuttings and accumulated seepage water and placing the shaft concrete in a relatively ‘ dry excavation. Please note, however, that there may be limitations on the amount of water that is allowed in the shaft over a specified time period to qualify for the dry construction techniques Version 1: 12-02 3-11 Participant WorkbookLesson 3- Dry Shaft Construction Version 1: 12-02 3-12 Participant WorkbookLesson 3- Dry Shaft Construction FHWA Publication IF-99-025 xxx.31 DRY CONSTRUCTION METHOD: Commentary It is also important to establish during pre-construction meetings with the Contractor how much water and loose geomaterial on the bottom of the borehole will actually be permitted at the time the concrete is poured. Ordinarily, 3 inches (75 mm) of water is tolerable if cohesive concrete mixes are used, and loose sediment up to % inch (12.7 mm) thick over one-half of the area of the base is acceptable. However, there may be situations in which these criteria are not strict enough (e.g., when high base resistance is required), so that the base cleanliness conditions for each job must be discussed and clearly understood prior to the start of construction. Version 1: 12-02 3-13 Participant WorkbookLesson 3- Dry Shaft Construction POSITION 14 xxx.50 REINFORCING STEEL CAGE CONSTRUCTION AND PLACEMENT: The reinforcing stee! cage, consisting of longitudinal bars, ties, cage stiffener bars, spacers, centralizers, and other necessary appurtenances, shall _be completely assembled and placed as a unit immediately after the shaft excavation is inspected and accepted, and prior to concrete placement. COMMENTARY Occasionally the Contractor may excavate beyond the specified bottom of hole elevation either due to excessive cleaning or errors in measurement during drilling. The question of whether or not to require the Contractor to extend the reinforcing cage should be made by the designer on a project-by-project basis. If a full-length cage is required for structural reasons the following could be included in the specification: “if the bottom of the constructed shaft elevation is lower than the bottom of the shaft elevation in the plans, a minimum of one half of the longitudinal bars required in the upper portion of the shaft shall be extended the additional length by adding longitudinal reinforcing bars at the bottom of the cage. Tie or spiral bars shall be continued for the extra depth and the stiffener bars shall be extended to the final depth. All longitudinal and transverse bars must be lap spliced or spliced with mechanical splices. Welding to the reinforcing stee! will not be permitted unless specifically shown in either the plans or special provisions.” Version 1: 12-02 3-14 Participant WorkbookLesson 3- Dry Shaft Construction Commentary Continued Reinforcing steel can corrode by rusting in the zone above the zone of full soil or rock saturation. Below the zone of full saturation, galvanic corrosion can occur. Therefore, it is important that no steel rebar be allowed to come in contact with the soil or rock, not even incidentally. Steel skids or chairs, or skids or chairs constructed from any other electrical conductor, should never be permitted Version 1: 12-02 3-15 Participant WorkbookLesson 3- Dry Shaft Construction FHWA Publication IF-99-025 xxx.60 CONCRETE PLACEMENT: ..Conerete shall be placed as soon as possible after reinforcing steel placement. Concrete placement shall be continuous from the bottom to the top elevation of the shaft..... COMMENTARY A desirable slump-time relationship for a typical drilled shaft concrete mix is to have a minimum slump of 4 inches (102 mm) existing everywhere within the concrete column after placement of shaft shall be extended the additional length by adding longitudinal reinforcing bars at the bottom of the cage. Tie or spiral bars shall be continued for the extra depth and the stiffener bars shall be extended to the final depth. All longitudinal and transverse bars must be lap spliced or spliced with mechanical splices. Welding to the reinforcing steel will not be permitted unless specifically shown in either the plans or special provisions. Reinforcing steel can corrode by rusting in the zone above the zone of full soil or rock saturation. Below the zone of full saturation, galvanic corrosion can occur. Therefore, it is important that no steel rebar be allowed to come in contact with the soil or rock, not even incidentally. Steel skids or chairs, or skids or chairs constructed from any other electrical conductor; should never be permitted Version 1: 12-02 3-16 Participant WorkbookLesson 3- Dry Shaft Construction LEARNING OBJECTIVE # 1 Describe the dry shaft construction process. What are the 4 general steps in dry shaft construction? What is perhaps the most important step in getting a good shaft? Version 1: 12-02 3-17 Participant WorkbookVersion 1: 12-02 Lesson 3- Dry Shaft Construction LEARNING OBJECTIVE # 1 Describe the dry shaft construction process. What determines if a shaft is constructed in the dry? What is the purpose of a “trial shaft” when the Contractor proposes the Dry construction method? 3-18 Participant WorkbookVersion 1: 12-02 Lesson 3- Dry Shaft Construction TYPICAL PROBLEMS * Soils are unstable and Contractor attempts to force dry shaft construction - caving problems will lead to soil inclusions in the shaft concrete thereby affecting shaft integrity. + Water table is too high - caving problems will lead to soil and sediment inclusions in the shaft concrete thereby affecting shaft integrity. Participant WorkbookLesson 3- Dry Shaft Construction TYPICAL PROBLEMS | | + Excavation open too long prior to concrete placement- soils that were capable of maintaining hole stability slowly lose that ability, resulting in caving leading to soil inclusions in the shaft concrete. Version 1: 12-02 3-20 Participant WorkbookLesson 3- Dry Shaft Construction LEARNING OBJECTIVE #2 Describe typical/potential construction problems associated with dry shafts. Name a soil type that can present a problem with dry shaft construction. Water tables above the bottom of shaft elevation may present what potential problems for dry shaft construction? - 321 Version 1: 12-02 3-21 Participant WorkbookVersion 1: 12-02 Lesson 3- Dry Shaft Construction LEARNING OBJECTIVES * Describe the dry shaft construction process. * Describe typical/potential construction problems associated with dry shafts 3-22 Participant WorkbookLesson 3- Dry Shaft Construction Version 1: 12-02 3-23 Participant WorkbookLesson 3- Dry Shaft Construction NOTES Version 1: 12-02 3-24 Participant WorkbookLesson 4- Wet Construction Method LESSON 4 WET CONSTRUCTION METHOD DRILLED SHAFT FOUNDATION INSPECTION DECEMBER 2002 Version 1: 12-20 4-1 Participant WorkbookLesson 4- Wet Construction Method LESSON 4 WET SHAFT CONSTRUCTION NOTES Version 1: 12-20 4-2 Participant WorkbookLesson 4- Wet Construction Method | LESSON 4 | WET SHAFT | | CONSTRUCTION Version 1: 12-20 4-3 Participant WorkbookVersion 1: 12-20 Lesson 4- Wet Construction Method Where Are We? + Dry Method > Wet Method Construction Process 44 Participant WorkbookLesson 4- Wet Construction Method LEARNING OBJECTIVES | + Recognize the difference between dry and wet | | shaft construction. + Describe the wet shaft construction process. + Describe and identify mineral and polymer slurry and other drilling fluids. + Describe typical construction problems associated with wet shafts. Version 1: 12-20 45 Participant WorkbookLesson 4- Wet Construction Method - — _| WHAT IS A WET SHAFT? Often called the “slurry-method”, wet shaft construction is when a slurry or water is used to keep the hole stable for the entire depth of the shaft. Version 1: 12-20 46 Participant WorkbookLesson 4- Wet Construction Method = OO re =|| WHEN USED? FHWA Publication IF-99-025 xxx.32 WET CONSTRUCTION METHOD: The wet construction method may be used at sites where a dry excavation can not be maintained for placement of the shaft concrete. This method consists of using water or slurry (mineral or polymer) to maintain stability of the borehole perimeter while advancing the excavation to final depth, placing the reinforcing cage, and concreting the shaft WHEN USED. «When a dry excavation cannot be maintained; cannot manage water seepage + When the sides and bottom of the excavation are unstable; collapsing, caving, sloughing + When loose material cannot be properly removed; sediment, cuttings, slurry, water Version 4: 12-20 47 Participant WorkbookVersion 1: 12-20 Lesson 4- Wet Construction Method WET -VS- DRY? It is more expensive. Requires more Contractor expertise Requires more equipment. The sides of the hole will not remain stable. Accumulated loose material & water cannot be removed. Has more than 12" of accumulated water in the bottom of the shaft. 48 Because the dry method is the least expensive and requires the least expertise, many Contractors will push for the dry method, even when geological conditions indicate that it probably won't be successful. The differences between the two are like night and day. A Contractor experienced at wet shafts can generally handle dry shaft construction, while the opposite is not true. 4-8 Participant WorkbookLesson 4- Wet Construction Method | wer -VS- DRY? The Inspector cannot |F visually inspect the shaft and cannot see what is happening underground Version 1: 12-20 4-9 Participant WorkbookLesson 4- Wet Construction Method WHEN A DRY EXCAVATION CANNOT BE MAINTAINED 74 More than 12° _ | Less than 12" | = Dry | in one hour ae «10 FHWA Pul jon IF-99-025 xxx.32 WET CONSTRUCTION METHOD: The wet construction method may be used at sites where a dry excavation can not be maintained for placement of the shaft concrete... The shaft is considered “wet method’ if more than 12” of water accumulates in the shaft over a one hour period without pumping. Version 1: 12-20 4-10 Participant WorkbookLesson 4- Wet Construction Method WHEN THE SIDES AND BOTTOM OF | HOLE CAN NOT REMAIN STABLE — f oy | As discussed below, if the sides and bottom of the hole cannot remain stable without caving or swelling over a 4 hr period following excavation, then the dry shaft method cannot be used and either the wet or cased method is to be employed. — FHWA Publication IF-99-025 xx,31 DRY CONSTRUCTION METHOD: Commentary the sides and bottom of the hole remain stable without detrimental caving, sloughing or swelling over a four-hour period immediately following completion of excavation;... Version 1: 12-20 411 Participant WorkbookLesson 4- Wet Construction Method WHEN LOOSE MATERIAL AND WATER CAN NOT BE SATISFACTORILY REMOVED - ne If the loose material and accumulated cannot be satisfactorily removed prior to inspection or concrete placement, the wet or cased method is to be employed. : FHWA Publication IF-99-025 xxx.31 DRY CONSTRUCTION METHOD: Commentary and any loose material and water can satisfactorily be removed prior to inspection and prior to concrete placement... Version 1: 12-20 412 Participant WorkbookVersion 1: 12-20 Lesson 4- Wet Construction Method LEARNING OBJECTIVE #1 Recognize the difference between dry and wet shaft construction What constitutes the difference between wet and dry shafts? What is perhaps the most significant difference between dry and wet construction to the Inspector? 4-13 Participant WorkbookVersion 1: 12-20 Lesson 4- Wet Construction Method LEARNING OBJECTIVE #1 Recognize the difference between dry and wet shaft construction Why do Contractors, in general, try to avoid wet shaft construction? a 414 Participant WorkbookLesson 4- Wet Construction Method —_ | CONSTRUCTION PROCESS | Dri the shaft excavation Wet Method Stabilize the hole (Pain ‘water, mineral slurry or polymer slurry) | “ | Drill Stabilize \ Nowe Place Unlike the dry construction method, in this situation the water table may be above the shaft tip elevation or the geology consists of unstable or “caving” soils. Think of trying to dig a hole at the beach or lake near the water's edge. The hole stays open until you reach or get just below the water table or waterline. Then what happens? It collapses. Well the same goes for drilled shafts excavated below the water table or in unstable soils. During the drilling of the hole, a slurry is introduced that “stabilizes” the sides of the hole and prevents the soils from collapsing into the hole. Upon reaching the designed shatt tip elevation, the hole is cleaned, then the rebar cage placed. Unlike the dry shaft method, the concrete is being placed “under the water’ and therefore a tremie is lowered into the hole and the concrete placed through the tremie, which is carefully removed a little at a time to avoid “breaching” the concrete. Version 1: 12-20 4-15 Participant WorkbookLesson 4- Wet Construction Method THE PROCESS Performing wet shaft construction is generally more expensive and difficult than dry shaft construction. Key elements to quality wet shaft construction are: + Experienced Contractor + Proper maintenance of slurry + Clean hole The three items listed above account for the majority of all problems or bad drilled shaft installations. Experienced Contractor- It all starts here. Many General Contractors want to “do it all” and really do not have the experience, expertise or equipment to properly install wet : shafts. If an inexperienced Contractor happens to get the project, you the Inspector are in for a real headache. In fact, the Contractor's inexperience leads to the next two items. Proper Maintenance of Slurry- If the slurry is not maintained properly, (.e.,sand content, viscosity, pH, etc.), there will be problems with either the hole caving, being unable to clean the hole properly or displace the slurry during concrete placement. Clean Hole- if the hole is not clean there is litle chance of having a good quality shaft in the end. Sediment, cuttings and slurry can prevent the concrete from being placed and forming within the shaft in the manner the designer assumed Version 1: 12-20 416 Participant WorkbookLesson 4- Wet Construction Method -—— oo — THE PROCESS There are two forms of “wet” shaft construction: * Static Process + Circulation Process | aa FHWA Publication IF-99-025 There are two general processes for accomplishing wet-method construction. The first process is termed here the "static" process. It is by far the most common process in the United States, The second process is termed the "circulation" process. The primary difference in the two processes is that the cuttings are lifted by the drilling tool in the static method, but they are transported to the surface in the slurry in the circulation method. Circulation driling has the advantage that the cuttings can be pumped in the slurry to a remote point before being removed from the slurry and spoiled Some experts also contend that reverse circulation drilling, the most common form of circulation drilling, produces a cleaner borehole base than ordinary static drilling. Version 1: 12-20 447 Participant WorkbookLesson 4- Wet Construction Method THE PROCESS THE STATIC PROCESS | + Drilled down to the piezometric level | | + Slurry introduced + Cuttings are lifted from the hole FHWA Publication IF-99-025 The first step in the static construction process is to position the drilling equipment and to drill using the dry method until the piezometric surface is reached, the elevation of which has been determined during the subsurface : investigation. At this point, slurry is introduced into the hole, as for the casing method, and drilling is continued. The excavation is carried to the fill depth of the hole, with the slurry in place. During excavation, the top of the slurry column is always kept at an elevation above the piezometric surface. If the piezometric surface is at or above the ground surface (artesian or near- artesian conditions), a surface casing that protrudes above the ground surface to serve as a standpipe is necessary to keep the slurry head at its proper position. Maintaining head position in the slurry column is particularly important with polymer slurries. Either mineral slurry (such as bentonite-based slurry) or polymer slurry can be employed in the static process. Mineral slurry is mixed such that some of the particles of granular soil being excavated are put and kept in suspension and are brought out of the hole when the slurry is flushed from the hole by placing the fluid concrete. Much of the soil being excavated, however, is lifted out with the drilling tool. Polymer slurries, on the other hand, have insufficient gel strength to hold sands in suspension (although silts may be held in suspension for a considerable time) so that all of the cuttings down to the size of fine sand must be lifted out with the driling tool Version 1: 12-20 4-18 Participant WorkbookLesson 4- Wet Construction Method The Static Method | 4 ol om Ly || level SS | 5 Ef | "Temporary surface casing installed (optional Slurry ee i ) } | Hole drilled to completion depth with slurry Slurry Piezometric level __ Version 1: 12-20 4-19 Participant WorkbookLesson 4- Wet Construction Method THE PROCESS THE CIRCULATION PROCESS + Hole is drilled +Slurry level maintained at the ground surface + Cuttings and sand, is circulated to the surface, where it is cleaned and reintroduced down the hole. 0 The circulation process is similar to the static process, except that only bentonite slurries are used, since other minerals and polymers are not capable of transporting solid cuttings effectively. The most common of the circulation processes, the "reverse circulation" process, is summarized here. It is also possible to drill using the ‘direct circulation process.” The general differences in the two will be pointed out In reverse circulation drilling the drill rod (illustration next page) is a hollow pipe. The top of the pipe is connected to a flexible hose that is mated to a vacuum pump located on the ground surface. As the borehole is drilled, the cuttings at the bottom of the hole, directly under the drilling tool, are pushed to the center of the borehole by the special design of the drill and then sucked, along with the slurry, into an orifice at the bottom of the drill pipe and transported to the surface by the vacuum pump. After going through the pump the slurry/cuttings are pumped through another line to a cleaning plant, where the sand, silt and larger particles are removed. The clean slurry is then pumped back to the top of the borehole to be reused, resulting in a "closed loop" process. The slurry level is always maintained at the ground surface to allow the vacuum pump to lift the slurry and cuttings efficiently. Version 1: 12-20 4-20 Participant WorkbookLesson 4- Wet Construction Method The Circulation Method Hole drilled to completion depth with slurry level maintained at ground level ‘Slurry Processor Slurry, with sand & cuttings is re-circulated for processing and reintroduced into Hole cleaned Version 1: 12-20, 4-21 Participant WorkbookLesson 4- Wet Construction Method FHWA Publication IF-99-025 xxx.35.21 STANDARD EXCAVATION: Standard excavation is excavation accomplished with conventional tools such as augers, drilling buckets, and overreaming (belling) buckets attached to drilling equipment of the size, power, torque, and down thrust (crowd) approved for use by the Engineer after successful construction of a trial drilled shaft. The shaft hole is advanced. A temporary surface casing may be installed. Version 1: 12-20 4-22 Participant WorkbookLesson 4- Wet Construction Method STABILIZE Proper cleaning and ee | maintaining of slurry is | z ____ imperative FHWA Publication IF-99-025 xxx,38 SLURRY: Mineral or polymer slurries shall be employed when slurry is used in the drilling process unless other drilling fluids are approved in writing by the Engineer... Aslurry is added to the hole to stabilize the sides and prevent caving. Version 1: 12-20 4-23 Participant WorkbookLesson 4- Wet Construction Method Proper cleaning and maintaining of slurry is imperative. The video shows a cleanout bucket being used to remove sediment from a drilled shaft hole. FHWA Publication IF-99-025 xxx.40 EXCAVATION INSPECTION: Final shaft depths shall be measured with a suitable weighted tape or other approved methods after final cleaning. Unless otherwise stated in the plans, a minimum of 50 per cent of the base of each shaft will have less than 1/2 inch (12.7 mm } of sediment at the time of placement of the concrete. The maximum depth of sediment or any debris at any place on the base of the shaft shall not exceed 1-1/2 inches (38 mm). Shaft cleanliness will be determined by the Engineer. The shaft hole is cleaned to ensure excessive sediments, cuttings and water are removed from the hole. Version 1: 12-20 4-24 Participant WorkbookLesson 4- Wet Construction Method POSITION Proper cleaning and maintaining of slurry is imperative. FHWA Publication IF-99-025 x0x.50 REINFORCING STEEL CAGE CONSTRUCTION AND PLACEMENT: The reinforcing steel cage, consisting of longitudinal bars, ties, cage stiffer bars, spacers, centralizers, and other necessary appurtenances, shall be completely assembled and placed as a unit immediately after the shaft excavation is inspected and accepted, and prior to conorete placement The reinforcing cage is positioned in the hole. Version 1: 12-20 4-25 Participant WorkbookLesson 4- Wet Construction Method xxx.60 CONCRETE PLACEMENT: Concrete placement shall be performed in accordance with the applicable portions specifications on concrete materials in Section xxx.20 of this specification and with the requirements herein. Conerete shall be placed as soon as possible after reinforcing steel placement. Concrete placement shall be continuous from the bottom to the top elevation of the shaft. Concrete placement shall continue after the shaft excavation is filled until good quality concrete is evident at the top of shaft The concrete is placed Version 1: 12-20 4-26 Participant WorkbookLesson 4- Wet Construction Method LEARNING OBJECTIVE #2 Explain the wet shaft construction process. What are the general steps in wet shaft construction? What is perhaps the most important step in getting a good shaft with wet construction? sar Version 1: 12-20 4-27 Participant WorkbookVersion 1: 12-20 Lesson 4- Wet Construction Method LEARNING OBJECTIVE #2 Explain the wet shaft construction process. What may be required at the surface to prevent caving? What are the two types of wet shaft construction processes? 4-28 Participant WorkbookLesson 4- Wet Construction Method xx.38 SLURRY: ..Mineral or polymer slurry shall be employed when slurry is used in the drilling process. During construction, the level of the slurry shall be maintained at a height sufficient to prevent caving of the hole. In the event of a sudden significant loss of slurry to the hole, the construction of that foundation shaill be stopped until either a method to stop slurry loss or an alternate construction procedure has been approved by the Engineer. ssulf approved by the Engineer, the Contractor may use only water as a drilling fluid. Version 1: 12-20 4-29 Participant WorkbookLesson 4- Wet Construction Method WHAT DOES THE SLURRY DO? +Maintains a Stable Borehole Prior to | Concreting Soil While the Hole is Open (Retard | : Maintains High Effective Stresses in the Softening or Loosening) + Facilitates Removal of Cuttings in “Circulation Drilling” FHWA Publication IF-99-025 Drilling slurry is employed as a construction aid in two of the three general methods of drilled shaft construction (the casing method and the wet method), and there can be no doubt that slurry plays an important role in the construction of drilled shafts, When an excavation encounters soil that potentially may cave, filing of the excavation with drilling slurry, with the proper characteristics and at the proper time, will allow the excavation to be completed to full depth with litte difficulty. The slurry must have the proper characteristics during the drilling operations and at the time the concrete is placed. Version 1: 12-20 4-30 Participant WorkbookLesson 4- Wet Construction Method TYPES OF SLURRY Mineral Slurry + Natural mineral clays + Bentonite, attapulgite and sepiolite + Attapulgite and sepiolite are typically used in + Bentonite is the most common saltwater environments + Must be hydrated 431 FHWA Publication IF-99-025 Bentonite slurries have been used commonly in drilled shaft construction in the United States since the 1960's, Other processed, powdered clay minerals, notably attapulgite and sepiolite, have been used on occasion in place of bentonite, usually in saline ground water conditions Bentonite and other clay minerals, when mixed with water in a proper manner, form suspensions of microscopic, plate-like solids within the water. This suspension, in essence, is the drilling slurry. If the fluid pressures within the slurry column in the borehole exceed the fluid ground water pressures in a permeable formation (e.g., a sand stratum), the slurry penetrates the formation and deposits the suspended clay plates on the surface of the borehole, in effect forming a membrane, or "mudcake" that assists in keeping the borehole stable. In order for bentonite particles to break down into these separate plates, the mixing water must first hydrate the bentonite. Not until this process is completed will bentonite slurry be effective. The process requires both mixing effort (shearing) and time -- generally several hours. One of the cardinal rules of drilling with bentonite slurry is that all newly mixed bentonite must be allowed to be hydrated for several hours before final mixing and introduction into a borehole. Bentonite slurry should be added to the borehole only after its viscosity (resistance to flow, discussed later) stabilizes, which is an indication that the bentonite has become fully hydrated. Version 1: 12-20 4-31 Participant WorkbookLesson 4- Wet Construction Method TYPES OF SLURRY / Polymers- are semi-synthetic or totally | synthetic chemical slurries. | FHWA Publication IF-9 Drilling slurries can also be made of mixtures of chemicals called polymers and potable water. Polymers have been used in preference to bentonite in well drilling for some time in Soil profiles that contain considerable clay or argillaceous (clay-based) rock, because bentonite slurries have a tendency to erode clayey rocks and to produce enlargements and subsequent instabilities in the boreholes. Polymer slurries have become popular in drilled shaft construction in all types of soil profiles because they require less conditioning before reuse than bentonite slurries and because they can be disposed of more inexpensively than bentonite slurries. Version 1: 12-20 4-32 Participant WorkbookLesson 4- Wet Construction Method Take Care With Polymers + “iffy” in Silt-Rich Soils + 40-Weight PHPA’s Seem to Perform Better than 30- Weight + Different Products are Different Chemically + Specific Polymer Products Should be Specified on a Site-Specific Basis + Need to be Premixed FHWA Publ Polymer slurries have a mixed record in drilled shaft construction. Their chemistry is different from that of mineral slurries. The normal construction strategy with polymer slurry is to drill the hole under polymer and then let any suspended cuttings settle out before cleaning the hole and conoreting. The time required for this to happen is almost impossible to predict, especially with silts, and for this reason alone, site-specific technique shafts with the proposed polymer product should be prescribed for jobs on which the contractor wishes to use a polymer slurry product. When suspended soil is still settling as the concrete is placed, it can accumulate on top of the column of concrete and become lodged in the rebar cage at an unknown depth, causing a defect. It is also important that polymers be kept out of contact with cement as much as possible during the construction process, since cement will cause the polymer to agglomerate. It is generally regarded at present to be good practice to use heavier weight ("40 weight") polymers than lighter-weight polymers. It is also important that all polymers be premixed prior to placing the polymer in the borehole. Version 1: 12-20 4-33 Participant WorkbookLesson 4- Wet Construction Method TYPES OF SLURRY Blended + a mixture of mineral and polymer slurry. FHWA Publication IF-99-025 Xxx.38 SLURRY: ..If the Contractor proposes to use a blended mineral-polymer slurry, the Contractor shall submit a detailed report specific to the project prepared and signed by a qualified slurry consultant describing the slurry materials, the mix proportions, mixing methods and quality contro! methods. Version 1: 12-20 4-34 Participant WorkbookVersion 1: 12-20 SLURRY COMPARISONS Mineral Slurry Best Application Cohesionless soils Clays and argillaceous rock Difficult- must be hydrated Lesson 4- Wet Construction Method Polymer Slurry Mixabilty | easy Mix Water Sensitivity | Saltwater sensitive YeaiNo “Caking” Ability Best ok Suspension Ability | Best ok _ 1 4-35 Participant WorkbookWater FHWA Publication IF-99-025 xxx.38 SLURRY: If approved by the Engineer, the Contractor may use only water as a drilling fluid. In that case, all of the provisions in the table shown in this section for mineral slurries shall be met, except that the maximum density shall not exceed 70 pof (11.0 kN/mm') Table referred to from Chapter 15, Page 444, SLURRY TESTING - BENTONITE!/ | Item to be OTHER DRILLING FLUID Lesson 4- Wet Construction Method 496 Range of Values | Range of Values. measured | @Time of Slurry | @ Time of est ened _—___Lintraluesian Conetating oo Mud density balance Density | 63.4" - 69.1" pof | 643° - 75.0" pot oY rate = so wAmn® | tor stage | APEt38-1 Secon 1 Viscosity 5 «| Marsh Cone Method 28 to 45 seciquart le {048 seclquart™* | 51.438-1; Section 2.2 - Electric pH meter or pH pH 8-11 8-11 indicator paper strips Sand 7 | Ee ent Moores 4% or less AP LA38-4 “Increase by 2 pef (0.31 kN/m’) in salt water * Standard measurements are in seconds per quart ** 4% at base of drilled shaft excavation for polymer slurries Version 1: 12-20 4-36 Participant WorkbookLesson 4- Wet Construction Method FHWA Publication IF-99-025 xxx.38 SLURR’ .. Desanding equipment shall be provided by the Contractor necessary to control slurry sand content to less than 4 percent by volume at any point in the borehole at the time the slurry is introduced, including situations in which temporary casing will be used. Desanding will not be required for sign post or lighting mast foundations unless shown in the plans or special provisions... Version 1: 12-20 4-37 Participant WorkbookLesson 4- Wet Construction Method The charged slurry passes from the hopper (1) to a scalping vibrating screen (2,) which removed fractions 7% inch (>5mm) and from there to a storage reservoir (3). A circulating pump (4) pumps it into the cyclone (5), which separates the fines from the slurry. Fine particles are discharged via the cyclone underflow (6) and drop onto vibrating dewatering screen (7), which separates out any fines still remaining in the slurry. The treated slurry is discharged into a holding tank (9) via the cyclone overflow (8), then to a separate outside storage tank. An automatic level control (10), operated by a float, keeps the slurry level in the storage reservoir constant during the desanding process. The sand is then discharged from the unit (11). Version 1: 12-20 4-38 Participant WorkbookLesson 4- Wet Construction Method PRINCIPLES OF DESANDING UNIT The charged slurry passes from the hopper (1) to a scalping vibrating screen (2) which removed fractions 7% inch (>5mm) and from there to a storage reservoir (3). A circulating pump (4) pumps it into the cyclone (5) which separates the fines from the slurry. Fine particles are discharged via the cyclone underflow (6) and drop onto vibrating dewatering screen (7), which separates out any fines still remaining in the slurry. The treated slurry is discharged into a holding tank (8) via the cyclone overflow (8), then to a separate outside storage tank, An automatic level control (10), operated by a float, keeps the slurry level in the storage reservoir constant during the desanding process. The sand is then discharged from the unit (11). Version 1: 12-20 4-39 Participant WorkbookVersion 1: 12-20 Lesson 4- Wet Construction Method -—— ke DESANDER ' HYDROCYCLONE {@) Surry rotation develops high ‘contifugal forces ‘throughout the cyclone (4) Liquid moves.“ Inward ana spiraling vortex (9) Suspended sods driven towards Sand downward in Solids Discharge 4-40 Participant WorkbookLesson 4- Wet Construction Method DESANDER HYDROCYCLONE Liquid Discharge (2) Slurry rotation develops high centrifugal forces throughout the cyclone... (1) Pressurized slurry enters tangentially... (4) Liquid moves (3) Suspended solids inward and driven towards wall upward as and downward in spiraling vortex accelerating spiral... y Solids Discharge This figure shows the principles on how a hydrocyclone works. The slurry is pumped from the shaft and enters the hydrocyclone tangentially under pressure. The slurry rotation develops high centrifugal forces throughout the cyclone. The suspended solids are driven outward towards the wall and downward due to the shape of the hydrocyclone. As they move downward they increase in acceleration while at the same time liquid moves inward and upward as a spiraling vortex. Solids are discharged out of the bottom of the cone, liquid is discharged at the top. Along with mud testing technologies, desanding units are for the most part, a product of the oil drilling industry. Consequently there are a number of manufacturers in the United States producing for various. needs including the oil industry, slurry wall construction and for drilled shaft contractors. Some contractors have assembled their own components and created their own designs. As an inspector therefore, you are apt to see a number of different configurations and brand names. Efficiencies are likely to vary depending on how well the units are designed for the specific materials being excavated. Version 1: 12-20 4-41 Participant WorkbookLesson 4- Wet Construction Method MANAGING SLURRY FOR BOREHOLE STABILITY + Proper Dosage and Solids Content for Proper Flowability and Cake Properties + Thorough Mixing / Adequate Time for Hydration (Bentonite / Polymers) + Maintenance of Head in Borehole + Maintenance of pH, Hardness, Salts + Minimize Pressures from Tools This slide is the first of three that should be considered a checklist for proper slurry construction. Discuss each point briefly in turn. Be sure to mention that all slurries hydrate water, including polymers. This means that they should be mixed in tanks and held for an appropriate time before introduction in a borehole. Mixing should only be with fresh, potable water, which is buffered with a manufacturer-acceptable compound to raise its pH to a range acceptable to the manufacturer of the product before the slurry stock is added. This is especially important with polymers. Head should always be maintained well above the piezometric surface, as mentioned earlier. This is especially critical for polymer slurries, which are lightweight compared to mineral slurries. Version 1: 12-20 4-42 Participant WorkbookLesson 4- Wet Construction Method RANGES OF SLURRY PROPERTIES (FINE SANDS) —secaeeams Property Bentonite PHPA _ Polymer || Marsh Funnel 28-45 33-45% | (sec / quart) Unit weight 64 - 69" 62-63 (ib/ cu ff) pH 8-11 8-11" Sand Content <4%* <1% Hardness N/A <50 ppm as Ca++ *Before introduction into borehole. Up to 75 pcf or 10% sand permitted before concreting. | |** Higher for vinyls. _| FHWA Publication IF-99-025 These are typical desirable slurry properties. Those shown for polymer slurries are not industry consensus values, but merely guidelines. For example, higher viscosities are acceptable with some products, especially in siltrich soils (to keep the silt in suspension). Some suppliers require slightly different pH ranges for optimum performance. So, consider this only as a general guideline. In actual practice, the manufacturer's guidelines for polymers should be followed, but they should be proved for the project at hand through the construction of one or more technique shafts on the project site. Version 1: 12-20 4-43 Participant WorkbookLesson 4- Wet Construction Method | CONTROLLING SLURRY condition, Tests are conducted for: + Density- the slurry weight + Viscosity- flow: consistency + pH- acidity: alkalinity + Sand Content Control tests are used to maintain proper slurry | | FHWA Publication IF-99-025 Mineral and polymer slurries will have certain desirable characteristics when being used to facilitate excavation. Therefore, certain key properties must be measured to ensure that these characteristics are operative. Testing will be desirable just before the slurry is introduced into the borehole, perhaps on occasion as drilling progresses, and always before concrete is placed For blended slurry, the tests and criteria are the same as for mineral slurry. ‘Some of the tests would normally be used only for designing slurry mixes or for troubleshooting during construction. For most jobs, the mud balance for density, the Marsh funnel or rheometer (preferred) for viscosity, and a pocket pH meter or pH paper are adequate to monitor the properties of the slurry during routine construction operations. Version 1: 12-20 4-44 Participant WorkbookLesson 4- Wet Construction Method [ HISTORY OF PROBLEMS WITH SLURRY T SLURRY PROBLEMATIC TYPES PREPARATION RATING Bagged Properly Mixed and Commercial Hydrated ronee. Bentonite Polymer Premixed (2-4 Slurries hours for hydration) oe Polymer Numerous Slurries Mixed in hole (Not {|| Recommended) | Water Mixed os with Natural Soil {Not Recommended) This slide indicates that the history of drilled shaft construction on FHWA projects has indicated that defects occur in drilled shafts constructed with various types of slurry at different frequencies. This slide indicates the order, with the slurry producing the fewest defects first. Although there is relatively little information on blended slurries, these appear also to have some of the same problems as polymer slurries and should be treated in a like manner (insist on technique shafts with careful inspection of the concrete near the top of the shaft) until more is known. Version 1: 12-20 4-45 Participant WorkbookVersion 1: 12-20 Lesson 4- Wet Construction Method LEARNING OBJECTIVE # 3 Describe and identify miner polymer slurry and other drilling fluids. What are the 2 main types of slurries? What purpose does the slurry serve? 4-46 Parlicipant WorkbookLesson 4- Wet Construction Method LEARNING OBJECTIVE #3 Describe and identify mineral and polymer slurry and other drilling fluids. | If desanding is required, the sand content | of mineral slurry is to be no greater than what %? What common control tests are performed on slurry? | Version 1: 12-20 4-47 Participant WorkbookLesson 4- Wet Construction Method TYPICAL PROBLEMS + Inexperienced Contractor * Dirty Hole + Improper Slurry Control Version 1: 12-20 4-48 Participant WorkbookVersion 1: 12-20 Lesson 4- Wet Construction Method inexperienced Contractor + Doesn't understand the mechanics of what is happening + Underestimates the need for slurry + Uses improper slurry for conditions | + Fails to properly use & control slurry + Doesn't adequately clean the hole | | | | —EEEE a4 4-49 Participant WorkbookLesson 4- Wet Construction Method Dirty Hole + Leaves cuttings and sediment which prevents good placement of concrete + Creates voids in the shaft concrete + Impacts shaft functionality One of the most common problems is improperly controlled slurry, which has more sediment in it that it can hold in suspension. If not properly sampled and tested, goes un-noticed and therefore it settles out. Version 1; 12-20 4-50 Participant WorkbookVersion 1: 12-20 Lesson 4- Wet Construction Method | Dirty Hole | | | Granuiar Soll, Defect In Shatt Granular Soll That. Has Settled Fresh: Concrete ©) 4-51 Participant WorkbookVersion 1: 12-20 Lesson 4- Wet Construction Method Improper Slurry Control + Fails to properly suspend and facilitate the removal of sediments and cuttings * Does not control caving | * Does not control swelling of soils + Hinders slurry displacement during concrete placement + Leads to a dirty hole — 4-52 Participant WorkbookLesson 4- Wet Construction Method FHWA Publication IF-99-025 The shaft on the left was constructed in an uncontrolled bentonite slurry whose unit weight was about 100 pcf and sand content was above 20 percent. Note the exposed rebar at the bottom (trapped sediment) and the ‘exposed rebar about 1/3 of the way down from the top. This coincided with the level of the water table. Apparently, as the sediments being pushed up by the concrete column lost buoyancy at this level the concrete column broke through, trapping the sediments there, The shaft on the right was constructed using bentonite slurry whose properties fell within the ranges recommended here. No defects and no malformations. We should expect to produce shafts like this if specifications are written properly, inspection is competent and contractors are qualified. Version 1: 12-20 4-53 Participant WorkbookVersion 1: 12-20 Lesson 4- Wet Construction Method LEARNING OBJECTIVE #4 Describe typical construction problems associated with wet shafts. What are the 3 main problems associated with wet shaft construction? What is often underestimated by the inexperienced Contractor? 4-54 Participant WorkbookLesson 4- Wet Construction Method LEARNING OBJECTIVE # 4 | Describe typical construction problems. associated with wet shafts. | Improper control of slurry can lead to__? Version 1: 12-20 4-55 Participant WorkbookLesson 4- Wet Construction Method LEARNING OBJECTIVES + Recognize the difference between dry and wet shaft construction. + Describe the wet shaft construction process. + Describe and identify mineral and polymer slurry and other drilling fluids. + Describe typical construction problems associated with wet shafts. Version 1: 12-20 4-56 Participant WorkbookQUALIFIED DRILLED SHAFT INSPECTOR, Any questions in mind? Ask them. Version 1: 12-20 4-57 Lesson 4- Wet Construction Method Participant WorkbookLesson 4- Wet Construction Method NOTES Version 1: 12-20 4-58 Participant WorkbookLesson 5- Casing Construction LESSON 5 CASING CONSTRUCTION DRILLED SHAFT FOUNDATION INSPECTION DECEMBER 2002 Version 1: 12-02 5-1 Participant WorkbookLesson 5- Casing Construction LESSON 5 CASED CONSTRUCTION METHOD NOTES Version 1: 12-02 5-2 Participant WorkbookVersion 1: 12-02 Lesson 5- Casing Construction LESSON 5 | CASING CONSTRUCTION 5-3 Participant WorkbookLesson 5- Casing Construction Where Are We? | —— Dry Method Construction Process Version 1: 12-02 5-4 Participant WorkbookLesson 5- Casing Construction LEARNING OBJECTIVES | + Explain why casing is used in both dry and wet holes + Describe the cased shaft construction process | + Describe typical construction problems associated with the use of casing 55 Version 1: 12-02 5-5 Participant WorkbookLesson 5- Casing Construction WHEN USED? + Where an open hole cannot be maintained. + Where soil or rock deformation will occur, shafts below the water table or caving + Where constructing | overburden. | FHWA Publication IF-99-025 xxx.33 CASING CONSTRUCTION METHOD: The casing method may be used either when shown on the plans or at sites when construction methods are inadequate to prevent hole caving or excessive deformation. in this method the casing may be either placed in a predrilled hole or advanced through the ground by twisting, driving or vibration before being cleaned out. Casings and liners play an important role in the construction of drilled shafts, and special attention must be given to their selection and use. Casings are tubes that are relatively strong, usually made of steel, and joined, if necessary, by welding. Liners, on the other hand, are light in weight and become a permanent part of the foundation. Liners may be made of sheet metal, plastic, or pressed fibers (e.g., SonotubeTM). While their use is much less frequent than that of casings, liners can become important in some situations. Version 1: 12-02 5-6 Participant WorkbookLesson 5- Casing Construction — = 2 SOMEWHAT MIS-NAMED 2 | Though called a construction method, the Contractor is installing either wet or dry shafts, and casing is considered another tool by some | 87 Version 1: 12-02 57 Participant WorkbookLesson 5- Casing Construction [ IN DRY HOLES Casing Vn “P Caving Soils Stable Soils (Non-caving) 58 FHWA Publication IF-99-025 The most common scenario for the use of casing is construction in generally dry soils or rocks that are stable when they are cut but which will slough soon afterwards. In such a case the borehole is drilled, and casing (a simple steel pipe) is quickly set to prevent sloughing, Version 1: 12-02 5-8 Participant WorkbookLesson 5- Casing Construction IN WET HOLES | Casing \ <— Caving Soils ——«— Water table Competent rock! soil shaft is to go into 59 FHWA Publication IF-99-025 Another notable example of a scenario in which casing could be used is a clean sand below the water table underlain by a layer of impermeable limestone or low permeability clay into which the drilled shaft will penetrate. In this case, since the overlying sand is water bearing, it is necessary to seal the bottom of the casing into the underlying rock/soil to prevent flow of water and caving of soils into the borehole. Version 1: 12-02 5-9 Participant WorkbookVersion 1: 12-02 Lesson 5- Casing Construction LEARNING OBJECTIVE #1 Explain why casing is used in both dry and wet holes. Why is casing used in dry holes? What are some reasons for casing in wet holes? 5-10 Participant WorkbookLesson 5- Casing Construction CONSTRUCTION PROCESS Dil the shaft excavation Install casing through caving soils and sealed into relatively imperious, tater Ne shaft by removing the cutings & seepage water Ne the “ee Place the concrete YS ‘Clean Position “Whee ee Dri Caving Sollg. Casing (May be permanent or temporary) ~ Version 1: 12-02 5-11 Participant WorkbookLesson 5- Casing Construction THE CASING CONSTRUCTION PROCESS Generally the casing method is more expensive and difficult than the dry construction method, Key elements to quality cased holes are: + Experienced Contractor + Good casing material + Experienced rig operator Version 1: 12-02 5-12 Participant WorkbookLesson 5+ Casing Construction It is necessary in some construction procedures to seat a temporary casing into an impervious formation such as massive rock. This temporary casing is used to relain the sides of the borehole only long enough for the fluid concrete to be placed. The temporary casing remains in place until the concrete has been poured to a level sufficient to withstand ground and groundwater pressures. The casing is removed after the concrete is placed. Additional concrete is placed as the casing is being pulled to maintain the pressure balance. Thereafter, the fluid pressure of the concrete is assumed to provide borehole stability, The wall thickness of temporary casing should be determined by the Contractor to ensure stability. Most casing is made of steel, and wall thicknesses usually vary from 0.5 inches (13 mm) upwards, with larger thickness for larger-diameter casings. One of the most important uses of casing is to protect workers who must go into the borehole. In the picture above, workers have had to go down the hole to place ‘a chain around a large boulder, which was then lifted to the surface. This is a temporary casing. Version 1: 12-02 5-13 Participant WorkbookLesson 5- Casing Construction Most drilled shaft contractors keep a supply of temporary, reusable steel casing in their yard in a variety of lengths and diameters. Most casing is specified according to its outside diameter. If an inside diameter is specified, the Contractor may have to purchase new casing for the project, which would be costly. Casing comes rolled in outside diameters of 30, 36, 42, 48, etc., inches. Most tools have similar diameters. So to drill a hole with a particular diameter below the casing the Contractor will likely need to use a casing 6 in. larger in OD than the hole diameter below the casing Version 1: 12-02 42° OD casing (probably % inch wall thickness = 41 inch I.D.) Specified shaft Dia = 36 inches 5-14 Participant WorkbookLesson 5- Casing Construction Permanent Casing Uses Effective Karstic High~Capacity Formation Drilled Shaft to Sound Rock River Crossing FHWA Publication IF-99-025 The use of permanent casing is implied by its name; the casing remains and becomes a permanent part of the foundation. An example of the use of permanent casing is when a drilled shaft is to be installed through water and the protruding portion of the casing is used as a form. A possible technique that has been used successfully is to set a template for positioning the drilled shaft, to set a permanent casing through the template with its top above the water and with its base set an appropriate distance below the mudline, to make the excavation with the use of drilling slurry, and to place the concrete through a tremie to the top of the casing One possible objection to the use of such a technique is that the steel may corrode at the water level and become unsightly. Version 1: 12-02 5-15 Participant WorkbookLesson 5- Casing Construction Permanent Casing Uses (Continued) Permanent | Casing | Abandoned Caving Soil at Mine Ground Surface | Version 1: 12-02 5-16 Participant WorkbookLesson 5- Casing Construction TYPICAL, PROCESS. a | Introduce Slurry (and | Maintain Head) Before Caving Soils are Reached | Drill Through Caving Soil Insert and Seal Casing Continue Drilling Below Casing, If Needed Competent Soil Caving Soil Competent Soil FHWA Publication IF-99-025 This is a common situation for casing construction. It is anticipated that casing will be used and the excavation through the zone to be cased proceeds until the caving soil is encountered, at which time slurry may be introduced into the borehole, and the excavation proceeds. Drilling is continued until the stratum of caving soil is penetrated and a stratum of impermeable soil or rock is encountered, The casing is introduced at this point and is dropped, tapped, rotated, and/or pushed into the impermeable soil or rock a distance sufficient to effect a seal. The casing must be tight fitting to the walls of the hole. A bailing bucket or submersible pump may be used to clean the slurry from the casing. A smaller drill is introduced into the hole, one that will just pass through the casing, and the excavation is carried to the projected depth. Version 1: 12-02 5-17 Participant WorkbookLesson 5- Casing Construction Drilling Slurry Competent Soil Caving Soil Competent Soil Introduce Slurry (and Maintain Head) Drill Through Caving Soil Before Caving Soils are Reached Minas Caving Soil | | Caving Soil ‘Competent Soil : Insert and Seal Casing Continue Drilling Below Casing, If Needed Version 1: 12-02 5-18 Participant WorkbookLesson 5- Casing Construction ert TYPICAL PROCESS (cont.) | Drill below the casing ———— Completed Shaft Competent Soil Underreaming Caving Soil Remove casing | | Completed shaft FHWA Publication IF-99-025 A belling tool can be placed on the kelly and the base of the drilled shaft can be enlarged After any reinforcing steel has been placed, the hole should be completely filled with fresh concrete having good flow characteristics. Under no circumstances should the seal at the bottom of the casing be broken until the concrete produces a hydrostatic pressure greater than that of the fluid external to the casing (trapped slurry or ground water). The casing may be pulled and the seal broken when there is sufficient hydrostatic pressure in the column of concrete to lift the slurry that has been trapped behind the casing from the hole. The casing should be pulled slowly during the concrete placement to avoid “preaching” and trapping sediment or slurry in the conerete. Version 1: 12-02 5-19 Participant WorkbookCompetent Soil Lesson 5- Casing Construction Caving Soil Competent Soil Drill below Competent Soil "Caving Soil Underreaming Level of fluid concrete Drilling fluid forced from space between casing and soil Completed shaft Competent Soil = Version 1: 12-02 Remove ca: Competent Soil 5-20 Participant WorkbookLesson 5- Casing Construction 2 == 22 THE PROCESS (FULL-DEPTH CASING) Vibratory - Driver Installation of Casing Drilling ahead of casing Weter Table Remove casing Remiove casing There are sites where the caving formation is a cohesionless soil beneath the water table, with a soft clay or rock below that stratum. An acceptable construction procedure that eliminates the need for slurry in such a case could be the driving of the casing with vibratory equipment, or with other pile- driving equipment, through the cohesionless soil into the impermeable geomaterial below. The use of special drilling rigs, sometimes termed “full-depth casing’ rigs, that simultaneously excavate, rotate and push heavy-walled casing into place, keeping the base of the casing at or below the elevation of the excavating tool at all times. The casing on such rigs, which may be equipped with cutting teeth, actually helps make the excavation. These types of rigs have proved very successful in excavating soils with small boulders on occasion. They can also often be used where otherwise a wet drilling process would be required. Version 1: 12-02 5-21 Participant WorkbookLesson 5- Casing Construction Vibratory TI Driver Vibratory Caving Soil Version 1: 12-02 5-22 Participant WorkbookLesson 5- Casing Construction | TELESCOPING CASING Casing often needs to be inserted into very deep boreholes and/or into very strong geomaterials, which may make it difficult to remove the casings. In such instances, contractors may choose to "telescope" the casing. That is, the first 10 or so feet will be excavated and a large-diameter casing sealed into the geomaterial at the bottom of the hole. A smaller-diameter borehole will then be advanced below the bottom of the casing, and a second casing, of smaller diameter than the first casing, will be sealed into the geomaterial at the bottom of the second-stage borehole. The process can be repeated several times to greater and greater depths until the plan base elevation is reached. With each step, the borehole diameter is reduced, usually by about 6 in. (152 mm ). This procedure is often used where the geomaterial to be retained contains boulders. A Ee ~ »S : “al 42 > “36" ee) yxy Q SHAFT, YS SS go inch DIA. Version 1; 12-02 5-23 Participant WorkbookLesson 5- Casing Construction LEARNING OBJECTIVE #2 Describe the cased shaft construction method. What are the two types of casing? Name three uses for Permanent casing? Version 1: 12-02 5-24 Participant WorkbookLesson 5- Casing Construction LEARNING OBJECTIVE #2 Describe the cased shaft construction method Is slurry sometimes used in the Casing construction method? Version 1: 12-02 5-25 Participant WorkbookLesson 5- Casing Construction TYPICAL PROBLEMS | * Casing not “clean” + Casing not sealed properly + Poor conerete control + Breaching of tremie FHWA Publication IF-99-025 Temporary casing must be cleaned thoroughly after each use to have very low shearing resistance to the movement of fluid concrete. Casing with bonded concrete should not be allowed, because the bonded concrete will increase the shearing resistance between the casing and the column of fluid concrete placed inside the casing, and as the casing is lifted, it is possible that the column of concrete will be picked up, creating a neck or a void in the concrete, usually at the bottom of the casing, that will manifest itself as a defect in the completed drilled shaft. Obviously, the casing should be free of soil, lubricants and other deleterious material. It is important that the casing be sealed in the impermeable formation so as to prevent the slurry from flowing beneath the casing, If the concrete slump is too low, arching of the concrete will occur and the concrete will move up with the casing as it is pulled, thereby creating a gap for slurry to flow into. In addition, if the concrete mix design and time of placement are out of line, the concrete can start setting up and as the casing is pulled the same problem will occur. Breaching (raising the bottom of the tremie above the concrete level) of the “tremie" results in a discontinuous placement, creating voids for slurry and sediment to contaminate the concrete. Version 1: 12-02 5-26 Participant WorkbookLesson 5- Casing Construction Do you have any Questions? Version 1: 12-02 5-27 Participant WorkbookLesson 5- Casing Construction LEARNING OBJECTIVES + Explain why casing is used in both dry and wet holes + Describe the cased shaft construction process + Describe typical construction problems associated with the use of casing 528 Version 1: 12-02 5-28 Participant WorkbookLesson 5- Casing Construction Quiz 1. The Dry shaft method shall only be approved when the trial shaft demonstrates that less than inches of water accumulates above the base over a one hour period when no pumping is permitted gom> OO e Fs 2. Wet shaft construction, which of the following is perhaps the most critical element in getting a good shaft? A clean hole prior to casing A clean hole prior to concreting The use of temporary casing A clean belling tool vom> 3. Vibratory is one of the two forms of wet shaft construction. True False 4, Which of the following describes soils most likely to create a problem with dry shaft construction? A. Loose, cohesionless soils B. Loose, fat clay C. Dense, unfractured hard rock D. Cohesive soils 5. Slurry is never used in the casing construction method. True False 6. Of the following slurries, for which must the Contractor submit a detailed report signed by a qualified slurry consultant? Polymer Water Blended Mineral com> Version 1: 12-02 5-29 Participant WorkbookLesson 5- Casing Construction 7. The specified maximum sand content for polymer slurries at the base of the shaft just prior to concreting is_? A 1% Ba 256 Cc. 3% ey 8. The specified maximum sand content for mineral slurries at any time in the shaft is 2 1% 2% 3% 4% 9Om> 9. List the common slurry control tests. Version 1: 12-02 5-30 Participant WorkbookLesson 6- Auger Rigs & Equipment LESSON 6 AUGER RIGS & EQUIPMENT DRILLED SHAFT FOUNDATION INSPECTION DECEMBER 2002 Version 1: 12-02 6-4 Participant WorkbookLesson 6- Auger Rigs & Equipment LESSON 6 AUGER RIGS AND EQUIPMENT NOTES Version 1: 12-02 6-2 Participant WorkbookLesson 6- Auger Rigs & Equipment | LESSON 6 | AUGER RIGS | a | | EQUIPMENT Version 1: 12-02 6-3 Participant WorkbookLesson 6- Auger Rigs & Equipment Where Are We? + Auger Rigs Version 1: 12-02 6-4 Participant WorkbookLesson 6- Auger Rigs & Equipment LEARNING OBJECTIVES + Identify auger rig components + Locate and employ information on auger rigs + Identify drilling tools and explain their uses 6s Version 1: 12-02 65 Participant WorkbookLesson 6- Auger Rigs & Equipment Crane- This is the carrier or main component- Most common rotary- Can be truck, track, crane or crawler mounted. Power Unit- This unit provides the power that turns the table and kelly Kelly- This is the rod that runs through the table and the tools are attached to. Can be one-piece or telescoping. Table- This is connected to the power unit and is what turns the kelly. Tool- These are the bits, auger, buckets, etc. that go down the hole. Version 1: 12-02 6-6 Participant WorkbookLesson 6- Auger Rigs & Equipment TERMINOLOGY Buckets- generally two types; Digging- for excavating soils or soft rock Cleanout- for cleaning of the shaft Bits- typically are for excavating (drilling) and can be either auger or barrel type. Certain types used for soil and certain types for rock. er Version 1: 12-02 67 Participant WorkbookLesson 6- Auger Rigs & Equipment NING OBJECTIVE # 4 Identify auger rig components Version 1: 12-02 6-8 Participant WorkbookLesson 6- Auger Rigs & Equipment Predominately | - American Manufacturer Types | + European Manufacturer Types The variety of auger rigs available to contractors is considerable, particularly when you include both U.S. and European technology. Catalogs from the early 1900's show that bucket type auger drills were available even then, if you owned a horse to power it. Mechanical units were developed in the 1920's with production models in the late 1930's This early history appears to have had its roots in Texas. 69 Reportedly the famous Hughes LL Series of diggers were being manufactured at the rate of 70 to 80 units per year in the late 1970's and early 1980's. Beginning in the early 1980's, it was clear that most equipment manufacturers in the U.S. were moving away from mechanical designs, opting instead for torque converters to deliver power to the rotary table/kelly bar drills. Importing of European designed drills began roughly a decade ago and is gaining popularity among some contractors. Out of Germany are units built by Delmag and Bauer. SoilMec is one of the leading Italian manufacturers as are Casagrande and IMT. All of these companies now have manufacturers’ representatives in the United States. Perhaps one of the most attractive features of the European designs is the ability of the drill equipment to install casing. Many of these units are capable of drilling holes 120° (3 m) in diameter, to a maximum depths of 120 feet (40 m). Where casing is required, the drill utilizes a high torque, top-head drive along with down pressure to advance sections of casing which can be easily bolted to the casing adaptor (drive head). An auger or drilling bucket can remain attached to the kelly and used to remove material as required to facilitate advancement of the casing Version 1: 12-02 6-9 Participant WorkbookLesson 6- Auger Rigs & Equipment TYPES OF RIGS + Truck-Mounted Rigs | + Carrier-Mounted Rigs Crane-Mounted Rigs Crawler-Mounted Rigs 6-10 Crane attachments in conjunction with large vibratory hammers appear to be the most popular equipment combination for contractors on big projects today. However, contractors tend to own equipment that works best for the type of work they do most often. There also appears to be a certain “mind-set among some who favor a particular line of equipment and simply won't consider any other kind. What this means to us as Inspectors is that we are apt to see a wide variety of drill units on DOT work. In this lesson, the basic types of both American and European equipment are discussed so that the majority of the name brands will be familiar and you can better identify the relative sizes and capabilities of the various drill units Version 1; 12-02 6-10 Participant WorkbookLesson 6- Auger Rigs & Equipment TYPESOFRIGS- | LIGHT TRUCK-MOUNTED | Calweld | The design diameter and depth of the shafts for a particular job will largely dictate what types of equipment will be the most economical to use. For instance, most high mast lighting foundations can be excavated with truck-mounted equipment similar to that illustrated above. Version 1: 12-02 6-11 Participant WorkbookVersion 1: 12-02 Lesson 6- Auger Rigs & Equipment | TYPES OF RIGS- LIGHT TRUCK-MOUNTED H&T 635 | 48” Dia.; 35 ft. 6-12 Participant WorkbookLesson 6- Auger Rigs & Equipment TYPES OF RIGS- CARRIER-MOUNTED Texoma Taurus XL 120 in. Dia; 120 ft. For large hole diameters and greater depths, equipment weights dictate that crane carriers be used if rubber-tired transport is desired. Version 1: 12-02 6-13 Participant WorkbookLesson 6- Auger Rigs & Equipment TYPES OF RIGS- CARRIER-MOUNTED IMT AF16-A 80 in. Dia; 200 ft. Version 1: 12-02 6-14 Participant WorkbookLesson 6- Auger Rigs & Equipment TYPES OF RIGS- CRAWLER-MOUNTED Soilmec R622 100 in. Dia; 245 ft. Version 4: 12-02 6-15 Participant WorkbookLesson 6- Auger Rigs & Equipment TYPES OF RIGS- CRAWLER-MOUNTED Bauer 120 in. Dia; 195 ft. Version 1: 12-02 6-16 Participant WorkbookLesson 6- Auger Rigs & Equipment TYPES OF RIGS- CRANE-MOUNTED — 140 in. Dia.; 285 ft. If there is a need for a larger drill, with greater torque and depth capability, contractors frequently use, what is termed in the industry as “crane attachment’ drills. The power of some of these rigs can be truly impressive. Crane attachments come as a unit, including a diesel engine, transmission and torque converter driving a heavy duty rotary table through which a kelly is installed. The entire drill unit is attached to a crane using a “bridge” which allows the rotary table to be rigidly held and sufficiently elevated to accommodate the drilling tools anticipated for the job. Given the power advantages offered by large crane attachments, it is the ability to vary the working room (clearance) under the rotary table which makes this type of drill so attractive for many jobs The depth capability of crane attachment drills is dependent on the crane used Version 1: 12-02 6-17 Participant WorkbookLesson 6- Auger Rigs & Equipment a = TYPES OF RIGS- CRANE-MOUNTED Hain 754 Diameter and Depth dependent upon configuration. Version 1: 12-02 6-18 Participant WorkbookLesson 6- Auger Rigs & Equipment RIG INFORMATION ] Contact the Manufacturers for the latest information on the various models and capabilities See Following detailed information sheets for contact information and rig capal Ss Version 1: 12-02 6-19 Participant WorkbookLesson 6- Auger Rigs & Equipment DRILLED SHAFT AUGER RIGS AMERICAN MANUFACTURERS ATLANTIC EQUIPMENT COMPANY Post Office Box 1 3710 Lee Highway Gainesville, VA 22065 Tel:(800) 822-8248 (703) 754-7114 Fax:(703) 754-7437 Drill Master TMCO6OT 5° Dae] 900mm | mm 33,333 ft-lbs Drill Master DMB0T 2400 mm | $1,622 lbs ‘Williams LDH . 2235 mm Y 49,410 ftlbs ‘Williams LLOH e 3048 mm 99,557 flbs AMERICAN EQUIPMENT & FABRICATING CORP. 100 Water Street 3710 Lee Highway East Providence, RI 02914 Tel:(401) 438-2626 Faax:(401) 438-0764 www, american-equipment.com CASING LOAD TEST DRIVERS EQUIPMENT Soilmec H.M. Vibro Osterberg Load Cell Models PTC Version 1: 12-02 6-20 Participant WorkbookLesson 6- Auger Rigs & Equipment DRILLED SHAFT AUGER RIGS AMERICAN MANUFACTURERS CALWELD 190 Industrial Boulevard Post Office Box 534 McKinney, TX 75070-0534 Tel:(214) 548-9211 Fax:(214) 548-9956 ~ MAX. SHAFT] MAX. TORQUE 1828 mm Tom] 64.806 tits | BBKNm | 88 kN ADM 1524 mm 64,896 fi-lbs_ | 88 kKNm 125 CH (Crane) 4730 mm 124,631 ft-lbs | 169kNm 155 CH (Crane) A730 mm 152,654 ft-lbs | 207 kKNm 400 CH (Crane) 5180 mm 399,706 ftbs | 642 kNm STEVEN M. HAIN CO. Post Office Box I 3710 Lee Highway Gainesville, VA 22065 Tel: (800) 822-8248 (703) 754-7114 Feax:(703) 754-7437 4-7113531-3 (Crane) 8V71/754 (Crane) 3-531/3331-1 (Crane) * Dependent upon crane size and capability Version 1: 12-02 6-21 Participant WorkbookLesson 6- Auger Rigs & Equipment DRILLED SHAFT AUGER RIGS AMERICAN MANUFACTURERS REEDRILL/TEXOMA 190 Industrial Boulevard Post Office Box 534 McKinney, TX 75070-0534 Tel:(214) $48-9211 Fax:(214) 548-9956 Texoma 600 Texoma 700 Texoma 800 Texoma 900 Texoma Taurus XL Texoma C-100 1,828 mm 1,828 mm 2,438 mm 2,438 mm 3,048 mm 2,438 mm 40,560 ft-lbs 53,834 fl-lbs 57,522 ftbs. 104,719 ftbs. 143,805 ft-lbs. 99,557 ft-lbs. WATSON Post Office Box 1 3710 Lee Highway lle, VA 22065 Tel(800) 822-8248 (703) 754-7114 Fax: (703) 754-7437 Gain 1,930 mm 56,047 fi-lbs. 2,440 mm. 80,383 ft-lbs. 2,440 mm 99,557 ft-lbs. S00CA (Crane) 3,050 mm_ 98,820 ft-lbs EDT-7 (Crane) 1,370 mm 53,834 fe-lbs Version 1: 12-02 6-22 Participant WorkbookLesson 6- Auger Rigs & Equipment DRILLED SHAFT AUGER RIGS EUROPEAN MANUFACTURERS BAUER Post Office Box 1 3710 Lee Highway Gainesville, VA 22065 Tel:(800) 822-8248 se i, Fax:(703) aan | MAX. TORQUE DEPTH 68,584 ftlbs 103,244 ft-lbs 162,241 f-lbs 265,486 ftlbs 265,486 fi-Ibs, BGS BGI14 BG18 BG30 1300 mm 1800 mm, 1800 mm 3000 mm 2500 mm, CASAGRANDE 190 Industrial Boulevard Post Office Box 534 McKinney, TX 75070-0534 Tel:(214) 548-9211 Fax:(214) 548-9956 MAX. TORQUE 93,657 ft-lbs 127 kNm 152,654 fils | 207 KNm 401,917 ftlbs 294,985 ft-lbs 545 kN. 400 kNm Version 1: 12-02 6-23 Participant WorkbookLesson 6- Auger Rigs & Equipment DRILLED SHAFT AUGER RIGS EUROPEAN MANUFACTURERS IMT Post Office Box 1 3710 Lee Highway Gainesville, VA 22065 Tel:(800) 822-8248 (703) 754-7114 46,460 ftlbs | 63kNm 75,221 ftlbs | 102 kNm 84,808 ftibs | 115kNm. 156 kNm. 185 kNm 200 kNm 500 kNm. rt SOILMEC 190 Industrial Boulevard Post Office Box 534 McKinney, TX 75070-0534 Tel:(214) 548-9211 Fax:(214) 548-9956 exe Suae MAX. TORQU _ DEPTH 1,200mm |} 130" 40m |) 77,651 ftibs | 82kKNm 1,500mm |} 130 40m | 83,333 ftibs | 113 KNm. 1,500mm |} 150° 46m} 80,383 ftbs | 109 kNm 1,500mm |} 200° 62m} 105,457 ftibs | 143 KNm. 2,000mm | 193 60m} 126,843 ftbs | 172 KNm 2,500mm |} 245) 148,230 ftbs | 201 kNm 2,500mm_||_ 260° 151.916 ftlbs | 206 kNm. Version 1: 12-02 6-24 Participant WorkbookVersion 1: 12-02 Lesson 6- Auger Rigs & Equipment LEARNING OBJECTIVE #2 Locate and employ information on auger rigs The Contractor is to install drilled shafts 96” in diameter to a depth of 110 feet. Using the Rig Manufacturer information sheets, identify the rigs capable of doing the job by manufacturer and model. No crane rigs please. 6-25 Participant WorkbookLesson 6- Auger Rigs & Equipment AUGER BITS AND TOOLS It has often been said that an auger drill, no matter how large or powerful, is no better than the tool at the end of the kelly. If you have ever tried to use a ‘small hand drill with a worn bit, you can relate to how it can affect production For that reason, tools have been fabricated for virtually every below ground condition imaginable. The most common augers can be classified as either dirt (soil) or rock types, with variations of each as to the number of flights, teeth, and lead bit. Many contractors build their own designs, but there are a number of manufacturers who specialize in drilling tools as well Version 1; 12-02 6-26 Participant WorkbookVersion 1: 12-02 é Lesson 6- Auger Rigs & Equipment AUGER BITS & TOOLS | Earth Auger Bits + Single or double flight | Auger bits are * Double flight has superior | generally classified as soil removal capability | either: | Rock Auger + Earth (Soil) or + Double or Triple flight + Rock * Single Core Barrels + “Air Barrels" (Double Wall | Core Barrel) ear 6-27 Participant WorkbookLesson 6- Auger Rigs & Equipment [ WHY IS THIS IMPORTANT The Inspector must be able to: + Compare to the approved Drilled Shaft Installation Plan + Note on daily activity report the equipment on-site + Recognize and document the tool being used + Recognize and document the condition of the tools The Inspector must have the knowledge to identify the various drilling tools being used by the Contractor. Remember- it is not the Inspector's responsibility to direct the Contractor’s work or technique. However, the Inspector must make accurate notes as to the tools and equipment on-site and being used. If the Contractor only has earth augers on site and rock needs to be penetrated, it is important to have this information notes, as the Contractor may say the material cannot be penetrated and was misrepresented or harder than indicated. May not really be so if they had the right bit. The Inspector's accurate, unbiased observations and documentation can help alleviate problems or questions that might arise. Version 1: 12-02 6-28 Participant WorkbookLesson 6- Auger Rigs & Equipment EARTH AUGERS | Earth augers are generally used in sands and cohesive materials. Single Flight Double Cut Dirt augers are usually made with single or double flights. Above is a single flight auger designed so as to cut on both sides of the stem. These are distinguished from rock augers by the use of lighter weight material and flat edge blades as cutting teeth. Because of their superior removal capacity, double flight designs are usually best for the fine sandy soils. Full size drawing follows. Version 1: 12-02 6-29 Participant WorkbookLesson 6- Auger Rigs & Equipment SINGLE FLIGHT - DOUBLE CUT EARTH AUGER SINGLE FLIGHT ADDED CUTTING EDGE AND IT'S SUPPORT TO MAKE THE AUGER FACE “DOUBLE CUTTING'' Version 1: 12-02 6-30 Participant WorkbookLesson 6- Auger Rigs & Equipment EARTH AUGERS Double Flight Double Cut 6st Full size drawing follows. Double cut augers make it easier to keep the hole straight since they are less likely to “walk” to one side. Version 1: 12-02 6-31 Participant WorkbookLesson 6- Auger Rigs & Equipment DOUBLE FLIGHT - DOUBLE CUT EARTH AUGER TWO DIFFERENT FLIGHTS 44 DOUBLE CUT Version 1: 12-02 6-32 Participant WorkbookLesson 6 Auger Rigs & Equipment EARTH AUGERS Single-Flight | Soil Auger | Soil Teeth (Blunt/Wide) Guide Shaft (“Stinger”) This is a standard single-helix (flight) auger for excavating relatively weak soils that have some cohesion. Sometimes, it can be used to excavate IGM's or soft rock if the IGM or rock is horizontally bedded and bedding planes are very closely spaced. Note the tooth design for gouging out large volumes of soil and the several turns on the auger, which allows for transport of considerable soil to the surface at one pass. Version 1: 12-02 6-33 Participant WorkbookLesson 6- Auger Rigs & Equipment Fish Tail Stinger | Cutting | Tooth These are typical of the cutting teeth used on earth augers. The Pocket, which holds the cutting teeth, is welded onto the auger. This allows for changing out broken or worn teeth. The stinger bit aids in keeping the axial alignment and minimizing “walking off” Stinger Bits Cutting Tooth Spade Fish Tail Version 1: 12-02 6-34 Participant WorkbookLesson 6- Auger Rigs & Equipment Double-Flight Soil Auger te The Contractor may have trouble maintaining hole alignment or jamming the auger in the hole if the hole diameter becomes larger than 5 to 8 feet (1.5 to 2.5 m), depending upon the hardness and regularity of the soil. In such a case, he or she should change to a double helix auger such as this. Note that the opposing rows of teeth will give a balanced torque reaction on the cutting face. The auger has only a little more than one turn to reduce torque reaction from the sidewalls. Version 1: 12-02 6-35 Participant WorkbookLesson 6- Auger Rigs & Equipment ROCK AUGERS Rock augers are generally used in soft to hard rock formations. | Tapered Geometry Conical (Bullet) | Carbide Teeth When soil augers and buckets fail to excavate the geomaterial, contractors frequently use rock augers. A typical rock auger is shown here. The rock is broken into small pieces by the ripping (tungsten carbide) teeth and either lifted out on the auger or removed with a claim or other tool. Some rock is so hard, however, that rock augers will not be effective. Pockets Carbide Bit Teeth Version 1: 12-02 6-36 Participant WorkbookLesson 6- Auger Rigs & Equipment ROCK AUGERS Pocket Carbide tip tooth | Carbide tip Replaceable tooth Stinger Version 1: 12-02 6-37 Participant WorkbookLesson 6- Auger Rigs & Equipment Non-replaceable teeth Replaceable teeth.se Version 1: 12-02 6-38 Participant WorkbookLesson 6- Auger Rigs & Equipment y ROCK AUGERS This is typical rock auger designed for drilling in soft to medium rock. Rock auger for soft rock. Version 1: 12-02 6-39 Participant WorkbookLesson 6- Auger Rigs & Equipment ROCK AUGERS These are typical of rock augers designed for drilling in hard rock. BULLET STEP TYPE eo Way Rock Augor R-5000 Step Type Rock Auger Version 1: 12-02 6-40 Participant WorkbookLesson 6- Auger Rigs & Equipment ROCK BITS | This is typical of rock bits designed for drilling in hard to very hard rock. Circulating bit oN Replaceable Roller Bits oat L ___ _ eee —____} When rock augers are not sufficient to excavate rock because it is too hard, these (and other) tools might be considered. Above is a cluster drill. This tool beats (pulverizes) the rock, and using a process known as "reverse circulation," sucks the slurry-cuttings suspension off the bottom of the borehole. These devices will work in massive rock even when core barrels will not. This is a step-faced roller bit, which grinds rock first in a small pilot hole (near the center), which weakens the remaining rock inthe borehole, followed by the remainder of the hole (near the outer circumference). Cuttings are forced to the surface with compressed air with this tool. Version 1: 12-02 6-41 Participant WorkbookLesson 6- Auger Rigs & Equipment Other Options in Hard Rock Does not use circulation to remove cuttings and is designed for small jobs with minimal footage. Uses replaceable roller bits Version 1: 12-02 6-42 Participant WorkbookLesson 6- Auger Rigs & Equipment [Gouging | | Aeeth ai Side Cutting ‘Teeth | An auger will not work well in a truly cohesionless soil, like a sand or gravel, especially below the water table, where boreholes are often filled with drilling fluid. In such soil contractors often use drilling buckets, like this one. It is a good idea that these tools be vented to allow drilling fluids to bypass them during insertion and extraction of the tool when drilling under a fluid. This circumvents creating a piston effect during insertion or suction during extraction, which may cause the borehole to collapse. A flattened side or simple pipe passing through the tool can often be used for this purpose. Although it is the Contractor's responsibility to excavate the drilled shafts, when he or she cannot do so, it becomes the Engineer's problem. So, details such as this can be important. Version 1: 12-02 6-43 Participant WorkbookVersion 1: 12-02 Lesson 6- Auger Rigs & Equipment DRILLING BUCKET Borehole Smeared with Cuttings Borehole Cleaned = with Side Cutter on 6-44 Auger Participant WorkbookLesson 6- Auger Rigs & Equipment BOULDER BUCKET & AUGER Drilling Contractors and their suppliers have devised many ingenious tools. The one on the left, by the Stephen Hain Company, is a barrel (open-bottom bucket with tungsten carbide teeth around the perimeter of the bottom edge) that is used to maneuver boulders into the borehole and flaps that then grab the boulder to allow the driller to lift it to the surface for disposal. This tool can be used to augment drilling augers and buckets. Other devices, such as boulder rooters (tapered augers) can also be used for this purpose. Version 1: 12-02 6-45 Participant WorkbookLesson 6- Auger Rigs & Equipment CORE BARREL Soft Rock Hard Rock Harder, more dense rock formations may require the use of core barrels to speed advancement of the hole. The concept of a core barrel is to minimize the amount of rock that has to be “cut” in order to deepen the hole, thereby accelerating the process. By using a single tube design, shown above left, the cutting force (down pressure and torque) can be concentrated along the perimeter of the barrel. This barrel uses replaceable carbide tipped “bullet” teeth, Larger drill units with sufficient down pressure and torque can utilize “air barrels" (on right above) effectively. This system uses large volumes of compressed air in conjunction with a double wall core barrel which can be equipped with a variety of cutting devices. These cutters can be replaced when worn, or exchanged for button- type bits for harder rock formations. Version 1: 12-02 6-46 Participant WorkbookLesson 6- Auger Rigs & Equipment CORE BARREL Above is a 10-foot-diameter, double-walled core barrel. Version 1: 12-02 6-47 Participant WorkbookLesson 6- Auger Rigs & Equipment BELLING TOOL This is typical of a Belling tool used to “bell” the bottom of an excavation. A belling tool can be used to make enlarged bases for drilled shafts in the dry or casing drilling processes. Version 1: 12-02 6-48 Participant WorkbookLesson 6- Auger Rigs & Equipment PERCUSSION DRILLING Percussion drilling involves lifting and dropping a heavy tool on rock or boulders to break it up (such as the "chum drill" on the left) and then lifting out the debris (as with the borehole clam on the right). This method can be used in hard rock when core barrels will not work. More frequently it is used in boulder fields or zones of fragmented rock. Version 1: 12-02 6-49 Participant WorkbookLesson 6- Auger Rigs & Equipment -— _ CHOPPING BIT This bit is for breaking up rock that may not be augerable. | Drop repeatedly | from a crane. Version 1: 12-02 6-50 Participant WorkbookLesson 6- Auger Rigs & Equipment [This is typical of a ‘cleanout (muck) bucket used to cleanout the cuttings and sediments from the bottom of the shaft. These rotating bottom muck buckets are used to remove the sediments and cuttings from the bottom of the shaft. Normally cleanout buckets are at least 6 inches to 1 foot or more, smaller than the hole diameter, enabling movement around the hole bottom while reducing the danger of putting large negative pressures on the shaft excavation when the tool is withdrawn. Holes incorporated in this design assist in minimizing suction as well. This can be very important where rock formations contain significant amounts of sand Version 1: 12-02 6-51 Participant WorkbookLesson 6- Auger Rigs & Equipment CLEANOUT TOOL Final cleaning down-the-hole pump sz For final cleaning of the shaft, contractors frequently use down-the-hole pumps. A hydraulically driven version of such a pump is shown here. Normally mineral slurry is pumped from the bottom of the shaft to a desanding unit while fresh slurry is replaced in the top of the shaft. Pumping shafts from the bottom greatly speeds the operation of shaft cleaning and gets better end results as opposed to extended periods of using muck buckets alone. Version 1: 12-02 6-52 Participant WorkbookLesson 6- Auger Rigs & Equipment Hydraulic |) gear motor “ Oil-filled bearing pump Impeller This is a schematic of a hydraulic submersible pump. Version 1: 12-02 6-53 Participant WorkbookVersion 1: 12-02 Lesson 6- Auger Rigs & Equipment | VIBRATORY HAMMER MANUFACTURERS Vibratory hammers are used to install and remove casing 6-54 Participant WorkbookLesson 6- Auger Rigs & Equipment VIBRATORY HAMMERS MKT Post Office Box 1 3710 Lee Highway Gainesville, VA 22065 Tel:(800) 822-8248 (703) 754-7114 Fax:(703) 754-7437 119,829 119,829 159,847 299,910 ICE 190 Industrial Boulevard Post Office Box 534 McKinney, TX 75070-0534 Tel:(214) 548-9211 Fax:(214) 548-9956 ECC MOME 6.36-19.0 mm] 1,100 in-Ibs 59,850 Ibs 6.35-19.0 mm} 2,200 in-Ibs 3 80.035 Ibs 12,7-25.4 mm] 4,400 in-lbs | 5, 80,035 Ibs 12.7-25.4 mm} 4,400 in-Ibs 100,044 Ibs 25.4-38.1 mm} 10,000 in-Ibs F 300,134 Ibs Version 1: 12-02 6-55 Participant WorkbookVersion 1: 12-02 Lesson 6- Auger Rigs & Equipment | MISCELLANEOUS OTHER TOOLS | Desanders 6-56 Participant WorkbookLesson 6- Auger Rigs & Equipment Casing Twister | Version 1: 12-02 6-57 Participant WorkbookVersion 1: 12-02 Lesson 6- Auger Rigs & Equipment Overreaming Bucket 6-58 Participant WorkbookLesson 6- Auger Rigs & Equipment | LEARNING OBJECTIVE #3 Identify drilling tools and explain their uses Version 1: 12-02 6-59 Participant WorkbookLesson 6- Auger Rigs & Equipment LEARNING OBJECTIVES + Identify auger rig components + Locate and employ information on auger rigs « Identify drilling tools and explain their uses Version 1: 12-02 6-60 Participant WorkbookLesson 6- Auger Rigs & Equipment AUGER RIGS} AND EQUIPMENT, Version 1: 12-02 6-61 Participant WorkbookLesson 6- Auger Rigs & Equipment NOTES Version 1: 12-02 6-62 Participant WorkbookLesson 7- Soil and Rock Identification LESSON 7 SOIL AND ROCK IDENTIFICATION DRILLED SHAFT FOUNDATION INSPECTION DECEMBER 2002 Version 1: 12-02 TA Participant WorkbookLesson 7- Soil and Rock Identification LESSON 7 SOIL AND ROCK IDENTIFICATION NOTES Version 1: 12-02 7-2 Participant WorkbookLesson 7- Soil and Rock identification PF LESSON 7 | IDENTIFICATION - | | SOILS & ROCK | Version 1: 12-02 7-3 Participant WorkbookLesson 7- Soil and Rock Identification p _Role ‘ a 7 . Version 1: 12-02 7-4 Participant WorkbookVersion 1: 12-02 Lesson 7- Soil and Rock Identification LEARNING OBJECTIVES + Describe the soil/rock drilling/coring process + Calculate percent recovery (REC) and Rock Quality Designation (RQD) + Prepare a field soil description + Identify and describe the sections of a boring log and how this information is used 15 . Participant WorkbookLesson 7- Soil and Rock Identification 7 Why a Subsurface Study? For design : + Must know subsurface materials + Must know engineering properties + Must know capability to support loads For construction: | + Materials dictate rig and tool choices + Materials dictate construction method + Identifies potential problems 7 The site investigation for a project anticipating the use of deep foundations is critical. For example, the presence of a stratum of soft, compressible clay, below a dense sand deposit may preclude the use of end-bearing foundations in the sand Unknown subsurface conditions can be extremely detrimental to construction of drilled shafts and hence, the performance of the drilled shafts. ‘Accurate detailed information is gathered in the site investigation stage so as to minimize these ‘little surprises” for the Engineers and Contractors. Version 1: 12-02 7-6 Participant WorkbookVersion 1: 12-02 Lesson 7- Soil and Rock Identification GOALS OF THE SUBSURFACE STUDY To gather data about the site: * Geologic formations * Soil & Rock units + Material engineering properties > THE BORING | Loc + Groundwater conditions + Ground surface elevation + Localized conditions a TT Participant WorkbookVersion 1: 12-02 Lesson 7- Soil and Rock Identification THE EXPLORATION WHAT? | A variety of subsurface exploration methods | can be employed Most common include (ref AASHTO R 13): + Standard Penetration Test Borings (AASHTO T 206) + Undisturbed Sampling (AASHTO T 207) * Rock Coring (AASHTO T 225) | 18 7-8 Participant WorkbookLesson 7- Soil and Rock Identification Standard Penetration Test Borinas (AASHTO 1206) ' Advance the hole 19 Metric Equivalents 140 Ib. (hammer) = 63.6 Kar 30 inch (drop) = 750 mm 18 inches (of penetration)= 450 mm 6 inch increment= 150 mm 5 it. (core run)= 1.5m Place split-spoon sampler into the hole to the desired sample depth, attach the 140 Ib. (63.6 Kgr) hammer SEE FOLLOWING PAGE FOR OTHER PHOTOGRAPHS AND DESCRIPTIONS. Version 1: 12-02 79 Participant WorkbookLesson 7- Soil and Rock Identification Raise and drop the hammer 30" (750 mm), which constitutes 1 blow. Repeat until 18° (450 mm) of penetration have been achieved. Record the number of blows it takes to go each 6 inch (150 mm) increment, Remove split. spoon from hole and disassemble to get sample. Perform visual field identification of material and note material type and blow counts on field boring log. Place representative sample in moisture proof container. RR. ss TAN Version 1: 12-02 7-10 Participant WorkbookVersion 1: 12-02 Lesson 7- Soil and Rock Identification ee —— _ ROCK CORING- AASHTO T 225 * Core runs are generally 5 feet (1.5 m) in length + Minimum core diameter is 2.4 in. (61 mm) + Most common size is 4 in. (101.6 mm) TA Participant WorkbookVersion 1: 12-02 Lesson 7- Soil and Rock Identification LEARNING OBJECTIVE #1 Describe the soil/rock drilling/coring process What is the weight of the hammer and the distance of the hammer drop when performing Standard Penetration Tests (split-spoon sampling)? What is the normal length of rock core run? 7-12 Participant WorkbookLesson 7- Soil and Rock Identification ROCK CORE RECOVERY Version 1: 12-02 7-13 Participant WorkbookLesson 7- Soil and Rock Identification ROCK QUALITY Rock Quality Designation (RQD) RQD is defined as the sum of all recovered pieces of rock core greater than 4” (100 mm) in length divided by the length of core run and is expressed and reported as a percentage. —__| FHWA Soils & Foundation Manual The RQD is based upon a modified core recovery procedure that, in turn, indirectly provides information on the number of fractures and the amount of softening or alteration observed in the rock cores. Version 1: 12-02 7-14 Participant WorkbookLesson 7- Soil and Rock Identification ROCK QUALITY - DESCRIPTION OF (Rap) ROCK QUALITY 0-25 Very Poor 25-50 Poor 50-75 Fair 75-90 Good 90 - 100 Excellent ae Version 1: 12-02 TAS Participant WorkbookVersion 1: 12-02 Lesson 7- Soil and Rock Identification ROCK CORE RECOVERY (REC REC is defined as the length of core recovered divided by the length of core run and is expressed and reported as a percentage. Length of Core Recovered (499) Length of Core Run \ EXAMPLE PROBLEM Can REC be greater than 100%? % REC \ % 7 Length of Run = 5.0! Recovered 3.2’ / REC = 76 Le So 7-16 Participant WorkbookVersion 1: 12-02 Lesson 7- Soil and Rock Identification ROCK QUALITY DESIGNATION (RQD | RQD is defined as the sum of all recovered pieces of rock core greater than 4” (100 mm) in length divided by the length of core run and is expressed and reported as a percentage. | __ Sum of Pieces >4" (100 mm) (100) | Length of Core Run | PROBLEM — Can RAD be greater | k than REC? % RQD | Length of ] Recovered pieces | Run = 5.0' 7 than 100%? Can RQD be greater | RQD= T-AT Participant WorkbookVersion 1: 12-02 Lesson 7- Soil and Rock Identification LEARNING OBJECTIVE #2 Calculate percent recovery (REC) and Rock Quality Designation (RQD) ROCK CORE RECOVERY (REC) ) PROBLEM \, Length of Run = 5.0' Recovered 2.6' REC = 7-18 Participant WorkbookLesson 7- Soil and Rock Identification LEARNING OBJECTIVE #2 Calculate percent recovery (REC) and Rock Quality Designation (RQD) ROCK QUALITY DESIGNATION (RQD) iT PROBLEM Length of 41 Recovered pieces Run = 5.0 4 a" | RQD = 2 Version 1: 12-02 7-19 Participant WorkbookVersion 1; 12-02 Lesson 7- Soil and Rock Identification T don't know : what this is but TTS I'm not going) ast € What is that >) HN MATERIAL IDENTIFICATION 7-20 Participant WorkbookLesson 7- Soil and Rook Identification Material Identification The Inspector needs to determine if the materials coming out of the hole are as expected from review of the Boring data Version 1: 12-02 7-21 Participant WorkbookLesson 7- Soil and Rock Identification In its natural state may 4 look like this. Coming out of the hole may 5 | look like this. me Version 1: 12-02 7-22 Participant WorkbookLesson 7- Soil and Rock Identification | What is Soil ? Naturally occurring mineral particles which are fairly readily separated into small pieces. | What is Rock ? | | Naturally occurring material composed of mineral particles so firmly bonded together that relatively great effort is required to separate the particles. FHWA Soils & Foundation Manual The foundation engineer is usually concemed with the construction of some type of engineering structure on or in the earth. For engineering purposes, we shall consider the earth to be made up of rock and soil. Rock is that naturally occurring material composed of mineral particles so firmly bonded together that relatively great effort is required to separate the particles (i.e., blasting or heavy crushing forces). Soil will be defined as naturally occurring mineral particles which are fairly readily separated into relatively small pieces, and in which the mass may contain air, water, or organic materials (derived from decay of vegetation). The mineral particles of the soil mass are formed from decomposition of the rock by weathering (by air, ice, wind, and water) and chemical processes. Version 1: 12-02 7-23 Participant WorkbookLesson 7- Soil and Rock Identification Soil Types Granular Soils: Fine-grained Soils: Sands and Gravel Silts and Clays Peat, Organic clays and silts | Organic Soils: 124 FHWA Soils & Foundation Manual Soils are defined by their principal size components. Gravel and sand are coarse-grained components that can be distinguished by eye. Silt and clay are fine-grained components, too fine to distinguish individual grains. Therefore they are identified by their physical behavior. Version 1: 12-02 7-24 Participant WorkbookLesson 7- Soil and Rock Identification fo eee Rock Types Igneous Rock: Granite, Diorite, Basalt Sedimentary Rock: Sandstone, Limestone, Shale | Metamorphic Rock: Quartzite, Schist, Gneiss FHWA Soils & Foundation Manual Rock is classified with respect to its geological origin as follows: a. Igneous Rocks, such as granite, diorite, and basalt, are formed by the solidification of molten materials, either at depth in the earth’s crust or by extrusion at the earth's surface. b. Sedimentary Rocks, such as sandstone, limestone, and shale, are formed by the lithification of sedimentary soils. c. Metamorphic Rocks, such as quartzite, schist, and gneiss, which were originally igneous or sedimentary rocks, have been altered physically, sometimes chemically, by the application of intense heat and/or pressure at some time in their geologic history. Version 1: 12-02 7-25 Participant WorkbookLesson 7- Sail and Rock Identification | Soil Identification Terms Identify Visually identify which components exist within the sample (Sand, Gravel, etc.) | | | Describe Process of estimating the relative percentages of components of a sample and preparing a word picture (dark gray fine Sand) Classification Process of grouping soils based upon engineering properties tests . FHWA Soils & Foundation Manual Three terms which are used in the site exploration process are IDENTIFY, DESCRIBE, and CLASSIFY. Identification is the process of determining which components exist in a particular soil sample, i.e., gravel, sand, silt, clay, etc. Description is the process of estimating the relative percentage of each component and preparing a word picture of the sample (ASTM D2488- Standard Practice for Description and Identification of Soils (Visual-Manual Procedure). Identification and description are accomplished primarily by both a visual identification and the feel of the sample. Classification is the process of grouping soils with similar engineering properties into categories. The important distinction between classification and both identification and description is that standard AASHTO or ASTM tests must be performed to determine a soil's classification... Version 1; 12-02 7-26 Participant WorkbookLesson 7- Soil and Rock Identification Unified S Classification System The Unified Classification System (ASTM D 2487) groups soils with simitar engineering properties into categories base on grain size, gradation and plasticity. The table provides a simplification of the group breakdown. Version 1: 12-02 7-27 Participant WorkbookVersion 1: 12-02 Lesson 7- Soil and Rock Identification Soil Sample Identification Procedure Decision #1 Decision {Decision B Decision _#4 cy Is sample coarse-grained, fine-grained, mixed-grain or organic? If mixed- grained, which predominates? What is principal component? Use a noun in soil description. Ex: Sand What is secondary component? Use as adjective in soil description. Ex: Silty Sand Are there additional components? Use as additional adjectives. Ex: Silty Sand, Gravelly 128 Detailed information presented in Appendix F, MUD. 7-28 Participant WorkbookLesson 7- Soil and Rock Identification FIELD IDENTIFICATION OF SOILS This chart is a combination of ASTM D-2488 and Modified Unified Description (MUD). Version 1: 12-02 7-29 Participant WorkbookLesson 7- Soil and Rock Identification FIELD IDENTIFICATION OF SOILS/ROCK SOILS + REMEMBER, Rock are not sure what it ‘Squeezed in Hand & Pressure Released | Rolled Between il Type Visual Appearance Thumb & Finger eum cums When Air Dry When Moist when Moist SAND Individual ran sizes canbe detected. itis | wit atom aca awit | Fors a cast which wit | Connotbertnon free-flowing when ina dry condin, fa apa when pease | cure when iy ‘sraned tered SILT Contains +80% sit particles with vey lite | For» ast wien cn | Fama oct ihc | Hea ene tin ine sand & cay, When dry, itm anded witout | fel be handed. When | who tron epee fine sand & clay, When cry. tmaybe | Seana it can sly | weltreaayyposes. | nels es, eb lot, readily puverzes to a powder wih | be token sowdey sreom asoftfourtke fel Washes off easily. | tomb tans CLAY Fine tent braks into har ump when | Fens «as wc an | Foms a cat whh an [For ig fe Sil dry. Diffclt to pulverize ito a soft four andes witout | be handed wine | ribo. Can bo worad ike powder wn 1 based on | retg hos dn cmon cohesive properties of most cl ROCK (Terms to describe rock hardness) formations are tough to classify, IFit's hard (+50 blow count on Boring Log Report) and you is- call it Rock. Collect cuttings whenever recovery is not possible. Description Friable Low Hardness Field Observations (Characteristics) Easily crumbled by hand, pulverized or reduced to powder and 1s too soft to be cut with @ pocket knife. Can be gouged deeply or carved with a pocket knife. Moderately Hard Can be readily scratched by a knife blade; scratch leaves a heavy trace of dust and scratch is readily visible after the powder has been blown away. Gravelly Sand Sandy Gravel, Silty = Can be readily scratched wit Gficuly, soraich produces lle power and fs fen faintly visible; traces of the knife steel may be visible Vey nad [Cannot be scratched with a pocket knife. Leaves knife sleol marke on surface Example Descriptions of the Soil Components Type eros Sond Describes a camplo thal consists of both ne and coarse sand paricles, Gravel Desorbes a sample that consists of both ine and coarse gravel particles Sily Fine Sand | Malorcomponent fine send, wth non plato fines Sandy Gravel Major component grevel sz, wth fine and coarse sand. May contain small amount of Gravelly Sand, Sity | Major component sand, with gravel and non-plastic fines, Gravelly Sand, Clayey| Major component sand, with gravel and plastic fines, ‘Sandy Gravel, Clayey | Major component gravel size, with sand and plastic fines fines Major component sand, with gravel. May contain small amount of fines. Major component gravel size, with sand and non-plastic fines. sect ok Version 1: 12-02 7-30 Participant WorkbookVersion 1: 12-02 BUILD A SOILS WORD PICTURE Lesson 7- Soil and Rock Identification sre7s10 UROA sou"WoRD PICTURE” ; {one} — Detailed information presented in Appendix F, MUD. 7-31 Participant WorkbookLesson 7- Soil and Rock Identification STEPS TO BUILD A SOIL “WORD PICTURE” Cohesionless Cohesive color Boulders i 7 Silt Cobbles Soil Clay Gravel Components maa Sand Dry Moisture Dry Moist ii Moist Wet Condition Wet Plastic Plastic Low Plastic Plasticity Low Plastic Nonplastic Nonplastic Fissured Fissured Blocky Structure Bae Varved vanes Layered evele. Angular Particle Rounded Shape Subrounded Cemented Cemented Fragments of Other Slickensided Roots indurated Version 1: 12-02 7-32 Participant WorkbookLesson 7- Soil and Rock Identification THE BORING LOG Shelby Tube Sampler — | Split-spoon Sampler —| Version 1: 12-02 7-33 Participant WorkbookLesson 7- Soil and Rock Identification THE SOIL BORING LOG The boring log is the basic record of almost every geotechnical exploration and provides a detailed record of the work performed and the findings of the investigation. The field log should be written or printed legibly, and should be kept as clean as is practical. All appropriate portions of the logs should be completed in the field prior to completion of the field exploration. A wide variety of drilling forms are used by various agencies. The specific forms to be used for a given type of boring will depend on local practice. A boring log is a description of exploration procedures and subsurface conditions encountered during drilling, sampling and coring, Version 1: 12-02 7-34 Participant WorkbookLesson 7- Soil and Rock Identification SAMPLE Project: ABC zg Log of Boring 3 Project Location: ABC : 3 Project Number: ABC Sheet 1 of 1 Bates 11/01/02 [gree J. Smith gree B. Jones, [iro Oa To opt ~ Method Rotary Stafyoe_4” Drag bit Debaters) 3.0 Et ore We fe’ Failing 1500 3" BB Jeters Bet 3 6 Ker!750 mm Area eee Depth 2.5m ATD 9. matter _2 hrs -2_mattor 3 brs | Beistan tnater $100.00 — See Grout fain MSL SAMPLES rs Fs a g,| | ® | gels 3 | 25 MATERIAL DESCRIPTION 8 ale - Bi lh a £| BF and other remarks ab [3232 £3 Be 21 oe 221365) oe 0 | 1 | 19 | Medium dense brown, well graded SAND,) | moist and angular 1 | | 1 I ss}2 | 7 Medium stiff silty CLAY, moist, plastic | I 3 | | i | Hard unweathered BASALT ae 90 3. | | 4- ! + Tenant FTE Tae Version 1; 12-02 7-35 Participant WorkbookLesson 7- Soil and Rock Identification fre or = KEY TO SOIL (ce ana SYMBOLS & TERMS This is the Key to Soil Symbols and Terms used in the preparation of the Soil Boring Log. Version 1: 12-02 7-36 Participant WorkbookLesson 7- Soil and Rock Identification Key to Soil Symbols and Terms Sheet 1 of 2 Depth, meters ° MATERIAL DESCRIPTION and other remarks Other Tests ‘DESCRIPTIONS OF SAMPLER AND FIELD TEST CODES. The numbor of blows (16) of » 63.8 Kar hammer foling E 780 mm used to diva a 80 mm 0.0. aplit-bar [for the last 300 mm of penetration, E OTTSO- Number of blows (50) used to dive the spit-barrol a bertain number of millmetore (150). tube pushed hydraulically, using a certain pressive (1,724 kPa} to push the lost 150 mm. ‘SAMPLER CODES P. -Thin-wall tube sample. © = Denison or Prchertype core-barrel sample. Be Piston sample. ‘AL = Auger sample, Bs ~ult'samale. 55 ~ Standard apoon samala, GL California iner sarnpie. a4 = apa TET S 6 5 T Sample recovered: indicated by blackened box in Nesation® column ‘Sample not recovered: indicated by vorticl bar sn Tloeaton” cok and "AR (no recovery i "Type ‘OTHER FIELD TEST DESIGNATIONS: EV _ -Field vane shear test BHS Borehole sheer tast | ABBREVIATIONS FOR “OTHER TESTS" COLUMN + Geng an pei emits. 1 Mra and mor ry. Dict on tr Sees Unwed nara our cana, Spun ee paforod aoe borat at es xgegtznogoo Tae SOE RET Version 1: 12-02 7-37 FERRER Pines WBF Participant WorkbookVersion 1: 12-02 Lesson 7- Soil and Rock Identification LEARNING OBJECTIVE #1 Identify and describe the sections of a boring log and how this information is used What size diameter core does a NX core barrel produce? What does the “N” value represent? 7-38 Participant WorkbookVersion 1: 12-02 Lesson 7- Soil and Rock Identification LEARNING OBJECTIVE #1 Identify and describe the sections of a boring log and how this information is used What is Soil? | Why is the Boring Log of interest to the Inspector? 7-39 Participant WorkbookVersion 1: 12-02 Lesson 7- Soil and Rock Identification LEARNING OBJECTIVE #3 Prepare a field soil description Build a Soils Word Picture for the sample provided. 7-40 Participant WorkbookVersion 1: 12-02 Lesson 7- Soil and Rock Identification + Describe the soil/rock drilling/coring process | + Calculate percent recovery (REC) and Rock | Quality Designation (RQD) + Prepare a field soil description + Identify and describe the sections of a boring 1 log and how this information is used | : 7-41 Participant WorkbookLesson 7- Soil and Rock Identification Version 1: 12-02 7-42 Participant WorkbookLesson 8- Construction Documents LESSON 8 CONSTRUCTION DOCUMENTS DRILLED SHAFT FOUNDATION INSPECTION DECEMBER 2002 Version 1: 12-02 8-41 Participant WorkbookLesson 8- Construction Documents LESSON 8 CONSTRUCTION DOCUMENTS NOTES Version 1: 12-02 8-2 Participant WorkbookVersion 1: 12-02 Lesson 8- Construction Documents LESSON 8 | CONSTRUCTION | DOCUMENTS | 83 Participant WorkbookLesson 8- Construction Documents [ WHERE ARE WE Version 1: 12-02 84 Participant WorkbookLesson 8- Construction Documents LEARNING OBJECTIVES + Identify key inspection elements of the contract | documents + Locate Plan Sheet Details Related to Drilled Shafts + Identify key elements of the Drilled Shaft Installation Plan + Explain the governing order of specifications Version 1: 12-02 8-5 Participant WorkbookVersion 4: 12-02 PLANS AND ‘SPECIFICATIONS CHECKLISTS Lesson 8 Construction Documents Participant WorkbookLesson 8- Construction Documents PLANS AND SPECIFICATIONS CHECKLIST The Inspector needs to be able to locate the following in the Plans and Specification and be familiar with them before the job commences. These documents should be| with you at the job site and all times for reference. YES| NO| PLANS Revisions Key Sheets Construction Estimate Shee} Plan/Profile Sheets Traffic Control Plans Drainage Plans Utility Adjustments LYES| NO|_ STRUCTURES PLANS General Notes Report of Core Borings Foundation Layout Details Bridge Hydraulic Sheet |YES| NO| SPECIFICATIONS Technical Special Provision Standard Specifications Supplemental Specs Drilled Shaft Installation Pla Version 1: 12-02 8-7 Participant WorkbookLesson 8- Construction Documents | “MUST HAVE” REFERENCES FOR INSPECTORS [ MUST HAVE NICE TO HAVE [ oproved Dried Stat rstataten ~ This dass Notebook Pen "Dil Sat inspect’ Merl + Project Gece Repot * Stand Specicatons for | “compl sett reject ars wth Roa and Brg Constcten | "Payton + Supplemental Speieatons + Mints of Previous Meetings + Road Design, Stucures and * Special Provsions Trae Operatons Stndace “Tecmncal Specal provision for project | + ADSC Died Sat spat Mena As a drilled shaft Inspector you can perform your duties only if you know and understand the construction of drilled shafts as well as the project to be constructed. That is, you must know what the design intent was, how the Contractor proposes to construct the shafts, and the specifications which are your tools to assure that the drilled shafts are properly constructed, Several of the pertinent items that a drilled shaft Inspector needs are standard specifications and documents applicable to drilled shafts on all Department of Transportation projects. Other items are project specific items such as plans, special provisions, shop drawings, and contractor submittals. Presented above is a brief list of items that the drilled shaft Inspector should have in his or her possession prior to start of the drilled shaft work. Version 1: 12-02 8-8 Participant WorkbookLesson 8- Construction Documents KEY PARTS OF THE PLANS & SPECIFICATIONS COMPONENT | IMPORTANGE Plan Revisions| Always check for revised sheets to see if there are any changes that affect the shaft construction. Other Plans | Familiarize yourself with the plans, know where to find things quickly. Key Sheet ey Sheet | shows what is contained in the plan set, revisions, location, project number Const. Est. Sheet 4) Quantities 2) Pay Items Version 1: 12-02 8-9 Participant WorkbookVersion 1: 12-02 Lesson 8- Construction Documents KEY PARTS OF THE PLANS & SPECIFICATIONS ‘COMPONENT TWPORTANCE Drainage Map Good for showing area- usually an aerial map Plan and Good for project layout- shows location Profile of utilities. All utilities are not necessarily ‘shown and locations may not be correct. ‘Shows utilities, & relocations/ Utilities abandonments/removals ‘fh Can show how project may be phased. [Traffic Control | tay control foundation installation. 8-10 Participant WorkbookVersion 1: 12-02 Lesson 8- Construction Documents KEY PARTS OF THE PLANS & SPECIFICATIONS STRUCTURAL PLAN: IMPORTANCE General Notes 11) This sheet may contain notes that changes application of specifications. Also lwill have design assumptions made. [Scour should agree with Bridge Hydraulics Table. Standard Drawings ‘Standard Index Drawings showing Drilled \Shaft details. General Plan & Elevation 1) Shows layout and elevation of bridge & lroundation (one or more sheets) 2) Will |show number of bents/piers. Can tell whether pier of bent. fn 8-11 al Participant WorkbookLesson 8- Construction Documents KEY PARTS OF THE PLANS & SPECIFICATIONS ‘STRUCTURAL PLAN IMPORTANCE: Bridge Hydr. _ |Shows scour elevations- should match Sheet Drilled Shaft Data Table Rpt. of Core | Shows subsurface conditions used in | |_Borings design of the drilled shafts. Must know. Foundation _| Shows the specific location of drilled shafts Layout and test shafts. Data Table. |Shows specifics of each bentipier including pene len Elate elevation of top-of-shaft. Version 1: 12-02 8-12 Participant WorkbookVersion 1: 12-02 Lesson 8- Construction Documents Technical Special Provisions EXAMPLE Participant WorkbookVersion 1: 12-02 Lesson 8- Construction Documents EXAMPLE TECHNICAL SPECIAL PROVISION FOR em Number 2455-111 Core (Shaft Excavation) State Project Numbers: 59110-3508 Work Program Nuckers: 3118647 SR 30, Wakulla County 8-14 Participant WorkbookPAGE 431. coring shall Practice for Diamond Core -tube core bavrel wi! isturbed samples a singl che ur Version 1: 12-02 Subarticl. Excavations is in accordance ing for site not be allows: during Lesson 8- Construction Documents expanded as follows: Participant WorkbookVersion 1: 12-02 Lesson 8- Construction Documents LEARNING OBJECTIVE #1 Identify key inspection elements of the contract documents ‘Scour elevations can generally be found on which plan set sheet(s)? Generally, drilled shaft top elevations can be found ‘on which plan set sheet(s)? __-| 8-16 Participant WorkbookLesson 8- Construction Documents | LEARNING OBJECTIVE #1 Identify key inspection elements of the contract documents ‘Subsurface conditions information can generally be found on which plan set sheet(s)? Where is the Drilled Shaft Data Table usually found? Version 1: 12-02 8-17 Participant WorkbookLesson 8- Construction Documents CONTRUCTION DRAWING REVIEW one Itis extremely important that not only you know how to locate pertinent parts of the plans but have them with you on the job-site at all times, Version 1: 12-02 8-18 Participant WorkbookLesson 8- Construction Documents Construction Drawing 1 Version 1: 12-02 8-19 Participant WorkbookLesson 8- Construction Documents Construction Drawing 2 Version 1: 12-02 8-20 Participant WorkbookLesson 8- Construction Documents Version 1: 12-02 8-21 Participant WorkbookLesson 8- Construction Documents —— = \ lace Clear-water \ conmeionsoor CON 7 The embankment material beneath this abutment was removed by scour forces. Version 1: 12-02 ‘Scour | ‘Long-term degradation 4 Live-bed contraction scout Shortterm scour | | Scour around the pier and timber piles from a 50-year storm caused the collapse of the This abutment was protected by riprap, but still was undermined by scour forces. 8-22 Participant WorkbookLesson 8- Construction Documents Version 1: 12-02 8-23 Participant WorkbookLesson 8- Construction Documents Construction Drawing 5 Version 1: 12-02 8-24 Participant WorkbookVersion 1: 12-02 Lesson 8- Construction Documents Construction Drawing 6 8-25 Participant WorkbookLesson 8- Construction Documents Construction Drawing 7 Version 1: 12-02 8-26 Participant WorkbookLesson 8- Construction Documents Construction Drawing 8 Version 1: 12-02 8-27 Participant WorkbookVersion 1: 12-02 Lesson 8- Construction Documents Construction Drawing 9 READ ALL NOTES| EVERY SHEET 8-28 Participant WorkbookLesson 8- Construction Documents Construction Drawing 10 Version 1: 12-02 8-29 Participant WorkbookLesson 8- Construction Documents Construction Drawing 11 Version 1: 12-02 8-30 Participant WorkbookLesson 8- Construction Documents Construction Drawing 12 Version 1: 12-02 8-31 Participant WorkbookLesson 8- Construction Documents DRILLED SHAFT LOAD TEST | “24. Static 2. Statnamic 3. Osterberg | Version 1: 12-02 8-32 Participant WorkbookLesson 8- Construction Documents Construction Drawing 14 Version 1: 12-02 8-33 Participant WorkbookLesson 8- Construction Documents DRILLED SHAFT INSTALLATION PLAN REQUIRED ON DOT PROJECTS WITH DRILLED SHAFT FOUNDATIONS. OVERVIEW The Drilled Shaft Installation Plan is a shop drawing describing in detail the Contractor's tools and methods of constructing the drilled shafts. Section xxx. SUBMITTALS of FHWA Publication IF-99-025, Drilled Shafts: Construction Procedures and Design Methods, describes the minimum requirements of the Drilled Shaft Installation Plan. The idea behind having the Contractor submit this item is to cause him to put thought and planning into the project. Normally contractors want to take a “wait and see" attitude, where a general approach to the task is identified and a list of probable equipment to be used is given. For most contractors, that is the extent of their pre-job planning, relying heavily on flexibility to adjust once on site, as the job begins to develop. There are so many uncontrollable unknowns when dealing with subsurface conditions, that it seems the Contractor would benefit himself to pay closer attention to details regarding methods of installation and equipment ahead of time, minimizing some of the unknown factors. A smooth and successful start will usually be carried all the way through the job. Version 1: 12-02 8-34 Participant WorkbookLesson 8- Construction Documents SAMPLE SUMMARY OF DRILLED SHAFT INSTALLATION PLAN 4, Name of riled Shaft Superintendent FHWA Pub. Experience, IF-99-025 xxx-12 (a) EDUPWENT ; MANUFACTURER see. Dri Rig Crane Augers Casing Bailing Bucket Final Cleaning Equipment Desancing Slurry Pump Core Sampling Equipment Conerete pump _ «¢. Sequence of Construction:How many crews_ ‘Sequence of Shaft Construction: ents or Shaft groups How many hats 4. Detalls of Shaft Excavation Methods |e, Detalls of Slnry:Type__ Method o mica Testing: Name of Lat Details of method to clean Shafts alter nal excavation: ¢, Detallsof Shaft Reinforcement: h, Details of Concrete placement procedumConcrete or Pump verig Raising curing placement vetting sat Provisions to onsure final shaft Cutoff Elovations: |. Details of Casing Removal: 3, Prevention of Displacement of Casing/Shafts during Placement Compaction of Fil__ Method __—_Equipmont 4. Environmental control procedures to prevent Toss of slurry or concrete into watorways: 5. Other infomation: Version 1: 12-02 8-35 Participant WorkbookLesson 8- Construction Documents DRILLED SHAFT INSTALLATION PLAN Contractor prepares riled “Changes to Contractor | Shaft Installation Plan | | within 14 days of receipt Contractor resubmits to Engineer Submits to Engineer, for Approval Acceptance { Engineer accepts No changes may be made Plan without the Engineers approval FHWA Publication IF-99-025455 xxx, 12 SUBMITTALS No later than one month prior to constructing drilled shafts, the Contractor shall submit an installation plan for review. This plan shall provide information on the following: . The Engineer will evaluate the drilled shaft installation plan for conformance with the plans, specifications and special provisions. Within 14 days after receipt of the installation plan, the Engineer will notify the Contractor of any additional information required and/or changes necessary to meet the contract requirements. All procedural approvals given by the Engineer shall be subject to trial in the field and shall not relieve the Contractor of the responsibility to satisfactorily complete the work as detailed in the plans and specifications. Version 1: 12-02 8-36 Participant WorkbookLesson 8- Construction Documents DRILLED SHAFT INSTALLATION PLAN XXX.12 SUBMITTALS a. Name and experience record of diilled shaft superintendent who will be in charge of drilled shaft operations for this project. Version 1: 12-02 8-37 Participant WorkbookLesson 8- Construction Documents DRILLED SHAFT INSTALLATION PLAN | XXX.12 SUBMITTALS b. List of proposed equipment to be used, including cranes, drils, augers, bailing buckets, final cleaning equipment, desanding equipment, slurry pumps, core sampling equipment, tremies or concrete pumps, casings, ete Version 1: 12-02 8-38 Participant WorkbookLesson 8- Construction Documents DRILLED SHAFT INSTALLATION PLAN XXX.12 SUBMITTALS ¢. Delails of sequence of construction Es | operations and sequence of shaft |2%. construction in bents or shaft groups. oo a =—— Version 1: 12-02 8-39 Participant WorkbookVersion 1: 12-02 Lesson 8- Construction Documents DRILLED SHAFT INSTALLATION PLAN XXX.12 SUBMITTALS. d, Details of shaft excavation methods. 8-40 Participant WorkbookLesson 8- Construction Documents | DRILLED SHAFT INSTALLATION PLAN XXX.12 SUBMITTALS e. When the use of slurry is anticipated, details ofthe mix design and its suitabilty for the subsurface conditions at the construction site, mixing and storage | methods, maintenance methods, and disposal procedures. Version 1: 12-02 8-41 Participant WorkbookLesson 8- Construction Documents DRILLED SHAFT INSTALLATION PLAN XXK.12 SUBMITTALS f. Detalls of methods to clean the shaft |= excavation, Participant Workbook 8-42 Version 1: 12-02Version 1: 12-02 DRILLED SHAFT INSTALLATION PLAN Lesson 8- Construction Documents. XXX.12 SUBMITTALS, g. Details of reinforcement placement, including support and centralization |: methods. 8-43 Participant WorkbookLesson 8- Construction Documents LED SHAFT INSTALLATION PLAN XXX.12 SUBMITTALS h, Details of concrete placement, including |, proposed operational procedures for free |= fall, tremie or pumping methods. Version 1: 12-02 8-44 Participant WorkbookVersion 1: 12-02 DRILLED SHAFT INSTALLATION PLAN XXX.12 SUBMITTALS i. Details of casing installation and removal methods. Lesson 8- Construction Documents 8-45 Participant WorkbookVersion 1: 12-02 Lesson 8- Construction Documents DRILLED SHAFT INSTALLATION PLAN Other Information may be requested including,: ‘List of required submittals (Shop [= drawings, Concrete Mix Designs, etc.) + Detals of load tests, if required, including equipment, calibration charts, etc. Methods to prevent displacement shafts during earthwork or other construction activites, |__| Ei + Environmental conttls, =] 8-46 Participant WorkbookLesson 8- Construction Documents LEARNING OBJECTIVE #3 Identify key elements of a Drilled Shaft Installation Plan Does the Contractor have to detail how they intend to install and remove casing? ‘The Contractor merely needs to state he will have the right equipment for the project. True or False? “| _ Version 1: 12-02 8-47 Participant WorkbookVersion 1: 12-02 Lesson 8: Construction Documents LEARNING OBJECTIVE #3 | Identify key elements of a Drilled Shaft Installation Plan | Which of the following is not required in the Contractor's Drilled Shaft Installation Plan? + Details on Concrete Placement + Details on Cage Reinforcement + Details on shaft excavation + Details on Maintenance of Traffic + Details on cleaning of the excavation 8-48 Participant WorkbookLesson 8- Construction Documents | PLAN SET GOVERNING ORDER Contact the Project Engineer for any clarifications or discrepancies Fechnic ‘Special Provisions Plans fncuding revisions) Standard Drawings Supplemental Specifications Standard Specifications “Technical Special Provisions- Specifications prepared, signed and sealed by an Engineer registered in the State other than the State Specifications Engineer, or his designee, which are made part of the Contract as an attachment to the Specifications Package. + Plans- The approved plans, including reproductions thereof, showing the location, character, dimensions and details of the work to be done. + Standard Drawings- Some sheets in the Plans are “standard” sheets that are not designed specifically for this individual project. An example of this type of sheet might be a standard prestressed pile data sheet -Developmental Standards- A specification developed around a new process, procedure, or material and designated as a developmental specification + Supplemental Specifications- Approved additions and revisions to the Standard Specifications. + Standard Specifications- The directions, provisions and requirements contained herein, together with all stipulations contained in the plans or in the contract documents, setting out or relating to the method and manner of performing the work, or to the quantities and qualities of materials and labor to be furnished under the contract. Version 1: 12-02 8-49 Participant WorkbookVersion 1: 12-02 Lesson 8- Construction Documents LEARNING OBJECTIVE # 4 Explain the governing order of specifications T or F- The Standard Specifications supercede all other contract documents. The most narrowly focused set of documents are the? 8-50 Participant WorkbookVersion 1: 12-02 Lesson 8- Construction Documents LEARNING OBJECTIVES | + Identify key inspection elements of the contract documents. + Locate plan Sheet Details Related to Drilled Shafts + Identify key elements of the Drilled Shaft Installation Plan + Explain the governing order of specifications 8-51 Participant WorkbookLesson 8- Construction Documents ONSTRUCTIO! DOCUMENTS Version 1: 12-02 8-52 Participant WorkbookLesson 9- Assembling Your “Too! Box" LESSON 9 ASSEMBLING YOUR “TOOL BOX” DRILLED SHAFT FOUNDATION INSPECTION DECEMBER 2002 Version 1: 12-02 9-1 Participant WorkbookLesson 9- Assembling Your “Tool Box LESSON 9 ASSEMBLYING YOUR TOOL BOX NOTES Version 1: 12-02 9-2 Participant WorkbookLesson 9- Assembling Your "Tool Box” LESSON 9 ASSEMBLYING YOUR TOOL BOX NOTES Version 1: 12-02 9-3 Participant WorkbookLesson 9- Assembling Your "Tool Box" SO LESSON 9 ASSEMBLE YOUR TOOL BOX Version 1: 12-02 9-4 Participant WorkbookLesson 9- Assembling Your “Tool Box" LEARNING OBJECTIVES + Identify the documents and tools needed by the Inspector + Describe the importance of the Pre-constru meeting. Version 1: 12-02 9-5 Participant WorkbookLesson 9- Assembling Your “Tool Box" | INSPECTOR’S VIEW OF DRILLED SHAFT PROJECT ‘CONTRACTOR SET UP. ‘SHAFT EXCAVATION PLACING STEEL CONGRETING OPERATION] ae POST INSTALLATION oo See following full size version. Version 1: 12-02 9-6 Participant WorkbookLesson 9- Assembling Your "Tool Box" THE INSPECTOR’S VIEW OF A DRILLED SHAFT PROJECT Responsible to: + Test Slurry + Describe Soils & Rock + Prepare Soil & Rock Excavation Logs + Verify Shaft Depth + Perform Shaft Inspection + Prepare Shaft Inspection Log + Verify hole cleanliness + Document casing use, type, length CONTRACTOR SET UP |—— Responsible to: Check Drilled Shaft Installation Plan * Check Contractor Equip. * Check hole location * Check template + Check setup for plumbness, etc. Responsible to: + Verify hole cleanliness + Test concrete SHAFT EXCAVATION PLACING STEEL + Monitor concrete volumes «Prepare Concrete Placement Log + Check Const. Tolerances CONCRETING OPERATION Responsible to: + Verify proper steel size, length, etc. + Verify proper ties, + Verify proper spacers and intervals + Verify Instrumentation protection Version 1: 12-02 POST INSTALLATION Responsible to: + Verify pay quantities + Verify integrity testing * Complete required forms + Verify Load Tests Participant WorkbookLesson 9- Assembling Your “Too! Box" INSPECTOR’ OOLS” CHECKLIST [Checklists Prevent Our Forgetting See following full size version. Version 1: 12-02 9-8 Participant WorkbookLesson 9- Assembling Your "Tool Box SAMPLE INSPECTOR’S “TOOLS” CHECKLIST Approved Job Information Daily Essentials 1 Project Plans & Specifications O Hard Hat w/ Revisions 1 Boots I Special Provisions & Technical Cl Ear & Eye Protection Special Provisions 11 Pen / Pencil (with spare) 0 Drilled Shaft Installation Plan 1 12' Tape (Preferably 25') 0 150’ Tape 1 Builders Square Ref LI Life Jacket or reflective jacket ferences mIWaee 1 Standard Specifications 7 Galeuletor 0 Drilled Shaft Inspector's oSale Manual (Local Department) Level 11 Drilled Shaft inspector's 1 Weighted Tape (100°) Qualification Course Manual ane ee (NHI #132070) Testing Equipment 1 Sampler 0 Sand Content Testing Equipment 1 Mud Density Test Equipment 0 Viscosity Test Equipment Blank Forms C1 Drilled Shaft Soil/Rock Excavation Log 0 Drilled Shaft Rock Core Log 0 Drilled Shaft Inspection Log Concrete Placement Log Concrete Volume Form O Drilled Shaft Log 0 Drilled Shaft Construction & Pay Summary Version 1: 12-02 9-9 Participant WorkbookLesson 9- Assembling Your “Tool Box" Review Project Documents _/ and come up to speed as quickly as possible. The designers have lived with this project for years and the Contractor became very knowledgeable of the project during the bidding process. Whereas the Inspector is almost brought in at the last moment and therefore is the least knowledgeable of the project specifics. It is imperative that the Inspector come up to speed as quickly as possible. Version 1: 12-02 9-10 Participant WorkbookLesson 9- Assembling Your “Too! Box" KEY PARTS OF THE PLANS & SPECIFICATIO! [COMPONENT [ CHECK Plan Revisions Always check for revised sheets to see if there are any changes that affect the shaft construction Key Sheet | Does Project ID No., location, ete. agree with the information you were provided? Const. Est. | Do the pay quantities and items agree? Sheet L____ Version 1: 12-02 9-11 Participant WorkbookLesson 9- Assembling Your “Too! Box" KEY PARTS OF THE PLANS & SPECIFICATIONS | COMPONENT _| CHECK Does there appear to be any conflicts Utilities | with production or test shafts? If so, are there provisions for addressing these conflicts? Does there appear to be any conflicts Traffic Contro!| with production or test shafts? Does the sequence of shaft installation conflict? Ifso, are there provisions for addressing these conflicts? | Version 1: 12-02 9-12 Participant WorkbookLesson 9- Assembling Your “Tool Box” KEY PARTS OF THE PLANS & SPECIFICATIONS | STRUCTURAL PLANS CHECK ‘Compare with the Drilled Shaft Data Table. Do any “Notes” contain changes to the [specifications or specification applications? General Notes General Plan & Does the number of bent/piers or shaft Elevation liocations match the Drilled Shaft Data |Table? Do the elevations shown compare ltavorably with the Drilled Shaft Data [Table? Version 1: 12-02 9-13 Participant WorkbookLesson 9- Assembling Your “Tool Box” KEY PARTS OF THE PLANS & SPECIFICATIONS [STRUCTURAL] is | PLANS, Cues Bridge Hydr. [Are the scour elevations shown? Do they | | Sheet match the Drilled Shaft Data Table? | Rpt. of [Are water tables/piezometric levels shown?| Borings [Do the boring(s) extend beyond the proposed bottom of shaft elevations? Foundation —_|Does the foundation layout match the Layout Drilled Shaft Installation Plan relating to number, sequencing, elevations,etc.? Version 1: 12-02 9-14 Participant WorkbookLesson 9- Assembling Your "Tool Box” LEARNING OBJECTIVE #1 Identify the documents and tools needed by the Inspector Which Structural Plans should the Inspector review? Version 1: 12-02 9-15 Participant WorkbookLesson 9- Assembling Your "Too! Box" LEARNING OBJECTIVE #1 | Identify the documents and tools needed by the Inspector In addition to the Project Plans & Specifications, what are some of the other documents the Inspector should have? Version 1: 12-02 9-16 Participant WorkbookLesson 9- Assembling Your "Tool Box” TYPICAL INSPECTION FORMS Drilled Shaft Soil/Rock Excavation Log Drilled Shaft Rock Core Log Drilled Shaft Inspection Log Concrete Placement Log Concrete Volumes Form | Drilled Shaft Log Drilled Shaft Construction & Pay Summary Forms will vary by local agencies but herein are sample forms containing the information typically requested. Do not go to the jobsite without them. Drilled Shaft Soil/Rock Excavation Log- This is the form used to log the shaft excavation. Drilled Shaft Rock Core Log- This is the form used to log the sampling beneath the bottom elevation of the shaft that is required. Drilled Shaft Inspection Log- This form is used for the inspection of the shaft once excavated Concrete Placement Log- This is the form used to record the concrete placed into the shaft, Concrete Volumes Form- This form is used to plot the concrete volume being placed versus the shaft's theoretical concrete volume. Drilled Shaft Log- This form is used to summarize and provide the data on how the shaft was constructed Drilled Shaft Construction and Pay Summary- This form is used to record the pay quantities. Version 1: 12-02 9-17 Participant WorkbookLesson 9- Assembling Your "Tool Box" SAMPLE DRILLED SHAFT INSPECTION CHECKLIST Full-size version follows. Version 1: 12-02 9-18 Participant WorkbookLesson 9- Assembling Your “Tool Box" SAMPLE DRILLED SHAFT INSPECTOR’S CHECKLIST “The flowing is a ane checki! fo folow whan constucing ale Sat. The answer o each of hose shal bo "yes ures pln, spcetns ce soecte pol hasbeen gn aherise CONSULT WITH RESPONSIBLE ENGINEER FOR YOUR SPECIFIC PROJECT RESPONSIBILITIES, Contractor & Equipment Arrive On-Site Yes Naf WA [Has the contractor submited his diled shaft installation plan (xxx.12, Submis) ? 2. Has the Drilled Shaft Installation Plan been aporoved ? a 3, Does the contractor have an approved concrete mix design (xxx 60, Concrete Placement}? 4, Has the contractor run the required Trial Mix and slump loss test for his driled shaft mix design (00.60, Concrete Placement)? 5, I concreting is estimated to take over two hours, has the contractor performed a satisfactory slump loss test forthe E ‘extended time period in accordance with xxx.60, Concrete Ptacement? 6. tthe Contractor proposed a blended minerial-polymer or a polymer slurry, do they have an approved Siurry Management Plan (00x38, Slury}? 7. 1s the Contractor prepared to take soll samples or rack cores on the bottom of the shat in accordance with x00.35.5, Excavations? |B, Has the contractor met the requirements of xxx.30.1, Protection of Existing Structures? 9, Has the site preparation baen completed fr footing in accordance with xxx. 30.2, Construction Sequence? 10. If cofferdam is required, does the contractor have a qualified diver and safety diver for inspections in accordance with 10,35, Excavations? 11. Does the contractor have all ofthe equipment and tools shown in his drilled shat instalation plan to install the dled shat? 12, if casing is to be used, isi the correct size in accordance with xx%.36, Casing? 13. lf the contractor plans on using a manufactured slurry, does he have the equipment fo mix it? 4, a desander required (x0« 38, Sury)? 15. Ifa desander is required, does the contractor have ion ste and operational? +8, Doas the contractors tremie meet the requirements of x 61, Tremies? 17. Do you have the required driled shaft forms that need tobe filed out during shaft construction? +8, Do you understand the forms (i not, contact the responsible engineer for help) Trial Shaft 19, the tial Shaft positioned away from the production shafts or as inthe contract documents (xxx.13 Trial Shaft Installation]? 20. Has the contractor performed a successful test hole in accordance with xxx 31, Trial Shaft Installation? 21. Did the Contractor cut ofthe shaft 2 feet (0.6 m) below grade in accordance with xxx. 13, Trial Shaft Installation? 22. Has the contractor revised his technique an equipment (and the revision is approved) to successfully construct a shaft? ‘Shaft Excavation & Cleaning 23. 1s the shaft being constructed in the correc location & within folerance (orx.41, Tolerances)? 12. Does the contractor have a bench mark so the shaft can be constructed and inspected tothe proper elevations? 25, fa core hole is required, has the contractor taken them in accordance with xxx.35.5, Excavations? 26. Ifa core hole was performed, was the Rack Core Form completed and the Contractor maintained a log (xxx.35, Excavation)? 27. Ifthe contractors using slury, can they perform tests and repor the results in accordance with xxx.38, Stury? 28. Is te slur level boing properly maintained in accordance with x«x.38, Sty? 29. Is the proper type and numberof tests being run onthe slurry in acoordance with wxx.38, Slurry? 30, Are you filing out the SollRRack Excavation forms? 31. Ifpermanent casing Is used, dovs it meet xxx 36 & 96.2, Casing? 32. if temporary casing is being used, does it meet xxx.36.1, Temporary Casing? 33, ir beling is required, does it meet the requirements of xox, 35, Excavations? 3¢. Is the Contractor maintaining a excavation log in accordance with xxx.35, Excavations? 35, Is the shaft within allowable Vertical alignment tolerances (xxx 41, Construction Tolerances)? 36. isthe shat of proger death? 37. Does te shaft excavation ime meet the spectid time limit (x1x.34, Excavation & Driling Equipment)? 58. tre shaft required over reaming, was itperformed in accordance with xxx. 34, Excavation & Driling Equipment? 38, Does the shaft bottom meet the requirements of xxx 40, Excavation Inspection? 40. Die you complete the Shaft Inspection Form? HEE B Version 1: 12-02 9-19 Participant WorkbookLesson 9- Assembling Your "Tool Bo» SAMPLE DRILLED SHAFT INSPECTOR’S CHECKLIST ‘Tha fotonngis a gneracheckit to fclow when costucing a Oiled Sta. The ane each ol hee shel ba ys uss ans, speeatons or specie agro has been gen cherie CONSULT WITH RESPONSIBLE ENGINEER FOR YOUR SPECIFIC PROLECT RESPONSIBILITIES. ra inforeing Gage Si 441. Is the rebar the correct size and configured in accordance with the project plans? @ 42 Is the rebar propery tied in aocordance with xxx.50, Reinforcing Steel Cage Construction & Placement? fa 43, Does the Contractor have the proper spacers for the steel cage in accordance with xxx50, Reinforcing Steel Cage fy Construction & Placement? 44, Does the Contractor have the proper amount of spacers fr the steel cage in accordance with xxx.50, Reinforcing Steel fq rag Cage Construction & Placement? 45. Ihe cages spiced, was it done in accordance wth the contract documents? fs 48, [Is the sle! cage secured from setting and ftom floating (during concrete placement cages sometimes rise withthe concrete) (xxx.50, Reinforcing Stee! Cage Construction & Placement)? ea 47. Isthe top ote see cage a the proper elevation in aocordance wth x0x41, Construction Tolerances? a Conereting Operations 48, ror to contete placement, has the stury (bah mancfactuted & rata) been tested in accordance with 038, fq q Slury? 5 48, required was casing removed per xxx 3.4, Temporary Casings? ae 50, Wes the cscharge end ofthe remie mainsined in the concrete mass wth proper concrete heed above it xc, ley pay ‘Tremies)? ‘51. If free-fall placement (dry shaft only), was concrete placed in accordance with xxx.60, Concrete Placement? rz) 52, id the placement occur win te tm iit pected (ox, Conerste Placement? u 53, Are you filing out the concrete placement and volume forms? ele] 54, When placing concrete, cd the Contractor vero the shat unl good conerete lowed (xx.0, Conrete Placement)? [fl 56, Were concrete acceptance tests performed as required? a Post Installation 58. sha is constucted in pan water, the shal roeced for seven days or unl the conorete strength reaches @ fea ga minimum of 2800 ps (17MPa}n accordance wth wx, 36, Casings? 57. Is all casing removed to the proper elevation in accordance with xex.96.2, Permanent Casing? B 58. Has the Contactor comple wih xx. 6, Nondestuctve Evaluation, frequred? [sca 59 the shaft within the apoleabe constuction tolerances (xx 41, Constucon Tolerances)? faq 60. Has the Driles Shaft Log been completed? 6'. Have you documented te Pay items? Ss Notes/Comments Version 1: 12-02 9-20 Participant WorkbookLesson 9- Assembling Your "Tool Box” THE PRE-INSPECTION & CONSTRUCTION MEETING ATTEND ATTEND ATTEND + Get clarification of your duties & responsibilities + Get clarification on any issues of disagreements you found in your review of the project documents + If documents were unclear on elevations, etc. requiring calculations on your part, present your data to Engineer for approval * Clarify line of communication and distribution + Clarity reports required, frequency and schedule Lo "| The Inspector should attend any pre-inspection and/or pre-construction meeting Version 1: 12-02 9-21 Participant WorkbookLesson 9- Assembling Your “Too! Box" LEARNING OBJECTIVES + Identify the documents and tools needed by the | Inspector + Describe the importance of the Pre-construction meeting. Version 1: 12-02 9-22 Participant WorkbookVersion 1: 12-02 ASSEMBLE YOUR ‘TOOL BOX Do you have any questions? 9-23 Lesson 9- Assembling Your "Tool Box" Participant WorkbookLesson 9- Assembling Your "Tool Box" NOTES Version 1: 12-02 9-24 Participant WorkbookLesson 10- Contractor & Equipment Arrive On-site LESSON 10 CONTRACTOR AND EQUIPMENT ARRIVE ON SITE DRILLED SHAFT FOUNDATION INSPECTION DECEMBER 2002 Version 1: 12-02 10-1 Participant WorkbookLesson 10- Contractor & Equipment Arrive On-site LESSON 10 CONTRACTOR & EQUIPMENT ARRIVE ON-SITE NOTES Version 1: 12-02 10-2 Participant WorkbookVersion 1: 12-02 Lesson 10- Contractor & Equipment Arrive On-site LESSON 10 CONTRACTOR & EQUIPMENT ARRIVE ON-SITE 10-3 Participant WorkbookLesson 10- Contractor & Equipment Arrive On-site Version 1: 12-02 10-4 Participant WorkbookVersion 1: 12-02 Lesson 10- Contractor & Equipment Arrive On-site (/- Contractor & Equip. Arrive On-site + Shaft Excavation & Cleaning + Reinforcing Cage + Concreting Operations | + Post Installation Inspector’s Role 10-5 Participant WorkbookVersion 1: 12-02 Lesson 10- Contractor & Equipment Arrive On-site LEARNING OBJECTIVES + Describe how to verify Checklist Questions 1-18 + Explain how to assess Contractor compliance with the approved Drilled Shaft Installation Plan + Explain how to assess Contractor compliance with Protection of Existing Structures 10-6 Participant WorkbookVersion 1: 12-02 Lesson 10- Contractor & Equipment Arrive On-site INSPECTOR DUTIES | Responsible to: | Contractor & Equipment Arrive On-site | | * Check Contractor Equip. vs Drilled Shaft Installation Plan Check for Protection of Existing Structures Check Concrete and Slurry Data 107 When the Contractor and their equipment arrive on-site, there are a variety of items that you, the Inspector, are responsible for checking and verifying From verifying the equipment on-site matches that in the approved Drilled Shaft Installation Plan to assessing Contractor compliance with any required Protection of Existing Structures, the Inspector is quite busy. 10-7 Participant WorkbookLesson 10- Contractor & Equipment Arrive On-site SAMPLE DRILLED SHAFT INSPECTION CHECKLIST ‘SAMPLE DRILLED SHAFT INSPECTOR’S CHECKLIST. ‘Contractor & Equipment Arve On- Sie cs eta ey henna Seat treo Sm)? Vc ett ht ri Pe iepenel? fn cts nape Cro Pamet? J in uaa nn bog Sr an the el oh a Ga, Cee omer sown mae a noe a nat ee oy 2p oe eythane sh cnn Pam sites conse pees oss a one. naps Sy Maced LS commas! em nome LSESReas are een oe [Esti wusnaneresanmtnt omnes tSerenseccmenegreemesn sen Hemet tee aa Retire eeieateemermetrmee Scare Sa en Full-size version follows. Version 1: 12-02 10-8 Participant WorkbookLesson 10- Contractor & Equipment Arrive On-site SAMPLE DRILLED SHAFT INSPECTOR’S CHECKLIST The folowing a genes check ooo when conekuting a Os Sal. The answer a cach of hse shold be "es" ness las, spcatins a space npoval has een pv otterw'es CONSULT WITH RESPONSIELE ENGINEER FOR YOUR SPECIFIC PROJECT RESPONSIBILITIES. Contractor & Equipment Arrive On-Site ves Naf Nv Has the contractor submitted his drilled shaft installation pian cx. 12, Submits) ? o 2. Has the Drilled Shalt Installation Pian been aporoved ? (ae) 3. Does the contractor have an approved concrete mix design (xxx.60, Concrete Placement)? @ 4. tas the contractor run the required Thal Mix and slump loss test fr his dflled shaft mix design (xxx60, Concrete Placement)? ie) 5. If concreting is estimated to take aver two hours, has the contractor performed a satisfactory slump loss test for the io extended time period in accordance wih xx. 60, Concrete Placoment? 6. the Contractor proposed a blended minarak plymor ora polymer sly, do they have an approved Slury Management {E] [=] Plan (038, Slury)? 17. Is the Contactor prepared to take soil samples or rock cores on the bottom of the shaft in accordance with 30% 35.5, Excavations? Has the contractor me the requirements ofxx. 30.1, Protection of Existing Structures? fo. Has the ste preparation been completed for footing in accordance with x 302, Construction Sequence? 0. Ia coferdam is required, does te contactor have a qualified diver and safety diver for inspections in accordance with 14x35, Excavatons? +1. Does the contractor have al ofthe equipment and tols shown in his dil shaft installation plan to install he dled shat? 12. casing isto be used, iit the corct size in accordance wth 19x.36, Casing? 13. the contactor plans on using a manufactured slury, does he have the equipment to mix? 14. Is a desander required (xxx.38, Slurry}? 15. fa desander is required, des the contractor have ion ste and operational? 16. Does the contractor's tremie meet the requirements of xxx.61, Tremies? +7, Do youhave the requied dried shaft orms that ned tobe filed out dung shat constuction? 18, Do you understand he forms (fn, contacto responsible engineer for hel) Trial Shaft “Is the bal Shaft postioned away from the production shafts or as inthe contract documents ox. 13 Tiel Shaft nstallation? 20. Has the contractor performer a succassul ast hol in accordance with x31, val Shaft Installation? 21. Did the Contactor cut ff tho shaft 2 foot (0.6 m) bolow grade in aooordance with vot 13, Tal Sha nstalaon? 22. Has te contractor revised his technique and equipment (and the revision is approve) to successuly construct a shat? fe Shaft Excavation & Cleaning 23s the shat being construed in te cowect location & within tolerance (aac 4%, Tolerances)? 24, Does the contactor have a bench mark 0 the shaft canbe constructed and inspected tothe proper elevations? 25. a core hoe i requied, has the canractor taken them in accordance with x0. 35.6, Excavations? 26. If @ core hole was parformed, was the Rock Core For competed and the Contactor mainained a log (x01, Excavation)? 27 the contactors using slur, can they pexorm tests and report the results in acordance wth xx.38, lary? 28s the slury level being propery maintained in accoriance with xox. 38, Shay? 29. isthe proper type and number of tests bing un onthe sun in accordance wth 30%.38, Slt? 30: Ave you fling ut the SoilRack Excavation forms? 31. permanent casing is used, does it meet xxx.98 & 96.2, Casing? 52 temporary casings being used, doositmoet 0x 36.1, Temporary Casing? 33. fbeling is required, doos it moet te requirements of wee. 5, Excavations? 34s the Contractor maintaining a excavation login accordance with xx 38, Excavations? 351s he shaft wihin allowable Verica alignment olerances (out, Constucin Tolerances)? 56. Is the shat of proper dapth? 57. Does the shaft excavation ime meet he speci time limi (ox. 94, Excavation & Dlling Equipment)? 38. the shat required aver reaming, was i porfrmod in accordance wih x3, Excavation & Dring Equipment? 59. Does the shaf boom moet tne requirements of ee-40, Excavation Inspection? 20. Did you complete the Shaft Inspection Form? Version 1: 12-02 10-9 Participant Workbook