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GSP 136 Innovations in Grouting and Soil Improvement

Underpinning of Drilled Shafts Using Jet Grouting

Timothy H. Bedenis1, P.E., Member, ASCE ,
Larry P. Jedele2, PE, Member, ASCE,, and Steve Maranowski3
ABSTRACT: Two drilled shaft supported columns for a pedestrian bridge exhibited
excessive settlement. Jet grouting techniques were used to extend the support for the
drilled shafts to a deeper dense sand stratum. Upon completion of the jet grouting,
the bridge deck was raised to its original position using temporary shoring with heavy
steel transfer beams and hydraulic jacks.

INTRODUCTION
The project includes three major buildings integrated with a new parking deck. A
pedestrian bridge spans a drive and connects two of the buildings to allow for foot
traffic between the buildings. Refer to Figure 1 for general plan view of the bridge
area.
One end of the connector bridge is supported off the Life Science Building on the
south, the other end of the bridge is supported on two columns designated AA-19 and
AA-20 on Figure 1, located adjacent to Commons Building on the north. The Life
Science Building has a below-grade level that extends about 7.6 meters (25 feet)
below the ground surface, and this building is supported on drilled shafts (caissons)
which extend into dense sands. The Commons Building also has a lower level, but is
supported on spread footings.
__________________________
1

Principal, Soil and Materials Engineers, Inc. 43980 Plymouth Oaks Blvd.,
Plymouth, Michigan 48170, USA., bedenis@sme-usa.com
2
Principal, Soil and Materials Engineers, Inc. 43980 Plymouth Oaks Blvd.,
Plymouth, Michigan 48170, USA., jedele@sme-usa.com
3
President, Spartan Specialties, Ltd., Sterling Heights, Michigan, USA

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Innovations in Grouting and Soil Improvement

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GSP 136 Innovations in Grouting and Soil Improvement

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Caissons with a diameter of 1.5 meters (5 feet) support the two 96-cm square by 8.2meter high (36-inch by 2 feet) concrete columns. The columns in turn support a grid
of reinforced concrete beams which support the concrete slab for the connector
bridge.

FIGURE 1: Site Plan

Initially, the caissons for the two bridge columns were constructed to bear at a depth
of about 4.6 meters (15 feet) below the ground surface. The Commons Building, on
the north, was constructed after the two bridge caissons were installed and the
temporary retaining wall for the lower level of the building was within 1.5 meters (5
feet) of the two bridge caissons. An underground utility tunnel, linking the Commons
and Life Science building with the floor matching the basement level 7.6 meters (25
feet) below the ground surface, along with numerous utilities, were subsequently
constructed.
Settlement of the caissons occurred after the concrete deck for the bridge was placed.
The magnitude of the settlements ranged from about 50 to 100 mm (2 to 4 inches).
The loading on the columns was 535 kN and 1070 kN (120 kips and 240 kips),
respectively. Additional construction on the bridge deck was expected to further
increase the column loadings to 1070 kN and 2140 kN (240 kips and 480 kips),
respectively.

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Innovations in Grouting and Soil Improvement

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GSP 136 Innovations in Grouting and Soil Improvement

A supplemental soil boring was performed between the two bridge columns after the
settlement was reported. The soil profile at the soil boring is summarized in Table 1:

Depth
(m)

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(1)
0 to 2.4
2.4 to 4.0
4.0 to 8.5
8.5 to 12.2

Table 1: Soil Profile at Drilled Shafts

Soil Type
SPT NValue
(blows/0.3m)
(2)
(3)
Fine to Medium Sand Fill Loose
3 to 6
Silty Clay Hard to Very Stiff
13
Silty Clay Stiff to Medium
9 to 11
Fine to Medium Sand Dense
29 to 53

Shear
Strength
(kPa)
(4)
130 to 220+
35 to 60
-

The soil boring indicated the drilled shafts were constructed over the stiff to medium
clay layer. Further analysis indicated the shear strength of the clay was not sufficient
to support the applied bearing pressure for the existing loading conditions, resulting
in large plastic deformations (i.e., bearing capacity failure).
Since the bridge deck was not physically tied to the Commons Building to the north,
the effect of the column settlement was a vertical drop at the joint between the deck
and upper building floor slab. Therefore, very little damage to the bridge deck was
observed. Some small hairline cracks were visible at the connection between
concrete beams supporting the deck and the top of the concrete columns.
JET GROUTING
Jet grouting consists of using high pressure pumps to erode or jet soils from a
radially-shaped zone around a small diameter drill rod. The jetting is done with a
cementbased grout mix, air, water, or some combination of all three. The liquefied
soils are either mixed with the injected grout or displaced by the grout. The grout
typically consists of a mixture of cement and water (i.e., neat cement grout), but other
additives can be used to improve grout properties.
Jet grouting was chosen for the underpinning because it provides a number of
advantages over other techniques. The jet grouting could be done in the relatively
confined area between the edge of Palmer Drive and the Commons Building and does
not require a large excavation around the columns. Relocation of utilities was not
required and there would be little interference with existing structures. Since the soils
below the caisson would be improved, load transfer with a pile cap was not required.
The jet grouting process is relatively fast and jacking of the columns could begin as
soon as the jet grouting was completed.

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The size and strength of the resulting jet grouted column is determined by a number
of factors including the following:

Soil Type and Strength or Density

Type of fluids used for jetting (e.g., water and/or grout)
Grouting and jetting pressures (up to 70,000 kPa/10,000 psi)
Location, size, and shape of nozzles for jets on grout tubes
Rate of rotation of drill rod
Rate of withdrawal of drill rod
Type of Jet Grouting System (e.g, single, double, or triple tube fluid systems)

For the underpinning of the caissons, it was determined by the jet grouting contractor
that a triple tube jet grouting system would be the most efficient method, primarily for

FIGURE 2: Jet Grouting Plan

its ability to cut the clay and fully displace the soil with cement grout. The triple tube
system is the most complex of the jet grouting systems and uses air and water pumped
under high pressures to cut the soils with immediate injection of neat cement grout
just below the cutting nozzles. This system forces all the soil cuttings (spoil) to the
surface resulting in relatively large and uniform columns consisting of mostly grout.

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GSP 136 Innovations in Grouting and Soil Improvement

FIGURE 3: Temporary Shoring

Four overlapping jet-grouted columns were installed in each of the four quadrants
around and beneath each caisson. Each grout column had a design diameter of 1.8
meters (6 feet) extending to about 10 meters (33) feet below the ground surface, or
about 1.5 meter (5 feet) into the dense sand stratum. To ensure transfer of the load to
the jet grouted columns, the cut-off for the top of the grout columns was 0.9 meter (3
feet) above the bottom of the caissons (i.e., 3.7 meters or 12 feet below the ground
surface). This resulted in 6.4 meter (21-foot) long jet grouted columns, extending
from about 3.7 to 10 meters (12 to 33) feet below the ground surface. Figure 2
provides a plan and section at each column location.
The effective bearing area in the dense sand of the overlapping column group is about
2.4 meters by 2.4 meters (8 feet by 8 feet). The larger bearing area (compared to the
1.5-meter/5-foot diameter caisson) and resistance of the dense sand combined to
provide more than sufficient support for the existing and new loads imposed on the
caissons.

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GSP 136 Innovations in Grouting and Soil Improvement

FIGURE 4: Temporary Shoring

FIGURE 5: Jet Grouting Rig

Since a portion of the soils below the caissons would be in a semi-liquid state until
the cement grout had set, some additional settlement of the caissons was likely.
Therefore, temporary steel columns were installed below the concrete beams to
support the deck during the jet grouting until the grouting was completed (see Figure
3 and Figure 4).
The following equipment was used for the jet grouting operation.

Skid mounted drill rig with electronic controls

Two high pressure hydraulic pumps
High pressure air compressor
Two portable grout mixing plants
Grout batching stations and grout pumps
Portable cement silo

The drill rig was relatively small and compact and could be positioned around the
columns with conventional construction loaders and lifts (see Figure 5). The pumps,
compressors, and grout mixing equipment could be located off to the side of the
columns so as not to interfere with the drilling operations. Only one set-up was
required for the pumping and mixing operations, while the drilling rig could be easily
moved from one location to another within a short period of time. The silo and
batching stations allowed sufficient quantities of grout to be mixed prior to and
during the jet grouting to allow a continuous flow of grout when required.
A total of eight jet grouted columns were required at the two caisson locations (four
at each column). Figure 5 shows the jet grouting rig installing the grout column next
to the bridge column. The locations of the grout columns were alternated from one
bridge column location to the next to allow at least 24 hours of cure time between jet

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grouting at each bridge column. Approximately 110,000 kg (240,000 lbs.) of cement

was used at the eight grout column locations.
The grout consisted of mixture of Type II Portland Cement and water with a water to
cement (w/c) ratio of 1.0 and a specific gravity of about 1.5. The design strength of
the grout at 28 days was 28 MPa (4000 psi). Compressive tests on grout samples
indicted 28-day strengths of typically in excess of 34 MPa (5000 psi). The insitu
grout (i.e., after the jet grouting) below the caissons was estimated to have a specific
gravity of 1.7 to 1.8 due to some mixture with the native soils and bleeding of water
from the grout.
The jet grouting operations were monitored for depth of penetration, fluid pressures,
rate of grout flow, rate of rotation, rate of uplift, and total grout take. The grout
volumes were typically in excess of the theoretical values for the design size of the jet
grouted columns. Probing was performed from the surface at several locations to
determine the lateral extent of the jet grouting. The probes indicated the diameters of
the shafts were somewhat larger than the design size of the columns, possibly by as
much as 0.3 to 0.45 meters (1 to 2 feet).
The spoils from the jetting were allowed to gravity flow from the jet grouting area
into a nearby pit. The spoils contained some residual cement which resulted in the
spoils becoming solid over a period of a day or two. The pit was cleaned out
periodically with a backhoe and the spoils trucked to an off-site disposal area.
Estimated volume of spoil was approximately equal to the volume of the jet grouted
columns or about 135 cubic meters (4800 cubic feet).
SHORING AND JACKING OF COLUMNS
Once the jet grouting was completed and equipment removed, temporary shoring was

FIGURE 6: Steel Collar

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installed at each of the bridge columns. The purpose of the shoring system was to
support the upper portion of each bridge column, while a lower section of the column,
just above the top of the caisson, was removed. The vertical steel for the column and
dowels extending up from the caisson were overlapped in this zone. Therefore, once
the concrete was removed in this area (leaving the reinforcing steel), the columns
would be completely disconnected from the caisson. The column and bridge deck
could then be raised to near their original position with the use of hydraulic jacks.
To support the columns, steel collars were installed around the columns above the
cut-off level (see Figure 6). The collars consisted of two deep channels on opposite
sides of the column with two I-beams connecting the channels. High strength
threaded steel bars were installed through holes cored between the vertical reinforcing
steel of the columns. Grout was placed in the annulus around the threaded bars. The
channels were then bolted to the columns while the bars and I-beams were welded to
the channels to complete the collar.

FIGURE 7: Temporary Shoring Frame

Cribbing with timber mats and steel beams was placed on either side of the columns
to act as temporary footings (see Figure 7). Heavy steel transfer beams were placed
on the temporary footings and on either side of the columns. Hydraulic jacks (two per
column) were placed on top of each beam directly below the I-beams of the steel

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GSP 136 Innovations in Grouting and Soil Improvement

FIGURE 8: Removal of Concrete at Base of Column

collar. The hydraulic jacks had
special screw heads which would
lock the ram in place after the
hydraulic pressure was released. A
manifold was used to pressurize the
jacks evenly. A pressure gauge was
used to determine the approximate
jacking load.
Once the shoring and jacking system
was in place, the jacks were loaded
to the estimated current loads 535
kN and 1070 kN (120 kips and 240
kips) respectively, and then locked
off. The concrete was then removed
below the steel transfer beams to the
top of each caisson (see Figure 8 and
Figure 9). The shoring and concrete
removal was done simultaneously at
each column to allow the columns to
be raised
independently and
sequentially, as necessary.
FIGURE 9: Concrete Removal
Completed

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Each of the columns were independently raised by activating the hydraulic jacks in
small load increments. The vertical position of the bottom of the columns and
selected points on top of the deck were measured to the nearest 0.4 mm (1/64 inch) at
each load increment. The sequencing of the loads on each column was adjusted until
the deck was back to within 0.8 mm (1/32 inch) its original position. The jacks were
then locked off and the position of the deck rechecked.
Forms were installed around the base of each column and new concrete placed at the
base of each column to within 100 mm (2 inches) of the bridge column extending
down from the deck. The concrete was allowed to cure for 2 weeks to allow most of
the shrinkage in the new concrete to occur. A non-shrink cement grout was then hand
packed into the gap between the old and new concrete. After the grout reached the
required strength, the jacks were unloaded to transfer the load back to the caissons.
The temporary shoring and steel collar were removed to complete the repair.
Survey points on columns indicate no measurable movements upon completion of the
jet grouting and reconstruction of the base of the columns.
CONCLUSIONS
Jet grouting techniques have been used for a number of years. In the past, jet grouting
was generally limited to larger projects due to the relatively high cost associated with
the development, purchase and maintenance of the specialized equipment. The recent
availability of newer, less costly, easier to use, and more efficient jet grouting
equipment has increased its use for smaller specialized projects. The versatility of the
jet grouting process makes this method especially appealing for underpinning of
foundations, either in new construction or for remedial measures. The ability of the
jet grouting to extend relatively deep without the requirement of open excavations is
especially useful in underpinning drilled shaft or caisson foundations.

ACKNOWLEDMENTS
The authors would like to thank the Barton Malow Construction Co., and J.T.
Crawford, Inc. for their help and assistance in this challenging project.

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Innovations in Grouting and Soil Improvement