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Industrial Concrete Products (ICP) Spun Cast Piles in Florida

2011 FDOT/FTBA CONSTRUCTION CONFERENCE. Industrial Concrete Products (ICP) Spun Cast Piles in Florida. Rodney Chamberlain, P.E. Construction Structures Engineer. ICP Piles – What Are They?. Spun Cast Cylinder Piles Prestressed Sections Weldable Splice Plate Cast-In Made in Malaysia.

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Industrial Concrete Products (ICP) Spun Cast Piles in Florida

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  1. 2011 FDOT/FTBA CONSTRUCTION CONFERENCE Industrial Concrete Products (ICP) Spun Cast Piles in Florida Rodney Chamberlain, P.E. Construction Structures Engineer

  2. ICP Piles – What Are They? • Spun Cast Cylinder Piles • Prestressed Sections • Weldable Splice Plate Cast-In • Made in Malaysia FLORIDA DEPARTMENT OF TRANSPORTATION - STATE CONSTRUCTION OFFICE

  3. ICP Piles versus Index 20654 Piles • Spun cast cylinder piles • Pre-tensioned Sections • Weldable Splice Plate Cast-In • Sections lengths are made to order ICP Piles Index 20654 Piles • Vertically cast in a static form • Reinforced Concrete Sections • Sections are spliced by post-tensioning • Generally made in 16ft sections FLORIDA DEPARTMENT OF TRANSPORTATION - STATE CONSTRUCTION OFFICE

  4. ICP Piles – FDOT Approval • Component acceptance through strength testing • Meet driveability requirements in Section 455 • Meet domestically-produced steel requirements (23 CFR 635.410) • Quality Control Plan approved by the State Materials Office FLORIDA DEPARTMENT OF TRANSPORTATION - STATE CONSTRUCTION OFFICE

  5. ICP Pile Strength Testing • Testing conducted at the Structural Research Center in Tallahassee, FL • Flexural strength testing of the pile • Flexural strength testing of the splice • Report is available online at the Structures Design Office website FLORIDA DEPARTMENT OF TRANSPORTATION - STATE CONSTRUCTION OFFICE

  6. ICP Pile Driving Demonstration FLORIDA DEPARTMENT OF TRANSPORTATION - STATE CONSTRUCTION OFFICE

  7. ICP Pile Driving Demonstration Details of the Test • State Road 79 near Vernon, FL in District 3 • Drive one out-of-position pile • Drive pile in two 49ft sections to test constructability of splice • Drive pile to practical refusal; overstress pile FLORIDA DEPARTMENT OF TRANSPORTATION - STATE CONSTRUCTION OFFICE

  8. ICP Pile Driving Demonstration Bottom Section of Test Pile FLORIDA DEPARTMENT OF TRANSPORTATION - STATE CONSTRUCTION OFFICE

  9. ICP Pile Driving Demonstration Splicing Top and Bottom Sections FLORIDA DEPARTMENT OF TRANSPORTATION - STATE CONSTRUCTION OFFICE

  10. ICP Pile Driving Demonstration Splicing Top and Bottom Sections FLORIDA DEPARTMENT OF TRANSPORTATION - STATE CONSTRUCTION OFFICE

  11. ICP Pile Driving Demonstration Splicing Top and Bottom Sections FLORIDA DEPARTMENT OF TRANSPORTATION - STATE CONSTRUCTION OFFICE

  12. ICP Pile Driving Demonstration Splicing Top and Bottom Sections FLORIDA DEPARTMENT OF TRANSPORTATION - STATE CONSTRUCTION OFFICE

  13. ICP Pile Driving Demonstration Overstressing the Pile During Driving Real time monitoring of a fully-instrumented pile FLORIDA DEPARTMENT OF TRANSPORTATION - STATE CONSTRUCTION OFFICE

  14. ICP Pile Driving Demonstration Overstressing the Pile During Driving FLORIDA DEPARTMENT OF TRANSPORTATION - STATE CONSTRUCTION OFFICE

  15. ICP Pile Driving Demonstration Overstressing the Pile During Driving Localized concrete spalling at pile top FLORIDA DEPARTMENT OF TRANSPORTATION - STATE CONSTRUCTION OFFICE

  16. ICP Pile Driving Demonstration Overstressing the Pile During Driving Loss of Pile Cushion FLORIDA DEPARTMENT OF TRANSPORTATION - STATE CONSTRUCTION OFFICE

  17. ICP Pile Driving Demonstration Results and Conclusions • Exceeded maximum allowable compressive stress by approx. 28% • Exceeded maximum allowable tensile stress by approx. 200% • Ultimate static pile load bearing capacity of 504 kips • Was not driven to practical refusal; driven beyond allowable limits FLORIDA DEPARTMENT OF TRANSPORTATION - STATE CONSTRUCTION OFFICE

  18. ICP Pile Driving Demonstration Recommendations • Steel plate between pile and pile cushion • Vented pile helmet to reduce water hammer effects • Increase bevel at ends of piles to facilitate welding • Alignment pins or similar to assist in pile alignment during splicing FLORIDA DEPARTMENT OF TRANSPORTATION - STATE CONSTRUCTION OFFICE

  19. ICP Piles FDOT Approval • Strength testing has been established • Pile drivability to Specification 455 has been demonstrated • Quality Control plan needs to be approved by State Materials Office • Piles need to be produced domestically to comply with Buy America Provisions FLORIDA DEPARTMENT OF TRANSPORTATION - STATE CONSTRUCTION OFFICE

  20. 2011 FDOT/FTBA CONSTRUCTION CONFERENCE New Design Standards and Construction Details Rodney Chamberlain, P.E. Construction Structures Engineer

  21. Discussion TopicsNew Design Standards and Construction Details that Contractors should be aware of • New Wind Bracing Standard • Elimination of End Diaphragms • Squaring of Beam Ends • New Florida-I Beam – FIB 84 and FIB 96 FLORIDA DEPARTMENT OF TRANSPORTATION - STATE CONSTRUCTION OFFICE

  22. New Wind Bracing StandardNew tables in the Plans • Index No. 20005 in the 2010 Interim Design Standards • Applicable to FIB’s, Bulb-Tee’s and AASHTO beams • Work Standard Index with tables shown in the plans. Contractor must either: Provide certification that construction loads will not exceed loads specified in the plans Provide signed & sealed calculations for the bracing plans • Overhang bracing is still Contactor’s responsibility FLORIDA DEPARTMENT OF TRANSPORTATION - STATE CONSTRUCTION OFFICE

  23. New Wind Bracing StandardRevisions to Section 5 of the Specifications OLD Contractor solely responsible for the design of wind bracing system and ensuring the stability of the beams throughout the duration of construction (from placement on bearings to casting of deck). NEW When temporary bracing requirements are shown in the plans, the EOR takes responsibility for the construction loads shown in the tables, Contractor is responsible for the design of the bracing members and connections. Contractor must certify that the construction loads do not exceed the loads shown in the tables. FLORIDA DEPARTMENT OF TRANSPORTATION - STATE CONSTRUCTION OFFICE

  24. Elimination of End DiaphragmsReasons for the Change • Diaphragms are costly and difficult to form • Few bearing replacements are being performed and fewer expected • Beam stability can be provided by temporary bracing FLORIDA DEPARTMENT OF TRANSPORTATION - STATE CONSTRUCTION OFFICE

  25. Elimination of End DiaphragmsThickened Slab End Details • Added a thickened slab end at deck discontinuities • Details are shown in the plans FLORIDA DEPARTMENT OF TRANSPORTATION - STATE CONSTRUCTION OFFICE

  26. Elimination of End DiaphragmsAdvantages • Less Formwork: saves time • Less Concrete: saves money • Faster deck casting schedule: not required to wait 48 hours after diaphragms are poured before casting deck as per Specification 400-7.13.7 FLORIDA DEPARTMENT OF TRANSPORTATION - STATE CONSTRUCTION OFFICE

  27. Elimination of End DiaphragmsAreas of Concern • Issue:Beam ends extend to expansion joint. In previous practice, a portion of the end diaphragm is cast in front of beam end, allowing for casting and placement tolerances. • Solution: Monitor casting lengths in real time Pour backwall after beams have been set Larger expansion joints (up to 3” for joints poured with backer rod FLORIDA DEPARTMENT OF TRANSPORTATION - STATE CONSTRUCTION OFFICE

  28. Squaring of Beam EndsWhat’s Changed PREVIOUS CURRENT FLORIDA DEPARTMENT OF TRANSPORTATION - STATE CONSTRUCTION OFFICE

  29. Squaring of Beam EndsAdvantages and Disadvantages • Simplified casting operations • Reduced chances of spalling • Better distribution of stresses into the bearing pad Advantages Disadvantages • May require a larger bent cap • Gap at intermediate joints between beam ends FLORIDA DEPARTMENT OF TRANSPORTATION - STATE CONSTRUCTION OFFICE

  30. Squaring of Beam EndsDetails • Details will be shown in the plans • Preferred details are shown in the Structures Detailing Manual, Chapter 15 • Includes details for end bent and intermediate bents with and without expansion joints • Beam top flange is required to be clipped at end bent locations Int. Bent without Exp. Joint Int. Bent with Exp. Joint FLORIDA DEPARTMENT OF TRANSPORTATION - STATE CONSTRUCTION OFFICE

  31. New Florida-I BeamsFIB 84 and FIB 96 FIB 84 FIB 96 FLORIDA DEPARTMENT OF TRANSPORTATION - STATE CONSTRUCTION OFFICE

  32. New Florida-I BeamsMaximum Span Lengths FIB 96 FIB 84 208 Feet 6ft Beam Spacing 8.5 ksi concrete 191 Feet 6ft Beam Spacing 8.5 ksi concrete 170 Feet 14ft Beam Spacing 8.5 ksi concrete 153 Feet 14ft Beam Spacing 8.5 ksi concrete FLORIDA DEPARTMENT OF TRANSPORTATION - STATE CONSTRUCTION OFFICE

  33. New Florida-I BeamsFlorida-I Beams FLORIDA DEPARTMENT OF TRANSPORTATION - STATE CONSTRUCTION OFFICE

  34. THANK YOU! FLORIDA DEPARTMENT OF TRANSPORTATION - STATE CONSTRUCTION OFFICE

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