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THERMAL INTEGRITY PROFILING AS A DRILLED SHAFT
QUALITY ASSURANCE TOOLMark Gaines, PE
State Bridge Construction EngineerWashington State Department of Transportation
September 10th, 2015
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PRESENTATION OVERVIEW
• WSDOT’s drilled shaft construction program
• Traditional shaft quality assurance at WSDOT
• Thermal Integrity Profiling Basics
• Implementation on Construction Contracts
• What we learned
• The way forward
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WSDOT’S DRILLED SHAFT CONSTRUCTION PROGRAM
• WSDOT’s started drilled shaft construction in late 70’s.
• For past 10 years, average exceeds 100 shafts per year.
• Range from 4-12 feet in diameter and 40-200 feet in length.
• Vast majority (95%) constructed as “wet” shafts.
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TRADITIONAL SHAFT QUALITY ASSURANCE AT WSDOT
• Primary QA has been cross-hole sonic log (CSL) testing
• 100% of the “wet” shafts are CSL tested
• Backed up by:
• Inspector observations
• Monitoring of concrete and slurry levels
• Concrete yield plots
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TRADITIONAL SHAFT QUALITY ASSURANCE AT WSDOT
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TRADITIONAL SHAFT QUALITY ASSURANCE AT WSDOT
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TRADITIONAL SHAFT QUALITY ASSURANCE AT WSDOT
• Limitations on CSL Testing:
• Can be a “sensitive” test.
• “False anomalies” aren’t uncommon.
• Only validates core of shaft.
WSDOT has used Thermal Integrity Profiling on two recent projects.
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THERMAL INTEGRITY PROFILING BASICS
• Uses heat generated by hydrating concrete to determine quality.
• Measurements taken near shaft perimeter and uniformly around and along shaft.
• Adjustments for shaft geometry, concrete properties, water table, type of soils, presence of casing, etc.
ASTM D7949 – Standard Test Methods for Thermal Integrity Profiling of Concrete Deep Foundations
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THERMAL INTEGRITY PROFILING BASICSTHERMAL WIRE METHOD
• One wire per foot diameter of shaft
• Sensors located every foot
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THERMAL INTEGRITY PROFILING BASICSTHERMAL PROBE METHOD
• One access duct per foot diameter of shaft
• Reusable thermal probe to get temperatures
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THERMAL INTEGRITY PROFILING BASICS
• Basic output is temps at each node
• Data is further post-processed (discussed later)
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IMPLEMENTATION AT WSDOT
• Participated in research testing in 2010
• Used the thermal probe method
• WSDOT purchased testing equipment and used for QA testing and shaft acceptance on two contracts
• Selected the thermal wire method
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IMPLEMENTATION AT WSDOTINSTALLING THE THERMAL WIRES
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IMPLEMENTATION AT WSDOTPROTECTING THE TAPS
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IMPLEMENTATION AT WSDOTOBTAINING DATA READINGS
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IMPLEMENTATION AT WSDOTCOLLECTING THE TAPS
• TAP’s obtained:• Once slurry pumped
down, and• Once sufficient time
has elapsed• If needed, TAP’s can be
reconnected.
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IMPLEMENTATION AT WSDOTDOWNLOADING THE THERMAL DATA
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IMPLEMENTATION AT WSDOTDATA SUPPLIED BY THE FIELD
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IMPLEMENTATION AT WSDOTPOST-PROCESSING AND RESULTS
LEVEL 1 – Performed in the field using TIP Main Unit• Verify shaft length – Identify top and bottom• Locate immediate areas of concern
LEVEL 2 – Added Element – Field Records• Find relationship between concrete volume and
measured temperature• Predict as-built shaft radius, shape, and cover
Level 1 AnalysisInformation and graphics courtesy of Pile Dynamics Inc.
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IMPLEMENTATION AT WSDOTPOST-PROCESSING AND RESULTS
Level 3 AnalysisInformation and graphics courtesy of Pile Dynamics Inc.
LEVEL 3 – Thermal Modeling using TIP Reporter• Completed with desktop software • Top & Bottom Roll Off Corrections• Analyze Radius vs. Depth
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WHAT WE LEARNEDSOME EXAMPLES FROM WSDOT PROJECTS
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WHAT WE LEARNEDMANETTE BRIDGE SOIL CAVING
• After placing cage, 40 CY of material sluffed into shaft
• Cage was extracted and soils removed
• Used TIP to evaluate actual shaft geometry
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WHAT WE LEARNEDMANETTE BRIDGE SOIL CAVING
0
5
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
65 75 85 95 105 115 125 135
Temperature (deg F)
Dep
th (f
t)
-81
-76
-71
-66
-61
-56
-51
-46
-41
-36
-31
-26
-21
-16
-11
-6
-1
4
9
Ele
vati
on (f
t)
Avg
Model
TOS
BOS
BOC
C-7926 Manette BridgePier 2 South Shaft
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
5 5.5 6 6.5 7 7.5 8Effective Shaft Radius (ft)
Dep
th (f
t)
-81
-76
-71
-66
-61
-56
-51
-46
-41
-36
-31
-26
-21
-16
-11
-6
-1
Elev
atio
n (ft
)
T1
T2
T3
T4
T5
T6
T7
T8
T9
T10
T11
T12
Avg
TOS
BOS
BOC
C-7926 Manette BridgePier 2 South Shaft
Actual vs. Modeled Temps. Predicted Shaft Radius
• Results showed as-built geometry
• Limits of voiding
• Effective radius at all shaft locations
• Good correlation with concrete yield plot
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WHAT WE LEARNEDI-5 M-STREET TO PORTLAND “BULGE”
Flat view of Temps. Estimated concrete cover
• “Bulge” of concrete identified.
• Potential for affecting seismic design.
• Allowed Engineer to review for structural acceptance.
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WHAT WE LEARNEDI-5 M-STREET TO PORTLAND CAGE RACKING
Section near shaft tip
Estimated concrete cover
• Detailed for 6” cover
• Testing identified cage racking near shaft tip
• Min. cover approx. 3.5”
• Due to low corrosion potential at shaft tip, shaft was accepted.
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THE WAY FORWARDPROS AND CONS OF THERMAL INTEGRITY PROFILING
Pros
• Indicates quality of shaft core and cover
• Testing as early as 24 hours after placement
• Builds a 3D model of shaft geometry
Cons
• A bit of a “black box”
• Thermal wires prone to damage/failure
• Thermal wires are a proprietary product
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THE WAY FORWARDOTHER OBSERVATIONS
• Cost-wise, comparable to CSL testing.
• CSL tubes and thermal wires have similar costs
• Equivalent labor for each method
• TIP methods/materials are improving!
• New wire just released to reduce failures
• TIP data often leads to more acceptance evaluation• This is a good thing.
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THE WAY FORWARDFUTURE USE AT WSDOT
• WSDOT is generally pleased with the TIP methods
• Provides deeper review than CSL testing
• Currently reviewing/updating specifications
• Likely expand use to additional projects
• Still want to keep CSL testing
• May reserve TIP for larger, deeper shafts
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Comments/Thoughts?
Mark Gaines, PE
(360) [email protected]
THERMAL INTEGRITY PROFILING AS A DRILLED SHAFT QUALITY ASSURANCE TOOL