THE UPLIFT CAPACITY OF PILES ON THE EASTERN DISTRIBUTOR, SYDNEY

Paul B. Hewitt, 1Craig S. Curnow

ABSTRACT This paper presents a case study of the uplift capacity of rock socketed grout injected piles used along a section of the Eastern Distributor Project in Sydney. A significant component of the Eastern Distributor is a 600m long tunnel underpass on South Dowling Street constructed using cut and cover techniques in water bearing sands. Along this section the motorway was lowered below surface level, requiring piles subject to both compressive loads and uplift loads due to buoyancy effects. This paper discusses the geotechnical model and the design procedures developed for auger grout injected piles socketed into Hawkesbury Sandstone. Procedures were developed to account for uncertainties with variations in the buried sandstone topography and constraints of the chosen construction method. Results of full-scale pile uplift tests are discussed. Comparisons are made between measured load capacity, and uplift capacity predictions using published design methods. INTRODUCTION The six kilometre long Eastern Distributor is a privately funded $A700 million transport link and is part of Sydneys orbital road network. It connects the eastern side of Sydneys CBD with Southern Cross Drive and Sydney Airport, and will link the M5 East (under construction) to the Harbour Bridge and Harbour Tunnel. Leighton Contractors constructed the Eastern Distributor during the period August 1997 to December 1999. Maunsell McIntyre Pty Ltd (Maunsell) was the Principal Design Consultant. A significant component of the Eastern Distributor includes a tunnel underpass on South Dowling Street from 100m south of the ODea Avenue / Todman Avenue intersection in Zetland to 100m north of the Lachlan Street / Dacey Avenue intersection. In this Dacey-Todman section the road pavement is about 5m below adjacent ground level and is constructed within a 600m long cut-and-cover tunnel. Precast concrete beams in the tunnel roof support the southbound and northbound surface road. The outer walls were built using diaphragm wall construction (see Figure 1). The central tunnel wall is supported on 182 piles subject to both compressive loads and uplift loads due to buoyancy effects. In most cases uplift loads governed design. Foundations in both sand and rock were required as a result of the variations in the rock profile. This paper describes the design methodology and the pile load test program developed for auger grout injected piles founded in rock. Approximately half of the 182 piles are founded in rock and are located near the centre of the tunnel. This paper also describes the methods used to verify the pile capacity, which included three static tension (uplift) tests of the piles. The objectives of the testing program on this section of the project were to: 1. Assess that the piles achieved the design uplift capacity, and, 2. Evaluate the design parameters of the rock sockets in the sandstone thus providing confidence in the design of piles. Given that the pile installation procedures generally do not yield information to validate assumptions on subsurface conditions between borehole locations, a method was devised to correlate rock quality with penetration rates of the piling rig.

Golder Associates, 88 Chandos Street, St. Leonards, NSW, 2065, Australia. Email: phewitt@golder.com.au

DESIGN CONCEPT The Maunsell documented design required the construction of 0.6m diameter bored piles founded both in sand alluvium and/or socketed into rock. Foundation sub-contractor Bachy Pty Ltd proposed an alternative design featuring 0.6m diameter auger grout injected / continuous flight auger (CFA) piles. The Bachy alternative featured similar pile capacities to the bored pile design, but due to the construction method it was difficult to assess the rock-socket quality during installation. Consequently, three static tension tests were carried out to assess the design parameters.

DIAPHRAGM WALL

CENTRAL PILES (DEPTH VARIES) Pile toe socketed into rock or dense sand. Source: Maunsell McIntyre Drawing N641/S/CV/2153

Figure 1: Dacey-Todman Tunnel Section, Ch 4450 to Ch 4800 GROUND CONDITIONS IN THE TUNNEL UNDERPASS The geological model developed for the Dacey-Todman section of the route was based on multi-phased geotechnical investigations carried out between 1985 and 1998 (Burgess and Associates, Pells Sullivan Meynink, Maunsell McIntyre, and Golder Associates) including cored boreholes, auger boreholes, cone penetration tests, test pits, and geological mapping. Observation during construction of sections of the outer diaphragm walls by Golder Associates was also used to supplement information on rock levels near the piles. Subsurface conditions typically comprise alluvial sand over Hawkesbury Sandstone bedrock. The alluvial sand was generally loose to medium dense to between 3m and 6m depth, becoming medium dense to dense sand to about 14m to 17m, over dense sand. Groundwater was encountered within the loose to medium dense sands (about RL 20m south of ODea Avenue). A significant feature of the subsurface conditions in the Dacey-Todman section is the irregular buried rock surface topography. The depth to rock varies from about 3m to greater than 30m below existing ground level over the 600m section length. Between approximately Ch 4480 and Ch 4680 the depth to rock is relatively shallow, and over a length of about 125m the base slab for the tunnel underpass is below rock level. A steep buried slope marks the northern margin of this elevated rock feature, with the depth to rock changing from about 12m to 16.5m over a horizontal distance of 3m. The sandstone was classified using the Pells et al (1998) scheme. In general, the weathering profile of the bedrock comprised a layer of Class V/IV sandstone (generally 0.5m to 2.5m thick) over Class III or Class II sandstone. Inferred rock levels (metres, AHD) in the tunnel underpass area are shown in Figure 2.

GEOTECHNICAL DESIGN In addition to structural capacity, piles in uplift were checked for failure at the pile-sandstone interface (plug pullout), and pullout of a cone or slab of rock attached to the pile. The ultimate limit state loads of the 600mm diameter piles in the rock socket zone are up to +2000kN (compression) and 1200kN (tension) applied at base slab level. Prior to construction, Maunsell determined characteristic geotechnical parameters for bored piles for each of the geological units. The characteristic parameters were based on results of previous investigations, typical values adopted for the design of bored pile foundations in sandstone of similar quality (Pells et al, 1980 & 1998), and geotechnical parameters in the Austroads Bridge Design Code (Maunsell, 1997). The bored pile parameters require the shaft sidewalls to be rough and free of smear (ie. remoulded) material.

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AIRPORT

Figure 2: Inferred Rock Levels (m, AHD) around the Dacey-Todman Underpass Since the proposed alternative pile installation method provides little control over sidewall cleanliness or roughness there was concern that the grout injected piles may not develop similar shaft resistance to a bored pile. As a result, a series of reduction factors were applied to ultimate bond stress between the sandstone and the pile shaft, thus requiring a greater socket length for equivalent uplift performance. A summary of the reduction factors incorporated into the design of auger grout injected piles to resist tension loads on this section of the project are provided below in Table 1. Table 1: Reduction Factors and Design Bond Stress for Auger Grout Injected Piles in Tension
Estimated ULS Bond Stress(1) (kPa) 375 875 1,500 Reduction Factors Geotechnical Strength(2) (g) 0.72 0.72 0.72 Smear Effects in CFA Piles 0.5 0.5 0.5 Tension Design (Serviceability) Bond Stress in Tension (kPa) 100 240(3) 400

Sandstone Rock Class IV III II

0.75 0.75 0.75

(1) Ultimate Limit State, based on Maunsell design for 600mm diameter bored piles. (2) A factor of 0.72 was applied to ultimate geotechnical capacities in accordance with the Austroads Bridge Design Code. (3) Revised following pile tests discussed later in paper.

The contribution to pile uplift capacity from the sand overlying bedrock was ignored in the design of working piles for two reasons: (1) displacement incompatibility between bond stress from the sand and the bedrock, and (2), drilling the rock socket usually resulted in over-rotation of the auger, thus removing a volume of sand greater than the volume of grout injected. Consequently the density of the surrounding sand was lowered. Any estimate of final sand density and its contribution to shaft resistance would be unreliable.

Load-deflection acceptance criteria for the direct tension tests are defined in Table 2. The figures are based on criteria in the Australian Piling Code (AS2159). In some cases the criteria are greater (ie less conservative) than the code values as the effect of movement on the overall structure is not significant, and the ultimate pile capacity is the critical value. Table 2: Acceptance Criteria for Static Tension Pile Tests
Load Serviceability Load After removing Serviceability Load Maximum Test Load After removing Maximum Test Load Maximum Deflection (mm) 15 7(1) 40(2) 10

(1) Limit defined in Australian Piling Code (2) Provided no reduction in load over 1 hour duration (3) Source: Maunsell McIntyre drawing N641/S/ST/19031/SD/BACHY-1/A

FIELD PERFORMANCE Piles were installed by Bachy Pty Limited under subcontract to Leighton Contractors using a single flight hollow auger operated by a CH-400 drill rig. The drill rig was mounted on a Linkbelt 318 crane equipped with a 33m mast (see Figure 3). The drilling unit weighed about 50 tonnes and was rated for a torque of 8 tonne metres. Golder Associates observed the installation of rock-socketed piles during the period July through September 1998. The purposes of our observations were to confirm the levels of inferred rock class and to provide Leighton with assurance that the piles were being installed within the design rock class, and were thus capable of achieving the design uplift capacity. Between cored borehole locations, the rock class was inferred during pile installation by observing the penetration rate of the auger string and machine behaviour, and correlation with samples obtained from diaphragm wall construction of the adjacent outer walls (see Figure 1). The piling rig was not equipped with downforce or torque gauges or equipment for monitoring grout delivery volumes. This method of inferring rock class was initially calibrated by observing installation of piles adjacent to cored boreholes, both on the Dacey-Todman and the nearby South Dowling Street Parkway/ Drivers Triangle sections of the Project. The continuous flight auger (CFA) rig used for installing piles was capable of penetrating the three main rock classes at the site, namely Class IV, III and II sandstone. Difficulty was experienced in penetrating iron cemented and stronger zones of Class II sandstone, but the required rock-sockets were still achieved. In general, we found that attempts to infer rock class by observing and recording auger penetration rates were only moderately successful. Penetration rates were subject to many external variables, including new or broken auger teeth, operator methods, choking of the auger face with cuttings, and layers of iron cemented rock. Class III and Class II sandstone could generally be inferred, but where the top-of-rock level was defined by Class V sandstone, the change from overburden soil to weathered rock could not be confidently identified. Inferring Class IV Sandstone was difficult but possible with experience. Nevertheless, we assessed that in the absence of cored borehole information the auger penetration rates presented in Table 3 could be used as an approximate guide to assess rock class during pile installation using the Bachy CH-400 drilling rig (after allowing for external variables).

Figure 3: Piling at South Dowling Street, North of the Todman Avenue Intersection

Table 3: Inferred Correlation Between Rock Class and Auger Penetration Rate
Inferred Sandstone Rock Class (1) V or Soil IV III II Penetration Rate(2) (m/min) >0.6 0.3 0.6 0.1 0.3 < 0.1

(1) Rock class based on Pells et al, 1998. (2) Applicable only to Bachy CH-400 drill rig, 600mm diameter CFA piles, subject to external variables.

PILE TESTING To verify pile performance and the assumed design values static tension pile tests were carried out. To exclude the contribution of the overlying alluvial sands to uplift capacity due to shaft friction, sleeves were installed around the piles and the annulus filled with a water-bentonite mix. Sleeves at two test piles refused in overburden sand during installation prior to inferred top of rock level. As a result, it was expected that some of the pile tension would be taken by the overburden sand at relatively large displacements. The test interpretation accounted for the corresponding loss of friction due to overburden stresses expected after excavation. Tension tests were carried out on working piles in accordance with the Australian Piling Code (AS2159) using the incremental sustained test load procedure, except for tests carried out during a night lane closure which were limited to a 7 hour single load cycle due to access constraints and program considerations. No piles were tested to ultimate failure, i.e. where there is no increase in load capacity with increasing deflection. To carry out the static tension tests a hydraulic jack was mounted on a frame comprising two steel beams resting on reaction platforms constructed on grade. Following pile tests and prior to construction of additional working piles, the nominal shaft bond stress used to calculate socket lengths was reviewed, and for Class III Sandstone was reduced to 220kPa. A summary of the static tension pile load test results in rock is provided in Table 4, with an example load-deflection curve for pile P66 shown in Figure 5. The results of Pile Driving Analyser (PDA) tests were variable and not directly comparable with the static tension tests. Table 4: Results of Static Pile Tension Tests
Pile Constructed Socket Length (corrected for sleeve depth)(2) (m) P58 P66 2.2m v. dense sand 1.0m of Class III SST 1.9m of Class III SST ServiceMaximum ULS Design ability Test Load Axial Tension St* Design Axial Tension (kN) 350 1100 1200 (kN) 250 790 865 (kN) 490 1540 1680 Inferred Test Failure Load (kN) 390 880 830 Mobilised Bond Stress in Tension (kPa) At inferred At Failure Maximum Load Test Load 207 246 232 260 430 223(1)

P110(1 2.1m of Class V SST or ) very dense sand 1.9m of Class III/II SST

(1) Pile re-drilled after grouting operation following partial collapse of overburden material into pile hole. The maximum test load occurred at large deflection; hence bond stress at this load was distributed between the sand and rock. (2) SST = Hawkesbury Sandstone. All piles 600mm diameter.

Tension Load (kN)

1800 1600 1400 1200 1000 800 600 400 200 0 0 1 2 3 4 5 Vertical Deflection (mm) Load Cycle 1 Load Cycle 2

Figure 5: Example Load-Deflection Curve for Static Pile Tension Test (P66) CONCLUSIONS 1. A good correlation was achieved between the design bond stresses, the bond stresses interpreted from pile test results, and the conditions encountered during pile installation. The load tests of auger grout injected piles provided information to confirm the design of the rock sockets for these piles. A principal limitation of the auger grout injected (continuous flight auger) piles is that the construction of the pile is carried out blind and a high degree of reliance is placed on the rig operator and nondestructive testing to establish pile integrity. The test results have provided additional data to refine our understanding of the tension behaviour of auger grout injected piles in Hawkesbury Sandstone. The results of static tension tests have supported the use of reduction factors when calculating the capacity of auger grout injected piles, and piles in tension. A reduction factor of 0.5 should be applied to the pile shaft bond stresses to allow for smear effects on auger grout injected piles installed using the Bachy CH400 rig. This reduction factor should be verified by appropriate pile tests. The ultimate shaft bond stress (shaft adhesion) should be selected from the lower end of the range of accepted values for bored piles - which depend substantially on socket roughness. Attempts to correlate rock quality purely with auger penetration rates were moderately successful, given that external variables effected the rate of auger penetration. However, in the absence of borehole data it is a useful guide provided each piling rig is calibrated against cored borehole data, and provided the observer is experienced and is aware of the limitations of the procedure.

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ACKNOWLEDGEMENTS The authors thank Leighton Contractors Pty Ltd and Maunsell McIntyre Pty Ltd for their permission to publish this paper, and Golder Associates staff for assistance in the preparation of this paper. Steve Griffiths and Rob Day of Maunsell McIntyre provided useful comments and review regarding design aspects of the project. REFERENCES AS2159 (1995). Piling Design and Installation, Standards Australia. Leighton Contractors (1999). Website http: //www.ed2000leighton.com.au Review of Geotechnical Maunsell (1997). NR641/RP/D/CV/021/A, (unpublished). Design Issues (South Dowling Street), Report

Pells PJN, Mostyn G, and Walker BF (1998). Foundations on Sandstone in the Sydney Region, Aust. Geomechanics Journal, No 3, Dec, pp 17-29. Pells PJN, Rowe RK, and Turner RM (1980). A Laboratory and Field Investigation into Side Shear Values for Piles Socketed into Sandstone. Proc. International Conference on Structural Foundations on Rock, Balkema, Sydney, May, Pells (ed), pp. 291-302.