Louisiana Transportation Conference February 17-20, 2013

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1 Case Study: Rapid Embankment Construction of US 17 Bypass Interchange Over Soft Compressible Soils Using Lightweight Aggregate Myrtle Beach, South Carolina Presented By: Ed Tavera, PE Louisiana Transportation Conference February 17-20, 2013 Jeff Speck, PE Big River Industries, Inc.

2 Presentation Agenda Project Overview & Design Requirements Project Constraints Geotechnical Challenges Rapid Embankment Construction Lightweight Aggregate Borrow Proposed Compaction Verification Lightweight Aggregate Supply & Delivery Automated Geotechnical Instrumentation & Results Project Construction Pictures Closing

3 PROJECT OVERVIEW

4 Project Location Myrtle Beach, SC

5 Project Location

6 Project Site Murrels Inlet SC 707 US17 Bypass N. Myrtle Beach East

7 Purpose Relieve growing traffic congestion Provide a facility to handle future development and growth Construct a safe, signature project for the stakeholders (Horry County, SC)

8 Project Layout SC 707 US 17 Bypass Ramp C Ramp D Ramp B Ramp A Farrow Parkway

9 Proposed Interchange

10 Bridge Span Lengths (Bridge Length 1,240 Feet)

11 Bridge Aesthetic Features

12 Bridge Features Interior Bent Cap Extensions

13 Retaining Wall Features (Rendering)

14 Wall Features Columbia International Airport Interchange

15 Schedule Local Funding - led to higher expectations for project completion Heavy traffic volumes necessitated accelerated construction Elimination of long settlement waiting period Led to innovative geotechnical design and construct techniques

16 DESIGN REQUIREMENTS

17 Design Requirements AASHTO LRFD Design Strength Limit State Service Limit State Extreme Event I Limit State (Seismic) Extreme Event II Limit State (Collision) Performance Based Design Service Limit State Extreme Event I Limit State (Seismic) Extreme Event II Limit State (Collision)

18 US Earthquakes Seismic Hazard 1886 Charleston Earthquake MW 7.3

19 SC Seismic Hazard Charleston fault zone ( Woodstock fault) and the Zone of River Anomalies (ZRA) fault source Moment magnitude from 7.0 to Charleston Earthquake

20 SC Seismic Hazard FEE PGA B/C Boundary SEE PGA B/C Boundary

21 Extreme Event I Limit State SC Design Earthquakes Safety Evaluation Earthquake (SEE), ground shaking having a 3% probability of exceedance in 75 years (2,500 year return period) PGA = 0.39g Functional Evaluation Earthquake (FEE), ground shaking having a 15% probability of exceedance in 75 years (500 year return period) PGA = 0.13g

22 PROJECT CONSTRAINTS

23 Traffic Control High existing traffic volume No lane closures during summer months Maintaining access to numerous businesses Complex construction traffic control plan 8 proposed stages of construction Maintain existing number of lanes Temporary pavement Multiple traffic shifts Temporary alignments Detour routes

24 Project Constraints Traffic Control Maintain Existing Number of Lanes & Access to Numerous Business Embankment Construction Traffic Control Stages 2, 3, and 4 Project Geometry and Layout Existing Alignment Limited R/W Limited Construction Staging Areas Construction Time Requirements 3.5 years

25 GEOTECHNICAL CHALLENGES

26 Myrtle Beach, SC Regional Experience Fantasy Harbour 2 Miles Away! US 17/SC 707 (Backgate)

27 Fantasy Harbour 2 Miles North of US 17 /SC 707 Interchange New Alignment Bridge Over the Atlantic Intracoastal Waterway 3.1 Miles Roadway Approaches and Bridge

28 Fantasy Harbour West Abutment Subsurface Soils SB2 RB-24 RB-25 RB-27 SB1 RB-28 RB-29 Very loose to medium SANDs (SP/SC/SM) 0 ftmsl Very soft to medium CLAYs (CL/CH) -50 ftmsl Pee Dee Formation

29 Fantasy Harbour East Abutment Subsurface Soils SB3-A 0 ftmsl RB-13 SB6 SB1 RB-11 RB-16 SB2-A Very loose to medium SANDS (SP/SM/SC Very soft to medium CLAYs (CL/CH) SB5-50 ftmsl Pee Dee Formation

30 Fantasy Harbour Geotechnical Experience Embankment, Settlement 9 to 67 Liquefaction Loose Sands Embankment Slope Instability (Static/Seismic) Ground Improvement!!! 2 Year Embankment Construction Contract 2-3 Year Bridge Construction Contract

31 Let s Return To US 17/ SC707 Interchange (Backgate) South Bridge Approach North Bridge Approach

32 South Bridge Approach Subsurface General Profile

33 North Bridge Approach Subsurface General Profile

34 Geotechnical Challenges 30 to 60 - Soft to Firm Clay Pockets of Loose Sands in upper 10 Intermediate Medium Sands ( to ) Loose Sands above Dense Sands (Liquefiable) Pee Dee Formation

35 Bridge Abutment Settlement (Normal Weight Fill 120 pcf)

36 Geotechnical Challenges Poor Site Subgrade (2 3 Bridging Required) Excessive Settlement (Total & Differential) Static Slope Embankment Instability/Bearing Seismic Slope Embankment Instability (Liquefaction)

37 RAPID EMBANKMENT CONSTRUCTION

38 Rapid Embankment Construction Project Constraints Geotechnical Challenges

39 Geotechnical Key Design Issues Settlement Total & Differential Embankment Slope Instability / Bearing (Static/Seismic) Bridge Abutment Foundation Performance - Extreme Event I and II Limit States MSE Wall Construction Over Soft Soils

40 Geotechnical Design Approach Lightweight Aggregate Borrow Reduce Magnitude of Settlement Prefabricated Vertical Drain (PVD) / Granular Surcharges Increase Rate of Settlement and Facilitate Rapid Construction Deep Soil Mixing Improve Seismic Slope Stability and Bridge Abutment Foundation Performance Mechanically Stabilized Earth (MSE) Walls 2-Stage and 3-Stage MSE Wall Construction Vertical Slip Joints

41 Granular Surcharge & Lightweight Aggregate Borrow Granular Surcharge Properties: = 32 degrees Unit Weight: 125 pcf Granular Surcharge ½ Normal Weight Lightweight Aggregate Borrow Material Lightweight Aggregate Properties: = 40 degrees Short Term Unit Weight: 60 pcf Long Term Unit Weight: 70 pcf MSE Wall Backfill Properties Normal Weight Lightweight Aggregate

42 Lightweight Aggregate Borrow (Rotary Kiln Produced) 226,000 CY

43 PVD Installation 3 Million LF

44 PVD Installation S s = 3 and 4 PVD PVD Triangular Installation Pattern PVD 2 Drainage Sand Layer Geotextile Separator Fabric

45 PVD Installation Obstructions!!! 309,000 LF Predrilling PVD Installation

46 MSE Walls Permanent MSE Walls Two-Stage Construction Three-Stage Construction (w/drainage Structures) Temporary MSE Walls (Welded Wire Mesh Facing) 30,500 SF 51,500 SF

47 Deep Soil Mixing Columns (Overlap Block Pattern) 35,600 CY Seismic Slope Stabilization Shear Key Improved Performance of Bridge Abutment Foundations 2013

48 Deep Soil Mixing Columns (Overlap Block Pattern) Longitudinal DSM Bridge Abutment DSM Longitudinal DSM

49 10 Feet Min. Deep Soil Mixing Test Sections 10 Feet Min Test LCC No Test Pile 1 (HP 14x117) DSM-LCC Test Section 1 (Block Type Pattern) Test LCC Sampling Quadrants DSM-LCC Test Section 2 (Single Line Pattern) Legend Test Lime-Cement Columns (Test LCC)

50 CONSTRUCTION SEQUENCE

51 Project Construction Stages (North Abutment ) Ramp D Stage 3 Bridge Approach Embankment Stage 4 Ramp B Stage 2

52 Bridge Abutment Construction (North Abutment End Bent 7)

53 Bridge Abutment Construction Bridge Wing Wall Vertical Slip Joints MSE Wall Concrete Panel Facing DSM-LCC Block Type Pattern MSE Wall Leveling Pad HP 14x Piles/row PVD (Wick Drains) 30 Feet

54 LIGHTWEIGHT AGGREGATE BORROW PROPOSED

55 Lightweight Aggregate Borrow (Proposed New Material)

56 Lightweight Aggregate Borrow (Rotary Kiln Produced)

57 % Passing Grain Size Curve 1 ½" ¾" 3/ 8" # 4 # 30 # 40 # 100 # Big River Proposed Lightweight Aggregate LWF Min LWF Max 713 Min 713 Max 70 BR Min BR Max 60 LWA (S15922) Section 713 MSE Wall Grain Size (mm)

58 Lightweight Aggregate Density Properties Lightweight Aggregate Borrow Soil Properties (Item ) Soil Properties SCDOT Specified Proposed Minimum: Dry Unit Weight, g Dry (pcf) * Maximum: Dry Unit Weight, g Dry (pcf) ** Minimum: Wet Unit Weight, g Wet (pcf) ** Maximum: Wet Unit Weight, g Wet (pcf) ** * 95% Maximum Density ** Estimated based on laboratory testing submitted by Big River Industries

59 Lightweight Aggregate Borrow (Proposed New Material Differences) Higher Fines Content Lower Dry Unit Weight Total Unit Weight 15% Less Than Designed High Absorption Gradation Coarse Sand Vs. Aggregate Compaction Verification Required by SCDOT

60 Test Section #1 (Dry)

61 Test Section #1 (Wet)

62 Granular Surcharge & Lightweight Aggregate Borrow Granular Surcharge Granular Backfill Lightweight Aggregate Borrow Material Design Team Performed a Redesign Reduced the Lightweight Quantity by 15% Saved Horry County $2 Million

63 COMPACTION VERIFICATION

64 Lightweight Aggregate Borrow Compaction Verification Challenges Interparticle Voids Particle Absorbed Moisture Particle Ceramic Solids Particle Pore Voids Interparticle Moisture

65 Compaction Control Laboratory Compaction Curves Target 95% Max Dry Density = 43 pcf Moisture Content Varied Significantly for the same Dry Density

66 Test Section #2 Compaction Control Test Section #2 - Evaluate Compaction Control Methods Compaction Control - 1 Cu. Ft. Steel Box, Calibrated Nuclear Density Gauge, Sand Cone, and EDG.

67 Test Section #2 Field Testing Set NG-1 MT-1 MT-3 MT-2 MC-1 MT-4 SC = Sand Cone NG = Nuclear Gauge EDG = Electric Density Gauge STB = Steel Test Box SC-1 EDG-1 SC-2 MTB-1 MC-2 MTB-2 MTB-3 STB NG-2 MT-5 SC-3 EDG-2 MC-3 MT-7 EDG-3 MT-6 MT-8 Compacted Lightweight Aggregate Borrow NG-3 MC = Hot Plate & Oven Moisture Content MT = Moisture Tester MTB = Moisture Tester in Steel Box

68 Test Section #2 1 Cu. Ft Steel Box (Control Test)

69 Test Section #2 Field Testing Sets Test Set Moisture Added Process Compaction Effort 1 As delivered Compact 3 passes with vibratory roller 2 No Water Added Scarify & Compact 4 passes with a vibratory roller 3 Added Water - 1 Pass Scarify & Compact 8 passes with a walk behind vibratory flat plate compactor 4 Added Water - 2 Passes Scarify & Compact 3 passes with a vibratory roller 5 No Water Added Scarify & Compact 4 passes with a vibratory roller 6 No Water Added Scarify & Compact 8 passes with a vibratory roller Added Water- 2.5 Passes Scarify & Compact 7 (Saturated) 3 passes with a vibratory roller

70 Test Section #2

71 Compaction Control Calibrated Nuclear Gauge

72 LIGHTWEIGHT AGGREGATE SUPPLY & DELIVERY

73 Big River Industries Livingston, AL Myrtle Beach, SC

74 Big River Industries 500 Mile Radius Livingston, AL

75 Livlite Big River Industries

76 Lightweight Aggregate Borrow Pre-conditioning

77 Lightweight Aggregate Borrow Pre-conditioning

78 Ramp B Construction Pre-conditioned Lightweight Aggregate CONSTRAINTS

79 Ramp B Construction Pre-conditioned Lightweight Aggregate CONSTRAINTS

80 GEOTECHNICAL INSTRUMENTATION

81 Geotechnical Instrumentation Settlement Monitoring 4 Magnetic Extensometer 10 Settlement Plates 12 VW Settlement Sensors 17 VW Piezometers 2 VW Data Collection Centers Slope Stability 6 Slope Inclinometers

82 VW Magnetic Extensometers Pre-Assembled ME Spider Magnet Telescoping Section

83 Settlement (Inches) Elevation (feet) Embankment Height (Feet) Instrumentation Results ME Extensometers Settlement (Inches) /1/ /7/ /14/ /19/ /21/ /27/ /29/2011 1/4/2012 1/12/2012 1/18/2012 1/25/2012 2/1/ Embankment Construction Finished Embankment Height Top of LWF Datum Magnet Days SA-1 SA-2-70

84 VW Piezometers

85 Instrumentation Results VW Piezometers

86 Settlement Plates

87 VW Settlement Sensors

88 VW Settlement Sensor Data Collection

89 Automated Data Collection VW Data Collection Center VW Settlement Sensors Cellular Phone Database Server VW Device Connection Board VW Data Collection Logger Internet VW Piezometers Power Source (Solar Power) Engineer

90 VW Device Connections VW Devices connected to 16-channel Board

91 Data Collection Center isite Logger with Solar Controller Charging Battery Inside DCC Enclosure & Solar Panel

92 X-Section End Bent 1 (South Bridge Abutment, )

93 Settlement Transverse Profile (South Bridge Abutment ) Ramp A

94 Settlement Embankment Height (Feet) Ramp A Settlement Measurements Embankment Construction Finished US-17 Bypass Settlement Sensor A-VWSS Surcharge Removed Days Since VWSS Installed Embankment Height Lightweight Fill Height SS Reading No. 1-5:00 SS Reading No. 2-12:00 SS Reading No. 3-19:00 SS Reading No. 4-23:00

95 Settlement Transverse Profile (South Bridge Abutment ) Ramp C

96 Settlement (Inches) Embankment Height (Feet) Ramp C Settlement Measurements Emankment Construction Finished Surcharge Removed Embankment Height Lightweight Fill Height SS Reading No. 1-5:00 SS Reading No. 2-11: Days Since VWSS Installed

97 X-Section End Bent 7 (North Bridge Abutment, )

98 Settlement Transverse Profile (North Bridge Abutment ) Ramp B

99 Settlement Embankment Height (Feet) Ramp B Settlement Measurements Embankment Construction Finished Settlement Sensor Surcharge Removal Days Since VWSS Installed Embankment Height Lightweight Fill Height SS Reading No. 1-5:0:0 SS Reading No. 2-12:0:0 SS Reading No. 3-19:0:0 SS Reading No. 4-23:0:0

100 Settlement Transverse Profile (North Bridge Abutment ) Ramp D

101 Settlement Embankment Height (Feet) Ramp D Settlement Measurements Emankment Construction Finished Surcharge Removed Days Since VWSS Installed Embankment Height Lightweight Fill Height SS Reading No. 1-5:00 SS Reading No. 2-12:00 SS Reading No. 3-19:00

102 PROJECT CONSTRUCTION

103 Traffic Control Stage 2 Ramp A Ramp B MSE Walls Lightweight Aggregate Borrow Material 2, and 3 Granular Surcharge (Normal Weight) 3 and 4 Triangular Spacing PVD Geotechnical Instrumentation

104 Traffic Control Stage 2 Ramp A Construction US 17 Bypass NB

105 Traffic Control Stage 2 Ramp B Construction US 17 Bypass NB

106 Construction Ramp A & B (PVD Installation)

107 Construction Ramp A & B (PVD Installation)

108 Construction Ramp A & B (MSE Wall Embankment Construction)

109 Construction Ramp A & B (MSE Wall Embankment Construction)

110 Sloped Lightweight Aggregate Embankment Lightweight Aggregate Borrow Material 4 Feet Long Biaxial Geogrids Placed on 2 Feet Vertical Spacing 2 Feet Thick Cover of Borrow Silty or Clayey Soil Materials

111 Sloped Lightweight Aggregate Embankment

112 Traffic Control Stage 3 Ramp C Ramp D MSE Walls Lightweight Aggregate Borrow Material 1, 2, and 4 Granular Surcharge (Normal Weight) 3 and 4 Triangular Spacing PVD Geotechnical Instrumentation

113 Traffic Control Stage 3 (Ramps A & B Completed) Ramps C/D Under Construction -Stage 3 Existing NB = Stage 3 SB Constructed Ramps A/B (Completed Stage 2)

114 Traffic Control Stage 3 (Ramps A & B Completed) Traffic on Ramp A Existing NB = Stage 3 SB

115 Construction Ramp C Traffic on Ramp C US 17 Bypass SB

116 Construction Ramp C Traffic on Ramp C US 17 Bypass SB

117 Construction Ramp C US 17 Bypass SB Ramp D

118 Construction Ramp D Traffic on Ramp B Ramp D

119 Traffic Control Stage 4 South Bridge Approach Backgate Bridge North Bridge Approach MSE Walls Lightweight Aggregate Borrow Material 1, 2, and 3 Granular Surcharge (Normal Weight) 3 Triangular Spacing PVD Geotechnical Instrumentation Bridge Abutment DSM (South 30 x 133 x 50 deep North 30 x 141 x 70 deep ) Longitudinal DSM (South 5 Wide / North 8 Wide)

120 CLOSING

121 Project Status Preliminary Engineering: Right of Way Acquisition: Construction: Approximately 33% complete

122 Under Construction Traffic Stage 3 Ramps C/D have been constructed and will be ready to be paved in the near future Traffic Stage 4 Scheduled to Start April 2013 Deep Soil Mixing : Test Section / Test Pile / Production Bridge Abutment Foundation Construction Construct Bridge Approach Embankment & MSE Walls

123 Closing Geotechnical techniques are speeding up construction Positive feedback regarding construction traffic congestion and shifts Estimated project completion: Fall 2014 Project Cost $75.8 Million

124 Thank You Any Questions?

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