Louisiana Transportation Conference February 17-20, PDF Free Download

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.

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

PROJECT OVERVIEW

Project Location Myrtle Beach, SC

Project Location

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

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)

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

Proposed Interchange

Bridge Span Lengths (Bridge Length 1,240 Feet) 175 225 300 225 175 140

Bridge Aesthetic Features

Bridge Features Interior Bent Cap Extensions

Retaining Wall Features (Rendering)

Wall Features Columbia International Airport Interchange

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

DESIGN REQUIREMENTS

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)

US Earthquakes 1705-1996 Seismic Hazard 1886 Charleston Earthquake MW 7.3

SC Seismic Hazard Charleston fault zone ( Woodstock fault) and the Zone of River Anomalies (ZRA) fault source Moment magnitude from 7.0 to 7.5. 1886 Charleston Earthquake

SC Seismic Hazard FEE PGA 0.06g @ B/C Boundary SEE PGA 0.24g @ B/C Boundary

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

PROJECT CONSTRAINTS

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

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

GEOTECHNICAL CHALLENGES

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

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

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

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

Fantasy Harbour Geotechnical Experience 10 42 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

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

South Bridge Approach Subsurface General Profile

North Bridge Approach Subsurface General Profile

Geotechnical Challenges 30 to 60 - Soft to Firm Clay Pockets of Loose Sands in upper 10 Intermediate Medium Sands (253+00 to 256+00) Loose Sands above Dense Sands (Liquefiable) Pee Dee Formation

Bridge Abutment Settlement (Normal Weight Fill 120 pcf)

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

RAPID EMBANKMENT CONSTRUCTION

Rapid Embankment Construction Project Constraints Geotechnical Challenges

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

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

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

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

PVD Installation 3 Million LF

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

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

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

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

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

10 Feet Min. Deep Soil Mixing Test Sections 10 Feet Min. 1 2 4 3 Test LCC No. 1 2 3 4 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)

CONSTRUCTION SEQUENCE

Project Construction Stages (North Abutment 252+01) Ramp D Stage 3 Bridge Approach Embankment Stage 4 Ramp B Stage 2

Bridge Abutment Construction (North Abutment End Bent 7)

Bridge Abutment Construction Bridge Wing Wall Vertical Slip Joints MSE Wall Concrete Panel Facing DSM-LCC Block Type Pattern MSE Wall Leveling Pad HP 14x117 22 Piles/row PVD (Wick Drains) 30 Feet

LIGHTWEIGHT AGGREGATE BORROW PROPOSED

Lightweight Aggregate Borrow (Proposed New Material)

Lightweight Aggregate Borrow (Rotary Kiln Produced)

% Passing Grain Size Curve 1 ½" ¾" 3/ 8" # 4 # 30 # 40 # 100 # 200 100 90 80 Big River Proposed Lightweight Aggregate LWF Min LWF Max 713 Min 713 Max 70 BR Min BR Max 60 LWA (S15922) 50 40 30 Section 713 MSE Wall 20 10 0 1000.000 100.000 10.000 Grain Size (mm) 1.000 0.100 0.010

Lightweight Aggregate Density Properties Lightweight Aggregate Borrow Soil Properties (Item 2033020) Soil Properties SCDOT Specified Proposed Minimum: Dry Unit Weight, g Dry (pcf) 55 43 * Maximum: Dry Unit Weight, g Dry (pcf) 60 45 ** Minimum: Wet Unit Weight, g Wet (pcf) 60 55 ** Maximum: Wet Unit Weight, g Wet (pcf) 70 60 ** * 95% Maximum Density ** Estimated based on laboratory testing submitted by Big River Industries

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

Test Section #1 (Dry)

Test Section #1 (Wet)

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

COMPACTION VERIFICATION

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

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

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.

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

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

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

Test Section #2

Compaction Control Calibrated Nuclear Gauge

LIGHTWEIGHT AGGREGATE SUPPLY & DELIVERY

Big River Industries Livingston, AL Myrtle Beach, SC

Big River Industries 500 Mile Radius Livingston, AL

Livlite Big River Industries

Lightweight Aggregate Borrow Pre-conditioning

Ramp B Construction Pre-conditioned Lightweight Aggregate CONSTRAINTS

GEOTECHNICAL INSTRUMENTATION

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

VW Magnetic Extensometers Pre-Assembled ME Spider Magnet Telescoping Section

Settlement (Inches) Elevation (feet) Embankment Height (Feet) Instrumentation Results ME Extensometers 1.0 20 10 0-10 -20-30 -40-50 -60 0.0-1.0 Settlement (Inches) -2.0-3.0-4.0-5.0-6.0-7.0-8.0-9.0-10.0 12/1/2011 12/7/2011 12/14/2011 12/19/2011 12/21/2011 12/27/2011 12/29/2011 1/4/2012 1/12/2012 1/18/2012 1/25/2012 2/1/2012 12 11 10 9 8 7 6 5 4 3 2 1 0-1 -2-3 -4-5 -6-7 -8 12-22-2011 Embankment Construction Finished Embankment Height Top of LWF Datum Magnet 0 7 14 21 28 35 42 49 56 63 70 Days SA-1 SA-2-70

VW Piezometers

Instrumentation Results VW Piezometers

Settlement Plates

VW Settlement Sensors

VW Settlement Sensor Data Collection

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

VW Device Connections VW Devices connected to 16-channel Board

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

X-Section End Bent 1 (South Bridge Abutment, 237+50)

Settlement Transverse Profile (South Bridge Abutment 237+83) Ramp A

0 7 14 21 28 35 42 49 56 63 70 77 84 91 98 105 112 119 126 133 140 147 154 161 168 175 182 189 196 203 210 217 224 231 238 Settlement Embankment Height (Feet) Ramp A Settlement Measurements 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0-1 -2-3 -4-5 -6 2-12-2011 Embankment Construction Finished US-17 Bypass Settlement Sensor A-VWSS-2 2-14-2012 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

Settlement Transverse Profile (South Bridge Abutment 237+83) Ramp C

0 7 14 21 28 35 42 49 56 63 70 77 84 91 98 105 112 119 126 133 140 147 154 161 168 175 182 189 196 203 210 217 224 Settlement (Inches) Embankment Height (Feet) Ramp C Settlement Measurements 13 12 11 10 9 9-13-2012 Emankment Construction Finished 12-14-2012 Surcharge Removed 8 7 6 5 4 3 Embankment Height Lightweight Fill Height SS Reading No. 1-5:00 SS Reading No. 2-11:00 2 1 0-1 -2-3 Days Since VWSS Installed

X-Section End Bent 7 (North Bridge Abutment, 250+26)

Settlement Transverse Profile (North Bridge Abutment - 250+26) Ramp B

0 7 14 21 28 35 42 49 56 63 70 77 84 91 98 105 112 119 126 133 140 147 154 161 168 175 182 189 196 203 210 217 224 231 238 245 252 259 266 Settlement Embankment Height (Feet) Ramp B Settlement Measurements 12 11 10 9 8 7 6 5 4 3 2 1 0-1 -2-3 -4-5 -6-7 -8-9 -10-11 -12 12-22-2011 Embankment Construction Finished Settlement Sensor 4-10-2012 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

Settlement Transverse Profile (North Bridge Abutment - 250+26) Ramp D

Settlement Embankment Height (Feet) Ramp D Settlement Measurements 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2-1 01-2 -3-4 -5-6 -7-10 -9-8 -11-12 -13-14 10-26-2012 Emankment Construction Finished 2-5-2013 Surcharge Removed 0 14 28 42 56 70 84 98 112 126 140 154 168 182 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

PROJECT CONSTRUCTION

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

Traffic Control Stage 2 Ramp A Construction US 17 Bypass NB

Traffic Control Stage 2 Ramp B Construction US 17 Bypass NB

Construction Ramp A & B (PVD Installation)

Construction Ramp A & B (MSE Wall Embankment Construction)

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

Sloped Lightweight Aggregate Embankment

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

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)

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

Construction Ramp C Traffic on Ramp C US 17 Bypass SB

Construction Ramp C US 17 Bypass SB Ramp D

Construction Ramp D Traffic on Ramp B Ramp D

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)

CLOSING

Project Status Preliminary Engineering: 2008-2009 Right of Way Acquisition: 2009-2011 Construction: 2011 2014 Approximately 33% complete

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

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

Thank You Any Questions?