Pile Base Grouting: Modern Technology for Constructing Earthquake-Resistant Higher Load Capacity Piles

Introduction:

Most of the soil of Bangladesh is made up of alluvial Holocene deposit, which forms through layers of soft clay or loose sand. Consequently, constructing foundations for buildings or other structures in our country is costly. In such soft soil, footing-type foundations are not appropriate. Buildings constructed on footing foundations may survive under normal conditions, but they are prone to collapse during earthquakes. Most of the cases, pile foundations are required. Among precast and cast-in-situ piles, cast-in-situ piles are more commonly used in Bangladesh. On one hand, quality control of cast-in-situ pile is challenging, and on the other hand, they are expensive. Pile base grouting is a cutting-edge technology that makes foundation design and construction affordable and earthquake resistant. Detailed information about this technology is provided in this article

What is Pile Base Grouting?

Pile base grouting is a modern method of strengthening the soil beneath a pile foundation by injecting a mixture of cement, chemicals, and water at high pressure. This method is effective in almost doubling the load capacity of a pile foundation. Pile base grouting is an advanced technology introduced and developed by Freehold Construction and Development (FCD) in Bangladesh, and it has been successfully applied in numerous pile foundation projects in Bangladesh. This technology was also used for the Padma Bridge’s pile foundation, under the guidance of foreign consultants, to increase the load capacity of the piles. The work was carried out by the Chinese contractor Sinohydro Corporation Limited. Due to the deep piles and fine-grained soil at the Padma Bridge site, grouting was done using expensive microfine cement imported from foreign counties. In Bangladesh, using locally available cement and chemicals, we have been able to treat the soil beneath the piles and increase their load-bearing capacity by 2.0 times using imported high pressure grouting machines. This technology has been used in advanced countries for decades, though their technology is more advanced and costly. We have developed a cost-effective method to implement this technology in Bangladesh, which has already been tested and proven effective in various projects. Pile base grouting has been successfully applied in Pakshey Bridge, Rupsha Bridge, Jamuna Bridge, and Padma Bridge under the supervision of foreign engineers using foreign machines and materials. Under the leadership of Professor Dr. Engineer Md. Jahangir Alam, FCD have developed a pile base grouting technology using locally produced materials at a lower cost, enabling the increase of pile capacity by 2 times and ensuring seismic resistance of pile foundation.

How is Pile Base Grouting Done?

Before starting pile base grouting, planning is essential. It is the best approach to conduct soil tests by any reputed organization and structural and foundation design must be done by an experienced BSc engineer who is a member or fellow of the Institution of Engineers Bangladesh (IEB). Pile base grouting in the design phase can reduce the number of piles by 30-50%. While there are additional costs associated with pile base grouting, the overall foundation cost saving is 20-40%. During the casting of cast-in-situ piles, PVC pipes and steel pipes are attached to the rod cage. The rod cage is then inserted into the pile boring, and the concrete is poured as usual. After the casting of all piles on site is complete, a pile base grouting machine injects the cement, chemical, and water mixture through pipes into the base of the piles. The mixture’s ratio depends on soil type, depth, pile size, etc., and is determined by a specialist. In the case of precast piles, a special PVC pipe is placed in the middle of the pile before casting. After the pile has hardened, it is driven into the ground, followed by pile base grouting to strengthen the soil at the pile base.

The quality of pile base grouting depends on the grouting machine’s pressure capacity, the ratio of cement-chemical-water mixture, and the total amount of the mixture volume injected. The correct ratio, grout volume, and grout pressure for different soil types are determined by a geotechnical engineer. Any mistake in selecting these parameters can lead to adverse effects.

Steps in Pile Base Grouting:

Conduct soil tests through a reputable and reliable organization.
Have foundation and structural design prepared by an experienced civil engineer with IEB membership or fellowship.
Hire a good contractor.
Make arrangements for pile base grouting before starting piling.
Perform pile base grouting after piling is complete.
One month after pile base grouting, confirm the quality of the piling through soil tests, dynamic load tests, or static load tests.

Problems and Solutions for Precast Driven Piles:

Precast driven piles are pre-made and then driven into the ground after hardening, using hydraulic push or hammering. Precast hollow round piles (PHC piles) are available now a days, which are hollow inside. The major advantage of precast piles is the ability to ensure 100% quality. If the quality is poor, the piles may break during driving, and broken piles can be replaced. Major disadvantages of precast piles include:

For long piles, joints are necessary, which can be resolved with proper jointing.
Increasing the diameter or size of long piles is challenging, potentially leading to failure during earthquakes if the piles are slender and prone to buckling.
If liquefaction of sandy soil occurs during an earthquake, precast piles may fail like slender columns. In such cases, larger diameter cast-in-situ piles are recommended.

Various machines are used for driving piles into the ground, including:

Hydraulic push pile driving machines
Diesel hammers
Manual hammers

Diesel hammers can drive precast piles to any depth but may cause vibrations that could damage nearby structures. Therefore, they are not used in urban areas or near existing buildings. Hydraulic push pile driving machines drive piles without vibrations but may not reach the required depths. This machine is large and heavy, making it expensive for small projects (up to 10 kathas) and difficult to transport to sites with narrow roads. Manual hammers cannot drive piles to great depths and may cause nearby structure damage due to vibrations. Therefore, manual hammers are often not practical.

From the discussion above, it is clear that precast piles have limitations. To overcome these limitations, pile base grouting can be utilized. By placing pipes inside the precast piles before making them and performing pile base grouting after driving the piles, the soil at the pile base can be strengthened, preventing liquefaction during earthquakes.

Problems and Solutions for Cast-in-Situ Piles:

Cast-in-situ piles are constructed by drilling deep holes into the soil, placing a rod cage, and pouring concrete. These piles can be made in any diameter, size, and depth. The major disadvantage of cast-in-situ piles is that it is extremely challenging to control quality using locally made winch machines and tripods. The quality control of cast-in-situ piles is difficult due to lack of skilled technicians and laborers. Before pouring concrete, soft mud and sand are sedimented at the pile base often result in very low load-bearing capacity.

Bentonite slurry, a sticky mix of special type clay and water, is used during the casting of cast-in-situ piles. Without this slurry, the shape of the pile bore may be irregular, and the side soil of borehole may collapse. To save costs, most of the clients do not use this slurry, leading to poor quality of cast-in-situ piles.

There are two methods for casting in-situ piles:

Rotary drilling rig
Percussion winch machine (Bangla method)

A rotary drilling rig can produce high-quality cast-in-situ piles, but it is costly. For smaller diameter piles and fewer piles, the Bangla method is more economical, though it is difficult to achieve quality with this method. The structural load capacity of cast-in-situ piles is often much higher than the geotechnical load capacity. That means structural capacity of pile is underutilized. Pile base grouting can provide a cost-effective solution to these issues by increasing the load-bearing capacity of the soil at the pile base.

How Pile Base Grouting Increases Pile Load Capacity:

The mixture of cement and chemicals solidifies the soil beneath the pile.
The density of the soil at the pile base increases, thereby enhancing its load-bearing capacity.
Pile base grouting acts as preloading, reducing the tendency of the pile settlement.
A bulb of treated strong soil forms at the base of the pile increasing bearing area of pile.
Reverse skin friction is created, which helps increase load capacity. When load applied on pile, initially some load is taken by the pile to neutralize the reverse skin friction.
The structural capacity of pile is always more than geotechnical capacity. Pile base grouting increases the geotechnical capacity. So, structural capacity utilization increases.

Applicability of Pile Base Grouting:

Pile base grouting is applicable to both precast driven and cast-in-situ piles, but it is more beneficial and economical for cast-in-situ piles. It is applicable to all types of soil. However, it is more effective and economical when the pile base is in sandy soil. Pile base grouting is highly effective in cases where there is soft clay at the top and loose or dense sand below the clay soil. When the pile base is in sand, pile base grouting can increase the load capacity of the pile by nearly 2.0 times. The effectiveness of pile base grouting must be verified by a geotechnical expert.

Benefits of Pile Base Grouting:

Increases pile load capacity by 2 times
Ensures building safety during earthquakes
Reduces the tendency of pile settlement
Improves pile quality
Reduces foundation costs by 20-40%

Testing the Effectiveness of Pile Base Grouting:

There are various methods to test the effectiveness of pile base grouting. Testing can be done one month after the grouting to examine its effectiveness.

Soil Test (SPT) Before and After Grouting: This method measures the increase in soil strength due to pile base grouting. It is the cheapest and quickest method.
Dynamic Load Test Before and After Grouting: This method proves the effectiveness of pile base grouting. Although it is expensive, it provides assurance about the load capacity.
Static Load Test Before and After Grouting: This method also proves the effectiveness of pile base grouting, but it is costly and time-consuming.

Use of Pile Base Grouting in Major Projects Around the World:

Dongxiaojiang Bridge at Shaoxing, China.

Piles used: 197 feet deep, 5 feet diameter
Design load capacity after grouting: 580 metric tons

Shishou Yangtze River Highway Bridge, China.

Pile diameter: 6.5 feet
Depth: 170 feet
Design load capacity: 1582 metric tons

Static load test shows that pile base grouting increases capacity by approximately 1.75 times compared to non-grouted piles.

Haimen–Tongzhou Section of the Tongxi Expressway, Nantong, Jiangsu, China.

Pile diameter: 6 feet
Depth: 180-260 feet
Design load capacity: 420-850 metric tons

Static load test shows that base grouting increases pile capacity by about 1.5-2.0 times compared to non-grouted piles.

Bridge over Odra River in Wrocław, Poland.

Pile diameter: 5 feet
Depth: 60 feet

Static load test shows that base grouting increases pile capacity by 2 times compared to non-grouted piles.

62-Storied Building “The Pinnacle” in London.

The building has 3 basements.
Pile diameter: 8 feet
Depth: 215 feet
Design load capacity: 4500 metric tons

Static load test proves the effectiveness of pile base grouting

Use of Pile Base Grouting in Major Projects in Bangladesh:

Rupsha Bridge, Khulna

Pile diameter: 5 feet
Depth: 147-196 feet
Design load capacity: 460-575 metric tons

Base grouting was done due to the initial insufficient load capacity of the piles.

Pakshi Bridge, Ishwardi, Pabna

Pile diameter: 5.2 feet
Depth: 230 feet

Load test proves the effectiveness of pile base grouting.

Jamuna Bridge

Pile diameter: 8.2-10.3 feet
Depth: 272 feet

Initially, steel pipes were driven into the ground. Soil was removed from inside the pipes except for the last 16.4 feet. The empty section was filled with concrete, and the last 16.4 feet was strengthened by base grouting.

Padma Bridge

Pile diameter: 10 feet
Depth: 98-122 feet
Design load capacity: 8100 metric tons

Steel pipes were driven into the ground, soil removed except for the last 16.4 feet. Inside was filled with concrete, compacted sand and RCC. Pile base grouting was done in all the piles. Side grouting was also done in some piles.

In a total of 40 pillars, 262 steel tube piles with a diameter of 3 meters, made from 60-millimeter-thick steel plates, were used. In 18 of these pillars, there are groups of 6 inclined (raked, 1:6 slope) piles, and in 22 pillars, there are 7 piles in each pillar. Among the 7 piles, the central pile is vertical, while the remaining 6 piles are inclined (raked). Out of the 40 pillars, side grouting was done in 77 piles of 11 pillars, and base grouting was done in all 262 piles.

During the design phase, each of the 40 pillars was designed with 6 inclined piles. However, during construction, load tests did not yield the desired results. A subsequent soil test revealed that the base of the piles had encountered clay soil, indicating uneven soil layers. To address this issue, one additional pile was added to each of the 22 pillars. Side grouting was done in all the piles of 11 pillars out of 22 pillars. Load tests were then performed to confirm the effectiveness of the grouting

Pile Base Grouting Projects by Freehold Construction and Development (FCD):

Ibne Sina Pharma Central Warehouse, Kaliakoir, Gazipur Two test piles were conducted. 750 mm diameter, 98 feet depth. One with base grouting and another without. Both were subjected to dynamic load tests. Base grouting increased pile capacity by 1.75 times. The final pile design was based on these load test results.

Ibne Sina Pharma Godhulia Project, Mauna, Gazipur

Piles were 14 inches x 14 inches and 36 feet long. Dynamic load tests before and after base grouting showed an increase in pile capacity by 1.5 times

Engineers Tower, Bonosree, Dhaka

Pile diameter: 24 inches
Depth: 65 feet

The effectiveness of base grouting was proven through soil test.

Sonali Palli, Chakaria, Cox’s Bazar

Pile size: 14 inches x 14 inches
Depth from basement floor: 15 feet

Base grouting was challenging but successful. The soil became as hard as concrete up to 10 feet above the pile base, making further soil testing impossible.

Market, Gournadi, Barisal

Pile size: 14 inches x 14 inches
Depth from basement floor: 40 feet

After base grouting, the soil became as hard as concrete up to 2 feet above the pile base, making further soil testing impossible after 38 feet.

What to Do If You Want to Use Pile Base Grouting in Your Project:

We Need Only

Soil Test Report

FCD has three mobile grouting plants for pile base grouting, allowing them to perform high-quality grouting quickly. If you wish to use base grouting in your project, contact an FCD representative along with your design engineer. Send the following documents via WhatsApp +8801324-433237

➤ Soil Test Report

➤ Architectural Drawings (if available)

➤ Structural and Foundation Drawings (if available)

➤ Analysis Files (if available)

An FCD representative will contact you with further details.

Directly Message to WhatsApp

Fill out the form below to inquire about Grouting

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