Lessons Learned in Re-Starting a Stalled Project-PPT Presentation

PPT Presentation

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A project was halted after concerns arose about the strength and quality of grout in 543 installed auger-cast-in-place piles, as well as discrepancies between pile installation records and special inspector logs. The owner considered relocating the building and abandoning the existing foundations.<br /><br />Langan was initially asked to assess grout strength. Its review found that the 5,000-psi requirement was intended for corrosion protection, but groundwater testing showed the site water was not corrosive; 4,000 psi was adequate for the piles’ design load. This resolved the grout-strength concern but left uncertainty about whether the installed piles could safely support the development.<br /><br />Rather than assume the foundation had to be discarded, the team documented accessible piles, reviewed installation records, and developed a risk-based testing program. Testing included low- and high-strain dynamic tests and lateral load tests. Axial static testing was ruled out because of cost and site constraints. Since the piles were already installed, testing was tailored to the loads they would actually experience in service, rather than an unnecessarily high proof load.<br /><br />Results showed that tested piles met project requirements. A limited number required remediation: some pile tops were repaired, and seven piles with deep core holes were replaced. The stop-work order was rescinded, and the project was completed without abandoning the foundation; only 1.2% of the piles needed replacement.<br /><br />Key lessons include investigating the cause and significance of concerns before making major decisions, reconciling conflicting construction records with field evidence, and using targeted testing to manage uncertainty. A stalled project may be recoverable through collaborative, evidence-based assessment and proportionate repairs.

Keywords

auger-cast-in-place piles

grout strength

foundation assessment

pile testing

construction records

dynamic testing

lateral load tests

remediation

stop-work order

corrosion protection