This document provides an overview of the drilled shaft and bored pile installation for the foundations of a new fitness and wellness plaza development project in New Brunswick, NJ. It discusses that Moretrench was contracted to install 77 drilled shafts ranging from 3-6 feet in diameter and averaging 30 feet in depth, as well as 246 18-inch diameter bored piles averaging 20 feet in depth. The document describes the equipment, materials, and procedures used for the installation, including dealing with logistical challenges of existing infrastructure and scheduling issues during construction.

1. DRILLED SHAFT / BORED IN PILE INSTALLATION
New Brunswick Fitness & Wellness Plaza
New Brunswick, NJ
Presentation to:
ADSC Northeast Chapter
Holiday Inn, Clark, NJ
November 30th, 2012
Presentation by:
Jeffrey B. Ayres
Moretrench American Corporation

2. PROJECT OVERVIEW
• Proposed Construction:
• Fitness Center
• Supermarket
• Parking Garage
• Owner
• City of New Brunswick
• General Contractor
• Joseph Jingoli & Sons,
Inc.
• Structural Engineer
• PS&S
• Foundation Contractor
• Moretrench

3. PROJECT OVERVIEW
• Scheduling / Coordination
• Difficult Schedule
• No relief in schedule
when schedule slid
• Additional subs added
when schedule slid

4. MTAC CONTRACT WORK – DRILLED SHAFTS
• 77 Total Drilled Shafts
• Provide support for new
column loads
• 39 @ 3’ diameter
• Reinforcing dowels
• 38 @ 6’ diameter
• Reinforcing dowels
• Anchor bolts (precast
connection)
• Average drill length: 30’

5. DRILL RIG (DRILLED SHAFTS)
• Soilmec SR-65
• Hydraulic Rotary Rig
• 22,500 mm (~74’) mast
• Equipped with:
• Self Handling Counterweight
• Kelly Drilling System
• Drilling Mate System
• Actively monitor drill depth,
crowd pressure, mast
verticality, pump pressures,
and more

6. DRILL RIG (DRILLED SHAFTS)
• Bottom of Mast Clearance
• Cable system feed on back of mast
• Enough clearance for casing “spinner”
WHY SOILMEC?

7. MTAC CONTRACT WORK – BIP’s
• 246 Bored In Piles (BIP’s)
• Provide support for new slab
• 18” Diameter
• 6 x #6 reinforcing cage
substituted with #18 grade 75
threadbar
• Average drill length: 20’

8. DRILLING EQUIPMENT (BIP)
• Bauer RTG RG 19 T
• Universal Piling Rig
• Up to 78’ Mast Height
• Equipped with:
• PIR (Pile Installation Recorder)
• Actively monitor drill depth,
grout volume per 5’
increment, and more

9. MATERIAL / EQUIPMENT SUPPLIERS
• Soilmec SR-65
• American Equipment & Fabrication, East
Providence, RI
• Bauer RTG RG 19T
• Moretrench owned, purchased from
Posillico, Inc.
• Temporary Casing
• Favor Steel & Fabricating, Bessemer, AL
• Drill Tooling
• Jeffrey Machine, Birmingham, AL
• Concrete
• Clayton Concrete, Edison, NJ
• Rebar
• Barker Steel, Avenel, NJ

10. LOGISTICS

11. LOGISTICAL ISSUES
• Existing Overhead Powerlines
• Existing Robert Wood Johnson (RWJ) Building
• Existing Utilities
• Northeast Regional Amtrak Line

12. EXISTING OVERHEAD POWERLINES

13. EXISTING OVERHEAD POWERLINES

14. EXISTING OVERHEAD POWERLINES

15. EXISTING OVERHEAD POWERLINES

16. RWJ BUILDING DEMOLITION
Existing RWJ Building

17. RWJ BUILDING DEMOLITION

18. RWJ BUILDING DEMOLITION
 Mobilized prior to
demolition
 22 caissons
unavailable during
demolition
 Obstructions /
Utilities encountered
beneath building
footprint while drilling

19. RWJ BUILDING DEMOLITION

20. EXISTING / NEW UTILITIES

21. AMTRAK PROXIMITY
• Required to be 15’ minimum between
mast & edge of Amtrak line

22. DRILLED SHAFTS

23. DRILLING PROCEDURE (3’ DRILLED SHAFTS)
• 48” diameter starter
can for top 5’
• 42” diameter “inner”
can to top of rock
• Socketed into
weathered shale
• Visual inspection
performed by PS&S

24. DRILLING PROCEDURE (6’ DRILLED SHAFTS)
• 87” diameter starter
can for top 5’
• 78” diameter “inner”
can to top of rock
• Socketed into
weathered shale
• Visual inspection
performed by PS&S

25. 6’ DRILL TOOLING

26. 3’ DRILL TOOLING
Soilmec equipped to switch between both 3’
and 6’ diameter tooling easily

27. REINFORCING CAGE / CONCRETE
• 26 x #11 bars per 6’ caisson
• 10 x #9 bars per 3’ caisson
• Cage placed with drill rig or crane

28. REINFORCING CAGE / CONCRETE
• Top of reinforcing cage @ 3” below top of caisson (minimum coverage of
reinforcement)
• Water removal (hydraulic pump) & shallow depth permitted end dumping of
concrete

29. DOWELS
• Issues Faced:
• All 77 caissons received either dowels or anchor bolts
• Connection to grade beam, column, etc.
• Drilling grade consistent at ~ elevation 47
• Top of caisson elevation varied from elevation 47 to elevation 40
• Drilling / epoxying dowels into 6’ shafts was not permitted
• Solutions:
• “Wet-Set” dowels for 6’ shafts using premade wooden templates
• Drill / epoxy any remaining dowels once top of caisson is exposed

30. DOWELS
• More than a dozen different dowel patterns
• Up to 7’ depth below drilling grade (worst case scenario)

31. DOWELS

32. ANCHOR BOLTS
• Issues Faced:
• Anchor Bolt location and embedment in top of drilled shafts were critical,
with nearly negligible tolerances
• Solution:
• Per the engineer, pour shaft concrete 3’ below top of caisson (cold joint).
• Place 6’ corrugated pipe around top of shaft
• Set template at correct elevation and plan location
• Pour remainder of concrete
• Monitor location of template before, during, and after pour

33. ANCHOR BOLTS
• Left: 6’ Diameter Caisson with Concrete 2’-3’ low
• Right: 6’ Diameter Corrugated Pipe

34. ANCHOR BOLTS
• Left: Typical Anchor Bolt Template
• Right: Placement of Anchor Bolt Template at exact elevation prior to pour

35. ANCHOR BOLTS

36. ANCHOR BOLTS

37. ANCHOR BOLTS

38. ANCHOR BOLTS
• Left: Finished Anchor Bolt Shaft
• Right: Precast Column @ Anchor Bolt Shaft

39. BORED IN PILES (BIP’s)

40. DRILLING PROCEDURE (BORED IN PILES)
• 18” Diameter Continuous Flight Hollow Stem Auger
• Advanced 5’ below top of first rock encountered or to auger refusal
• <1’ / minute
• Once tip reached, sand-cement grout pumped through auger
• 115% of theoretical volume (measured by PIR & stroke count)
• Slow positive rotation maintained during withdrawal

41. DRILLING PROCEDURE (BORED IN PILES)
• Upon grouting completion, pile top protector placed into hole (left picture)
• Top of Pile (grout) elevation reached by removing excess grout from top
• #18 Grade 75 Threadbar installed full length (right) along with 4 x #4 bars with
90 degree bends
• Average Production – 15 to 20 / DAY

42. BEFORE

43. AFTER

44. NEW BRUNSWICK WELLNESS PLAZA
QUESTIONS?