analysis, design, and construction stages of milad geosynthetic
Transcription
analysis, design, and construction stages of milad geosynthetic
ANALYSIS, DESIGN, AND CONSTRUCTION STAGES OF MILAD GEOSYNTHETIC REINFORCED SOIL BRIDGE ABUTMENT IN TEHRAN-IRAN1 S. Alireza (Sam) Mirlatifi Senior Geotechnical Engineer in AECOM Pty Ltd., Sydney, Australia - former Technical Manager in BPI Co. ABSTRACT Reinforced soil walls are one the most cost effective options for retaining structures, and are being increasingly used in recent years around the world. They have also proved that they have performed to an acceptable level under earthquake loading conditions. This paper presents the analysis, design and construction stages of the first major geosynthetic reinforced soil bridge abutment built in Iran. The bridge abutment was designed, analysed and constructed by BPI Company in Tehran, Iran in 2009. This abutment is analysed using both the Limit Equilibrium Method (LEM) for stability analysis and Finite Element Method (FEM) for deformation analysis under static and seismic loads. The design has been carried out according to the Federal Highway Administration Manual (FHWA-NHI-00-43, 2001) and National Cooperative Highway Research Program Report 556-2006 (NCHRP) as a guideline. Deformations of the abutment were monitored with an accuracy of ±1mm before and after the construction of the concrete sill and are compared with the outputs from the numerical methods. This project was undertaken on behalf of the Tehran Municipality with the aim of bringing this new method of abutment construction to the country. This project is likely to be the first of many to adopt this cost effective solution. 1 INTRODUCTION Instead of a conventional bridge deck supported on pile-cap or concrete wall abutments, Geosynthetic Reinforced Soil walls (GRS walls) use alternating layers of compacted fill material and inclusions of geosynthetic reinforcement such as geogrids or geotextiles to provide support for the superstructure. GRS abutments are similar in principle to GRS walls, except that GRS abutments are typically subjected to a much higher area load resulting from a spread footing (commonly referred to as a “sill”), and the loads are close to the wall face. The construction of the reinforced soil walls with metal strips (RE walls) and GRS walls in Iran dates back to the seventies and early nineties, respectively. Although many steel strips reinforced bridge abutments (RE system) have been constructed in Iran during the last decades, this paper presents the first major GRS bridge abutment in Iran, which was completed in 2009. Generally, GRS bridge abutments are easier and faster to construct and more cost effective (potentially 25–60 percent less than traditional methods ([FHWA- HRT-11-026, 2011]). The GRS abutments can also omit the use of pile caps and alleviate the chronic problem of “bumps” between bridge abutments and the approach slab. In addition they are one of the best solutions in sites with difficult access because they need small tools and light weight equipment. In addition, it is widely proved that they have acceptable seismic behaviour and high energy absorbing potential against impacts. They also provide a safer work environment for personnel in work zones. In addition, the technology is environmentally sensitive and results in minimal environmental impacts. The technology produces a reduced construction and carbon footprint, eliminates the need for installation of deep foundations or concrete walls, and can be adapted to fit the sitespecific environmental needs [FHWA- HRT-11-026, 2011]. Last but not least, they can have different facings giving more aesthetic results. 2 GRS CODES, MANUALS, GUIDELINES AND DESIGN METHODS The current GRS bridge has been analysed and designed according to Federal Highway Administration Manual (FHWA-NHI-00-43, 2001), which is based on Allowable Stress Design (ASD) method, also known as Service Load Design (SLD), and National Cooperative Highway Research Program (NCHRP REPORT 556, 2006) as a guideline. The recent new version of the FHWA manual (FHWA-NHI-10-024 &025, 2010) and also FHWA-HRT-11-026, 2011 for GRS Integrated Bridge Systems (known as GRS-IBS) have been revised to Load and Resistant Factor Design (LRFD). The LRFD method is the latest advancement in transportation structures design practice in the USA. The LRFD method in various forms is now being applied throughout the world. For example, EuroCode uses the Limit State Design (LSD) method, which is very similar to the LRFD method. Moreover RTA specification for Design of 1 This paper was presented at the Sydney Chapter YGP night 2011 Australian Geomechanics Vol 47 No 3 September 2012 125 ANALYSIS, DESIGN, AND CONSTRUCTION STAGES OF MILAD GEOSYNTHETIC REINFORCED SOIL BRIDGE ABUTMENT IN TEHRAN-IRAN ALIREZA (SAM) MIRLATIFI Reinforced Soil Walls (R57) in Australia and Code of Practice for strengthened/reinforced soils (BS8006) in UK, are based on LSD method. Although there are several other GRS construction guidelines provided by different authorities such as the American Association of State Highway and Transportation Officials, AASHTO (1998), the National Concrete Masonry Association, NCMA (1997), the Federal Highway Administration, FHWA (Elias and Christopher, 1997), the Colorado Transportation Institute, CTI (Wu, 1994), the Swiss Association of Geotextile Professionals, SAGP (1981), and the Japan Railways, JR (1998), still the lack of a rational and reliable design methods for GRS abutments and the lack of well-developed guidelines and specifications for constructing the structures is clearly being observed. 3 REVIEWED CASE STUDIES Depending on the facing rigidity, GRS bridge-supporting structures can be grouped into two types: “rigid” facing and “flexible” facing structures. A “rigid” facing is typically a continuous reinforced concrete panel, either precast or cast in place. A “flexible” facing, on the other hand, typically takes the form of wrapped-around geosynthetic sheets, concrete modular blocks, timbers, natural rocks, or gabions. GRS bridge-supporting structures with a flexible facing have been the subject of several studies (e.g., Gotteland et al.,1997; Adams, 1997; Ketchart and Wu, 1997; Miyata and Kawasaki, 1994; Werner and Resl, 1986; and Benigni et al.,1996), and recently have seen actual applications in the United State and other countries, including the Vienna railroad embankment in Austria (Mannsbart and Kropik, 1996), the New South Wales GRS bridge abutments in Australia (Won et al., 1996), the Black Hawk bridge abutments in Colorado, (Wu et al., 2001), the Founders/Meadows bridge abutments in Colorado, (Abu-Hejleh et al., 2000) and Ilsenburg bridge abutment in Germany (Andreas Herold, 2000). These structures have shown great promise in terms of ductility, flexibility, constructability and costs. The Milad bridge abutment is also a GRS bridge abutment with a flexible facing. 4 MILAD GRS BRIDGE ABUTMENT IN TEHRAN Milad Tower is located in Tehran, Iran and is the sixth tallest tower in the world at the moment and stands 435 m high from base to tip of the antenna. Milad GRS bridge abutment provides an access to Milad Tower. This bridge abutment carries the load of 20 m single span of a 114 m long cable-stayed bridge on west side of Milad Tower. The length of the sill is 23.7 m and the bridge consists of 4 lanes and the maximum height of the GRS abutment to below the sill (lower wall) is 3.5 m and the total height of the abutment to top of the pavement is 7.5 m. The geogrid length in lower wall is 9.5 m for GRS abutment section. Also, southern wing wall has 8 m height with geogrid length of 7 m in perpendicular direction to the GRS abutment section. The natural soil description of the location consists of very dense (Nspt>50) cemented mixture of gravel and sand with clay (GC/SC). The location of the bridge and abutment is shown in Figure 1 and 2. The reinforced geosynthetic material is Armatex M 80/30, 55/30 (Kordarna) with flexible facing which is wrapped geogrid. For aesthetic purposes, a layer of gabion has been added to the geogrid wrapped around the face. The Milad GRS bridge abutment characteristics are summarised in Table 1. Table 1: Milad GRS bridge abutment characteristics in Tehran/Iran Case Height Back fill Reinf. type Milad GRS Bridge abutment in Tehran 3.5 m (lower wall), 7.5 m total Sand, gravel with clay (GC/SC) c = 10kPa, f=35 g = 20 kN/m3 (>98% of T99)- Kordarna, Armatex M(80/30) for lower wall Tult = 80 kN/m @e = 6% and M(55/30) for upper wall 126 Reinf. Spacing/ length 0.4 m/9.5 m lower wall, 4 m upper wall Facing type/ connection Geogrid/ Wrapped with Gabion facing, with angle of 68˚ (2H:5V) Australian Geomechanics Vol 47 No 3 September 2012 Maximum Lateral Movement of Wall Face <1 mm, both vertical and lateral after Sill placement Sill 1.2 × 3.3 m with 1.35 m clearance from the face ANALYSIS, DESIGN, AND CONSTRUCTION STAGES OF MILAD GEOSYNTHETIC REINFORCED SOIL BRIDGE ABUTMENT IN TEHRAN-IRAN ALIREZA (SAM) MIRLATIFI Site Location Site Location Milad Tower The GRS abutment Figure 1: The location of the Milad GRS bridge abutment in Tehran (Courtesy of Google Map) Figure 2: Completion of the bridge deck in 2011 (Courtesy of Google Map) SIL L Figure 3: The view of the Milad GRS bridge abutment with gabion facing 5 Figure 4: A cross section from Milad GRS bridge abutment (lower wall=3.5 m, upper wall=4.0 m, total height=7.5 m) CONSTRUCTION MATERIALS The main elements of GRS bridge abutments include geosynthetic inclusions for reinforcement, suitable soil and drainage material. Armatex® M is used as a geosynthetic soil reinforcement material in this project. Armatex® M is a woven geogrid, made of high tenacity Poly Vinyl Alcohol (PVA) yarns with PVC coating. Some of the advantages of this type of geogrid are high tensile strength at low elongation (at 2, 3 and 6% strain), high resistance to chemicals in soils, acid and alkali earth (PH 0-14), high level of microbiological resistance, high resistance to damage during installation, optimal interlocking with coarse-grained soils, high pull-out resistance and low values of creep which ensure long-term stability. The material is usually delivered as 5m wide roles. The ultimate tensile strength (Tult) of Armatex M (80/30) which has been used in lower wall is 80 kN/m in 6% strain and Armatex M (55/30) in upper wall is 55 kN/m in 6% strain. According to the reinforcement manufacturer (Kordarna) datasheet, the total reduction factor to evaluate the design strength (Ta) of this product with consideration of creep (A1), installation damage (A2), connections (A3), acid and alkaline effects (A4) is 1.6 for design life of 120 years (Ta=Tult/A1×A2×A3×A4 × 1/γ). According to the laboratory testing results, the in situ soil of the area has been suitable material for soil reinforcement purposes. The soil consists of clayey gravel with sand or clayey sand with gravel (GC/SC) with Plasticity Index (PI) of lower than 15% and fine content of less than 20%. In addition, a non-woven 300 gr/m2 geotextile has been used as a barrier in facing. Hot-dip galvanized steel mesh has been used for gabion in facing. 300 mm thick granular material with size of 19-25 mm with slotted PVC pipe has been used as drainage. 6 ANALYSIS AND DESIGN CRITERA Milad GRS Bridge abutment has been analysed and designed according to the Federal Highway Administration Manual (FHWA-NHI-00-43, 2001) which is based on Allowable Stress Design (ASD) method and National Cooperative Australian Geomechanics Vol 47 No 3 September 2012 127 ANALYSIS, DESIGN, AND CONSTRUCTION STAGES OF MILAD GEOSYNTHETIC REINFORCED SOIL BRIDGE ABUTMENT IN TEHRAN-IRAN ALIREZA (SAM) MIRLATIFI Highway Research Program (NCHRP REPORT 556, 2006) as a guideline. Table 2 summarises the minimum required factors of safety for GRS abutments in ASD method based on the FHWA (2001). Table 2: Milad GRS bridge abutment design criteria based on FHWA2001 in static (1) condition External stability Overall slope stability(2) External/ Internal/ Compound 1.5 1. 2. 3. Internal stability Bearing capacity Deep seated Lateral squeezesoft soils Connection Overturning Sliding Pull out Rupture Eccentricity Wrapped Return length(3) >1m The above factor of safety should be reduced to %75 in seismic condition. The PGA of the area is 0.35 g for 475 years earthquake. The factor of safety against overall stability for bridge abutments is 1.6 in RTA standard (R57). The return lengths of geogrids are 1.6 m and the only upper geogrid layer beneath the sill is 3.5 m in this project with wrapped connection. 2.5 (NA) e>L/6 2 1.5 1.5 1.5 Based on field studies of actual structures, AASHTO (1996) suggests, that tolerable angular distortions (i.e., limiting differential settlements) between abutments or between piers and abutments should be limited to the following angular distortions: • 0.005 for simple spans and 0.004 for continuous spans. This criterion, suggests that for a 20 m span for instance, differential settlements of 80 mm for a continuous span or 100 mm for a simple span, would be acceptable, with no ensuing overstress and damage to superstructure elements. On an individual project basis, differential settlements of smaller amounts may be required from a functional or performance criterion. During last decades, general agreement has been reached that a complete design approach should consist of the Working Stress analyses, Limit Equilibrium analyses and Deformation Evaluations. All of the external and internal factors of safety in static and seismic condition have been satisfied in Working Stress analyses and checked with Limit Equilibrium method by Slide (6.0). The LEM results show that the factor of safety for overall stability in critical section has been assessed about 2 in the static condition and 1.65 in the seismic condition. The compound pseudo static overall stability analysis in the seismic condition is shown in Figure 5 as an example. Figure 5: Compound pseudo static overall stability analysis in seismic condition, Fs=1.65>1.1 The finite element method by Plaxis 2D V9.0 also has been undertaken to evaluate deformations, geogrids load distribution and the performance of the abutment and the relative shear stresses and plastic points are shown in Figures 6a and 6b as examples. 128 Australian Geomechanics Vol 47 No 3 September 2012 ANALYSIS, DESIGN, AND CONSTRUCTION STAGES OF MILAD GEOSYNTHETIC REINFORCED SOIL BRIDGE ABUTMENT IN TEHRAN-IRAN ALIREZA (SAM) MIRLATIFI Figure 6a: The relative shear stresses after construction of the bridge deck and traffic loading, 7 Figure 6b: Plastic points after the construction of the bridge deck and traffic loading CONSTRUCTION STAGES AND MONITORING The construction period of lower GRS wall was about two months. However, since the construction process applied in a GRS abutment is inherently simple, the construction time could be significantly reduced. First, the foundation preparation carried out by proof rolling and the gaps filled with lean concrete. Although the facing has been designed flexible, a shallow small strip foundation has been constructed beneath the facing to alleviate any possible differential settlement and to increase the construction accuracy. A large size gravel material has been used as a first layer to facilitate drainage. Then the second layer of geogrid material has been spread on the first layer and fixed with steel Ushape hooks. As the facing system is wrapped, steel cage with L-shape bars have been used in the facing to reduce facing deformation during the construction. Then the first 150 mm layer of suitable soil compacted with heavy vibratory roller. The soil has been compacted in 150 mm layers thickness with compaction of more than 98% of AASHTO T-99, and ±2% of optimum moisture, wopt. Compaction within 1 m of the back face of the wall including drainage material and backfill soil has been undertaken by at least three passes of a lightweight vibratory compactor. After the second 150 mm layer, the geogrid has been wrapped around and fixed with the steel hooks. Then the final layer of soil is compacted to finish the first 0.4 m reinforced mass (three 150 mm uncompacted soil is roughly about 400 mm compacted soil). This operation has been repeated to reach to the level of the sill. The geogrid sheets have had a minimum 300 mm overlap with each other in each layer. After finishing the construction of GRS bridge abutment, the gabion facing has been employed for aesthetic purposes with hot-dip galvanised steel mesh 50×50×5 mm. Deformations of the abutment from 28 points on facing were monitored in three dimensions with an accuracy of ±1 mm with the Total Station during and after the construction. The summary of the monitoring results is shown in Table 3 below. The results show that the performance of the GRS bridge abutment is within the design criteria and the reinforced abutment mass has a high stiffness and a high capacity for bearing heavy loads as anticipated. However, more accurate numerical calibrated models are going to be built to study the long term performance of the GRS abutment in more detail. Table 3: The summary of the monitoring results of Milad GRS bridge abutment in compare with the predicted values after construction of sill foundation and the upper wall [1] Case δH -maximum lateral disp. on the δV -maximum vertical disp. of the facing Sill Monitoring Results <1 mm <2-3 mm Predicted by the FEM analysis 3 mm 9.6 mm Design Criteria 80 mm 80 mm [1] The abutment is not under service loads yet and further monitoring has been scheduled after construction of the bridge and during the traffic loading. Australian Geomechanics Vol 47 No 3 September 2012 129 ANALYSIS, DESIGN, AND CONSTRUCTION STAGES OF MILAD GEOSYNTHETIC REINFORCED SOIL BRIDGE ABUTMENT IN TEHRAN-IRAN ALIREZA (SAM) MIRLATIFI Monitoring Points Monitoring Points Figure 7: The monitored points on GRS bridge abutment facing (b) (a) Figure 8: (a) The density test during construction – (b) geogrid layers with minimum 300 mm overlap Heavy weight roller Light weight roller near facing (a) (b) (c) Figure 9: (a) The compaction method by heavy and light weight roller- (b) The detail of the wrapped around connection to the gabion facing- (c) The view of the final gabion facing 8 CONCLUSIONS AND RECOMMENDATIONS The Geosynthetic Reinforced Soil (GRS) is one of the most appropriate solutions for bridge abutments in the view of the abutment performance, construction costs, time and safety in comparison to other conventional methods. The most effective factors in performance of the GRS walls are the quality of the compacted soil with the correct selection of the reinforcement materials according to the author’s experience. To reduce the cost and elapsed time of the construction in future projects it is recommended to omit the concrete sill, provided that suitable analysis and design concept with appropriate details is applied. This system is called Geosynthetic Reinforced Soil Integrated Bridge System (GRS-IBS) and has been presented in FHWA-HRT-11-026. 9 ACKNOWLEDGEMENT This project is the result of many engineers’ and technicians’ efforts. In addition, I acknowledge the BPI Co., Ardam Consulting Engineers Co., Band Construction Co. and Tehran Municipality, as the project main client, for their support and understanding to accept this new technology in the bridge and road industry. Special thanks to Mr. Salehabadi the 130 Australian Geomechanics Vol 47 No 3 September 2012 ANALYSIS, DESIGN, AND CONSTRUCTION STAGES OF MILAD GEOSYNTHETIC REINFORCED SOIL BRIDGE ABUTMENT IN TEHRAN-IRAN ALIREZA (SAM) MIRLATIFI CEO of the BPI Company and Mr. Shahabi, the construction manager. I would also like to commend Mr Clinton Every’s supports and valuable contributions in preparation of this paper. 10 REFERENCES Abu-Hejleh, N., Wang, T., and Zornberg, J. G. (2000). “Performance of geosynthetic-reinforced walls supporting bridge and approaching roadway structures.” Proc., ASCE Geotechnical Special Publication No. 103, GeoDenver 2000, Denver, 218–243. Adams M., Nicks J., Stabile T., Wu J., Schlatter W., and Hartmann J. (2011), “Geosynthetic Reinforced Soil Integrated Bridge System, Interim Implementation Guide”, Federal Highway Administration, U.S. Department of Transportation Washington DC. Publication no. FHWA-HRT-11-026. Elias V., Christopher B.R. and Berg R.R. 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(2010), “The case study of Milad Tower access bridge abutment, the first Geogrid reinforced soil abutment in Iran”, 4th International Conference on Geotechnical Engineering and Soil Mechanics in Iran, Tehran, 2010, Paper Code: (BMPSAL) 691. Sam M.B. Helwany, Jonathan T.H. Wu, and Akadet Kitsabunnarat, (2007), “Stimulating the Behavior of GRS Bridge Abutments”, Journal of Geotechnical and Geoenvironmental engineering, 10, 1061/ (ASCE) 1090-0241. S.R. Lo, (2004), “Application of Numerical Modelling to the Design of Reinforced Soil Walls for Infrastructure Projects - Some Australian Experiences” GeoAsia2004: 3rd Asian Regional Conference on Geosynthetics: Now and Future of Geosynthetics in Civil Engineering, June 2004, Seoul, Korea, p193. Wu, J. T. H., Lee, K. Z. Z., Helwany, S., and Ketchart, K. (2006), “Design and construction guidelines for geosynthetic reinforced soil bridge abutments with a flexible facing.” NCHRP Rep. No. 556, Transportation Research Board, National Research Council, Washington D.C. Australian Geomechanics Vol 47 No 3 September 2012 131 ANALYSIS, DESIGN, AND CONSTRUCTION STAGES OF MILAD GEOSYNTHETIC REINFORCED SOIL BRIDGE ABUTMENT IN TEHRAN-IRAN ALIREZA (SAM) MIRLATIFI 132 Australian Geomechanics Vol 47 No 3 September 2012