Drilled Shaft Construction and Some NDT Surprises at the Portal North Bridge

The existing, century-old Portal Bridge over the Hackensack River in New Jersey is a two-track moveable swing span bridge that is nearing the end of its functional life. A new fixed bridge with spans of approximately 400 feet will replace the existing bridge. The new Portal North Bridge will continue service to both Amtrak and NJ Transit rail passengers along the Northeast Corridor to an average of 200,000 passengers per day. Each of the four main span piers will be supported by eight, 8-foot diameter drilled shafts. Malcolm Drilling installed all shafts with permanent steel casing through the Soft Clay and Glacial Till layers with a short embedment into competent bedrock using the Oscillator method. Rock sockets below the casing were drilled with conventional drilling tools. Quality assurance included inspection of the shaft base using a MiniSID shaft inspection, the rock socket side walls using a Down-The-Hole Camera and the verticality using Sonic Caliper. In addition, specifications called for integrity testing using Thermal Integrity Profiling (TIP) and Crosshole Sonic Logging (CSL) on each shaft. Tomography analyses of CSL test data and destructive testing by means of concrete coring had also to be employed on the majority of shafts. This paper will highlight the surprises experienced by the project team when the concrete core specimens were evaluated in relation to the non-destructive testing data.