High-Capacity Driven-Pile Foundation for a 33-Story High-Rise in Milwaukee, Wisconsin, USA

"The project consists of a 33-story building with two levels of below-grade parking across the entire building footprint. Timely and cooperative teamwork among the owner/developer, geotechnical engineer, testing agency, structural engineer, construction manager, and pile-driving contractor resulted in an efficient, costeffective, high-capacity driven-pile foundation on a constrained urban site with significantly variable subsurface conditions. Design objectives included utilizing the highest allowable pile loads reasonably installed from a drivability perspective, using readily available equipment. A pre-production test program was performed on 16-inch-diameter (406-mm-diameter) steel pipe piles, driven closed-ended and subsequently filled with concrete. The test program included dynamic monitoring of 10 piles during installation, and of select piles during long-term restrike testing with a drop hammer, with one instrumented static load test. CAPWAP® analyses were performed on both end-of-initial-drive and beginning-of-restrike dynamic test records. The site exhibited significant soil set-up, even after relatively short wait times. Testprogram objectives included characterizing set-up profiles. A design set-up profile was used to develop depth-variable driving criteria for both 500- and 600-kip (2,224- and 2,669-kN) allowable load piles. Test program results permitted more-accurate reduced capacities to be assigned to damaged piles, and to piles which experienced practical refusal. These more-accurate assigned reduced capacities decreased the number of replacement piles required by 50 percent, saving both time and cost.PROJECT DESCRIPTIONThe project, located in Milwaukee, Wisconsin, USA consists of a 33-story mixed-use residential building with two levels of below-grade parking across the entire site footprint. Column service loads range from 1,400 to 4,200 kips (6,228 to 18,683 kN). The project is located immediately adjacent to an existing two-story masonry retail building with a partial basement, supported on shallow spread-footing foundations.Subsurface Conditions – The generalized soil conditions are presented in Fig. 1. Site grades were relatively level, with a ground-surface elevation of approximately +53 feet (16 m), Milwaukee City Datum (“MCD”). Fill material from previous construction was encountered to approximate Elev. +33 feet (10 m). Below the fill, medium dense silty sand, to silt with sand, was encountered to approximate Elev. +23 feet (7 m). Underlying deposits consisted of lean clay, with undrained shear strengths ranging from approximately 1,000 to 3,000 pounds per square foot (psf) (48 to 144 kPa). Silty sand, to silt with sand, exhibiting increasing relative density with depth, was found below the lean clay to approximate Elev. -92 feet (-28 m), where hard lean clay (glacial till) with undrained shear strengths in excess of 5,000 psf (239 kPa) was encountered. Borings did not extend below Elev. -103 feet (-31 m)."