From
2002 through 2007, the distinct sounds of hydraulic drills,
bull dozers and front end loaders became familiar to the traffic
goers of Toledo, Ohio. Fru-Con Construction Corporation, a
general contractor headquartered in St. Louis, Missouri, was
in the process of constructing a new bridge over the Maumee
River that was poised to be a lasting landmark for the city.
As part of a program to modernize Interstate 280, the six-lane,
$220 million bridge, boasts a 1,225 foot main span and cable
stay consisting of 156 individual strands, the biggest and
strongest ever used on a cable-stayed structure. It was made
from 14,000 tons of epoxy coated reinforcing steel, 3,900
tons of steel post-tensioning cables and 186,000 cubic yards
of concrete. To help with this record-breaking project, Fru-Con
contracted the services of Ohio Concrete Sawing & Drilling
of Sylvania, Ohio.
On Friday,
July 19, 2002 the last day of a grueling week of the busiest
month of the year, Ohio Concrete Sawing & Drilling received
a phone call from Fru-Con at 4:30 p.m. Fru -Con needed two
holes drilled, each approximately 70 feet deep and two inches
in diameter. At the moment, the proper equipment to
perform such a sizeable task was at one of Ohio Concrete’s
other branches. Therefore, they immediately sent someone to
their facility in Columbus, Ohio to retrieve special core
bits allowing them to drill to the desired depth. At 7:00
a.m. the next day, Saturday, operators began drilling the
first 2” holes on the Maumee River Crossing.
Fru-Con
uses a special testing technique called cross-hole sonic logging
(CSL) testing to show possible anomalies within the 8’
diameter piers supporting the bridge. The CSL testing works
by sending an electric pulse from one tube cast in the foundation
pier to another tube within the pier through the use of a
sending and receiving probe. The time it takes for the pulse
to travel is recorded, and velocities are calculated at one-inch
increments. Sent by e-mail, the results which are interpreted
by Conrad Felice, a geotechnical engineer in Seattle, Washington,
give a profile of the entire foundation pier from top to bottom.
Twelve total profiles are taken within each 8' diameter
pier.
CSL testing
has become an acceptable manner of determining the integrity
of concrete
in the last ten years. It is the first step in determining
the integrity of the concrete after the foundation pier is
complete. However, this method of testing is not always successful
due to slurry interfering with the electric pulse. Therefore,
core drilling is a secondary test to CSL. Core samples are
taken to determine if there are any voids present
within the foundation pier as well as to demonstrate compressive
strength at different intervals in the caisson.
Because
a core drill allows the operator to drill only as deep as
the bit, Continental tubing is used. Continental tubing is
hollow tubing threaded on each end and allows the drill operator
to drill very deep holes without continually retrieving the
cores. When the core drilling is complete, the 2” core
pieces are removed from the tubing and aligned in order from
top to bottom. Then, the pieces are tested to make sure the
foundation pier is solid and the concrete meets the Ohio Department
of Transportation’s specifications.
Fru-Con
has been very pleased with the service of Ohio Concrete. Matt
Hogan, a manager for Fru-Con, said, “Ohio Concrete
Sawing’s service to this project has been outstanding
both in the timely response to requests to perform the coring
as well as the experience shown while working on site.”
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