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i CONTENTS ACKNOWLEDGMENTS........................................................................... vi ABSTRACT ............................................................................................... viii SUMMARY .................................................................................................. ix Objectives of the Report......................................................................................................x Organization of Report ......................................................................................................xi Concluding Comments .....................................................................................................xiii CHAPTER 1 INTRODUCTION General..........................................................................................................................................1-1 Soft Ground Treatment Methods ..................................................................................................1-3 Types of Lightweight Fills............................................................................................................1-7 EPS-Block Geofoam.....................................................................................................................1-8 Functions.....................................................................................................................................1-10 History of Geofoam ....................................................................................................................1-11 Current State of Practice .............................................................................................................1-12 Objectives of the Report .............................................................................................................1-14 Report Organization....................................................................................................................1-15 References...................................................................................................................................1-17 Tables..........................................................................................................................................1-20 CHAPTER 2 RELEVANT ENGINEERING PROPERTIES OF BLOCK-MOLDED EPS Background...................................................................................................................................2-3 Physical Properties and Issues ......................................................................................................2-8 Mechanical Properties.................................................................................................................2-18 Thermal Properties......................................................................................................................2-62 References...................................................................................................................................2-63 Figures ........................................................................................................................................2-68 Tables..........................................................................................................................................2-89 CHAPTER 3 DESIGN METHODOLOGY Introduction...................................................................................................................................3-2 Major Components of an EPS â Block Geofoam Embankment ...................................................3-5 Design Phases ...............................................................................................................................3-6 Design Procedure ..........................................................................................................................3-7 Limitations to the Proposed Design Methodology and Design Guidelines ................................3-11 Background Investigations..........................................................................................................3-12 Design Loads ..............................................................................................................................3-17 References...................................................................................................................................3-26 Figures ........................................................................................................................................3-28 Tables..........................................................................................................................................3-40
ii CHAPTER 4 PAVEMENT SYSTEM DESIGN Introduction...................................................................................................................................4-1 Benefits of a Thicker Pavement System .......................................................................................4-3 Drawbacks of a Thicker Pavement System...................................................................................4-7 Utilizing Geofoam Layers with Varying Properties .....................................................................4-7 Separation Materials .....................................................................................................................4-8 Pavement Design Procedures......................................................................................................4-16 Flexible Pavement System Design Catalog ................................................................................4-20 Rigid Pavement System Design Catalog ....................................................................................4-24 Summary of Pavement System Data From Case Histories.........................................................4-26 Typical Dead Load Stress Range Imposed by a Pavement System............................................4-27 Summary.....................................................................................................................................4-30 References...................................................................................................................................4-31 Figures ........................................................................................................................................4-34 Tables..........................................................................................................................................4-36 CHAPTER 5 EXTERNAL (GLOBAL) STABILITY EVALUATION OF GEOFOAM EMBANKMENTS Introduction...................................................................................................................................5-4 Embankment Geometry ................................................................................................................5-5 Embankment Cover ......................................................................................................................5-7 Settlement of Embankment.........................................................................................................5-10 External Bearing Capacity of Embankment................................................................................5-25 External Slope Stability of Trapezoidal Embankments ..............................................................5-33 External Seismic Stability of Trapezoidal Embankments...........................................................5-45 External Slope Stability of Vertical Embankments ....................................................................5-59 External Seismic Stability of Vertical Embankments.................................................................5-68 Hydrostatic Uplift (Flotation) .....................................................................................................5-75 Translation and Overturning Due to Water (Hydrostatic Sliding and Overturning)...................5-84 Translation and Overturning Due to Wind .................................................................................5-91 References...................................................................................................................................5-99 Figures ......................................................................................................................................5-104 Tables........................................................................................................................................5-164 CHAPTER 6 INTERNAL STABILITY EVALUATION OF GEOFOAM EMBANKMENTS Introduction...................................................................................................................................6-3 Block Interlock .............................................................................................................................6-4 Translation Due to Water (Hydrostatic Sliding) ...........................................................................6-7 Translation Due to Wind...............................................................................................................6-8 Internal Seismic Stability of Trapezoidal Embankments..............................................................6-9 Internal Seismic Stability of Vertical Embankments ..................................................................6-20 Load Bearing...............................................................................................................................6-29
iii Abutment Design ........................................................................................................................6-50 Durability ....................................................................................................................................6-53 Other Internal Design Considerations.........................................................................................6-55 References...................................................................................................................................6-56 Figures ........................................................................................................................................6-59 Tables..........................................................................................................................................6-81 CHAPTER 7 DESIGN EXAMPLES Introduction...................................................................................................................................7-2 Design Example 1 â Trapezoidal Geofoam Embankment............................................................7-2 Design Example 2 â Lateral Pressures on an Abutment .............................................................7-36 References...................................................................................................................................7-39 Figures ........................................................................................................................................7-40 Tables..........................................................................................................................................7-49 CHAPTER 8 GEOFOAM CONSTRUCTION PRACTICES Introduction...................................................................................................................................8-2 Design ...........................................................................................................................................8-2 Manufacturing...............................................................................................................................8-5 Construction................................................................................................................................8-10 Post Construction ........................................................................................................................8-18 Summary.....................................................................................................................................8-19 References...................................................................................................................................8-19 Figures ........................................................................................................................................8-21 CHAPTER 9 GEOFOAM MQC/MQA Introduction...................................................................................................................................9-3 Definitions ....................................................................................................................................9-3 Basis of the Provisional Standard .................................................................................................9-5 Proposed EPS Material Designation and Minimum Allowable Values of MQC/MQA Parameters.............................................................................................................................9-9 MQC/MQA Test Requirements ..................................................................................................9-12 Basis of the Proposed Manufacturing Quality Control (MQC) and Manufacturing Quality Assurance (MQA) Procedure..............................................................................................9-18 Product Manufacturing Quality Control (MQC) Requirements .................................................9-22 Product Manufacturing Quality Assurance (MQA) Requirements.............................................9-26 Product Shipment........................................................................................................................9-35 Summary.....................................................................................................................................9-35 References...................................................................................................................................9-37 Figures ........................................................................................................................................9-38 Tables..........................................................................................................................................9-43 CHAPTER 10 TYPICAL DESIGN DETAILS FOR EPS-BLOCK EMBANKMENTS Introduction.................................................................................................................................10-1
iv Design Details for Trapezoidal EPS Embankments ...................................................................10-2 Design Details for Vertical EPS Walls .......................................................................................10-3 Design Details for Bridge Abutments.........................................................................................10-4 Utility and Roadway Hardware Details ......................................................................................10-4 Design Details for Protective Load Distribution Slab ................................................................10-6 Anchoring Details for Hydrostatic Uplift ...................................................................................10-6 Installation of EPS-Block Geofoam............................................................................................10-7 References...................................................................................................................................10-7 Figures ........................................................................................................................................10-9 CHAPTER 11 CASE HISTORIES Introduction.................................................................................................................................11-2 Hawaii: Highway H-3 (Likelike Highway) Emergency Escape Ramp for the Kaneohe Interchange, Island of Oahu................................................................................................11-2 Indiana: State Route 109, Noble County ....................................................................................11-5 New York: State Route 23a, Town of Jewett, Greene County ...................................................11-7 Utah: I-15 Reconstruction.........................................................................................................11-10 Washington: State Route 516 - Lake Meridian Settlement Repair, King County ....................11-13 Wisconsin: Bayfield County Trunk Highway A.......................................................................11-15 Wyoming: Moorcraft Bridge, Crook County............................................................................11-16 Wyoming: Bridge Rehabilitation, N.F. Shoshone River ..........................................................11-18 Other Cases and State DOT Experiences..................................................................................11-19 Summary ......................................................................................................................11-21 References ............................................................................................................................................ 11-22 Figures................................................................................................................................................... 11-24 Tables .................................................................................................................................................... 11-46 CHAPTER 12 ECONOMIC ANALYSIS Introduction.................................................................................................................................12-1 Background.................................................................................................................................12-3 Scope...........................................................................................................................................12-5 Research Approach .....................................................................................................................12-5 Soft Ground Treatment Alternatives...........................................................................................12-6 Summary of EPS-Block Geofoam Cost Data ...........................................................................12-13 Summary...................................................................................................................................12-19 References.................................................................................................................................12-20 Tables........................................................................................................................................12-22 CHAPTER 13 FUTURE RESEARCH AND DEVELOPMENT General........................................................................................................................................13-1 Material Properties......................................................................................................................13-1 Analytical Issues .........................................................................................................................13-2 Conceptual Issues .......................................................................................................................13-5 References...................................................................................................................................13-5 APPENDIX A GEOFOAM USAGE SURVEY: QUESTIONNAIRE
v A.1. Introduction..........................................................................................................................A-2 A.2. Copy of Survey ....................................................................................................................A-3 A.3. Summary of Results ...........................................................................................................A-10 Tables.........................................................................................................................................A-29 APPENDIX B PROVISIONAL DESIGN GUIDELINE B Message................................................................................................................................... B-1 APPENDIX C RECOMMENDED EPS-BLOCK GEOFORM STANDARD FOR LIGHTWEIGHT FILL IN ROAD EMBANKMENTS AND BRIDGE APPROACH FILLS ON SOFT GROUND C Message................................................................................................................................... C-1 APPENDIX D BIBLIOGRAPHY D.1 Introduction...........................................................................................................................D-2 D.2 General ..................................................................................................................................D-3 D.3 Material Properties and Constitutive Modeling ..................................................................D-12 D.4 Lightweight Fill Applications .............................................................................................D-17 D.5 Design Manuals...................................................................................................................D-46 D.6 U.S. Patents .........................................................................................................................D-48 APPENDIX E GLOSSARY OF TERMS E.1 Glossary................................................................................................................................. E-2 APPENDIX F CONVERSION FACTORS F.1 Introduction ........................................................................................................................... F-2 F.2 Conversion Factors from Inch-Pound Units (I-P Units) to the Le Système International dâUnités (SI Units)................................................................................................................. F-3 F.3 Conversion Factors from the Le Système International dâUnités (SI Units) to Inch-Pound Units (I-P Units)..................................................................................................................... F-5