U.S. Department of Transportation Publication No.

FHWA NHI-05-039
Federal Highway Administration December 2005

NHI Course No. 132078_______________________________

Micropile Design and Construction
Reference Manual
NEW BRIDGE STRUCTURE
EXISTING
FOOTING & PILES

NEW MICROPILES
EXISTING BRIDGE
BRIDGE ABUTMENT PIER W/PILE
SUPPORTED
A FOOTING

NEW FOOTING
EXTENSION
SECTION A – A

EXISTING DRIVEN
NEW MICROPILE PIPE PILES (TYP)
FOUNDATION SUPPORT
(TYP) NEW MICROPILES

FOUNDATION SUPPORT SEISMIC RETROFIT OF BRIDGES

SURCHARGE
ORIGINAL CONCRETE CAP
GRADE

CONCRETE CAP
ROAD SURFACE CASE 2 RETICULATED
FINISHED GRADE MICROPILE WALL
WALL FACING

SLIDE PLANE

FINAL GRADE
CASE 1
NON RETICULATED
MICROPILE STRUCTURE

SLOPE STABILIZATION EARTH RETENTION

National Highway Institute

 TABLE OF CONTENTS
CHAPTER 1 INTRODUCTION
1.1 PURPOSE AND SCOPE OF MANUAL........................................................................ 1 – 1
1.2 MICROPILE DEFINITION AND DESCRIPTION ....................................................... 1 – 4
1.3 HISTORICAL BACKGROUND .................................................................................... 1 – 5
1.4 REFERENCES ................................................................................................................ 1 – 8

CHAPTER 2 MICROPILE CLASSIFICATION SYSTEM

2.1 INTRODUCTION .......................................................................................................... 2 – 1
2.2 DESIGN APPLICATION CLASSIFICATION ............................................................. 2 – 1
2.3 CONSTRUCTION TYPE CLASSIFICATION.............................................................. 2 – 6
2.4 REFERENCES ................................................................................................................ 2 – 8

CHAPTER 3 MICROPILE APPLICATIONS IN TRANSPORTATION PROJECTS

3.1 INTRODUCTION........................................................................................................... 3 – 1
3.2 FEASIBILITY OF MICROPILES.................................................................................. 3 – 1
3.2.1 Overview............................................................................................................ 3 – 1
3.2.2 Physical Considerations ..................................................................................... 3 – 3
3.2.3 Subsurface Conditions ....................................................................................... 3 – 4
3.2.4 Environmental Conditions ................................................................................. 3 – 4
3.2.5 Existing Structure Adaptation............................................................................ 3 – 6
3.2.6 Micropile Limitations ........................................................................................ 3 – 6
3.2.7 Economics of Micropiles ................................................................................... 3 – 6
3.3 STRUCTURAL SUPPORT ............................................................................................ 3 – 7
3.3.1 Overview............................................................................................................ 3 – 7
3.3.2 New Foundations ............................................................................................... 3 – 7
3.3.3 Underpinning of Existing Foundations.............................................................. 3 – 9
3.3.4 Seismic Retrofit ............................................................................................... 3 – 12
3.4 IN-SITU REINFORCEMENT ...................................................................................... 3 – 14
3.5 REFERENCES .............................................................................................................. 3 – 20

CHAPTER 4 CONSTRUCTION TECHNIQUES AND MATERIALS

4.1 INTRODUCTION........................................................................................................... 4 – 1
4.2 DRILLING ...................................................................................................................... 4 – 1
4.2.1 Overview............................................................................................................ 4 – 1
4.2.2 Drill Rigs............................................................................................................ 4 – 3
4.2.3 Drilling Techniques ........................................................................................... 4 – 6
4.2.4 Overburden Drilling Techniques ....................................................................... 4 – 9
4.2.5 Open-Hole Drilling Techniques....................................................................... 4 – 13
4.3 GROUTING .................................................................................................................. 4 – 14
4.3.1 General............................................................................................................. 4 – 14
4.3.2 Grout Equipment ............................................................................................. 4 – 16
4.3.3 Grout Mixing ................................................................................................... 4 – 19
4.3.4 Grout Placement Techniques ........................................................................... 4 – 19

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Micropile Design & Construction i - iii December 2005
 4.3.4.1 Gravity Fill Techniques (Type A Micropiles)................................. 4 – 19
4.3.4.2 Pressure Grouting Through the Casing (Type B Micropiles) ......... 4 – 20
4.3.4.3 Postgrouting (Type C and D Micropiles) ........................................ 4 – 21
4.3.5 Top-Off (Secondary) Grouting ........................................................................ 4 – 26
4.4 REINFORCING STEEL ............................................................................................... 4 – 26
4.4.1 General............................................................................................................. 4 – 26
4.4.2 Placement of Reinforcement............................................................................ 4 – 26
4.4.3 Reinforcement Types ....................................................................................... 4 – 26
4.5 REFERENCES .............................................................................................................. 4 – 35

CHAPTER 5 DESIGN OF MICROPILES FOR STRUCTURE FOUNDATIONS

5.1 INTRODUCTION........................................................................................................... 5 – 1
5.2 STEP 1: EVALUATE FEASIBILITY OF MICROPILES ............................................ 5 – 3
5.3 STEP 2: REVIEW AVAILABLE INFORMATION & GEOTECHNICAL DATA ..... 5 – 5
5.4 STEP 3: DEVELOP APPLICABLE LOADING COMBINATIONS ........................... 5 – 7
5.5 STEP 4: PRELIMINARY DESIGN OF MICROPILES................................................ 5 – 8
5.5.1 Selection of Micropile Spacing.......................................................................... 5 – 8
5.5.2 Selection of Micropile Length ........................................................................... 5 – 8
5.5.3 Selection of Micropile Cross Section ................................................................ 5 – 9
5.5.4 Selection of Micropile Type ............................................................................ 5 – 10
5.6 STEP 5: STRUCTURAL DESIGN OF MICROPILE CASED LENGTH .................. 5 – 10
5.7 STEP 6: STRUCTURAL DESIGN OF MICROPILE UNCASED LENGTH ............ 5 – 17
5.8 STEP 7: REVISE MICROPILE DESIGN ................................................................... 5 – 18
5.9 STEP 8: EVALUATE GEOTECHNICAL CAPACITY OF MICROPILE................. 5 – 18
5.9.1 Establish Stratum for Bond Zone..................................................................... 5 – 18
5.9.2 Select Ultimate Bond Stress and Calculate Bond Length................................ 5 – 19
5.9.3 Evaluate Micropile Group Compression Capacity .......................................... 5 – 22
5.9.4 Evaluate Micropile Group Uplift Capacity...................................................... 5 – 27
5.10 STEP 9. ESTIMATE MICROPILE GROUP SETTLEMENT .................................. 5 – 29
5.10.1 General........................................................................................................... 5 – 29
5.10.2 Micropile Group Settlement .......................................................................... 5 – 29
5.10.3 Micropile Elastic Movement.......................................................................... 5 – 36
5.11 STEP 10. DESIGN MICROPILE CONNECTION AT PILE CAP........................... 5 – 38
5.12 STEP 11. DEVELOP LOAD TESTING PROGRAM ............................................... 5 – 44
5.13 STEP 12. PREPARE DRAWINGS AND SPECIFICATIONS ................................. 5 – 45
5.14 CORROSION PROTECTION .................................................................................... 5 – 45
5.14.1 Background .................................................................................................... 5 – 45
5.14.2 Evaluation of Soil Corrosion Potential .......................................................... 5 – 46
5.14.3 Corrosion Protection Systems........................................................................ 5 – 46
5.14.3.1 Methods for Corrosion Protection of Reinforcing Steel ............... 5 – 46
5.14.3.2 Methods for Corrosion Protection of Steel Casing ....................... 5 – 48
5.14.3.3 Corrosion Protection Requirements for Micropiles ...................... 5 – 50
5.15 PLUNGE LENGTH..................................................................................................... 5 – 51
5.16 END BEARING MICROPILE .................................................................................... 5 – 52
5.17 DOWNDRAG.............................................................................................................. 5 – 53
5.18 DESIGN OF MICROPILES FOR LATERAL LOADING ........................................ 5 – 54
5.18.1 General........................................................................................................... 5 – 54

FHWA NHI-05-039
Micropile Design & Construction i-iv December 2005
future U.S. projects appears to be quite limited. Also, the use of CASE 2 micropiles,
especially for public sector projects, will likely be disallowed until such time that an
appropriate database of performance data becomes available for these micropiles to allow for
a technically sound and safe design procedure to be developed.

2.3 CONSTRUCTION TYPE CLASSIFICATION

The method of grouting is typically the most sensitive construction process influencing
grout/ground bond capacity. Grout/ground bond capacity varies directly with the grouting
method. The second part of the micropile classification consists of a letter designation (A
through D) based primarily on the method of placement and pressure under which grouting is
performed during construction. The use of drill casing and reinforcement define sub-
classifications. The classification is shown schematically in Figure 2-5 and is described
subsequently.

• Type A: For Type A micropiles, grout is placed under gravity head only.
Sand-cement mortars or neat cement grouts can be used. The micropile
excavation may be underreamed to increase tensile capacity, although this
technique is not common or used with any other micropile type.

• Type B: Type B indicates that neat cement grout is placed into the hole under
pressure as the temporary drill casing is withdrawn. Injection pressures
typically range from 0.5 to 1 MPa (72 to 145 psi) to avoid hydrofracturing the
surrounding ground or causing excessive grout takes, and to maintain a seal
around the casing during its withdrawal, where possible.

• Type C: Type C indicates a two-step process of grouting including: (1) neat

cement grout is placed under gravity head as with Type A; and (2) prior to
hardening of the primary grout (after approximately 15 to 25 minutes), similar
grout is injected one time via a sleeved grout pipe without the use of a packer
(at the bond zone interface) at a pressure of at least 1 MPa (145 psi). This pile
type appears to be used only in France, and is referred to as IGU (Injection
Globale et Unitaire).

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Micropile Design & Construction 2-6 December 2005
 TYPE A TYPE B TYPE C TYPE D
(GRAVITY) (PRESSURE THROUGH (SINGLE GLOBAL (MULTIPLE REPEAT ABLE
CASING) POSTGROUT) POSTGROUT)

PRESSURE GAGE

PACKER

Figure 2-5. Micropile Classification System Based on Type of Grouting.

• Type D: Type D indicates a two-step process of grouting similar to Type C.

With this method, neat cement grout is placed under gravity head (as with
Types A and C) and may be pressurized (as for Type B). After hardening of
the initially placed grout, additional grout is injected via a sleeved grout pipe
at a pressure of 2 to 8 MPa (290 to 1,160 psi). A packer may be used inside
the sleeved pipe so that specific horizons can be treated several times, if
required. This pile type is used commonly worldwide, and is referred to in
France as the IRS (Injection Répétitive et Sélective).

FHWA NHI-05-039 Chapter 2 – Micropile Classification System

Micropile Design & Construction 2-7 December 2005
Table 2-1 provides additional information on Type A, B, C, and D micropiles. Sub-
classifications (e.g., A1, A2, and A3) are included in Table 2-1 to indicate the type of drill
casing and reinforcement used for each method of grouting. These sub-classifications also
represent the type of reinforcement required by design (e.g. reinforcing bar, casing, none).
Therefore, the combined micropile classification system is based on design application (i.e.,
Case 1 or Case 2), micropile type (i.e., Type A, B, C, or D) and grouting method (i.e., 1, 2, or
3). It is emphasized that Table 2-1 is intended to present a classification system based on the
type of micropile construction. It is not intended to be used in contract specifications.

2.4 REFERENCES

FHWA (1997), “Drilled and Grouted Micropiles, State-of-Practice Review”, Bruce, D. A.

and Juran, I., Reports No. FHWA-RD-96-016, 017, 018, and 019.

Pearlman, S. L., and Wolosick, J. R. (1992), “Pin Piles for Bridge Foundations,”
Proceedings, 9th Annual International Bridge Conference, Pittsburgh, Pennsylvania,
June 15-17.

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Micropile Design & Construction 2-8 December 2005
 Table 2-1. Details of Micropile Classification Based on Type of Grouting
(after Pearlman and Wolosick, 1992).

Micropile Type and Sub-

Drill Casing Reinforcement Grout
Grouting Method type

Temporary or None, single bar, cage, tube or Sand/cement mortar or neat

A1 unlined (open hole structural section cement grout tremied to base of
or auger) hole (or casing), no excess
pressure applied
Type A
Permanent, full Drill casing itself
A2
length
Gravity grout only

Permanent, upper Drill casing in upper shaft,

A3 shaft only bar(s) or tube in lower shaft
(may extend full length)

Temporary or Monobar(s) or tube (cages Neat cement grout is first

B1 unlined (open hole rare due to lower structural tremied into drill casing/auger.
Type B or auger) capacity) Excess pressure (up to 1 MPa
(145 psi) typically) is applied to
Pressure - grouted Permanent, partial Drill casing itself additional grout injected during
B2
through the casing or length withdrawal of casing/auger
auger during
withdrawal Permanent, upper Drill casing in upper shaft,
B3 shaft only bar(s) or tube in lower shaft
(may extend full length)

Temporary or Single bars or tube (cages rare Neat cement grout is first
Type C
C1 unlined (open hole due to lower structural tremied into hole (or
or auger) capacity) casing/auger). Between 15 to
Primary grout placed
25 minutes later, similar grout
under gravity head,
C2 Not conducted – injected through tube (or
then one phase of
reinforcing pipe) from head,
secondary “global”
Not conducted – once pressure is greater than 1
pressure grouting C3
MPa (145 psi)

Type D D1
Primary grout placed
under gravity head
(Type A) or under
D2
pressure (Type B).
Then one or more
phases of secondary
“global” pressure
grouting D3
Temporary or Single bars or tube (cages rare Neat cement grout is first
unlined (open hole due to lower structural tremied (Type A) and/or
or auger) capacity) pressurized (Type B) into hole
or casing/auger. Several hours
Possible only if Drill casing itself later, similar grout injected
regrout tube placed through sleeved pipe (or
full-length outside sleeved reinforcement) via
casing packers, as many times as
necessary to achieve bond
Permanent, upper Drill casing in upper shaft,
shaft only bar(s) or tube in lower shaft
(may extend full length)

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Micropile Design & Construction 2-9 December 2005