There are certain concepts that seem so obvious that you often don’t realize how recently they were first formulated. PDCA or “Plan, Do, Check, Act” is one of those concepts. First proposed by Edwards Deming in the 1950’s, it describes the continuous cycle of planning your work, then executing that plan, followed by checking whether everything is proceeding in accordance with the plan, and finally taking corrective actions to improve the execution. This concept applies to any business, including pile driving, and pile driving simulation is the perfect tool to implement this. In this article the advantages of these simulations will be highlighted, hopefully leading to a more widespread use of this technique prior to actually driving the piles, because unfortunately there are still too many instances where pile driving simulation is viewed as a tool only suitable to analyze problems after the fact.
Pile driving simulation programs have been around since 1960, but the application didn’t become widespread until after the introduction of PCs. From then on engineers could perform driveability studies from behind their desks, which allowed them not only to predict whether the pile could be driven to a certain depth with a particular hammer, but also to optimize the pile driving process (by selecting the most appropriate hammer/pile combination). Obviously, the accuracy of these studies is directly (and predominantly) dependent on the accuracy of the soil investigation data and the soil models available in the simulation programs used to process these data. While a more elaborate model may make the data entry more cumbersome, the use of a very basic soil model may not accurately predict the outcome (as some engineers have experienced the hard way). But with good soil data and a detailed soil model these simulations can provide the user with realistic assessment of any pile driving project.
Such a piledriving simulation should therefore always be used to plan the actual work (the “P” in PDCA), eliminating the practice of basing a pile driving set-up on intuition, which is generally justified by pointing out that based on experience the chances that something will go wrong are minimal and that therefore there is no reason to incur the additional cost associated with a simulation. It is true that with local experience a workable set-up can be established for most cases, but the problem with this approach is that the set-up may not be optimal and therefore more costly. But a simulation can also be seen as an insurance policy to virtually eliminate the chances that a pile cannot be driven to the required depth. And the premium for that insurance (i.e. the cost of performing a simulation) is very reasonable given the potential expenditures associated with resolving a problem situation.
The next step in the cycle is “D”: doing the work. Let's assume that a contractor begins work on site without having access to the simulation data. In many respects this is similar to going on a trip without a map: you know your starting point and your destination, but you have no idea what to expect in between. Just as a map is a good idea for a trip, having access to a graph showing the expected blow count (in case of impact hammers) or penetration speed (in case of vibro hammers) as a function of the depth is a good idea when driving piles, because only then will you be able to determine whether the work is progressing according to plan, which brings us to the next step in the cycle.
This next step is “C”: checking the actual progress against the planned progress. As long as everything is basically going according to plan, the simulation is of limited value at the job site. It is when things are not going as planned when the simulation becomes an essential tool. As an example, the design engineer may have assumed that a pipe pile will plug as it is driven to the target depth, but actual pile driving results may indicate that this is not the case (as the pile is driven into the ground more easily than predicted), which would obviously affect the bearing capacity of the pile. It is essential that issues like these are identified before the pile foundation is finalized to allow for corrective action(s) if necessary. But without a pile driving simulation these issues cannot be identified, which means that not only the “C” step in the cycle is eliminated, but also the final “A” step.
After the differences between the predicted results and the actual results have been identified, it is important that these differences are carefully reviewed to determine their actual cause and whether any corrective action is appropriate (the “A” step). Too often this is when a simulation is done for the first time: only when it was impossible to drive the piles to the target depth the process was simulated to determine the actual cause of the problem. But when used to analyze the differences between the predicted and the actual results, pile driving simulation programs can provide valuable insight regarding the site conditions, especially when several alternatives are simulated (e.g. in case of a pipe pile with and without a plug). This enhanced insight can then be used to assess whether corrective actions are appropriate.
In conclusion, simulating pile driving is a valuable tool to determine in advance whether the pile driving can be done successfully and whether it can be done more economically. It also provides a clear road map to avoid any surprises during project execution (you will know how long it will take to drive a pile), and finally it may provide some insight in case the actual progress is not as predicted. Hopefully these reasons are enough to convince everybody involved with pile driving that driving piles without simulation (using a program like Profound’s PDPWAVE) and without the results readily available on the job site is simply not a good business practice.