Pier Foundations — SOP Additions for Review

Insert after project award confirmation / before mobilization planning. Responsible: Project Manager (PM).

Procedure

1. When the GC sends the subcontract for signature, read the entire document -- not just the scope and price sections.
2. Check insurance requirements against PF's current coverage:
   • General liability limits
   • Auto liability limits
   • Workers' compensation
   • Umbrella/excess liability (some projects require $5M umbrella -- see Section F)
   • Any specialty endorsements required
3. Verify payment terms match what was quoted in PF's proposal:
   • Pay-when-paid vs. pay-if-paid language
   • Invoice submission deadlines
   • Payment cycle (Net 30, Net 45, etc.)
4. Review retainage terms:
   • Retainage percentage (standard is 5-10%)
   • Release conditions (substantial completion vs. final completion)
   • Partial retainage release provisions
5. Flag any flow-down clauses for Brad's review:
   • Liquidated damages (LD) provisions
   • Indemnification and hold-harmless language
   • Warranty terms beyond PF standard (PF standard = 1 year workmanship)
   • No-damage-for-delay clauses
   • Dispute resolution provisions (arbitration vs. litigation, venue)
6. If all terms are standard -- PM may proceed with signature per existing authority.
7. If any unusual terms are present -- route to Brad for review before signing. Flag the specific clauses and explain the risk.

Insert after subcontract execution / before mobilization. Responsible: Field Operations Manager.

Procedure

1. Schedule a site visit with the GC superintendent before mobilizing any equipment to the project.
2. During the visit, confirm the following:

Access and Logistics

• Site access routes can handle heavy equipment (Cat 336 = 98,000 lbs gross weight)
• Identify any weight-restricted roads, bridges, or site paths
• Confirm gate locations and after-hours access if applicable

Pad Preparation

• Verify working pad has been prepared to specification
• Confirm proof roll has been completed and passed
• Check working grade elevation against design drawings
• Note any soft spots, standing water, or drainage issues

Staging Areas

• Identify stone stockpile location (must accommodate initial delivery + ongoing deliveries)
• Confirm equipment staging area
• Identify spoils stockpile or disposal location

Utilities

• Verify utility locates are current (call 811 if older than 14 days)
• Walk the work area and confirm no unmarked utilities
• Note overhead power lines and required clearances for mast operation

3. Document all site conditions with dated photos. Include:
   • Access roads and entry points
   • Working pad condition
   • Stockpile and staging areas
   • Any existing damage to roads, curbs, or adjacent work
   • Overhead obstructions
4. Save photos and visit notes to the project file.
5. If site conditions do not meet requirements, notify the GC superintendent in writing (email) and do not mobilize until conditions are corrected.

Insert after pre-mobilization site visit / before equipment loading. Responsible: Field Operations Manager.

Standard Mobilization Load

Check off each item before loading:

PF Equipment (Every Project)

• VSC Rig -- Deere 350G with mast and vibroflot assembly
• Predrill Rig -- Sany
• PF Parts Load -- gooseneck trailer with spare parts, hoses, fittings, hand tools
• Fall Off Load -- additional support equipment

Rental Equipment (As Required by Project)

• Track loader (CAT 289/299 or Deere 333)
• Mini excavator
• Telehandler
• Air compressor
• Other: _______________

Pre-Load Verification

Before loading any equipment:

1. Confirm all equipment is serviced per current maintenance schedule.
2. Verify fuel tanks are full.
3. Check fluid levels -- hydraulic oil, engine oil, coolant.
4. Inspect tracks, tires, and undercarriage for damage.
5. Verify fire extinguisher is present and current on each piece of equipment.
6. Confirm all rental equipment has been reserved and delivery is scheduled.

Transport Coordination

1. Confirm transport provider and schedule:
   • Paddacks (contact: Miah)
   • Stephan Trucking (contact: Mark Maller)
2. Verify permits for oversized loads if required.
3. Confirm delivery sequence -- rig arrives first, support equipment follows.

Insert after equipment checklist / before crew deployment. Responsible: Field Operations Manager.

Procedure

1. Assign crew members to the project based on scope, duration, and travel requirements.
2. Designate Crew Lead (Operator #1) for the project.
3. Before crew deploys, verify the following for each crew member:

Certifications

• OSHA 10-Hour card -- valid and on file
• OSHA 30-Hour card (if required by GC or project spec) -- valid and on file
• Equipment operator certifications -- current
• Site-specific certifications (if any -- confined space, fall protection, etc.)

Prevailing Wage Projects Only

• Crew has been briefed on certified payroll requirements
• Correct wage rates and classifications confirmed
• Crew understands daily reporting requirements for certified payroll

4. Brief the crew on project scope before departure:
   • Total column count and target depths
   • Column diameter (24" or 30")
   • Estimated production duration (LF / 1000 = working days)
   • Any unusual site conditions identified during pre-mob visit
   • GC contact and site rules
5. File certification copies in the project folder. Bring copies to the jobsite.

Insert after crew assignment / before first day of install. Responsible: Project Manager and/or Field Operations Manager.

Procedure

1. Schedule a pre-construction meeting with the GC before the first day of installation. This can be on-site or virtual, but must occur before work begins.
2. Meeting agenda -- cover the following items:

Scope and Schedule

• Review column layout, count, and target depths
• Confirm start date and anticipated duration
• Confirm daily working hours (start time, end time, overtime rules)
• Discuss schedule milestones or constraints

Points of Contact

• GC superintendent name, phone, email
• PF crew lead name, phone
• PF PM name, phone, email
• After-hours emergency contacts (both sides)

Stone Delivery Logistics

• Confirm stone delivery access route and staging area
• Discuss delivery timing (early morning preferred to avoid site congestion)
• Address any GC restrictions on delivery hours or truck traffic

Safety

• Review GC's site-specific safety requirements
• Provide PF's Job Safety Analysis (JSA) for VSC installation
• Discuss emergency procedures and muster points
• Confirm first aid and nearest hospital location

Administrative

• Confirm invoicing schedule and submission requirements (lien waivers, daily logs, etc.)
• Confirm GC's preferred method for daily reports
• Discuss change order process (see Section H)

3. Document meeting notes and distribute to all attendees within 24 hours.
4. Save meeting notes in the project file.

Insert after project award / before mobilization. Responsible: Project Manager.

Procedure

1. Upon project award, request a Certificate of Insurance (COI) from PF's insurance agent:
   • Name the GC as Additional Insured
   • Name any other required additional insureds per the subcontract (owner, lender, etc.)
   • Verify certificate reflects current policy limits
2. Before requesting the COI, check bid documents and subcontract for project-specific insurance requirements:
   • Standard commercial general liability limits
   • Auto liability limits
   • Workers' compensation
   • Umbrella/excess liability -- some projects require $5M or higher (flag for Brad if PF's current coverage does not meet the requirement)
   • Professional liability (rare for PF scope, but check)
   • Pollution liability (rare, but check)
3. Send the COI to the GC contact listed in the subcontract.
4. Send PF's W-9 to the GC with the COI (required for vendor setup and payment).
5. Track in the project file:
   • Date COI requested
   • Date COI sent to GC
   • Date W-9 sent to GC
   • Any special insurance requirements and whether they were met
6. If the GC requests revised or updated certificates during the project, respond within 48 hours.

Insert after pre-construction meeting / before first day of install. Responsible: Project Manager.

Procedure

1. Confirm stone supplier for this project location:
   • Select from approved suppliers based on proximity to site: Heidelberg, IMI, Martin Marietta, StoneCo/Shelly, Vulcan, Jergensen, Amirize, Rogers
   • Confirm pricing and haul rate for this project
   • Set up delivery account with supplier if new location
2. Verify stone specification:
   • Stone must be #57 washed, no fines
   • Regional equivalents: IN #8s, IL CA-7, MI 6-AA, WI 1" Clear
   • Obtain material certification or sample if new supplier
   • Get material approval from engineer (Dr. Ed Garbin, GGG) before first delivery
3. Calculate delivery schedule based on production rate:
   • Production rate: LF / 1000 = working days
   • Stone consumption: 0.209 tons per linear foot
   • Total stone required: total LF x 0.209 = total tons
   • Daily stone consumption: daily LF production x 0.209 = tons per day
   • Schedule deliveries to maintain minimum 1-day buffer on site
4. Schedule initial delivery:
   • First load must arrive before or at start of Day 1
   • Confirm delivery time with supplier and GC (coordinate with site access hours)
   • Verify stockpile location can accommodate initial delivery volume
5. Set up ongoing delivery coordination:
   • Provide supplier with estimated daily delivery volume
   • Establish reorder process -- crew lead calls supplier or PM coordinates
   • Confirm lead time for additional loads (same-day vs. next-day)
6. Track in the project file:
   • Supplier name and contact
   • Stone spec and approval status
   • Pricing (per ton delivered)
   • Delivery tickets (save all for invoicing and QA/QC)

Insert after all pre-construction sections / applies during field operations. Responsible: Field Ops Manager (identification), PM (pricing and submission).

When a scope change is identified in the field:

1. Stop work on the changed scope immediately.
   • Exception: work may continue only if stopping creates a safety hazard or causes damage to completed work.
   • Continue work on unchanged/original scope as normal.
2. Document the change at the time it is identified:
   • Take photos of the condition or issue
   • Record measurements, quantities, and affected column locations
   • Note the reason for the change (differing site conditions, design revision, GC-directed change, etc.)
   • Get the GC superintendent's verbal acknowledgment of the change if possible
3. Notify the PM within the same working day.
   • Field Ops Manager calls or messages PM with change description, photos, and measurements.
   • Do not wait until end of week or next visit.
4. PM prices the change within 24 hours:
   • Use original estimate rates as the basis for pricing
   • Include labor, equipment, material, and any additional mobilization costs
   • Include markup per PF standard or subcontract terms
5. PM submits the Change Order (CO) to the GC in writing within 48 hours of the change being identified:
   • Include description of changed conditions
   • Include supporting photos and measurements
   • Include pricing breakdown
   • Reference subcontract CO provisions
   • Request written approval before proceeding
6. Work does not proceed on the changed scope until the CO is approved by the GC, except in the safety/emergency situations noted in Step 1.
7. Track all pending COs in the project file:
   • CO number (sequential per project)
   • Date identified
   • Date submitted to GC
   • Amount
   • Status (pending / approved / rejected / negotiating)
   • Date approved (if applicable)
   • Date incorporated into subcontract (if applicable)

Purpose

Define the minimum acceptable installed depth for vibratory stone columns and establish the response procedure when a column does not reach design depth.

Procedure

1. Before starting installation on any project, confirm the design depth range from the Preliminary Design Summary. Typical range is 8-10 ft (2.5-3.0 m) depending on footing type and soil profile.
   • Example (POET project): Grain Bins = 10 ft depth; Beer Well / Fermentation Tanks = 8 ft depth.
2. During installation, the GUHMA system logs depth continuously in the Tiefe (depth) column. Monitor the maximum depth reached for each pier.
3. If a column falls short of design depth by more than 6 inches (0.15 m):
   • Stop -- do not backfill and move to the next column.
   • Flag the column in the GUHMA log. Record the pier number, actual depth reached, and design depth required.
   • Note the soil condition that caused the shortfall:
     • Refusal on dense layer (sudden pressure spike, no further penetration)
     • Obstruction (cobbles, buried debris, old foundation)
     • Unexpected stratigraphy (soil profile differs from boring data)
   • Notify Dr. Ed Garbin (GGG) for engineering evaluation before proceeding with adjacent columns in that area.
4. Do not assume a short column is acceptable. Short columns may need one or more of the following:
   • Reinstallation with modified technique (pre-drilling, different compaction energy)
   • Supplemental column(s) at closer spacing
   • Design revision by Dr. Ed
5. Document the resolution and who authorized it in the project file.

Reference Values

Purpose

Provide field personnel with guidelines for interpreting GUHMA pressure readings during installation to identify abnormal conditions in real time.

Normal Operating Ranges

Abnormal Conditions and Response

High Pressure Spike (P-Vibro above 230 bar)

• Possible cause: Hitting a dense layer, cobble, or obstruction.
• Action: Note the depth at spike. If the probe cannot advance further, this may be the refusal depth. Compare to design depth -- if short, follow Addition 1 (Short Column procedure).

Sustained Low Pressure (P-Vibro below 60 bar during penetration)

• Possible cause: Very soft or loose soil with minimal resistance.
• Action: Monitor depth carefully. The probe may over-penetrate past design depth. Soft zones may also indicate the column will require additional stone and compaction cycles to achieve adequate density.

Tilt Exceeding +/- 5 Degrees (X-Axis or Y-Axis)

• Possible cause: Probe deviating from vertical due to obstruction, sloped dense layer, or unstable working platform.
• Action: Stop penetration. Withdraw probe. Evaluate whether the column location needs pre-drilling or whether the working pad needs re-grading. A column installed at excessive tilt may not provide the designed load capacity.

P5/P6 Diverging from P-Vibro

• Normal: P5 tracks P-Vibro + 2-4 bar; P6 equals P-Vibro.
• Abnormal: If P5 or P6 diverge significantly from P-Vibro, this may indicate a hydraulic system issue. Notify equipment maintenance.

Quick Reference Card (Post in Cab)

GUHMA PRESSURE QUICK CHECK
---------------------------
P-Vibro 80-220 bar = NORMAL
P-Vibro > 230 bar  = DENSE LAYER / OBSTRUCTION -- check depth
P-Vibro < 60 bar   = SOFT SOIL -- watch for over-penetration
Tilt > 5 degrees   = STOP -- withdraw and evaluate

Purpose

Establish a daily tracking method to verify that actual stone consumption matches engineering expectations, identifying potential quality issues early.

Expected Consumption Rate

These rates assume stone density of 85 pcf and account for the area replacement ratio and compaction.

Daily Tracking Procedure

1. At the start of each day, record the cumulative linear feet installed to date (from GUHMA pier count x average depth).
2. At the end of each day, record:
   • Total linear feet installed that day
   • Total tons of stone delivered that day (from delivery tickets)
   • Running cumulative totals for the project
3. Calculate actual consumption rate:

Actual Rate = Tons Delivered Today / Linear Feet Installed Today

4. Compare actual rate to expected rate (0.209 tons/LF for 30-inch columns).
5. If actual consumption deviates more than 15% from expected, investigate:

6. Maintain a running stone tracking log:

Project-Level Verification

At project completion, total stone delivered should approximately equal:

Expected Total Stone = Total LF Installed x 0.209 tons/LF

Example (POET): 17,272 LF x 0.209 = 3,610 tons (design estimate: 3,650 tons).

Purpose

Ensure all QA/QC data is verified complete and accurate before the crew demobilizes from a project site.

Procedure

1. Before scheduling demobilization, the Field Ops Manager or PM must confirm ALL of the following:
   • Every column in the design layout has a corresponding GUHMA data file.
   • GUHMA pier count matches the as-built column count.
   • All installed depths meet or exceed design depth (no unresolved short columns).
   • All modulus tests are complete and results recorded.
   • Any anomalies (short columns, pressure spikes, tilt warnings) are documented and have an engineering disposition from Dr. Ed.
2. Compare GUHMA pier numbering to the as-built layout drawing. Check for:
   • Missing pier numbers (gaps in the sequence that are not accounted for in the layout)
   • Duplicate pier numbers
   • Piers installed but not in the design (added columns, supplemental columns)
3. Perform spot checks. Select at least 10 random GUHMA files and verify:
   • Max depth matches design depth for that footing area
   • Installation shows proper compaction cycles (typically 4-8 cycles visible in depth trace)
   • No unexplained anomalies in pressure or tilt data
4. If any discrepancy is found:
   • Do NOT demobilize until resolved.
   • Contact Dr. Ed with the specific discrepancy.
   • Document the resolution.
5. Sign off. The person performing the QC check initials and dates the QC completion checklist before equipment leaves the site.

Why This Matters

Returning to a site after demobilization to fix a missed column or re-test costs:

• Mobilization/demob charges
• Crew travel and per diem
• Equipment transport
• Project delay to the GC
• Reputation damage

Thirty minutes of verification on site prevents days of rework.

Purpose

Define the immediate response when a column does not meet depth or pressure requirements during installation.

Procedure

1. Identify the failure. A column is considered failed if:
   • It does not reach design depth (short by more than 6 inches) with no engineering disposition
   • Pressure data indicates inadequate compaction (sustained low pressure, insufficient cycles)
   • Tilt exceeds +/- 5 degrees for the majority of the installation
   • Modulus test on or near the column fails (see Modulus Testing SOP)
2. Do NOT continue to the next column without documenting the issue. Specifically:
   • Record the pier number, actual depth, target depth, and observed condition in the GUHMA log.
   • Take a photo of the column location if relevant (obstruction visible, soft ground, etc.).
3. Immediately notify:
   • Field Ops Manager (phone call, not just text)
   • Project Manager
   • Both must acknowledge the notification.
4. Engineering evaluation. The PM contacts Dr. Ed Garbin with:
   • Pier number and location on the layout
   • GUHMA data file for the failed column
   • Description of the observed condition
   • Soil boring data for the nearest boring to the failed column location
5. Dr. Ed makes the engineering call. Options include:

6. Document the decision.
   • Record which option was selected
   • Record who authorized it (Dr. Ed's name, date, and communication method)
   • File the documentation in the project QA/QC package
   • Update the as-built drawing to reflect any changes
7. Resume installation only after the disposition is documented.

Purpose

Define the complete set of documents required for project closeout, assembled before sending data to GGG (Garbin GeoStructural Group) for final review and certification.

Required Documents

Assemble the following into a single closeout package, organized in this order:

1. GUHMA Column Installation Report
   • PDF export of all pier data from the rig logging system
   • Must include every pier installed on the project
   • Organized by pier number in sequential order
   • For reference: GUHMA files are .guh format (INI-style header + semicolon-delimited time-series data). Export or convert to PDF for the submittal package.
2. Modulus Test Results
   • Completed Modulus Test Submittal Sheet for every test performed on the project
   • Typical requirement: per Prelim Design Summary (e.g., POET required 3 tests -- 2 for grain bins, 1 for fermentation area)
   • Each sheet must show measured Kp, design Kp, and PASS/FAIL determination
   • Include load-deflection data tables (loading and unloading phases)
3. As-Built Column Layout Drawing
   • Survey layout with actual installed column locations
   • Annotate each column with actual installed depth (from GUHMA data)
   • Flag any columns that deviated from design (short columns, supplemental columns, relocated columns)
   • Include column numbering that matches GUHMA pier numbers
4. Stone Delivery Tickets
   • All delivery tickets for stone brought to the project
   • Summarize total tonnage delivered
   • Cross-reference against expected consumption (Total LF x 0.209 tons/LF for 30-inch columns)
5. Daily Installation Logs
   • Field crew daily reports noting: date, weather conditions, columns installed (pier number range), any equipment issues, any soil conditions encountered that differed from the geotech report
6. Change Order Documentation
   • Any change orders that affected column layout, count, depth, or spacing
   • Include the engineering basis for the change (Dr. Ed's direction)
7. Warranty Letter (if applicable per contract)

Submission

• Send the complete package to Dr. Ed Garbin at GGG (Ed@GarbinGeo.com) for review.
• Dr. Ed reviews all installation data, QC data, and test results per the engineering services scope.
• Upon acceptance, Dr. Ed issues the stamped as-built/certification submittal.
• All submittals are electronic per GGG standard practice.

Checklist

Use this checklist before sending to GGG:

• GUHMA report -- all piers accounted for
• Modulus test sheets -- all tests complete and passing
• As-built drawing -- depths annotated, anomalies flagged
• Stone tickets -- tonnage reconciled
• Daily logs -- complete for all installation days
• Change orders -- all included with engineering authorization
• Warranty letter -- included if required

Purpose

Document the step-by-step field procedure for performing a modulus (plate load) test on an installed vibratory stone column.

Equipment Required

• Hydraulic jack (see Addition 4 for jack selection)
• Calibrated pressure gauge
• Bearing plate -- same diameter as the pier being tested (2.5 ft diameter for 30-inch piers)
• Reaction frame -- must be rated for 1.5x the design load (minimum)
• Two dial gages (0.001-inch resolution minimum)
• Two independent reference beams (minimum 8 ft long -- see Addition 4)
• Modulus Test Submittal Sheet (blank)
• Pen and clipboard

Setup

1. Verify the test column has been installed and is ready for testing. The column top should be trimmed level and clean.
2. Center the bearing plate on the test pier. The plate diameter must match the pier diameter (2.5 ft for 30-inch piers).
3. Position the hydraulic jack on the bearing plate, centered.
4. Attach the calibrated pressure gauge to the jack. Confirm the calibration is current (annual requirement).
5. Set up the reaction frame over the test pier. The frame must be anchored or weighted to resist the full test load without movement.
6. Install two dial gages on independent reference beams, positioned 180 degrees apart on the bearing plate. Reference beams must be independently supported -- they cannot touch the reaction frame, the jack, or the test pier.

Loading Procedure

7. Apply alignment load (AL): 5% of design load. Record dial gage readings. This is the zero reference point for deflection measurements.
8. Load in increments. At each increment, hold for a minimum of 2 minutes, then record both dial gage readings on the submittal sheet:

9. At 100% design load (Increment 5): this is the critical reading. The deflection at this increment determines the measured modulus. Hold for a full 2 minutes. Read both gages carefully.
10. At 150% design load (Increment 7): this is the maximum test load. Hold for 2 minutes. Record readings.

Unloading Procedure

11. Unload in the same increments, holding 2 minutes at each step and recording readings:

12. Record the final dial gage readings at full unload (Increment 14). The difference between the alignment load reading and the full unload reading is the residual deflection -- the permanent settlement of the pier under test loading.
13. Complete all fields on the Modulus Test Submittal Sheet before leaving the test location.

Purpose

Define the calculations and acceptance criteria for determining whether a modulus test passes or fails.

Calculations

Step 1: Determine plate deflection at 100% design load.

From the submittal sheet, the plate deflection at Increment 5 (100% design load) is the average deflection of both dial gages from the zero reference (alignment load).

Plate Deflection = average of (Gage 1 change + Gage 2 change) from AL to Increment 5

Step 2: Calculate applied stress at 100% design load.

Applied Stress (psi) = [Design Load (lbs)] / [Bearing Area (sq in)]

Bearing Area (sq in) = pi / 4 x (Plate Diameter in inches)^2

For a 2.5 ft (30-inch) plate:

Bearing Area = pi / 4 x 30^2 = 706.86 sq in

Step 3: Calculate measured reaction modulus.

Kp (measured) = Applied Stress at 100% design load (psi) / Plate Deflection at 100% design load (inches)

Result is in units of pci (pounds per cubic inch).

Step 4: Compare to design requirement.

PASS if Kp (measured) >= Kp (design)
FAIL if Kp (measured) < Kp (design)

Kp (design) is specified in the Preliminary Design Summary. Typical value for Pier Foundations projects: 150 pci.

Example (POET Project -- Pier Tp01)

Recording

Record the following on the submittal sheet:

• Measured Kp value
• Design Kp value
• PASS or FAIL
• Initials of the person performing the test

Purpose

Define how to select which columns are tested and how many tests are required per project.

Number of Tests

The number of modulus tests is specified in the Preliminary Design Summary prepared by Dr. Ed Garbin. Typical requirements:

Example (POET): 1,837 columns, 3 tests required -- 2 in the grain bin area, 1 in the fermentation tank area.

Selection Criteria

1. Test in worst-case soil areas. The Preliminary Design Summary identifies relevant borings for each structural area and notes which borings represent worst-case conditions. Select test columns near the worst-case boring locations.
   • Example (POET Grain Bins): Worst-case boring is B-213. Test column should be in the vicinity of B-213, not near best-case boring B-202.
2. Do not cherry-pick. Do not select test columns that appear to have installed especially well (deep penetration, high pressures). The purpose of the test is to verify that the design works in the most challenging conditions on the site.
3. Get approval. Test column locations must be approved by Dr. Ed before testing. Send the proposed test column pier numbers and their locations relative to the soil borings.
4. Spread tests across structural areas. If the project has multiple foundation areas with different design parameters (different bearing capacities, different depths), test in each distinct area as specified in the design.
5. Allow curing time. Confirm with Dr. Ed whether a waiting period is required between column installation and modulus testing. Some soil conditions benefit from allowing pore water pressures to dissipate before testing.

Purpose

Detail the hydraulic jack selection, calibration verification, and reference beam setup for modulus testing.

Jack Selection

How to determine which jack:

Max Test Load = 1.5 x Design Load

If Max Test Load < 175 kips --> Small jack (cal factor 49.84)
If Max Test Load >= 175 kips --> Large jack (cal factor 32.88)

Example (POET): Design load = 86 kips. Max test load = 129 kips. 129 < 175, so use the small jack with calibration factor 49.84 psi/kip.

Calibration Verification

• Jacks require annual calibration by an accredited laboratory.
• Before each test, check the calibration sticker on the jack. Confirm the calibration date is within the past 12 months.
• If calibration has expired, do NOT perform the test. Send the jack for recalibration first.
• Record the calibration date and calibration factor on the Modulus Test Submittal Sheet.

Gage Pressure Calculation

During the test, calculate the required gage pressure for each load increment:

Gage Pressure (psi) = Calibration Factor (psi/kip) x Load (kips)

Pre-calculate all gage pressures before starting the test and write them on the submittal sheet. This prevents arithmetic errors in the field.

Reference Beam Setup

• Use two reference beams, one for each dial gage.
• Minimum beam length: 8 feet, extending beyond the zone of influence of the test pier and reaction frame.
• Beams must be independently supported on stakes or stands driven into undisturbed ground.
• Beams must NOT touch:
  • The reaction frame
  • The hydraulic jack
  • The bearing plate
  • The test pier
  • Any part of the loading system
• If a beam is bumped or disturbed during the test, the test may need to be restarted. Protect the beams with flagging tape or barriers.

Dial Gage Placement

• Mount dial gages on the reference beams with magnetic bases or clamps.
• Position the gage contact points on the bearing plate, 180 degrees apart (opposite sides).
• Zero the gages or record the initial readings before applying the alignment load.
• Confirm both gages are reading (move the plate slightly and verify both gages respond).

Purpose

Define the post-test review, reporting, and documentation process for modulus test results.

On-Site Review (Immediately After Test)

1. Calculate the measured modulus on-site before packing up equipment. Use the formula:

Kp (measured) = Applied Stress at 100% load / Deflection at 100% load

2. Determine PASS or FAIL immediately. If PASS, the team knows the installation is meeting design requirements in that area. If FAIL, the response procedure (Addition 6) begins immediately -- do not wait until you are back at the office.
3. Review the load-deflection curve visually. The unloading curve should show significant elastic recovery (deflection decreasing as load decreases). If the pier shows very little recovery (nearly all permanent settlement), this may indicate a poorly compacted column even if the modulus technically passes.

Documentation Package (Per Test)

Assemble the following for each modulus test:

• Completed Modulus Test Submittal Sheet with all load increments, gage readings, and calculated modulus
• PASS/FAIL determination with measured Kp and design Kp
• Photo of the test setup (showing reaction frame, jack, gages, bearing plate on pier)
• Photo of the dial gages at 100% design load (if readable)
• Photo of the completed submittal sheet
• Jack calibration certificate (copy)

Submittal to Dr. Ed

• Include all modulus test packages in the project closeout package (see GUHMA SOP Addition 6).
• Dr. Ed reviews test data as part of the closeout engineering services.
• If all tests PASS, Dr. Ed includes the test results in the stamped certification submittal.

Multiple Tests on a Project

• All tests must pass. One failure does not get averaged with passing tests.
• If one test fails and others pass, the failure area requires investigation regardless of how well other areas performed.
• Track all test results in a summary table:

Purpose

Define the immediate response procedure when a modulus test does not meet the design requirement.

Identification

A modulus test fails when:

Kp (measured) < Kp (design)

Immediate Actions

1. STOP. Do not proceed with additional modulus tests until the failure is evaluated. A second failure without understanding the first wastes time and may indicate a systemic issue.
2. Notify immediately (phone call, not email):
   • Jonathan (PM / Estimating)
   • Dr. Ed Garbin (GGG) -- Ed@GarbinGeo.com / (844) 4-GEODOC
   • Field Ops Manager
3. Preserve the test setup if possible. Do not disassemble the reaction frame until Dr. Ed has reviewed the data and confirmed whether a retest at the same location is needed.

Failure Evaluation

Dr. Ed and the PF team evaluate the following:

Resolution Options

Dr. Ed makes the engineering decision. Options include:

1. Retest on a different column in the same area
   • Used when: Equipment issue suspected, or test column may have been anomalous
   • Select a column near the same worst-case boring
   • Must still pass -- two failures in the same area is a design/installation concern
2. Reinstall the failed column with additional compaction and retest
   • Used when: GUHMA data shows the original installation was inadequate
   • Re-drive the column with more compaction cycles and/or higher energy
   • Retest on the reinstalled column
3. Modify the design
   • Used when: Soil conditions are worse than assumed in the preliminary design
   • Options: additional columns at closer spacing, increased column diameter, deeper columns
   • Dr. Ed revises the design and issues updated shop drawings
4. Install supplemental test columns
   • Used when: The area needs additional verification after remediation
   • Additional columns installed near the failed area
   • New modulus tests performed on supplemental columns

Documentation

Document the entire failure and resolution in the project file:

• Failed test submittal sheet (complete with measured Kp showing failure)
• Narrative description of the failure and observed conditions
• GUHMA data for the failed test column
• Communication log with Dr. Ed (dates, decisions, authorization)
• Resolution implemented (which option, who authorized, date)
• Retest results (if applicable) -- must show PASS
• Updated as-built drawing if column layout changed

Gap Identified

The SOP ends when closeouts go to the GC. It does not address what happens to PF's own records. On a company with hundreds of projects over time, finding column data from a job done 18 months ago becomes a real problem without consistent file organization.

Recommended Addition

Before sending closeouts to GC, archive all project documents to a standard folder structure: [Project Name] - [GC] - [Year]/ containing subfolders for GUHMA Data, As-Builts, Modulus Test, GGG Closeout (stamped), Correspondence, and Invoicing. Use consistent file naming: [ProjectName]_AsBuilt_FINAL.pdf, [ProjectName]_ModulusTest_FINAL.pdf, etc. This archive becomes the reference if warranty claims, disputes, or future work on the same site come up.

Gap Identified

The SOP says GGG "will take a week or two" but does not define when PF should follow up if documents are late. Retainage dollars sit idle while closeouts are pending -- on a project with 5-10% retainage, that could be $15K-$50K+ waiting on paperwork.

Recommended Addition

Set a follow-up cadence -- if GGG closeout docs are not received within 10 business days, send a follow-up email. If not received within 15 business days, escalate with a phone call. Track closeout status in the project log with dates: Documents Sent to GGG, GGG Closeout Received, Corrections Sent (if any), Final Closeout Approved, Sent to GC, Retainage Invoice Sent. This turns closeout from a "whenever it happens" process into a managed timeline.

Gap Identified

The SOP covers the engineering closeout but does not mention lien waivers, which most GCs require before releasing retainage. Missing this step means the invoice goes out but payment gets held up waiting for a conditional or unconditional waiver.

Recommended Addition

Before or concurrent with sending the final invoice, prepare the appropriate lien waiver (conditional for retainage billing, unconditional for previously paid amounts). Confirm which waiver form the GC requires -- some use AIA G706A, others have their own. Include the lien waiver with the final invoice and closeout package. Track waiver status alongside payment status.

Gap Identified

The SOP starts after installation is complete but does not cover the physical transition off the jobsite. Equipment left on site, unreturned materials, or incomplete site restoration can create GC complaints that delay closeout payment.

Recommended Addition

Before starting the paperwork closeout, confirm demobilization is complete: all PF equipment removed from site, excess stone either hauled off or accounted for (credit back to stone supplier or used on next job), site restored per contract requirements (spoils removed, area graded), GC sign-off on site condition obtained. Any backcharges for site cleanup come directly out of project margin.

Gap Identified

Every project teaches something -- a soil condition that surprised the crew, a GC that was difficult to work with, a stone supplier that delivered late. Without capturing these, PF loses institutional knowledge every time.

Recommended Addition

Within one week of project completion, the PM or foreman should document: actual vs. estimated production rates (LF/day), any column issues encountered (obstructions, groundwater, short columns), GC relationship notes (easy to work with, slow on payments, good for future bids), stone supplier performance, and any change orders or scope adjustments. Keep this in a standard template and file it with the project archive. This data feeds directly into better estimating on future bids.

Gap Identified

Step 5 says to send "the closeout document and column logs" to the GC, but GCs often require additional items beyond the engineering closeout. If PF sends an incomplete package, it triggers back-and-forth that delays retainage.

Recommended Addition

Standard GC closeout package should include: (1) GGG stamped closeout letter, (2) as-built column layout with actual depths, (3) GUHMA column installation report (PDF), (4) modulus test results, (5) stone delivery tickets (proof of material), (6) daily installation logs, (7) any change order documentation, (8) warranty letter if applicable per contract. Check the subcontract for any project-specific closeout requirements before submitting. Some GCs also require O&M manuals or material certifications.

Gap Identified

The SOP mentions sending the final invoice with retainage but does not address reconciling what has been billed vs. what is owed. On projects with change orders, the total contract value may have shifted from the original subcontract amount.

Recommended Addition

Before preparing the final invoice, reconcile: original contract value + approved change orders = revised contract value. Subtract all previous payments received. The remainder (including retainage) is the final invoice amount. Use G702/G703 format. Confirm the GC's records match PF's records on total billed and total paid -- discrepancies are much easier to resolve before the final invoice than after. Attach a summary of all pay applications and change orders to the final invoice for the GC's reference.

Gap Identified

The SOP does not address what happens after closeout if the GC reports a problem -- a settled column, a failed load test on a future addition, or questions about the original design. Without a defined process, these requests get handled ad hoc.

Recommended Addition

Define PF's standard warranty period (typically per subcontract terms, often 1-2 years). For any warranty claims or callback requests: document the claim in writing, notify Dr. Ed at GGG for engineering review before any field response, do not admit fault or agree to remediation without engineering guidance. Keep warranty claim records in the project archive. After warranty period expires, note it in the project file.