REPORT ON

EXPERIMENTAL NOISE BARRIER WALL US-59 SOUTHWEST FREEWAY

RICE AVENUE TO CHIMNEY ROCK ROAD LARCHMONT SUBDIVISION

by

John B. Stokes, Jr., P.E. Supervising Designing Engineer

Construction Project Manager Lonnie B. Beckham, P.E.

Supervising Resident Engineer

Photographs by Mark G. Anthony

Engineering Specialist

and

E. B. L., Inc. General Contractor

FEBRUARY 1991

NOISE BARRIER WALL US 59 SOUTHWEST FREEWAY

RICE AVENUE TO CHIMNEY ROCK ROAD LARCHMONT SUBDIVISION

The Southwest Freeway, US 59 South, is located in the southwestern part of the

City of Houston, Texas. This freeway was constructed in the early to middle

sixties and consisted of four lanes inside IH 610 West Loop and three lanes

outside of the West Loop.

With the construction of the Southwest Freeway, residential and commercial

development accelerated in the southwestern portion of Houston and Harris County

and in the eastern portion of adjoining Fort Bend County. With this development

came increased traffic volumes and before long the freeway was operating at

capacity. As the years passed, traffic demands became so great that the outside

shoulders were converted into traffic lanes. Because of age and very high

traffic volumes, the Southwest Freeway pavement began deteriorating and in the

late seventies, the Texas State Department of Highways and Public Transportation

{SDHPT) began planning for reconstructing the Southwest Freeway to add greater

capacity and provide for mass transit.

The State legislature charged SDHPT with responsibility of coordinating with

local public transportation agencies in order to enhance public transportation.

The Harris County Metropolitan Transit Authority {Metro) is the local public

transportation agency for Houston and Harris Count~. Therefore, SDHPT and Metro

cooperated together in planning for, designing, and reconstructing the Southwest

Freeway. The reconstructed freeway provides for four to seven lanes with a mass

transit one way reversible lane in the median outside of IH 610 West Loop and

provides for five and six lanes with a mass transit lane inside West Loop.

1

Planning and environmental studies were begun in August 1977 and completed and

approved in October 1985. As a result of environmental studies, noise walls

were considered for residential neighborhood noise mitigation and public

meetings were held within each affected neighborhood to explain the purpose for

and expected benefits from noise walls. The property owners adjacent to the

right of way were then asked to choose whether or not they wanted a noise wall

constructed along the right of way line, between their property and the freeway,

in order to reduce noise impact on their homes. Several residential

neighborhoods along the Southwest Freeway corridor chose to have noise walls

constructed. The residential neighborhood known as Larchmont is one of the

areas that requested a noise wall be constructed.

As part of the cooperative agreement between SDHPT and Metro, Metro and SDHPT

chose a consulting engineering firm, 3D/Post, to prepare designs and plans for a

portion of US 59 Southwest Freeway which included the Larchmont area. The

Larchmont Noise Wall was included in the project, therefore, 3d/Post prepared

designs, plans, and details for the noise wall and included these in the freeway

project reconstruction plans. After the plans were submitted to SDHPT, there

was a long delay because of difficulties in obtaining all right of way required

for the project. However, the right of way in the Larchmont subdivision was

acquired earlier than the rest of the project right of way; therefore, the noise

wall portion of the plans was removed from the freeway project and made into an

independent project. The decision was made by SDHPT's Houston District Office

to permit commercial alternate noise barrier wall designs to be bid and

constructed in lieu of the consultant's design. This decision required the

consultant's plans to be revised by SDHPT. During the process of revising the

plans, close coordination with the Federal Highway Administration (FHWA) was

2

maintained. As a result of coordination with the FHWA the noise barrier wall

details prepared by SDHPT were included in the plans along with details prepared

by "the fanwall corporation." Although "fanwall' s" details were added to the

plans, provisions were included to permit other commercial noise wall designs if

those designs were acceptable to the project engineer.

The successful contractor, EBL, Inc., chose a commercial alternate design from

First Technology, Inc., with structural design done by Macon Engineering, Inc.

Shop drawings and calculations were submitted to SDHPT for review and approval.

Because this was the Houston District's first commercial alternate noise wall

project, close coordination with FHWA was maintained during the shop drawing

review and approval process and also during project construction.

The wall system is a stacked panel, trapezoidal pattern attached to a spread

footing by means of one half inch, epoxy coated, post-tensioned cables which are

cast into the footing and anchored at the top of the wall. The wall is

continuous with a total length of 2620 feet and consists of 940 feet of 20 foot

high wall and 1680 feet of 22 foot high wall. Surface finish is exposed

aggregate on both sides. The wall is designed to withstand a 40 pound per

square foot wind loading and has a 1.5 factor of safety against overturning.

The spread footing consisted of two sizes; one was four feet, six and one half

inches wide by six and five eighths inches thick and the other is nine feet wide

by two feet thick. Blackouts for the pest-tensioned cable anchorage were cast

into the footings and were later filled with concrete after the bottom panels

were placed and plumbed. Photo numbers 1, 2, and 3 show foundation forms,

poured footing, and post-tensioned cable blackouts respectively. Bearing

capacity calculations, which a geotechnical consultant performed on soil data

3

FORMS FOR SPREAD FOOTING

2

SPREAD FOOTING FOR NOISE WALL

...

3

BLOCKOUT IN SPREAD FOOTING FOR

PRESTRESSING STRAND ANCHORAGE

5

provided by SDHPT, indicated that soil bearing capacity was at least 3300 pounds

per square foot (psf) at each end of the project. No data were provided for the

internal part of the project (see Appendix for Lone Star Geotechnical Services

calculations). The minimum allowable soil bearing capacity required was 2500

psf.

The wall panels were cast off site in two and four foot heights, transported to

the construction site and erected. During the casting process, the fabricator

used vertical forms, and encountered several problems with this casting method.

First, hand finishing was required for the top edge of the panel, and any high

spots on the edge prevented the panels from seating properly when they were

erected. Second, forming tolerances were critical because of the protruding

trapezoidal wings (see shop drawings in Appendix A). If the form or wing headers

were not plumb, or if the top and bottom of the panel were not parallel, the

panels would not fit properly with adjacent panels when erected. The prime

contractor did experience problems with wall erection because casting tolerances

were not rigidly maintained. To solve those problems, the contractor used shims

and grout to plumb the walls, and silicone seal was used to seal the horizontal

and vertical joints.

The contractor threaded the epoxy coated cable through holes in each panel and

after all the panels were in place, he placed a calibrated jack and gauge on top

of the wall and applied the post tension required by the plans. Photo No. 4

shows an epoxy coated cable projecting through the end of a wall panel. Photo

No. 5 shows a partially erected wall, and Photo No. 6 shows a completed wall

section prior to post-tensioning operations.

4

PRESTRESSING STRAND PROJECTING

THROUGH END (BULL NOSE) OF WALL PANEL

5

NOISE WALL SHOWING PARTIAL WALL ERECTION 7

6

NOISE WALL BEFORE POST - TENSIONING

8

Photo Numbers 4 and 5 show six inches wide by three inches high drainage slots

through the wall. These slots were added in addition to the drainage system

which the design consultant had provided. Designers and planners had no data

relating to the effects these openings would have on noise mitigation;

therefore, noise readings were obtained in order to evaluate the amount of noise

that would pass through the openings. There is an insignificant difference in

the noise levels behind panels with the openings when compared with panels which

had the openings plugged. Refer to February 13, 1990, memorandum from Mr.

William E. Neyland, P.E. to Mr. Donald R. Garrison, P.E. which is contained in

the Appendix. As construction on the project progressed, several residents

became concerned about drainage in one section where a street was blocked by the

wall. After re-evaluating the situation the Department concurred with those

concerns and provided eight large openings beneath the wall. Each opening is

five feet wide by one foot eight inches high. Noise readings were obtained at

those openings and the noisemeter readings indicate that the large openings

conduct insignificant amounts of noise. Refer to Appendix to Mr. Neyland's

October 9, 1990, memorandum to Mr. Garrison.

This project is the Houston District's first experience with commercial

alternate noise wall designs and was therefore a new experience for designers

and for the resident engineer's personnel. Because of this new experience and

the lessons which have been learned, following are several items which designers

should consider when commercial alternate noise walls are permitted by the

project plans.

1. Design specifications that are to be used for commercial alternates should

be clearly set out in the plans.

9

2. Design wind loading and exposure type should be shown in the plans. (See

AASHTO Guide Specifications for Structural Design of Sound Barriers}

3. Include notes in the plans which require commercial alternates to meet plan

alignments, color, and texture or state what exceptions to these

requirements will be permitted.

4. Require contractor to submit design calculations and detailed shop drawings

for approval prior to fabrication.

5. Designer must provide soil data or he must tell contractor to obtain soil

data needed for any commercial alternate foundation design.

6. Drainage must be provided through, under, or around the wall.

7. Utilities must be considered, and adjusted if necessary.

B. If foundation types (e.g. drilled shaft, spread footing, piling, etc.} are

restricted, state which type is acceptable.

9. If form liners are to be used, determine if seams where liner sections are

joined together are acceptable, or state if a one-piece (without seams} form

liner is required.

10. Require reproducible tracing of approved commercial alternate shop drawings

for inclusion in final plans.

11. If wall must be designed to withstand a vehicle impact, state those

requirements in the plans.

10

APPENDICES

APPENDICES A - F

APPENDIX A

A-1 Vicinity map showing project location

APPENDIX B

B-1 Lone Star Geotechnical Services letter to Macon Engineering, Inc.

APPENDIX C

C-1 3D/Post Noise wall details C-5 Fanwall Noise wall details C-6 SDHPT Noise wall details C-7 Approved shop drawings for

commercial alternate noise wall

APPENDIX D

D-1 Memoranda from William E. Neyland, P.E. to Dcnald R. Garrison, P.E.

APPENDIX E

E-1 E.B.L., Inc. letter to Mr. Lonnie B. Beckham, P.E.

APPENDIX F

F-1 Work Plan for evaluating experimental wall

APPENDIX A

PROJECT LOCATION

N

HOUSTON

VICINITY MAP A- I

APPENDIX 8

LO,.E STAR GEOTECHNICAL SL.M.VICES

P.O. BOX 820125 • HOUSTON, TEXAS 77282-Q125

(713) 666-6030

July 26, 1989

Macon Engineering, Inc. 15422 El Padre Houston, Texas 77083

Attn: Mr. James D. Maberry, P.E.

Re: Sound Barrier Wall T.S.D.H.P.T. Project No. F 514(90)

Dear James:

In compliance with your request, the writer has studied the documents presented to determine the frictional shear resistance of the soil for the project referred to above.

Four (4) logs of borings furnished by the Texas State Department of Highways & Public Transportation (TSDPHT) were examined for soil characteristics in the surface or surficial stratum to use for determining the friction resistance or shear strength of the soil to overcome the wind loads on the sound barrier wall. Logs of borings 101 & 102 were labeled CHIMNEY ROCK OVERPASS - HIGHWAY U. S. 59, and dated 3/23/59 and 3/24/59, respectively. Logs of borings 103 & 104 were labeled RICE AVENUE OVERPASS - HIGHWAY U. S. 59 and dated 7/13/59 and 8/14/59, respectively. The following is a summary of information used from the logs.

LOG I DESCRIPTION ELEYATION.Ft, COHESION .P. S, I, FRICTION AUGLB. • 101 Hed. Stiff 68.0

Dark Gray Silty Clay 3 8

102 Stiff Dk. 69.0 Gray Silty Clay 8 9

103 Stiff Dk. 68.0 Gray Silty Clay 5 19

104 Med. Stiff Lt. Gray Tan Silty Clay 4 10

LSGS: 7036 MAPLERIDGE • HOUSTON, TEXAS 77081 B -I

--2- --- ----

To determine the soil resistance to the wind load, the cohesion and angle of internal friction have to be taken into account as the founding soil is a "mixed" soil and not a pure silt or a pure clay.

Coulomb's Law is applicable in this situation. It is expressed as follows:

s • c + p(tan ~~ * in which s = unit shear strength

c • unit cohesion p = normal stress on surface of sliding ~ = angle of internal friction

Using the lowest values provided (Log of Boring 101), the soil resistance is calculated as follows:

a • area of footing= 4.54'X56.56' • 257 S.F. c • 432 PSF (3 P.S.I.) p • 933241!Wall Wt.l + 192591!Footing Wt.l• 438.1 PSF

257 s.F.!Area of Footing) ~ • 8'

tan~ • .140541 s • 432 + 438.1(0.140541) • 493.57 PSF r • resistance • s X a • 493.57 PSF X 257 SF • 126,847 I

W.L. • Wind Load = 26 PSF X 22'X48.28'• 27,616 I ** S.F. • safety factor = r f W.L. • 126,847 f 27,616 • 4.6

A value of 0.4 for the coefficient of friction for concrete on concrete appears to be a very reasonable value. The value for concrete masonry units is 0.5 to 0.7, as noted on p. 147, para­graph preceeding equation (H.5), Structural Masonry by Sven Sahlin, 1971, Prentis-Hall, Inc.

* Coulomb's Law, equation (6-8), P. 194, Basic Soil Engineering by B. K. Hough, 2nd Edition, 1969, The Ronald Press.

** James D. Maberry, P.E. 113842 notes dated July 1, 1989 on Sound Barrier Wall, 10' Offset, S.D.H.P.T. Project F 514!90).

1.!:::::==========;;::::::== lONE STAR GEOTECHNICAL SERVICES ============:!J B-2

-3-

The bearing capacity of the soil is determined from the general bearing capacity equation derived by Dr. Karl Terzaghi, taking into account local shear in loose soil. This equation using bearing capacity factors has been modified by several soil engineers. Heyerhof, Bell, Peck, Hanson, & Thornburg to name a few. We are inclined to use the curves derived by W.A Taylor as shown on page 337, Figure 9-12, Basic Soils Engineering, B. K. Hough, 1969.

where

The equation is as follows:

q(ultl z cNc + q'Nq + o.5«BN~

q(ultl = bearing capacity, psf c = cohesion, psf

Nc • cohesion factor q' c surcharge (density X depth), psf Nq = surcharge factor

oc = wet unit weight, pcf B • width of footing, feet

Noc • solid friction factor

From Log of Boring 101: Dry Unit Weight • 107 pcf Moisture Content = 20.0

So, «, Wet Unit Weight • 128.4 pcf From Curves: Nc • 7

Nq • 2 Noc = 1

Since depth of footing is 1 foot, q' .. 128.4 psf Width of footing, B • 4.54 feet

Cohesion, c c 432 psf

q(ultl • 432(7)•(128.4x1)(2)+0.5(128.4)(1) q(ultl • 3345 psf Load capacity • q(ultl x Area

= 3345 psf x 257 sf .. 859665 lbs.

Safety Factor = Load capacity f Load (Dead Load Only) • 859665 f 112583 • 7.6

For overturning moments, use 150 pcf for the unit weight of the concrete and 3345 psf passive resistance for the soil.

It has been a pleasure serving you on this project, if we may be of further service on this or other projects, please call.

_#incerel , ·' ( .,r a.. "'-:-r::?'L~L • .... ___ ..., '--J v - /?'

James L. Hickey, P.E. V Senior Engineer

JLH/ohr

L!============= lONE STAR GEOTECHNICAL SERVICES =============.1 B-3

APPENDIX C

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APPENDIX D

M E M 0 R A N D U M

TO: Mr. Donald R. Garrison, P.E.

William E. Neyland, P.E. L0'>.'L

Date: February 13, 1990

FROM:

SUBJECT: Jnvesti gati on of Effect of Noise through Drainage Holes in Existing Noise Barrier US 59: SW Freeway@ Chimney Rock,

At Larchmont Subdivision CSJ 0027-13-149

Originating Office DDE-SD

On February 9, 1990, the above investigation was made. Drainage holes in one bay of the fan wall were closed by means of stuffing them with rags and placing wooden boards behind them. Drainage holes in the adjacent bay were left open. Noisemeters were placed on wooden blocks in the locations shown in the enclosed sketch. The portion of the barrier chosen was located far enough from Chimney Rock and Barrington to preclude cross street noise as a factor in the investi­gation. The following readings were observed:

READING READ lNG TIME METER f/2525 METER #2537

4:00-4:15 PM 55.7 dB A 56.0 dBA

4:15-4:30 PM 57.6 dBA 56.8 dB A

4:30-4:45 PM 56.7 dBA 57.3 dB A

4:45-5:00 PM 59.2 dBA 58.8 dBA

5:00-5:15 PM 57.9dBA 58.3 dBA

5:15-5:30 PM 56.6 dBA 57.3 dBA

5:30-5:45 PM 57.4 dBA 57.7 dBA

5:45-6:00 PM 56.6 dBA 57.9 dBA ----------------------------------------------------------AVERAGE 57.2 dBA 57.5 dBA

Based on the above, the conclusion is made that the open drainage holes conduct insignificant noise.

WEN :jcl Attachment

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M E M 0 R A N D U M

TO: Mr. Donald R. Garrison, P.E.

FROM: William E. Neyland, P.E. lO~

SUBJECT: Investigation of Effect of Noise through Drainage Apertures in Existing Noise Barrier US 59: SW Freeway at Larchmont Subdivision

(Near Chimney Rock) CSJ 0027-13-149

Date: October 9, 1990

Originating Office District 12

DDE-SD

On Monday, October 8, 1990, the above investigation was made. Noisemeters were placed on tripods (meter about 5' above ground) at the locations shown in the sketch. The follwing readings were observed:

READING (Leq) READING (Leq) TIME METER # 2525 METER # 2542

9:00 - 9:15 AM 59.1 dB A 58.7 dBA 9:15 - 9:30 59.0 57.6 9:30 - 9:45 59.0 57.2 9:45 - 10:00 58.6 57.8

10:00 - 10: 15 58.4 57.3 10:15 - 10:30 58.9 57.6 10:30 - 10:45 58.3 57.4 10:45 - 11: DO 57.9 57.2

AVERAGE 58.7 dB A 57.6 dBA

Based on the above, the conclusion is made that the drainage apertures conduct insignificant noise.

D-3

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ORA IN AGE API::RilJRE 5 IN SOTTOM 01= WA.\.L

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SECTION OF DRMNAGE APERTURE LARC.HMONT 5UBOIVI SION NOISI: BP.~RIER

ST~EL ROOS

C.ON(RI:l£ ~LOC.K

APPENDIX E

.r~c:::-

General Contractor 9702 Synott Road

Houston, Texas 77083 (713) 495-0842

9/21/90

State Department Of Highways And Public Transportation P.O. Box 1386 Houston, Texas 77251-1386

Attention: Mr. Lonnie B. Beckham P.E.

Reference:

Gentlemen;

Contract No. Project Name County

0027-13-149 MA-F 514(90) us 59 Harris

Per the request of Mr. John Stokes and yourself, below you will find the report on the precasting and erection of our alternate design on the above referenced project.

The Sound Attenuating Barrier Fence was built with a trapezoidal pattern that used both a ten foot and three and one half foot offset. The wall was post-tensioned to a cast-in-place footing with one half inch epoxy coated strand. The panels were cast by Brookshire Concrete Products (BCP) in four and two foot heights. The panels had a 14.14 foot flat side and two wings projecting 7.07 feet or 2.47 feet depending on the offset.The panels were cast in the vertical position. BCP used a form release agent, a concrete kill and water blasting to achieve the exposed aggregate finish. The appearance of the panels was acceptable and improved with experience and when Mr. Beckham modified the mix design of the concrete.

We encountered several problems with the vertical casting of the panels. First since the top edge had to be finished by hand any high spot kept the next panels from seating properly. Secondly, the forming tolerances were very important because of the two protruding wings. If the form was not plumb, if the wing header was not plumb, or if the bottom and top of the panel were not parallel the panels would not properly line-up with the adjacent panels. At times BCP found it difficult to keep all the tolerances perfect and this resulted in some erection problems. The erection problems were solved with a joint seal, shims or grouting the horizontal joints. In the vertical joints we used a silicone sealer to match-up Lhe ball and socket. Knowing what we know now , I doubt BCP or ourselves would cast the panels vertically with the two wings.

E.B.L., INC.

The footing was poured with block-outs in the strand locations. We provided the block-outs to ensure the proper location of the post tension strand. The block-outs were filled in after the first couple panels were set. This proved to be helpful as the wall grew as it was set.

The setting of the panels was slower than anticipated due to trying to get the panels both horizontal and vertical, while at the same time trying to get the ball and socket to look acceptable.

The threading of the epoxy coated strand and the tensioning went extremely smooth. Using a calibrated jack and gauge we were assured of a positive connection with the proper tension.

In conclusion, in spite of the initial design problems, a new precaster and other challenges inherent in a new product, we are confident that the State Department of Highways and Public Transportation and the public received an structurally sound and an aesthetically pleasing Sound Attenuating Barrier Fence.

We would like to take this opportunity to make a few comments on Commercial Alternate Designs. The building of the first commercial alternate sound wall has been a learning experience for us. Since bidding and building the sound wall many more jobs have been let, with suppliers proposing many new sound wall systems. These systems are approved "in concept only" and it is our actual experience that the details of a system are often incomplete even with approved designs. It is these incomplete details that leave field personnel (both SDH&PT and Contractor) without proper information to finish the project. We would recommend that the SDH&PT would pre-approve the sound wall systems with complete details so the contractor and the SDH&PT knows what is expected of the finished product.

If additional information is required please contact us.

Sincerely,

David E. Boehm E.B.L., Inc.

Vice President.

CC: Mr. John Stokes P.E.

E- 2

APPENDIX F

PROJECT: CONTROL: HIGHWAY: COUNTY:

MA-F514(90) 0027-13-149 us 59

Harris

WORK PLAN

EXPERIMENTAL FEATURE

Experimental Feature: Trapezoidal (zig-zag) noise wall installed on spread footing.

Construction Report: A report will be transmitted at completion of construction detailing the construction procedure and identifying any specific problems.

Annual Report: A report will be transmitted annually for three years after construction is completed detailing wall and foundation conditions. The report will include information on wall deviation from the vertical condition, exterior finish condition, and foundation cracking and settlement.

Mr. John Stokes, P.E. in Central Design "A'' will coordinate with the Resident Engineer, Mr. Lonnie Beckham, P.E., in preparing the post construction report. Mr. Stokes will also prepare the annual follow-up reports.

F-1