This thesis investigates the force transfer mechanisms between concrete substructures and steel pipe piles, specifically focusing on connections made using a concrete plug within the steel pipe pile. This thesis explores the mechanisms of force transfer in concrete plug connections within open-ended steel pipe piles, focusing on the viability of frictional (bond) transfer versus mechanical connections. The primary research objective was to determine the extent to which forces—both normal forces and bending moments—can be transferred through a concrete plug without the use of mechanical connections and to compare this with scenarios where mechanical connections, such as shear rings, are employed.

A comprehensive literature review revealed significant gaps in existing design codes and recommendations, which inadequately address concrete plug connections in steel pipe piles. Notably, regulations such as Rijkswaterstaat’s ROK V2.0 restrict the extent of force transfer through friction without clear justification. Existing standards like Eurocode 4 and the British Standard (BSI) offer bond strength values that vary widely and do not consider key parameters such as connection geometry and concrete shrinkage, potentially leading to inaccurate strength estimations. Although some models for grouted sleeve
connections might be applicable, their validation for concrete plug connections remains uncertain.

To address these gaps, a new analytical model was proposed to estimate the bond strength between
concrete and steel in plugged connections. The model incorporates factors including connection geometry, material properties, concrete shrinkage, surface irregularities, and the Coulomb friction coefficient. Push-out test results were used to update and validate the model, resulting in conservative bond strength values. Key parameters identified were the value for the surface and the Coulomb friction coefficient. The model’s predictions showed a Mean Average Error (MAE) of 0.589 MPa, primarily due to high variability in some test sets. However, the error was smaller for less variable data.

The findings indicate that connection geometry, particularly the diameter of the steel pipe pile, significantly affects bond strength. Smaller diameters exhibit higher bond strength due to better confinement and reduced concrete shrinkage effects. For larger diameter piles, where friction is insufficient to transfer normal forces, mechanical connections such as shear rings are recommended. These connections were evaluated using Eurocode 4 and CUR Recommendation 77 and found to provide substantially higher normal force resistance, enabling effective utilization of the geotechnical load-bearing capacity.

Regarding the transfer of bending moments, the study found that the wrenching mechanism between the concrete plug and steel pipe pile can manage the transfer through contact stresses. This stress distribution is linear along the plug height and sinusoidal around its circumference, provided it remains within allowable concrete compressive stress limits. The plug’s length should be designed to ensure these stresses do not exceed permissible values. A model for the interaction between bending moment and normal force was also developed, indicating that additional normal force resistance can be achieved under a certain bending moment, though this requires careful stress distribution verification.

In conclusion, while friction can achieve normal force transfer in concrete plug connections, it is often insufficient for larger piles. Mechanical connections such as shear rings offer a more effective solution, providing significantly higher normal force resistance and enabling efficient design. The wrenching mechanism can be used to transfer bending moments, but the ultimate bending moment resistance is governed by the concrete plug’s cross-sectional resistance. This is because the resistance of the concrete plug’s cross-section is lower than the wrenching resistance. This research provides a comprehensive framework for understanding and optimizing force transfer mechanisms in concrete plug connections within steel pipe piles, highlighting the importance of mechanical connections for effective and practical design.