Field Performance of a Pile-Cap Ground Improvement System for High-Speed Railway Embankments in Karst Terrain

High-speed railway embankments constructed over karst-prone ground conditions are often challenged by weak soils and subsurface cavities, which can lead to instability and excessive settlement. This study presents a full-scale field investigation conducted in the El-Gharbaniyat area, west of Alexandria, Egypt, where a pile–cap ground improvement system was implemented to support a high-speed railway embankment founded on clayey and silty soils overlying fractured limestone. A comprehensive site investigation program was performed, including 28 boreholes and integrated geophysical surveys using Electrical Resistivity Tomography (ERT) and Seismic Tomography (ST), enabling improved identification of weak zones and cavity-prone formations. Based on these findings, a pile–cap system was designed using reinforced concrete piles of 0.60 m diameter and an average length of 29 m, arranged in a 4 × 4 m grid and capped with reinforced concrete footings to ensure efficient load transfer to deeper competent strata. The system performance was validated through laboratory testing and full-scale in situ pile load tests. The average 28-day compressive strength of 122 tested piles reached approximately 50 MPa, exceeding the design value by approximately 30%. Load test results showed settlements ranging from 1.08 to 2.76 mm at the working load (2200 kN) and 2.16 to 5.10 mm at the maximum load (3300 kN), all well below allowable limits. Comparative evaluation indicated that the proposed system achieves significant material savings (>90%), lower treatment cost (150 USD/m2), reduced carbon emission (5.7 t per pile), and shorter construction duration (7 h per pile). These findings confirm that the pile–cap system provides a robust, cost-effective, and environmentally efficient solution for ground improvement in karst environments.