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Employer

Employer’s Contract No. Engineer

LBT/CONT/2017/03
TOKYO ELECTRIC POWER SERVICES CO., LTD.

EPC Contractor

LEKIR BULK TERMINAL EXPANSION PROJECT


PACKAGE 1 – DEDICATED BYPASS CONVEYOR
SYSTEM (“LEXPRO P1”)

Revision history
Rev. Revision Date Created by Checked by Approved by Description

A 9.10.18 CHONG LEE GAN FOR APPROVAL


As per comment TEPS-C/0071-
B 13.11.18 CHONG LEE GAN 00

Scale Other Document Code (if any)


TC1000-01
Responsible dept. Created by Checked by Approved by Format
QA-QC CHONG LEE GAN A4
Document Type Project Document Code
METHOD OF STATEMENT LEX/P1/C/EAC----F01/MS/008
Title, Subtitle Document Status
METHOD STATEMENT FOR APPROVAL
FOR Identification number
THE INSTALLATION AND PRELIMINARY TC1000-DOC-MS-01-08
LOAD TEST FOR 300MM Ø MICROPILE Rev. Date Lang. Sheet
B 13.11.2018 En 1/36
Project Document Code
METHOD STATEMENT FOR THE LEX/P1/C/EAC----F01/MS/008
Identification number
INSTALLATION AND PRELIMINARY
LOAD TEST FOR 300MM Ø MICROPILE TC1000-DOC-MS-01-08
REV. B P a g e | 2 of 36

Table of Contents

1. INTRODUCTION ........................................................................................................................................ 4
2. SCOPE OF WORK .................................................................................................................................... 5
2.1. GENERAL DESCRIPTION .......................................................................................................................... 5
2.2. REFERENCE .............................................................................................................................................. 5
3. MATERIAL, PLANT AND EQUIPMENT ................................................................................................ 6
3.1. MATERIAL ................................................................................................................................................. 6
3.2. PLANT AND EQUIPMENT .......................................................................................................................... 6
4. MANPOWER .............................................................................................................................................. 7
5. METHOD STATEMENT FOR MICROPILING ...................................................................................... 8
5.1. PRE-CONSTRUCTION ............................................................................................................................... 8
5.2. SETTING OUT ............................................................................................................................................ 8
5.3. DRILLING WORKS ..................................................................................................................................... 9
5.4. PREPARATION OF REINFORCEMENT (177.8MM Ø API PIPES) WITH MIN. STRENGTH OF 550N/MM2 10
5.5. PLACING OF GROUTING/ GROUT MIX ................................................................................................... 11
5.6. REMOVAL OF TEMPORARY M.S CASING .............................................................................................. 13
5.7. CONSTRUCTION PILE HEAD .................................................................................................................. 15
5.8. SPOIL REMOVAL .................................................................................................................................... 15
5.9. RECORDS................................................................................................................................................ 15
6. QUALITY ASSURANCE & QUALITY CONTROL ............................................................................. 16
7. PICTURES ILLUSTRATION OF MICROPILE INSTALLATION ...................................................... 17
8. TEST PILE & PRELIMINARY LOAD TEST ........................................................................................ 18
8.1. METHOD OF TESTING ............................................................................................................................. 18
8.2. LOADING SEQUENCE ............................................................................................................................. 18
8.3. LOAD TEST REPORT .............................................................................................................................. 19
8.4. INTERPRETATION.................................................................................................................................... 21
9. HIRARC ..................................................................................................................................................... 22
10. APPENDICES ...................................................................................................................................... 23
Appendix 1 : Micro Piling Layout Plan………………………………………………………….24

Appendix 2 : Micropile Detail Drawing…………………..….……………………………….....25

Appendix 3 : Micropile Construction Work Flow Chart….………………………………….26

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Project Document Code
METHOD STATEMENT FOR THE LEX/P1/C/EAC----F01/MS/008
Identification number
INSTALLATION AND PRELIMINARY
LOAD TEST FOR 300MM Ø MICROPILE TC1000-DOC-MS-01-08
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Appendix 4 : Micropile Record Form…………………….….………………………………….27

Appendix 5 : Micropile Check List………………………..….………………………………….28

Appendix 6 : Welder Qualification Test Record………..….………………………………….29

Appendix 7 : Drilling Fluid Additive – Polymer MSDS.….…………………….…………….30

Appendix 8 : BS 8004:1986 Pile Foundations…………..….…………………………………31

Appendix 9 : Micropile Specification...........................….……………………..……………..32

Appendix 10 : Pile Testing Specification ……...……..….………………………….………...33

Appendix 11 : Design Calculation of Steel Capping..….………………………….………...34

Appendix 12 : Kentledge Drawing and Calculation………………………………………….35

Appendix 13 : Machineries/Equipment Layout……………………………………………….36

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Project Document Code
METHOD STATEMENT FOR THE LEX/P1/C/EAC----F01/MS/008
Identification number
INSTALLATION AND PRELIMINARY
LOAD TEST FOR 300MM Ø MICROPILE TC1000-DOC-MS-01-08
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1. INTRODUCTION

1.1 Package 1 – Dedicated Bypass Conveyor System is part of the Lekir Bulk Terminal Expansion
Project. This Method Statement use piling system namely

a) 300mm dia micropile (use for restricted area for ES4 and SC3C near TT60)

b) Micropiles which uses compact and versatile Hydraulic Rig are may suited for restricted area.
As micropiles are essentially bare cast in situ piles are non displacement piles are also well
suited to provide minimum disturbance to nearby structures.

1.2 This Method Statement describes the construction methodology for 300mm dia. Micro pile
installation and Preliminary Load Test (2.5 x WL = 1187.5kN) for 1 no of test pile.

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Project Document Code
METHOD STATEMENT FOR THE LEX/P1/C/EAC----F01/MS/008
Identification number
INSTALLATION AND PRELIMINARY
LOAD TEST FOR 300MM Ø MICROPILE TC1000-DOC-MS-01-08
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2. SCOPE OF WORK

2.1. GENERAL DESCRIPTION

This method statement describes the typical construction methodology for Micropile Installation within
the LBT Expansion Bypass line, which comprises of boring into layer of soil, possibly into weathered
rock and sound bedrock to required depth and subsequently filing the hole with API pipe as
reinforcement prior to cement grout and preliminary load test for micropile. Refer below for breakdown
of the location and Appendix 13 for equipment/machineries layout.

No Area Quantity
1 ES4 2
2 SC3C/D 13
3 Trial Pile 1
Total 16

Micropile of 300mm diameter are constructed by bored cast in situ Method using 177.8mm O.D. API
pipe with 10.38mm thk as the reinforcement with the diameters no lesser than what are stated as
follows.

One (1) number Preliminary Load Test shall be carried out at location determine by the Consultant.

Temporary Micropile Drill Reinforcement Unit Drill Diameter Cement Grout G35
Casing Size Diameter (mm) Size (mm)

300 Ø O.D. 300 177.8mm O.D. API 300 Full grout inside and
pipe @ 10.38mm thk outside the API pipe
with within a pre-install
300mm Ø temporary
11.0mm thk casing

2.2. REFERENCE

~ Micropile Specification

~ BS8004 – Foundations (Section 7 – Pile Foundation)

~ Approved Construction Drawing

 LEX/P1/C/EAC----F01/CX/003
 LEX/P1/C/EAC----F01/CX/112

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METHOD STATEMENT FOR THE LEX/P1/C/EAC----F01/MS/008
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INSTALLATION AND PRELIMINARY
LOAD TEST FOR 300MM Ø MICROPILE TC1000-DOC-MS-01-08
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3. MATERIAL, PLANT AND EQUIPMENT

3.1. MATERIAL

a) Cement - Cement grout shall be mixed from Ordinary Portland Cement (OPC)
b) Non-shrink grout additives - Intraplast Z or equivalent product is used to prevent grout
shrinkage and improve workability.
c) API pipe as reinforcement as specified in the drawings. (API Pipe as in LEX/P1/C/EAC----
F01/CX/003)
d) Temporary steel casing to prevent collapse and assist in advancement during boring works
(Minimum 6.0m length).

3.2. PLANT AND EQUIPMENT

No Equipment / Plant / Description Quantity Remarks


Tools
1 Drill Rigs Main machine used in boring process for 1 no
micro-pile / steel pipe pile

2 Drill Rod & Bits High strength drilling equipment for boring. 1 set

3 DTH Hammer For drilling with temporary casing 1 no


installation.
4 Tremie Hose For placing of cement grout starting from 1 no
lowest point.
5 Temporary Casing For use when grouting or other measures set
are ineffective in treating cavities during
boring works.

6 Pump To channel cement grout to bore hole 1 set


through tremie plate.
7 Welding Set For welding temporary casing, 1 set
reinforcement plate.
8 Grouting Station For preparation of cement grout. 1 set

9 Bentonite Plant For preparation of bentonite. Optional


10 Air Compressor For flushing out drilled and loose materials. 1 set

11 Crane For lifting works include reinforcement, 1 no


casing, etc.
12 Misc. Tools Cutter, level, heavy duty cables, repair 1 set
tooling, water pumps, etc.

13 45KVA Generator Provide Power Supply for Grout Mixer, 1 set


Set Pump and other associated works.

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Project Document Code
METHOD STATEMENT FOR THE LEX/P1/C/EAC----F01/MS/008
Identification number
INSTALLATION AND PRELIMINARY
LOAD TEST FOR 300MM Ø MICROPILE TC1000-DOC-MS-01-08
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4. MANPOWER

No Type of Manpower Job Fuction Quantity Remarks


1 Construction Manager Construction activities, health and safety, 1 person
environmental impact
2 Site Coordinator Planning and coordinator of the project. 1 person

3 Site supervisor Supervision of construction works, 1 person


coordination of site activities.
4 Surveyor & Chainman Surveying and setting out of site work. 1 team

5 Machinery & Plant Operation of plants and machineries. 2 person


Operator
6 Skilled Driller General drilling works, housekeeping and 4 person
grouting works.
7 HSE Personnel Health, safety and environmental rules 1 person
and regulations to implement.
8 QA & QC Personnel Quality assurance and quality control of 1 person
work and end products.

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METHOD STATEMENT FOR THE LEX/P1/C/EAC----F01/MS/008
Identification number
INSTALLATION AND PRELIMINARY
LOAD TEST FOR 300MM Ø MICROPILE TC1000-DOC-MS-01-08
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5. METHOD STATEMENT FOR MICROPILING

5.1. PRE-CONSTRUCTION

a) Soil Investigation report (Refer to LEX/P1/C/EAC----F01/SI/001) is refer for design and casing as
well as API pipes purpose.

b) Preliminary works shall be including of identification and relocation of services and utilities.

c) Prior to commencement of work, grout mix design, relevant shop drawing and materials shall be
prepared and submitted for Engineer approval.

d) Reinforcement consist of API pipes shall be stored and stacked above the firm ground to allow
easy identification and lifting.

e) API pipe mill certificate are to be submitted prior to site work. Upon API deliveries, one sample of
API can taken and subject to tensile test

f) Platform shall be leveled and safe for drilling rig access purpose. If working of staging platform,
steel plate may be needed and arranged so that the imposed load (drilling machine) able to
distribute its load evenly.

g) Pile position will be set-out by qualified surveyor in accordance with the coordinates as shown in
the Approved for Construction drawings.

Note:
1. Dilap, cable mapping and trial pit will be done prior to start work for ensuring the site utilities is as
per drawing Attachment 1. In the event there is a deviation, it will be relocated accordingly.
2. Site clearing is as per Attachment 2.

5.2. SETTING OUT

a) Setting out shall be carried out using the data and reference points shown on the drawings.

b) Set-out the positions of steel pipe piles as per construction drawings.

c) The pile layout and the number of piles are as per the construction piling schedule.

d) Micropiles requirement shall follow the construction piling schedule.

e) Survey the existing ground level at the pile positions.

f) Pile Centrally Set-up can be checked by lowering the temporary casing to mark on ground and
check its position with measuring tape.

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METHOD STATEMENT FOR THE LEX/P1/C/EAC----F01/MS/008
Identification number
INSTALLATION AND PRELIMINARY
LOAD TEST FOR 300MM Ø MICROPILE TC1000-DOC-MS-01-08
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Sequence 1: Setting Out

Sequence 2: Pile Centrally Set-up

5.3. DRILLING WORKS

5.3.1) Drilling Activities

a) The drill machine shall be set up at the pile location. Then the first length of temporary casing of
correct size attached with a cutting shoe is positioned above drill point. The casing shall be
checked for vertically before drilling work start. The vertically or inclination shall be checked during
the whole process of drilling works using spirit level method as well as tolerance check against
control points installed at fixed distance from pile points.

b) If required, temporary casing shall be lengthened to bore through the initial obstruction follow by
Rotary Boring Method installation to prevent soil collapse over the initial unstable soil layer until
encountering stable or firm ground condition. Minimum depth of casing is 6.0m and exposed
above ground by 600mm to 800mm.

c) Advancement of micropile drillhole into ground shall be by Rotary method using the top drive
Hydraulic Crawler Rig equipped with Drag or tricone bit for hard formation drilling.

d) Flush the borehole during drilling using mud water (no special drilling fluid is used) or liquid
polymer may be added to assist the drill wall stabilization.

Sequence 3: Initial Boring/Temporary casing installation

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METHOD STATEMENT FOR THE LEX/P1/C/EAC----F01/MS/008
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LOAD TEST FOR 300MM Ø MICROPILE TC1000-DOC-MS-01-08
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5.3.2) Drilling Completion

a) Bored hole will be drilled to the design length or socket into firm/dense formation according to the
approved drawing.

b) If a cavity or unusual formation is encountered during the installation of casing, consultation shall
be sought from Consultant representative or Contractor.

c) When encountered dense foundation, drilling shall continue with the use of Drag or Tricone inside
the temporary steel pipe to required depth follow by flushing up to toe level.

d) If encountered any mechanical breakdown, drilling shall be stopped and drill string shall be lifted
up approx. 3.0m to 6.0m above depth achieved. Once breakdown has been resolved, continue to
drill as normal till toe level is achieved.

e) During final 6.0m of drilling, wash out samples shall be taken for visual inspection.

f) The termination depth of 36.0m pile length shall be measured from existing ground level (EL.±0 or
MLSD +3.30).

5.3.3) Clearing, completion and checking

a) Once the toe of pile is achieved and API have fully in placed, the final depth can be checked by
dipping method – Placing the Measuring tape down the central hollow section of the API pipes.

b) Once depth measurement are in order, the drillhole is now ready to receive grout.

c) The subsequent pile to be bored shall be in alternate position next to the recent completed piles in
order to optimize platform preparation.

d) The micropile boring shall be recorded as shown in Appendix 5.

5.4. PREPARATION OF REINFORCEMENT (177.8MM Ø API PIPES) WITH MIN. STRENGTH OF 550N/MM2

a) Due to the space and limited working area, the arrangement and length of 177.8mm Ø API pipes
(with minimum strength of 550N/mm²) shall be in various length to suit site condition.

b) Delivered API Steel Pipe shall be in length between 3.0m to 12.00m as according to design
requirement or site condition. Pipes shall be joined to suit pile length. Estimated pile length is
36.0m from ground level (EL.± 0/MLSD +3.30).

Micropile inside
i) Live plant – API between 3.0m to 6.0m
ii) Outside Plant – API between 6.0m to 12.0m

c) Joint between of API pipes reinforcement of various length shall be by threaded coupler type.

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METHOD STATEMENT FOR THE LEX/P1/C/EAC----F01/MS/008
Identification number
INSTALLATION AND PRELIMINARY
LOAD TEST FOR 300MM Ø MICROPILE TC1000-DOC-MS-01-08
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d) Steel spacer may be require in order to maintain the clearance between bored shafts and steel
bars as specified in the AFC drawings or suit site condition.

e) Upon API deliveries, one sample of API can taken and subject to tensile test.

Sequence 4: Installation of API Pipe

Sequence 5: Completion of API Pipe installation

5.5. PLACING OF GROUTING/ GROUT MIX

a) All grout mix for the Micropile shall have grout strength class G35 as specified on the drawings.
The proportion of cement grout mix and the minimum 28 days unconfined compressive strength

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METHOD STATEMENT FOR THE LEX/P1/C/EAC----F01/MS/008
Identification number
INSTALLATION AND PRELIMINARY
LOAD TEST FOR 300MM Ø MICROPILE TC1000-DOC-MS-01-08
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shall comply with the following requirements. Trial mix shall be carried out prior to actual work
being carried out at site.

Minimum Resistance to Crushing


Range of Water /
(Cube Strength, N/mm²) Additional proposed
Cement Ration
7 Days Strength 28 Days Strength
Sika Interplast Z,
0.45 25 35 Dosage :
500g/50kg OPC

Grout Design Mix

i) Type of cement used : Ordinary Portland Cement in 50kg bags


ii) Water Cement ratio (WC) : 0.45
iii) Mixing ratio
a. Portland Cement : 4 bags
b. Water : 90 liter
c. Sika Interplast Z : 2000 g

b) All grout shall be mixed on site and shall be pumped into bored wet hole until final position
immediately and in no case more than half hour after mixing. 1 set of test cube will be taken for
each pile (3 for 7days, 3 for 28 days and 3 for spare).

c) The method of placing and the workability of the cement grout shall be such that a continuous
monolithic grout shaft of full section is formed. If breakdown occur, immediate steps shall be taken
so that the grouting resume within the 2 hour limit.

However, if 2 hrs limit exceeded, grout shall be fully wash out and grout will only resume once
breakdown issue has been fully resolved.

d) Bored hole to be filled with designated grout mix as per AFC drawings by placing a tremie pipe
into the bottom of bored hole to prevent free falling.

e) Tremie pipe will be then lowered down to the bottom of bored hole prior to filling with grout (tremie
method) and grouting shall be only terminated when neat cement grout overflows from casing.
The steel API pipe can act as tremie pipe in this case.

f) The micropile toe-pin shall be over-grouted above designated cut-off level to permit all laitance
and weak grout to be removed. The grout overflow from temporary casing top is a good indication
sufficient over-grout is achieved.

g) Temporary casing will be extracted by Crawler Rig in not more than 1 hours after grouting has
completed.

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METHOD STATEMENT FOR THE LEX/P1/C/EAC----F01/MS/008
Identification number
INSTALLATION AND PRELIMINARY
LOAD TEST FOR 300MM Ø MICROPILE TC1000-DOC-MS-01-08
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Sequence 6: Cleaning prior to grouting

Sequence 7: Cement grouting

5.6. REMOVAL OF TEMPORARY M.S CASING

a) The casing shall be removed in such a manner that no damaged is sustained by Micropiles being
cast or by adjacent pile or structures. A sufficient head of grout is shall be maintained above the
micro-pile cut-off level at all times to prevent entry of ground water.

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Project Document Code
METHOD STATEMENT FOR THE LEX/P1/C/EAC----F01/MS/008
Identification number
INSTALLATION AND PRELIMINARY
LOAD TEST FOR 300MM Ø MICROPILE TC1000-DOC-MS-01-08
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b) The casing extractor shall be placed in position so that the extraction may commence as soon as
the grout is placed within the casing area. The casing shall be extracted within 1 hour of placing
the grout and shall be done by a vertical lift that remains continually plumb.

c) The top level of grout before and after casing extraction shall be checked and recorded. The
reduced grout level shall be continuously topping up meanwhile to ensure the grout is not lifted to
avoid necking of the newly formed Micropile. To ensure this, the following checks on the grout
level shall be made after grouting or during the commencement of the temporary casing :

i) The reduced level at the top of the casing or existing ground and top of grout shall be
measured before extraction commences.
ii) The reduced level at the top of the grout shall be measured after extracting the casing.
iii) The reduced level at the top of the grout shall be checked during and after extraction of the
casing by suitable means.

Sequence 8: Removal of Temporary casing

Sequence 9: Completion topping of grout

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METHOD STATEMENT FOR THE LEX/P1/C/EAC----F01/MS/008
Identification number
INSTALLATION AND PRELIMINARY
LOAD TEST FOR 300MM Ø MICROPILE TC1000-DOC-MS-01-08
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5.7. CONSTRUCTION PILE HEAD

a) Excavation is to be carried out to provide working space for welder to weld the capping plate in
pile head.

b) Preparation of Pile Heads: The micropiles shall be over-grouted above designed cut-off level to
permit all laitance and weak grout to be removed.

c) This to ensure that it can be properly keyed into the pilecap and all pile heads shall be
constructed to the details shown on the drawings.

d) Welder certificate is attached in the Appendices.

e) Temporary backfilling after grouting: After each pile has been grouted, any empty portion of the
pile shall be protected and shall be carefully backfilled as soon as possible with approved
materials.

f) A mock up sample shall be prepared for inspection and approval.

5.8. SPOIL REMOVAL

Spoil arising from bored hole will be cleared from boring location and stock piled in designated area
for drying purpose before removal off-site.

5.9. RECORDS

Upon completion of installation, reports shall be submitted to the Supervision Consultant (SC) for
review. Field sheet data available within 24 hours from completion of each installation. These shall
include the followings:

a) The identification number or reference position of the Micropiles


b) The reducer level of the existing ground level.
c) The diameter of the pile shaft
d) The type, size and number of steel reinforcement.
e) The top and bottom elevation of the pile shaft and the pile cut off level.
f) The depth of the borehole.
g) Details of rock coring, cavities, etc.
h) Details of all strata bored
i) The depth to the ground water table.
j) Details of the temporary and permanent casings.
k) Details of the drilling fluid used.
l) The volume of grout used in forming the micropile shaft
m) Details of grouting pressure
n) The date and time of starting, stopping, delays, if any, any finishing of the pile shaft.
o) Records of any unexpected conditions that could affect the integrity of the micro-pile
construction such as cavities.

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METHOD STATEMENT FOR THE LEX/P1/C/EAC----F01/MS/008
Identification number
INSTALLATION AND PRELIMINARY
LOAD TEST FOR 300MM Ø MICROPILE TC1000-DOC-MS-01-08
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6. QUALITY ASSURANCE & QUALITY CONTROL

6.1. Inspection & Testing

All inspection and testing shall inform Engineer through the submission of NOI at least 72 hours in
prior.

6.2. API Pipe Reinforcement

One sample of API Pipe of 177.8mm dia. shall be collected and sent for independent laboratory to
test the following:
 Tensile Strength Test

Engineer shall be involved in the following process:-


 Sample collection
 Marking and labelling of the sample
 Laboratory testing

Testing shall be done in prior to the installation of working Micropile and test result shall achieved
requirement and comply with the specification or statement stated in approved for construction
drawing.

6.3. Concrete/Grout mix

Proposed mixed design shall be tested and approved in prior to the installation of Micropile.

During operation period, concrete used will be tested on the following properties:-
 Cube test

Cube test shall prepare on site at 9 nos for every pile and shall be proper curing not later than 24
hours after placing into cube mold. Cubes shall be tested at 7 days (3 cubes) & 28 days (3 cubes). The
remaining cubes shall be keep for contingency cases.

A layer of wet blanket shall be covered on cube mold surface to prevent from moisture loss for first 24
hours.

Engineer shall be involved in the testing mentioned above.

6.4. Stabilizing Fluid Field Testing

The polymer slurry supplied to the borehole shall comply with M&W specification, listed as follows:

Property to be measured Range of results Test method


Viscosity 35s-55s Mash cone method
pH 7.0 – 8.0 pH indicator/electrical pH meter
Density Less than 1.10g/ml Mud Density Balance
Sand contents Less than 2% Screen

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METHOD STATEMENT FOR THE LEX/P1/C/EAC----F01/MS/008
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INSTALLATION AND PRELIMINARY
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7. PICTURES ILLUSTRATION OF MICROPILE INSTALLATION

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METHOD STATEMENT FOR THE LEX/P1/C/EAC----F01/MS/008
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INSTALLATION AND PRELIMINARY
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8. TEST PILE & PRELIMINARY LOAD TEST

To test one micropile up to 2.50 times the working load. The coordinate point for preliminary test pile
location is at N 57118.883, E -19672.786. Test pile can be carried out as indicated by the Engineer or
once the required strength have exceeded the design strength of 25 N/mm².

The pile cut off level for load test purpose is RL 3.80 (600mm higher than GL).

8.1. METHOD OF TESTING

The pile shall be tested using maintained load test. The test load shall be applied by Jack which obtain
its reaction static dead weight of concrete blocks (Kentledge).
The technical data and testing arrangement will be submitted prior to testing.

7.1.1 Preliminary Load Test to any working pile only can carry out after 14 days of driving. The test
pile location will be reviewed and selected by Engineer.
7.1.2 The test load shall be applied by means of our hydraulic jack (capacity of the jack must cover
a range in excess of the ultimate load of the pile) fitted with measuring device.
7.1.3 The kentledge will be provided by concrete blocks. The load of the Kentledge must be in
excess of three times the working load by 25% and supported centrally over the test pile on
temporary staging. The details of the Kentledge and the arrangement of testing equipment
will be submitted before testing (refer Appendix 12).
7.1.4 The settlement measurement shall be measured by dial gauges erected on reference beams
the supports of which are rigidly fixed to the ground.
7.1.5 An external fixed bench mark will be provided for cross checking of the reference beams by
leveling instrument.
7.1.6 A scale will be attached to the pile and levels will be taken to check that there are no gross
errors in the dial readings.

8.2. LOADING SEQUENCE

The test procedure shall be as follow:

First Cycle
a) Loading shall be in 4 equal increments up to working load.
b) The pile shall be maintained at working load for at least 2 hours.
c) It shall thereafter be unloaded in 4 equal steps and remain totally unloaded for 1 hour.

Second Cycle
a) Loading shall then be continued to proof load 2.5 x WL from working load in increments of
0.50 working load.
b) The pile shall be maintained at proof load for at least 48 hours.
c) It shall thereafter be unloaded in 4 equal steps and remain totally unloaded for 1 hour. The
testing procedures may be modified by the engineer on the basis of the response of the piles
to loading.

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METHOD STATEMENT FOR THE LEX/P1/C/EAC----F01/MS/008
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INSTALLATION AND PRELIMINARY
LOAD TEST FOR 300MM Ø MICROPILE TC1000-DOC-MS-01-08
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8.3. LOAD TEST REPORT

The contractor shall within 48 hours of the completion of the test, submit to the engineer for each pile
tested graphs showing :

a) Load and settlement plotted above and below a common base line of time.
b) Settlement and recovery plotted horizontally against the vertical line of load used.
c) For each load step, the load is to be held constant for not less than the period shown in the
loading table and until the rate of the pile displacement is less than 0.25mm per hour.

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METHOD STATEMENT FOR THE LEX/P1/C/EAC----F01/MS/008
Identification number
INSTALLATION AND PRELIMINARY
LOAD TEST FOR 300MM Ø MICROPILE TC1000-DOC-MS-01-08
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Table A
JOB TITLE : LEKIR BULK TERMINAL EXPANSION PROJECT PACKAGE 1 – DEDICATED
BYPASS CONVEYOR SYSTEM (“LEXPRO P1”).
SITE LOCATION : Lekir Bulk Terminal (LBT) Manjung Perak
PACKAGE : 300mm MICROPILE
Work Load : 475 kN
Test Load : 1187.5 kN

Increment of load and minimum holding time


Minimum Time of Notes
Applied Load as Factor Holding
Applied Load (kN)
of DWL
(Duration)
0 X DWL 0 0

0.50 X DWL 237.50 1 hour

1.00 X DWL 475 24 hours

0.50 X DWL 237.50 1 hour

0 X DWL 0 3 hours

0.50 X DWL 237.50 1 hour


1. Settelment reading
0.75 X DWL 356.25 1 hour shall be taken
immediately before and
1.00 X DWL 475 1 hour after each increment of
load and thereafter at
1.50 X DWL 712.50 3 hours every 15 minute.

2.00 X DWL 950 3 hours

2.25 X DWL 1068.75 3 hours


2. If reading exceed
2.50 X DWL 1187.50 48 hours 0.25mm in 1 hour, then
holding time need to be
2.25 X DWL 1068.75 1 hour extended by another
hour. (max. 3 hours)
2.0 X DWL 950.00 1 hour

1.75 X DWL 831.25 1 hour

1.50 X DWL 712.50 1 hour

1.25 X DWL 593.75 1 hour

1.00 X DWL 475.00 1 hour

0.75 X DWL 356.25 1 hour

0.50 X DWL 237.50 1 hour

0 X DWL 0 1 hour
20 | P a g e
Project Document Code
METHOD STATEMENT FOR THE LEX/P1/C/EAC----F01/MS/008
Identification number
INSTALLATION AND PRELIMINARY
LOAD TEST FOR 300MM Ø MICROPILE TC1000-DOC-MS-01-08
REV. B P a g e | 21 of 36

Note:

1) For each load step, the load shall be held constant for not less than the period shown in the table
and until the rate of the pile displacement is less than 0.25mm per hour and decreasing.

2) Load and displacement shall be recorded at 1 min, 2 min, 3 min, 4 min, 10 min, 15 min and every
other 15 min interval thereafter.
3) Maximum duration during transition load should be 15 min.
4) DWL = Design Working Load
= 475 kN (Subjected to MLT Result)

8.4. INTERPRETATION

The pile so tested shall be deemed to have failed if:

a) The residual settlement after removal of the test load exceed 6mm or
b) The total settlement under working load exceeds 12mm

Pile load test shall be reviewed and report to be submitted by geotechnical engineer in 1 week time.

21 | P a g e
Project Document Code
METHOD STATEMENT FOR THE LEX/P1/C/EAC----F01/MS/008
Identification number
INSTALLATION AND PRELIMINARY
LOAD TEST FOR 300MM Ø MICROPILE TC1000-DOC-MS-01-08
REV. B P a g e | 22 of 36

9. HIRARC

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Project Document Code
METHOD STATEMENT FOR THE LEX/P1/C/EAC----F01/MS/008
Identification number
INSTALLATION AND PRELIMINARY
LOAD TEST FOR 300MM Ø MICROPILE TC1000-DOC-MS-01-08
REV. B P a g e | 23 of 36

10. APPENDICES

Appendix 1 - Micro Piling Layout Plan

Appendix 2 - Micropile Detail Drawing

Appendix 3 - Micropile Construction Work Flow Chart

Appendix 4 - Micropile Record Form

Appendix 5 - Micropile Check List

Appendix 6 - Welder Qualification Test Record

Appendix 7 - Drilling Fluid Additive – Polymer MSDS

Appendix 8 - BS 8004:1986 Pile Foundation

Appendix 9 - Micropile Specification

Appendix 10 - Pile Testing Specification

Appendix 11 - Design Calculation for Steel Capping

Appendix 12 - Kentledge Drawing and Calculation

Appendix 13 - Machineries/Equipment Layout

23 | P a g e
Project Document Code
METHOD STATEMENT FOR THE LEX/P1/C/EAC----F01/MS/008
Identification number
INSTALLATION AND PRELIMINARY
LOAD TEST FOR 300MM Ø MICROPILE TC1000-DOC-MS-01-08
REV. B P a g e | 24 of 36

Appendix 1 - Micro Piling Layout Plan

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Project Document Code
METHOD STATEMENT FOR THE LEX/P1/C/EAC----F01/MS/008
Identification number
INSTALLATION AND PRELIMINARY
LOAD TEST FOR 300MM Ø MICROPILE TC1000-DOC-MS-01-08
REV. B P a g e | 25 of 36

Appendix 2 - Micropile Detail Drawing

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Project Document Code
METHOD STATEMENT FOR THE LEX/P1/C/EAC----F01/MS/008
Identification number
INSTALLATION AND PRELIMINARY
LOAD TEST FOR 300MM Ø MICROPILE TC1000-DOC-MS-01-08
REV. B P a g e | 26 of 36

Appendix 3 - Micropile Construction Work Flow Chart

MICROPILE CONSTRUCTION WORK FLOW CHART

Survey and Setting Out

Mobilization and Set up Plant &


Machinery

Start Temporary Boring process with


Steel Casing

Check if stable ground is achieved

Yes No

Continue driving to
Stop boring temporary casing and set
achieve refusal
up micropile DTHH at pile position

Start Hard formation drilling process

Drilling of Micropiles socket

Install API pipes

Cleaning of drill holes and proceed


with grouting

Grout consolidation occurance

Yes No

Immediate top up
to required level

Completed Micropile

26 | P a g e
Project Document Code
METHOD STATEMENT FOR THE LEX/P1/C/EAC----F01/MS/008
Identification number
INSTALLATION AND PRELIMINARY
LOAD TEST FOR 300MM Ø MICROPILE TC1000-DOC-MS-01-08
REV. B P a g e | 27 of 36

Appendix 4 - Micropile Record Form

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Project Document Code
METHOD STATEMENT FOR THE LEX/P1/C/EAC----F01/MS/008
Identification number
INSTALLATION AND PRELIMINARY
LOAD TEST FOR 300MM Ø MICROPILE TC1000-DOC-MS-01-08
REV. B P a g e | 28 of 36

Appendix 5 - Micropile Check List

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Project Document Code
METHOD STATEMENT FOR THE LEX/P1/C/EAC----F01/MS/008
Identification number
INSTALLATION AND PRELIMINARY
LOAD TEST FOR 300MM Ø MICROPILE TC1000-DOC-MS-01-08
REV. B P a g e | 29 of 36

Appendix 6 - Welder Qualification Test Record

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Project Document Code
METHOD STATEMENT FOR THE LEX/P1/C/EAC----F01/MS/008
Identification number
INSTALLATION AND PRELIMINARY
LOAD TEST FOR 300MM Ø MICROPILE TC1000-DOC-MS-01-08
REV. B P a g e | 30 of 36

Appendix 7 - Drilling Fluid Additive – Polymer MSDS

30 | P a g e
Project Document Code
METHOD STATEMENT FOR THE LEX/P1/C/EAC----F01/MS/008
Identification number
INSTALLATION AND PRELIMINARY
LOAD TEST FOR 300MM Ø MICROPILE TC1000-DOC-MS-01-08
REV. B P a g e | 31 of 36

Appendix 8 - BS 8004:1986 Pile Foundations

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Project Document Code
METHOD STATEMENT FOR THE LEX/P1/C/EAC----F01/MS/008
Identification number
INSTALLATION AND PRELIMINARY
LOAD TEST FOR 300MM Ø MICROPILE TC1000-DOC-MS-01-08
REV. B P a g e | 32 of 36

Appendix 9 - Micropile Specification

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Project Document Code
METHOD STATEMENT FOR THE LEX/P1/C/EAC----F01/MS/008
Identification number
INSTALLATION AND PRELIMINARY
LOAD TEST FOR 300MM Ø MICROPILE TC1000-DOC-MS-01-08
REV. B P a g e | 33 of 36

Appendix 10 - Pile Testing Specification

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Project Document Code
METHOD STATEMENT FOR THE LEX/P1/C/EAC----F01/MS/008
Identification number
INSTALLATION AND PRELIMINARY
LOAD TEST FOR 300MM Ø MICROPILE TC1000-DOC-MS-01-08
REV. B P a g e | 34 of 36

Appendix 11 - Design Calculation for Steel Capping

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Project Document Code
METHOD STATEMENT FOR THE LEX/P1/C/EAC----F01/MS/008
Identification number
INSTALLATION AND PRELIMINARY
LOAD TEST FOR 300MM Ø MICROPILE TC1000-DOC-MS-01-08
REV. B P a g e | 35 of 36

Appendix 12 - Kentledge Drawing and Calculation

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Project Document Code
METHOD STATEMENT FOR THE LEX/P1/C/EAC----F01/MS/008
Identification number
INSTALLATION AND PRELIMINARY
LOAD TEST FOR 300MM Ø MICROPILE TC1000-DOC-MS-01-08
REV. B P a g e | 36 of 36

Appendix 13- Machineries/Equipment Layout

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