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SPECIFICATION SECTION S21

PRECAST CONCRETE PILES

S21.1 GENERAL

S21.2 STANDARDS

S21.3 DEFINITIONS

S21.4 TOLERANCES

S21.4.1 Setting out


S21.4.2 Position
S21.4.3 Verticality
S21.4.4 Rake
S21.4.5 Forcible Correction

S21.5 PILING METHOD

S21.6 PILING PROGRAMME

S21.7 PILING RECORDS

S21.8 NUISANCE AND DAMAGE

S21.8.1 Noise, vibration and disturbance


S21.8.2 Damage to adjacent structures
S21.8.3 Damage to piles
S21.8.4 Temporary support

S21.9 ORDERING OF PILES

S21.10 CLASSIFICATION

S21.11 MATERIALS

S21.11.1 Cement.
S21.11.2 Steel reinforcement.
S21.11.3 Aggregates
S21.11.4 Water
S21.11.5 Admixtures
S21.11.6 Steel and iron components
S21.11.7 Test certificates

S21.12 MANUFACTURE

S21.12.1 Supervision and manufacturing process


S21.12.2 Concrete mix
S21.12.3 Placing and compacting concrete
S21.12.4 Protecting and curing concrete
S21.12.5 Handling
S21.12.6 Mould

S21-1
S21.13 PERMISSIBLE TOLERANCES IN PILE DIMENSIONS

S21.14 PILE JOINTS

S21.15 PILE SHOES

S21.16 PILE HEAD REINFORCEMENT

S21.17 REINFORCEMENTS

S21.18 PRESTRESSING

S21.18.1 General
S21.18.2 Concrete strength
S21.18.3 Records
S21.18.4 Post tensioned piles
S21.18.5 Grouting procedure
S21.18.6 Grout
S21.18.7 Testing works grout
S21.18.8 Batching grout
S21.18.9 Mixing grout
S21.18.10 Transporting grout

S21.19 RECORDS

S21.20 PILE QUALITY

S21.21 MARKING OF PILES

S21.22 BEND TESTS

S21.23 DRIVING PILES

S21.23.1 Strength of piles


S21.23.2 Driving Resistance
S21.23.3 Preliminary test piles
S21.23.4 Depth of Penetration
S21.23.5 Pile Acceptance Criteria
S21.23.6 Leaders and trestles
S21.23.7 Performance of driving equipment
S21.23.8 Driving procedures and redrive checks arising from interruptions to driving
S21.23.9 Redrive checks on time effects on piles
S21.23.10 Set
S21.23.11 Driving sequence and risen piles
S21.23.12 Preboring

S21.24 REPAIR AND LENGTHENING OF PILES

S21.24.1 Repair of damaged pile heads


S21.24.2 Lengthening of precast reinforced and prestressed concrete and prestressed spun piles
S21.24.3 Driving repaired or lengthened pile

S21.25 CUTTING OFF PILE HEADS AND REMOVAL OF SURPLUS LENGTH

S21-2
S21 PRECAST CONCRETE PILES

S21.1 General

The Contractor shall carry out detail design of the piles to the loads, dimensions and
Class specified and / or shown on the drawings and shall manufacture, deliver and install
the piles to such minimum lengths specified and to such lengths as to comply with the
design requirements and criteria of acceptance, all in accordance with the specifications.

This section contains specifications covering the design, certain materials and
workmanship required for construction and installation of precast reinforced concrete
piles, precast pretensioned concrete piles and precast prestressed spun concrete piles.
The materials and workmanship specified in other sections of the specifications apply to
precast concrete piles except where modified, amended or excluded herewith.

S21.2 Standards

The whole of the works and materials shall be in accordance with British Standard Code
of Practice BS 5328: 1981, BS 8110: 1985 and BS 8004: 1986; Malaysian Standard MS
1314: Part 1 : 1993 and MS : 1314 : Part 2 : 1993 and JKR Standard Specification
“Specifikasi ILP – 1 – 91 Precast Concrete Piles in Building Projects” (herein referred to
as JKR ILP 1-91)and other specifications referred to in the Specifications unless
otherwise stated and except where the requirements of the British and Malaysian
Standards are in conflict with this specifications, the latter shall take precedence.

S21.3 Definitions

In this section, the terms “approved”, “approval” and “required” shall mean “approved by
the ER”, “approval of the ER” and “required by the ER” respectively.

S21.4 Tolerances

S21.4.1 Setting out

Setting out shall be carried out from reference lines and points shown on the Drawings.
Immediately before installation of the pile, the pile position shall be marked with suitable
identifiable pins and markers.

S21.4.2 Position

The maximum permitted deviation of the pile center from the center point shown on the
setting out drawing shall be 75 mm in any direction.

S21.4.3 Verticality

The maximum permitted deviation of the installed pile from the vertical shall be 1 : 75.

S21.4.4 Rake

The piling rake shall be set and maintained to attain the required rake. The maximum
permitted deviation of the finished pile from the specified rake is 1 : 25 for piles raking
up to 1 : 6 and 1 in 15 for piles raking more than 1 : 6.

S21-3
S21.4.5 Forcible Correction

Forcible corrections to concrete piles shall not be made.

S21.5 Piling Method

The Contractor shall submit for approval all relevant details of the method of piling and
the plant he proposes to use. Any alternative method to that specified shall be in
accordance with the Specifications.

S21.6 Piling Programme

The Contractor shall inform the ER each day of the programme of piling for the following
day and shall give adequate notice of his intention to work outside normal hours and at
week ends.

S21.7 Piling Records

Comprehensive records shall be kept. The record shall include the following information:-

(i) Contract, Section;

(ii) Reduced level on the pile position;

(iii) Pile reference number;

(iv) Pile type and details of the pile

(v) Nominal cross sectional dimensions or diameter;

(vi) Length of preformed pile including the lengths of each segment;

(vii) Date and time of driving, re driving or pre boring from start to finish;

(viii) Ground level at pile position at commencement of installation of pile;

(ix) Working level on which the piling machine stands

(x) Pile toe level

(xi) Pile head level at end of installation

(xii) Cut off level

(xiii) Type, weight, drop and mechanical condition of hammer and equivalent
information for other equipment.

(xiv) Number and type of packing used and type and conditions of dolly used during
driving of the piles.

S21-4
(xv) Set of pile in millimeters per 10 blows or number of blows per 25 mm of
penetration.

(xvi) Temporary compression of pile.

(xvii) Driving resistance taken at 0.25 m intervals.

(xviii) All information regarding obstructions, delays and other interruptions to the
sequence of work.

(xix) Pile installation equipment including rig no.

(xx) For raking piles, the angle of the rake.

(xxi) Weather report.

(xxii) All other information as may be required by the ER.

On completion of piling, the Contractor shall deliver to the ER a drawing recording the
final depths of all piles relative to the Ordinance Datum.

S21.8 Nuisance and Damage

S21.8.1 Noise, vibration and disturbance

The Contractor shall carry out his works in such a manner and at such times as to
minimize noise, vibration and other disturbance in order to comply with current statutory
requirements and legislations. He shall comply with all the requirements of all the
relevant authorities.

The Contractor shall also comply with the recommendations of noise and vibrations given
in:

 BS 5228. Noise control on construction and open sites. Part 4. May 1992. Code of
practice for noise and vibration control applicable to piling operations.

 BS 7385. Evaluation and measurement for vibration in buildings.


Part 1: 1990. Guide for measurement of vibration and evaluation of their effects on
buildings.
Part 2: 1993. Guide to damage levels from ground borne vibrations.

 BRE Digest. Damage to structures from ground-borne vibration. Digest 403. March
1995.

The Contractor shall carry out measurements of noise and vibrations during the
installation of the preliminary piles and at such times as may be instructed by the E.R.

S21.8.2 Damage to adjacent structures

If in the opinion of the Contractor, damage may be caused to other structures or services
by the execution of his works he shall immediately notify the E.R. The Contractor shall
submit his plans for surveys and monitoring of movements and vibrations before the
commencement of Works.

S21-5
S21.8.3 Damage to piles

The Contractor shall ensure that during the course of the work, displacement or damage
that would impair either performance or durability does not occur to completed piles.

The Contractor shall submit to the E.R. his planned sequence and timing for installing
piles having regard to the avoidance of damage to adjacent piles.

S21.8.4 Temporary support

The Contractor shall ensure that where required, any permanently free – standing piles
are temporarily braced or stayed immediately after installation to prevent loosening of the
piles in the ground and to ensure no damage resulting from oscillation, vibration or
movement can occur.

S21.9 Ordering Of Piles

The Contractor shall ensure that the piles are available in time for incorporation in the
Works. All piles and production facilities shall be made available for inspection at any
time. Plies shall be examined at the time of delivery and any faulty units replaced. The
records of testing of the steel and concrete used in the piles shall be submitted.

S21.10 Classification

The classification of piles shall be as given in Table S21.1. The requirements of the
different classes are given in Table S21.2.

Pile type Classes


Precast reinforced concrete Class 1 Class 2
piles
Precast pretensioned Class X Class Y
concrete piles
Precase prestressed spun Class A Class B
concrete piles

Table S21.1

S21.11 Materials

The materials used for the manufacture of the precast concrete piles shall complying with
the following requirements:

S21.11.1 Cement.

Cement shall be Ordinary Portland cement and shall comply with MS 522. Other types of
cement shall be to the approval of the E.R.

S21.11.2 Steel reinforcement.

Steel reinforcement shall consist of cores, bars or strands complying with the following
requirements and specifications.

S21-6
(i) Rolled steel bars and hard drawn steel wire shall comply with MS 144 and MS
146.

(ii) Prestressing steel shall comply with JIS G3109 or BS 4486, BS 5896, or ASTM
A416.

S21.11.3 Aggregates

The coarse and fine aggregates shall be clean, durable and comply with MS 29. The
maximum size of aggregates shall be 20 mm. All batches of aggregates used shall be
tested in accordance with MS 29. Alkali reaction tests shall be carried out on the
different rock types used.

S21.11.4 Water

Water shall be free from harmful amounts of matter injurious to concrete and steel
reinforcements and shall comply with MS 28.

S21.11.5 Admixtures

Admixtures may only be used with the approval of the E.R. Admixtures, if used, shall
comply with MS 922. Admixtures with calcium chloride shall not be accepted.

S21.11.6 Steel and iron components

In the manufacture of precast concrete piles and jointed precast concrete segmental
piles, fabricated steel components shall comply with BS 4360 Grades 43A and 50A or
BS EN 10 025 Grades Fe 430A or Fe 510A, cast steel components with BS 3100,
grade A (A1, A2 or A3) and ductile iron components with BS 2789 Grades 420 / 12, 400
/ 18 or 350 / 22.

S21.11.7 Test certificates

Test certificates and / or mill certificates for tests on the following shall be made
available to the ER:

 cement,
 steel reinforcements,
 admixture (if used) from approved supplier
 aggregates;
 steel and iron components.

Test results showing failure to comply with the requirements of the Specifications shall
result in rejection of the entire piles produced from that batch of materials.

Records shall also be kept of suppliers, dates of supplies, quantities supplied, pile
referencing to batches of materials used.

The frequency of testing shall be in accordance with MS 1314: Part 1: 1993 Appendix
C.

S21-7
S21.12 Manufacture

S21.12.1 Supervision and manufacturing process

Experienced engineers, concrete technologists shall be employed and shall be


responsible for all tests and inspections specified in MS 1314 : Part : 1 : 1993. All mixing
and measuring equipment shall be maintained and calibrated regularly under supervision.

Production and transportation of concrete shall be in accordance with MS 523.

The manufacturing process shall comply to the requirements of MS ISO 9002.

S21.12.2 Concrete mix

Concrete shall be sampled and tested in accordance with MS 26. Concrete mixes shall
be designed and verified by trial mixes. The concrete strength shall be designed for a
mean strength greater than the required characteristic strength by a minimum margin of
1.64 times the standard deviation. In the absence of statistical data, a standard deviation
of 5.5 N / mm2 shall be adopted. The aggregates, cement and water shall be
proportioned and mixed using appropriate batching and mixing plant to produce a
consistent and homogeneous of the specified strength.

S21.12.3 Placing and compacting concrete

The method of placing and compacting concrete shall be such as to ensure that the
concrete in its final position is dense and homogeneous. The concrete shall be cast in a
continuous operation. The concrete shall be thoroughly compacted against the mould
and around the reinforcement by means of immersed and / or shutter vibrations or
spinning process. Vibrators shall be operated in such a manner that neither segregation
of the concrete mix constituents nor displacement of reinforcement occurs.

S21.12.4 Protecting and curing concrete

Immediately after completion of placing and compaction, concrete shall be adequately


protected from all harmful effects of weather including wind, rain, high temperatures and
rapid temperature changes and from all detrimental effects such as vibrations.

The piles shall be cured using any one of the following or a combination of the following
methods:

(a) Accelerated curing with either low – pressure steam or radiant heat in a moist
atmosphere.

(b) Water curing by covering the pile with water saturated material for a minimum period
of 3 days.

(c) Membrane curing with a sealing membrane applied to ensure loss of water not more
than 0.055 g / cm2 of surface area over a 72 hour period. The sealing membrane
shall conform to the requirements of ASTM C 309. Other methods of curing shall be
to the approval of the ER.

S21.12.5 Handling

S21-8
Lifting hooks or holes, specific for the purpose, shall be designed for and cast into each
pile. Piles shall not be removed from the moulds or lifted from the casting beds until the
concrete cube strength exceeds:

 16 N / mm2

 or until when the compressive stresses from handling (including that from the pile
weight) is less than the 0.33 the strength of the pile at time of handling

whichever the higher.

The method and sequence of handling, transporting and storing of piles shall be such as
to avoid shock loading and to ensure that the piles are not damaged. Only designed
lifting and support points shall be used. During transport and storage, piles shall be
appropriately supported under the marked lifting points or fully supported along their
length. Piles shall be stored only on stiff ground not liable to settlement under the weight
of the stack that will induce bending of the piles.

All piles within a stack shall be in groups of the same length. Packing of uniform
thickness shall be provided between piles at the same lifting points.

A pile shall be rejected when the width of any transverse crack exceeds 0.3 mm. The
measurement shall be made with the pile in its working attitude.

S21.12.6 Mould

The moulds used in the manufacturing of the piles shall be sufficiently rigid and accurate
to maintain the pile dimensions to within the tolerances stated in Clause S21.12 of the
specifications. All casting surfaces shall be of smooth nonporous material. Square piles
shall have chamfered corners.

The moulds shall be robust, clean and so constructed and maintained as to prevent loss
of grout or aggregate from the wet concrete and to ensure the production of uniform pile
sections, free from defects.

Piles shall be removed from the mould in such a manner as to prevent any damage to the
pile.

S21.13 Permissible Tolerances in pile dimensions

The cross sectional dimensions shall be not less than that specified and shall not exceed
them by more than 6 mm. Each face of the pile shall not deviate by more than 6 mm from
any straight line 3 m long joining two points on the face, nor shall the center of the pile at
any cross section deviate by more than 12 mm from a line joining the centers of area at
the ends of the piles.

Wall thickness of precast prestressed spun concrete piles shall be within – 3 mm to + 6


mm. Outside diameter of precast prestressed spun concrete piles shall be within –3 mm
to + 5 mm for 600 mm diameter and smaller and within – 4 mm and + 7 mm for larger
diameters.

The outside diameter shall be defined as the average of two measurements taken along
the axes at right angles to each other on a cross section. The wall thickness shall be the
S21-9
average of four measurements taken along the axes at right angles to each other in a
cross section.

The head of the pile element shall be square to the pile axis within a tolerance of 1 : 150.

S21.14 Pile joints

The joints shall conform to the requirements of JKR ILP-91.

The joints shall be close-fitting face to face and the locking method shall be such as to
hold the faces in intimate contact. Details of the design, manufacture and tests of the
jointing system shall be submitted and approved by the E.R. prior to the commencement
of the contract.

Joints shall have strengths in compression, bending, tension, shear and torsion during
installation and in service not less than that of a single unjointed pile of the same cross-
sectional dimensions and materials as that of the pile segments joined. The joints shall
also be able to withstand the stresses due to repeated impacts of driving hammers and
heat from welding.

The welding of a joint to main reinforcement in lieu of a lapped connection with projecting
bars affixed to the joint shall not be permitted.

Each joint shall be square to the axis of the pile within a tolerance of 1 : 150. The
centroid of the pile joint shall lie within 5 mm of the true axis of the pile element. The
minimum thickness of the steel plate shall be 15 mm. The diameter of the centering bar
shall be 32 mm with a minimum anchorage depth of 200 mm and protrusion length of 100
mm.

The length of anchor / starter bars shall be precast reinforced concrete piles shall be at
least 40 times the reinforcement of the pile segments joined. The cross section of the
anchor / starter bars shall be not less than the reinforcements of the pile segments
joined. A mild steel skirt of at least 1.6 mm thick and 50 mm high shall be provided
around the edges of the pile joint.

The requirements for anchor / starter bars for precast prestressed spun concrete piles
shall be as given in Table 4 of MS 1314: Part 1: 1993.

The contractor shall carry out Bending Strength tests on joints in accordance with MS
1314: Part 1 : 1993 as instructed by the E.R.

S21.15 Pile shoes

Pile shoes shall be constructed so as to ensure that damage is not caused to the pile
during installation.

Pile shoes shall be as shown on the drawings and shall comply with the following as
relevant:

(i) Chilled - hardened cast iron shoes as used for making grey iron casting to BS
1452, Grade 10;

(ii) Mild steel to BS 4360, Grade 43A or JIS 3101 Grade SS 41.

S21-10
S21.16 Pile head reinforcement

Pile heads shall be so reinforced or banded as to prevent bursting of the pile under
driving.

S21.17 Reinforcements

The required steel reinforcements shall be as stated in Table S21.2.

The main longitudinal reinforcing bars in piles not exceeding 12 m in length shall be in
one continuous length. In piles more than 12 m length, joints will be permitted in main
longitudinal bars so that the number of joints is minimized. Joints in reinforcement shall
be such that the full strength of the bar is effective across the joint, following BS 8110.

Lap and splice joints shall be provided with sufficient link bars to resist eccentric forces.
Reinforcement shall be incorporated for lifting and handling purposes. Lateral
reinforcements in the form of hoops, links or spirals shall be firmly fixed to the
reinforcement bars.

Spacing blocks shall be of mortar concrete or other materials comparable in durability


and strength as the main concrete and which shall not lead to corrosion of the
reinforcement or spalling of the concrete cover. Details of the means by which the
Contractor plans to ensure the correct cover to and position of the reinforcement shall be
submitted.

If a pile is constructed with a shaped point or shoe, then the end of the pile shall be
symmetrical about the longitudinal axis of the pile. Holes for handling or pitching shall be
lined with steel tubes; alternatively inserts may be cast in.

S21.18 Prestressing

S21.18.1 General

Tensioning shall be carried out only when the E.R. is present, unless otherwise
approved. In cases where piles are manufactured off the site, the Contractor shall
ensure that the E.R. is given adequate notice and every facility for inspecting the
manufacturing process.

Pre stressing operations shall be carried out only under the direction of an experienced
and competent supervisor. All personnel operating the stressing equipment shall have
been trained in its use.

The calculated extensions and total forces, including allowance for losses, shall be
agreed with the E.R. before stressing is commenced.

Stressing of tendons and transfer of prestress shall be carried out at a gradual and
steady rate. The force in the tendons shall be obtained from readings on a recently
calibrated load cell or pressure gauge incorporated in the equipment. The extension of
the tendons under the agreed total forces shall be within 5% of the agreed calculated
extension.

S21-11
S21.18.2 Concrete strength

The contractor shall cast sufficient cubes, cured in the same manner as the piles, to be
able to demonstrate by testing two cubes at a time, with approved intervals between pairs
of cubes, that the necessary in situ strength of the concrete has been reached.

Concrete in the piles shall not be stressed until two test cubes attain the necessary
strength.

S21.18.3 Records

The Contractor shall keep detailed records of times of tensioning, measured extensions,
pressure gauge readings or load cell readings and the amount of pull-in at each
anchorage. The Contractor shall also check the cover to reinforcement of each pile and
shall ensure that it is at least that specified. Copies of these records shall be supplied to
the E.R. within such reasonable time from completion of each tensioning operation, as
may be required, and in any case not later than noon on the following working day.

S21.18.4 Post tensioned piles

Apart for the requirements for ducts and vents in post – tensioned piles to be grouted
after the transfer of pre stress, the requirements for pre-stressed piles apply.

S21.18.5 Grouting procedure

Grout shall be mixed for a minimum of 2 minutes and until a uniform consistency is
obtained.

Before grouting is started all ducts shall be thoroughly cleaned by means of compressed
air which shall be free of oils.

Grout shall be injected near the lowest point in the duct in one continuous operation and
allowed to flow from the outlet until the consistency is equivalent to that of the grout being
injected.

Vents in ducts shall be provided in accordance with Clause 8.9.2 of BS 8110.

S21.18.6 Grout

Grout for prestress shall have the following properties.

(a) The design and workability of grout to be used in the formation of piles shall
produce a mix which is suitable for pumping.

(b) The grout shall consist only of ordinary Portland cement, water and approved
admixtures; admixtures containing chlorides or nitrates shall not be used;

(c) The grout shall have a water/cement ratio as low as possible consistent with the
necessary workability, and the water/cement ratio shall not exceed 0.40.

(d) The grout shall not bleed in excess of 2% after 3 hours, or in excess of 4%
maximum, when measured at 18oC in a covered glass cylinder approximately

S21-12
100mm in diameter with a height of grout of approximately 100mm, and the water
shall be re-absorbed after 24 hours.

S21.18.7 Testing works grout

Cube strength testing shall be carried out in accordance with BS 1881. A sample shall
consist of a set of six 100 mm cubes. Three cubes shall be tested at seven days and the
remaining three at 28 days after casting.

S21.18.8 Batching grout

The weighing and water – dispensing mechanisms shall be maintained at all times within
the limits of accuracy described in BS 1305.

The weights of each component of the mix shall be within 2 % of the respective weights
per batch.

S21.18.9 Mixing grout

Cement grout shall be mechanically mixed throughout to produce a homogeneous mix.

The grout shall be mixed on site until a homogeneous grout is obtained and shall be kept
in continuous movement until in used. It shall be used within 30 minutes from the start of
mixing. Following mixing, the grout shall be passed through a 5 mm aperture sieve and
shall be remixed if lumps are retained.

S21.18.10 Transporting grout

Grout shall be transported from the mixer to the position of the pile in such a manner that
segregation of the mix does not occur.

S21.19 Records

The Contractor shall keep records of grouting, including the date, the proportions of the
grout and any admixtures used, the pressure, details of interruption and topping up
required. Copies of these records shall be submitted within such reasonable time after
completion of each grouting operation, as may be required, and in any case not later than
noon of the following working day.

S21.20 Pile quality

A certificate of quality from the pile manufacturer shall be provided stating that the
requirements of this Specification have been fulfilled during manufacture.

S21.21 Marking of piles

Each pile shall be marked in such a manner that it can be identified with the records of
manufacture which shall state the date of casting, the cement type, the concrete grade,
element length, the prestressing force where appropriate and any other relevant data. On
delivery the piles shall be accompanied by records of manufacture. Lifting positions shall
be marked on each pile in accordance with the requirements of design.

S21-13
S21.22 Bend Tests

The Contractor shall carry out bend tests on the pile and on the pile joint in accordance
with MS 1314 : Part 1 : 1993 when instructed by the E.R.

S21.23 Driving piles

S21.23.1 Strength of piles

Piles shall be not be driven until the concrete cubes have achieved the specified
characteristic strength and the pile has attained the strength to resist driving stresses,
whichever is the greater.

S21.23.2 Driving Resistance

Unless otherwise specified in the contract piles shall be driven to achieve an ultimate
static resistance not less than twice the working load shown in the contract.

Before commencement of pile driving the contractor shall submit pile driving
methodology, equipment and details to the E.R. for his approval.

S21.23.3 Preliminary test piles

The Contractor shall carry out driving and testing of preliminary piles. The number of
preliminary test piles shall be specified or instructed by the E.R. The Contractor shall
propose a programme for carrying out the preliminary pile tests and shall give at least 24
hours notice of the commencement of driving and testing of the preliminary test piles.

The following tests shall be carried out on each preliminary test pile:

(a) Dynamic load tests or high strain dynamic pile test in accordance with ASTM D4945
– 96 : “Standard Method for high Strain Dynamic Testing of Piles” during the entire
driving process of the pile or over a length of the pile specified or directed by the E.R
to measure the dynamic stresses and dynamic resistance through depth and to
evaluate the hammer performance and driving stresses.

(b) Dynamic load tests to evaluate the integrity, pile capacity and load – settlement
behavior at 4, 8 and 14 days after completion of driving.

(c) Maintained static load tests in accordance with the Specifications with the additional
requirement that sufficient reaction shall be provided to enable the pile to be tested
up to three times the working load of the pile.

S21.23.4 Depth of Penetration

If the E.R. is not satisfied with the depth of penetration irrespective of the driving
resistance being attained, the Engineer shall specify the penetration and the contractor
shall carry on driving by increasing the driving energy which may include a change to a
heavier hammer. Driving shall be continued until the desired depth of penetration has
been attained.

S21.23.5 Pile Acceptance Criteria

S21-14
The E.R. shall select and instruct the Contractor on the working piles to be subject to
maintained static load tests.

Notwithstanding the E.R’s approval and acceptance of the contractor’s pile driving
equipment or system, driving and work methodology, when maintained static pile load
tests has been carried out as described in the Specifications, the pile so tested shall be
deemed to have failed if:-

EITHER

(i) After removal of the test load, the residual settlement under the working load
exceeds 3 mm;

OR

(ii) The total settlement under the working load exceeds 10 mm;

OR

(iii) The total settlement under twice the working load exceeds 30 mm, or exceeds
0.25mm per 10kN of test load; whichever is the lower value;

OR

(iv) The settlement under the working load exceeds 10% of the least width of the pile.

S21.23.6 Leaders and trestles

At all stages during driving and until incorporation into the structure the pile shall be
adequately supported and restrained by means of leaders, trestles, temporary supports
or other guide arrangements to maintain position and alignment and to prevent significant
damage to the pile.

S21.23.7 Performance of driving equipment

The efficiency and the energy of the driving equipment including when followers are used
shall be notified. Dynamic evaluation and analysis shall be carried out to verify the
efficiency and energy.

Where a drop hammer is used, the mass of the hammer shall be at least half that of the
pile. For other types of hammer the energy delivered to the pile per blow shall be at least
equivalent to that of a drop hammer of the stated mass. Drop hammers shall not be used
from floating craft in such a manner as to cause instability of the craft or significant
damage to the pile.

S21.23.8 Driving procedures and redrive checks arising from interruptions to driving

The driving procedure shall be such as to avoid damage to the piles.

The E.R. shall be given 24 hours notice of the commencement of the driving of the first
pile. The Contractor shall give adequate notice and provide all necessary facilities to
enable the E.R. to check driving resistances, sets and temporary compressions.

S21-15
The driving of the pile shall be continuous until the depth or set as required has been
reached. In the event of unavoidable interruptions to driving, the pile may be redriven
provided it can subsequently be driven to the desired depth and / or resistance or set
without damage. A follower shall not be used unless the set is revised where applicable
in order to take into account reduction in the effectiveness of the hammer blow.

Driving records shall be made for every pile. The record shall contain the weight and fall
of the ram and the number of blows for each 0.25 m of penetration.

The Contractor shall inform the E.R. without delay if an unexpected change in driving
characteristics is noted.

S21.23.9 Redrive checks on time effects on piles

The E.R. may at any time order re drive on piles already driven to set to check for farther
penetration on re drive. In the event that the re drives show the pile to penetrate farther,
the Contractor shall immediately inform the E.R. and shall submit for the acceptance of
the E.R.:

(a) His proposals for checking for time effects on all the already installed piles.

(b) The revised criteria for terminating the pile including the times for redrives, the
number of redrives on each pile and the minimum pile length.

(c) His proposals for additional dynamic and static maintained load tests.

S21.23.10 Set

The set and temporary compression shall be measured and recorded for each pile at the
completion of driving. When a set is being measured, the following requirements shall be
met:

(a) The exposed part of the pile shall be in good condition without damage or distortion.

(b) The helmet, dolly and any packing shall be in sound condition.

(c) The hammer blow shall be in line with the pile axis and the impact surface shall be
flat and at right angles to the pile and hammer axis.

(d) The hammer shall be in good condition, delivering adequate energy per blow, and
operating correctly.

(e) The temporary compression shall be recorded.

The set shall be recorded as the penetration in mm per 10 blows or as the number of
blows required to produce a penetration of 25 mm.

S21.23.11 Driving sequence and risen piles

Piles shall be driven in a sequence to minimize any detrimental effect of heave and
lateral displacement of the ground. The sequence and method of piling including
preboring shall limit uplift and lateral movement so that the final position of each pile is
within the specified tolerances. At all times the deflections of each pile from its axis as

S21-16
driven shall not be such as to cause damage or impair durability of the piles or any
structure or services.

The maximum permitted uplift of each pile due to any one pile driven within a pile center
to center radius of eight pile diameters is 3 mm unless it can be demonstrated by static
load testing that uplift exceeding the amount does not affect the ability of the pile to meet
the requirement of this Specifications.

Even if during the installation of preliminary piles uplift is shown to be within the permitted
maximum and the preliminary pile tested meet the requirements of the Specifications,
checks of uplift on working piles shall be made by the Contractor at least once a week
and the results reported to the E.R.

If preliminary piles are not installed the Contractor shall commence installation of working
piles taking measures to reduce or eliminate uplift until it can be established by site
measurements that such measures are no longer necessary. Thereafter checks on uplift
shall be made by the Contractor at least once a week and the results reported to the
Engineer.

If a static load test shows that piles have been laterally displaced so as to be outside the
permitted tolerance, damaged or of impaired durability the measures the Contractor plans
to adopt to enable the piles to comply with the Specification shall be provided to the
Engineer.

Laterally displaced piles shall not be corrected by forcible correction to the head.

S21.23.12 Preboring

Pre boring shall also be carried out if the pile cannot penetrate through a layer or layers
of stiff to hard materials. The Contractor shall submit his proposals for pre boring for the
agreement of the E.R.

S21.24 Repair and lengthening of piles

S21.24.1 Repair of damaged pile heads

If it is necessary to repair the head of the pile before it has been driven to its final level,
the Contractor shall carry out such repair in a way that allows the pile driving to be
completed without farther damage. If the driving of the pile has been completed but the
level of sound concrete of the pile is below the required cut off level, the pile shall be
made good to the cut off level, or the pile cap or the substructure may be locally
deepened, so that the completed foundation will safely withstand the specified working
load.

S21.24.2 Lengthening of precast reinforced and prestressed concrete and prestressed spun piles

Any provision for lengthening piles incorporated at the time of manufacture shall be
designed by the Contractor to resist all stresses to which it may be subjected.

If no provision for lengthening piles was incorporated at the time of manufacture, any
method of lengthening shall be such that the extended pile including joints is capable of
taking safely the stresses during driving and under load.

S21-17
S21.24.3 Driving repaired or lengthened pile

Repaired or lengthened piles shall not be driven until cubes for the added concrete have
reached the specified characteristic strength of the concrete of the pile.

S21.25 Cutting off pile heads and removal of surplus length

When the driving of the pile has satisfied the Specification requirements the concrete or
the head of the pile shall be cut off to the level specified. Reinforcing bars projecting
above this level shall be as specified.

Care shall be taken to avoid shattering or otherwise damaging the rest of the pile. Any
cracked or defective concrete shall be cut away and the pile repaired to provide a full
sound section to cut off level.

Surplus length cut off shall be removed to the Contractor’s own disposal areas off site.

S21-18
MINIMUM STRUCUTRAL REQUIREMENTS FOR PRECAST CONCRETE PILES

Type & Class of Piles Precast reinforced concrete pile Precast pretensioned concrete pile Precast pretensioned spun concrete pile
Requirements Class 1 Class 2 Class X Class Y Class A Class B
1. Grade of concrete 40 25 50 55 50 55
2. Minimum cement
content (Kg/m) 400 320 450 450 450 450
3. Min longitudinal Min 1.2% of cross Min 1.0% of cross Min effective stress of Min effective stress of Min effective stress Min effective stress of
reinforcement section or at least 4 section or at least 4 5 N/mm 7 N/mm² of 5 N/mm² 7 N/mm²
bars bars
4. Lateral 1.0% of gross 0.6% of gross Min bar size of 6mm diameter at 50mm spacing Spiral hard drawn steel wire shall be not less
reinforcement volume over distance volume over distance over distance of 3 x pile width from each end. than 4mm diameter at a pitch of 50mm over
- at pile/toe of 3 x pile width from of 3 x pile width from distance of 3 x pile size from each end.
each end. each end.
- at pile body 0.4% of gross 0.2% of gross Spacing gradually increased from pile end to Spacing gradually increased from pile end to
volume spaced at not volume spaced at not spacing not exceeding pile size less 60mm spacing not exceeding 100mm.
more than ½ x pile more than ½ x pile
width. width.
 Min  Min  For pile size exceeding 600mm
bar/wire size is bar/wire size is diameter, spiral hard drawn steel wire
6mm diameter 6mm diameter shall not be less than 6mm
 Min  Min
spacing 40mm spacing 40mm
5. Nominal cover 40mm 40mm 30mm 30mm 20mm 20mm
6. Minimum thickness 15mm 15mm 15mm
of mild steel plate
for joint (mm)
7. Centering bar 32mm diameter 32mm diameter 32mm diameter
(minimum
anchorage length
200mm and
protruded length of
100mm)
8. Standard sizes Square section of 200mm, 250mm, 300mm, Square section of 200mm, 250mm, 300mm Cylindrical hollow section of external diameter
350mm & 400mm 350mm & 400mm of 250mm, 300mm, 350mm, 400mm, 450mm,
500mm, 600mm, 700mm, 800mm, 900mm,
1000mm & 1200mm.
NOTE 1. Spacing of lateral reinforcement shall be gradually changed from pile head/toe to pile body
NOTE 2. Size of longitudinal reinforcement bars for precast R.C. piles shall not be less than 16mm diameter for casting length of 9m & above
NOTE 3. Sufficient reinforcement must be provided to ensure that the crack width is well within the tolerable limit as specified in Clause 12 of MS 1314: Part 1: 1993
when subject to the cracking bending moment specified in Table 1. Table 2 and Table 3 of MS 1314: Part 1: 1993 as appropriate.

Table S21.2

S21-19

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