Huta - Hegerfeld

Intersection of Prince Majid Street with Sari Street

Project # 566

Piling Works Method Statement

Huta - Hegerfeld

TABLE OF CONTENTS

Page

A) Introduction B) Reference Documents C) Equipments D) Execution E) Quality Control

3 3 3 3 4

Appendices: Appendix 1: Appendix 2: Appendix 3:

Graphical Illustrations Sample Piling Record Used Reference

Huta - Hegerfeld

A) Introduction This document outlines the procedure that shall be followed for the execution of the Piles for Intersection of Prince Majid with Sari Street at Jeddah, Saudi Arabia. Type of piles is bored cast-in-situ. B) Reference Documents 1- Project structural drawings providing pile layout, length and reinforcement details 2- Geotechnical data from soil investigation at the concerned areas 3- Standards ACI 543R and ACI 336.3R for Concrete Piles 4- Piling execution shall be conventional to the Project Technical Specifications Volume 2 of 5 sections 5.06 and MOC General Specifications 1998. C) Equipments A piling group shall consist of the following equipments: 1- Drilling machine with rotary table to perform drilling as well as driving and extracting the temporary casing. 2- Service crawler crane for installing the reinforcement cage and holding the concrete tremie pipe. 3- Drilling tools (auger, bucket, and core barrel). 4- Tremie pipe. 5- Welding machine, Cutting kit (oxygen). 6- Vibro-hammer if required for extracting the temporary casing. D) Execution The piles shall be executed according to the following procedure: The drilling rig will be set up at the pile position, which will be located by a steel pin driven into the ground.

At the location of each pile the temporary casing will be installed using the drilling ring rotary down to noticeable resistance depth so as to penetrate the dense layer as further driving becomes difficult, actual driving depth may very, either shorter encountered, or deeper of soil resistance to driving is found to be sill weak, the purpose of this temporary casing is to
1.

Huta - Hegerfeld

prevent soil collapse at the top and to serve as a guide for the drilling tool as well as support for the steel cage. Below the temporary casing, soil is deemed to be firm enough to sustain drilling without further protection. If exceptionally it appears that soil at deeper depth requires confinement, then temporary casing shall be extended accordingly. No bentonite shall be used. In fact, bentonite is known to behave poorly with underground salty water. 2- Drill the pile down to the required depth in accordance to shop drawings using rotary drilling equipment (auger and bucket typically, core barrel if rock is encountered). Drilling may alternate with further driving of the temporary casing as mentioned in item # 1 above. Excavated materials shall be progressively disposed off the piling area to keep it free from obstructions and allow easy access and handling for concrete and reinforcement. 3- Install the pre-assembled pile reinforcement cage (equipped with temporary hook bars, and fitted with suitable spacers) in the drilled hole and suspend it temporarily with hooks on the casing. 4- Concrete will be placed through the tremie pipe (approximately 200mm internal diameter) from bottom to top, the concrete will be brought up to a level at least 2 m above the pile cut-off level to ensure that the concrete at cut-off level is sound logging of concrete consumption and description of subsoil formation with depth will be recorded as indicated on the attached sample sheet, noting that actual volume of concrete cast in the pile can only be assessed per transit mixer. Concrete shall have high workability to suit this method, in compliance with standard requirements (slump 18cm to 23cm -ACI 336.3R, see Appendix 3). 5- Cut the hooks suspending the steel cage on the temporary casing and extract the casing with drilling machine rotary table or with vibrohammer while concrete are still fresh. 6- Once all the piles are completed, excavation / compaction / blinding concrete shall be done and piles shall be trimmed down to the required cut-off level. Bending of the pile dowels if required shall be done as per the design requirement. Waterproofing pile head treatment shall then be carried-out. Dewatering shall be implemented as and where necessary.

Above steps are schematically illustrated in Appendix E) Quality Control Quality control steps that shall be followed with regard to the execution of the piles are as follow:

Huta - Hegerfeld

1- Execution shall conform to Standards ACI 543R "Design, Manufacture and Installation of Concrete Piles" and ACI 336.3R "Design and Construction of Drilled Piers as applicable to bored cast-in-situ concrete piles.

Huta - Hegerfeld

2- Ensure that the drilling platform is stable for the piling equipment to operate on and at least 1.00 m above ground water level. The drilling platform shall also be at least 1.00 m above the top of pile cap, in order to m aintain the pile reinforcement dowel bars embedded below ground, thus not hindering the movement of the equipment. 3- The location of each pile shall be surveyed and clearly marked with a stick around which the temporary casing will be centered for driving. Tolerance on location at the pile head shall not be more than 75mm (ACI 543R - 2.4.1). 4- Verticality of the temporary casing and drilling tool shall be checked at regular intervals. Deviation of the pile from the vertical shall not exceed 2% (ACI 543R -2.4.2). 5- Soil extracted from the drill hole shall be regularly removed to a disposal area in order to keep the site free from obstructing materials and allow easy movement of machinery and access / handling for concrete and steel. 6- Drilling depth shall be regularly checked with a weight attached to a measuring tape, dropped to the bottom of the drill hole. Top level of temporary casing shall be recorded and used to monitor the drilling depth. Approximately 20cm over drilling will be implemented to ensure proper cover to the pile reinforcement at bottom. 7- Spacers shall be arranged around the steel cage at regular intervals (typically 1.5m) to ensure proper cover to reinforcement. 8- Steel cage segments shall be securely fastened to each other by tack welding to avoid slippage after installation in the drilled hole and concrete casting. 9- Concrete tremie pipe shall first be lowered down to touch the bottom of the drilled hole then lifted by approximately 20cm. This allows double-checking the depth of the drilled hole and ascertaining that muddy water will be entirely displaced during concrete casting. Tremie pipe is lifted up while casting the concrete but shall remain embedded in the fresh concrete by at least 1m to avoid mixing with muddy water in the drilled hole. 10- Special attention shall be given to have a highly workable concrete

with a slump range 180mm to 230 mm as appropriate for the method of casting, the slump range, the requirement of ACI 336.3R art.4.4.4 to have a highly workable concrete is a must considering the method of casting (by tremie pipe under water without vibration). In fact super plasticizer shall be added on site to achieve the 3/ required slump range. Maximum aggregate size inch. Sufficient should be retarding admixture shall be included in order to allow for the casting time and extraction of temporary casing (ACI 336.3-4.4.4). 11-A piling record shall be prepared for each pile listing the pile location, pile No., pile diameter, pile excavated and casting date, concrete type, concrete theoretical quantity, casing top level, casing length (C), platform level, cut off level, pile

Huta - Hegerfeld

bottom Level excavated level as well as the total depth (L) (see Appendix 2 attached sample).

(BOP), actual

12- in order to ensure that the concrete at cut-off level is sound a continuation of step # 11 shall proceed to record the actual concrete consumption based on Truck No., truck concrete quantity, total concrete quantity, actual casted depth per truck (Y), cumulated casted depth (D1), remained depth (D2), concrete temperature, concrete slump, plant batching time, concrete pouring time, as well as concrete finishing time noting that these registration shall be recorded as per each transit mixer. The casting shall be stopped only if assessment between the theoretical concrete volume and the actual concrete consumption is satisfactory (see Appendix 2 attached sample). 13-Steel and concrete shall be tested in accordance with the Project Specifications as per the approved general Quality Control procedure.

Appendix 1 Schematic Illustrations

Appendix 2 Sample Piling Records

Appendix 3 Used References

Extract of ACI 336.3R Standard for Drilled Piers. Extract of ACI 543R Standard for Concrete Piers.

336.3a.22

ACt COPIMITTEE REPORT

supplier giving the physical and chemical properties. of

the mud should be supplied to the

Geotechnical Engineer at the start of the work. The slurry should be mixed, stored, and transported

using equipment normally used on drilled pier projects.

The water used to mix the slurry should be clean, fresh

The bottom of the drilled shaft should be checked to confirm that drill cuttings and hole sides are not falling
to the bottom, "Sounding" a tremie pipe or air lift pipe,

water, of a quality approved by the Geotechnical Engineer. Any physical or chemical treatment of the water
or slurry that is considered necessary to have the slurry

meet the specification is the responsibility of the drilled pier constructor. The slurry should meet the specifications given in Table 1. Water may be used in place of mixed slurry, but it must provide pier excavation stabilization and be subject to the approval of the Geotechnical Engineer. Slurry testing should be performed and recorded for quality control. All field test equipment should be provided by the drilled pier constructor. The frequency of testing should be a minimum of two sets of tests per work shift, the first test being done at the beginning of the shift. Field conditions and the requirements of the
drilled pier constructor and the Geotechnical Engineer

may make more frequent testing necessary. such as multiple tests per pier, to assure an acceptable slurry. The drilled pier constructor should have available at the site, a slurry sampler capable of obtaining slurry samples at any depth within the drilled shaft excavation if requested by the Geotechnical Engineer. The constructor should use such drilling tools and excavation procedures that excessive negative fluid pressure in the excavations is prevented. At the completion of excavation, the drilled shaft bottom should be cleaned with an air lift system or a cleanout bucket equipped with a one-way flap gate that prevents spoils in the bucket from re-entering the shafts, or other suitable
tools. The hole specifications slurry should prior meet the

or "feeling" with a weighted line are acceptable methods for checking bottom build-up of material. The permissible amount of drill cu ttings at the bottom of the pier should be less than 6 in. (152 mm) in depth without recleaning the hole or modifying the slur ry for piers designed without end bearing. 4.4.3 Reinforcing steel-- Reinforcing steel should be placed in a shaft excavation after the Geotechnical Engineer has completed his observations and has approved placement. Following approval of the excavation, the reinforcing steel should be centered in the hole at the correct position and elevation using spacers as necessary. Reinforcing steel should not touch the sidewall of the excavation and should be completely encased in concrete using appropriate spacers as necessary. Minimum concrete cover of 3 in. (76 mm) should be maintained and the minimum clear spacing between reinforcing steel should be 4.0 in. (102 mm) between ho rizontal reinferable) the forcement and 3 times (5 times p re
size of the maximum coarse aggregate between vertical
re inforcement (a minimum of 3 in. [76 mm]). 4.4,4 Concrete-- All concrete should satisfy the following requirements:

a) b)

Concrete used in the slurry displacement method should have a slump of 7 - 9 in. (178 - 229 mm). Maximum aggregate size should be 44 in. (19 n

to facilitate feeling the bottom with a sounding rod or weighted tape. Slurry should be sampled and tested from the mud tank and from samples recovered within 1 ft (0.3 m) from the bottom of the drilled pier.

to concreting. If cleaning, recirculating, depanding, or replacing the slurry is necessary, the contractor should be prepared to do so. Concreting the drilled piers should be completed the same day that the excavation is complete. If this is not possible, the excavation should be redrilled, cleaned, and slurry tested before concreting. The theoretical concrete volume may be plotted graphically for each pier size and compared with the actual volume of concrete placed after each truck load (or at regular intervals if pumped) and For piers with end bearing, the slurry sand content should be limited to 4 percent; otherwise the sand content should be limited to 10 percent, but sand contents to 25 percent have been used successfully in some locations. The slurry density should not exceed 75 pef (1.2 mg/m) for end bearing piers. The closer restrictions in the case of end bearing piers are necessary
noted on the graph.

c)

r A dm quate retarder to produce a 5 in. (127 mm) or greater slump after 4 hours. The type of retarder should be approved by the Engineer.

Placement of concrete should be made following approval of the excavation by the Geotechnical Engineer and placement of the reinforcing steel. Pier excavations should be clean before the start of concrete placement. An air lift or a clean out bucket equipped with a onedirection flow gate should be used to clean the bottoms of each shaft, depending on the Contract requirements. If the design includes end bearing, the bottoms should be sounded again with the weighted tape after the steel placement and just prior to concrete placement. All concrete must be placed within the time limit during which the excavation remains clean and stable and the concrete remains fluid. Placement should not begin until adequate concrete supply is assured. 4.4.5 Concreting methods-- Concrete may be placed by tremie methods or by pumping. In either case, a plugged, capped, or "rabbit" plugged tremic should be inserted and seated in the excavation. The trcmie should extend to the bottom of the shaft prior to the commencement of concrete placement and care should be taken to ensure that all slurry suspension is expelled from

5438-20

ACt COMMITTEE REPORT

accurate positioning of the pile over its location stake; equipment inadequate to hold the pile on location; the pile drifting off location due to underground obstructions or A,P = 0.12 s,Ph,.fh(0.5+ 1.A sloping hard f,) (2.13) soil strata; misalignment of piles driven through overburden: or by general ground movements after the piles have been where driven caused by embankment pressures, construction operations, or other surcharge, loads. Ir, = cross-sectional dimension of pile core mal service axial load plus that produced measured by an earthquake. center-to-center of spiral or tic reinforcement and with 2.4-4nstallation and service the limit that conditions affecting 5 70,000 lb/in.2 (480 MPa). design The formats of the equations for high Several installation conditions can affect the overall pileseismic risk regions. but not the numerical constants, follow foundation design and the determination of pile capacity. research conSome of these relate to installation ducted in New Zealand (loon and Park 1990) methods, equipment, and and the New Zealand Standard Code of Practice techniques (Chapter 5). Others relate to for the Design of Concrete Structures (1982). the subsoil conditions or the qualifications of the pile 2.3.63 Needed research-Most of the contractor. Obviously. reversed bendthe engineer cannot allow for all ing tests of piles have been conducted on octagonal pretencontingencies in his design sioned members (Banerjee el a]. 1987). Other but many can be provided for by proper tests, including analysis of subsoil tests of square members with round and square data, preparation of competent reinforcespecifications, use of qualimen( patterns and round members of both tied contractors, and adequate inspection reinforced and preof the work, stressed concrete are needed, along with 2,4.1 Pile-head locution tolerances supposing Some tolerance analytical work. These tests should include a should be allowed between the asfull range of installed position of the confinement reinforcement ratios or areas, and pile head and the required plan location. should inDeviations from the clude tests with and without axial loads. Both plan pile-head locations can be caused solid and holby: survey errors; inlow members should be considered. In addition to studies of the rotation capacities that arc possible from various mem bers, studies of the rotational demands or requirements that can be imposed by the supported structure with various soil profiles are needed. 2.3.6.4 Vertical accelerations-Expe rience from the 1994 Northridge earthquake in California reveals that at and near the epicenter, vertical accelerations approached the magnitude of horizontal accelerations. This is significant because accelerations on the order of 1.0 g were recorded. The ramifications of high vertical accelerations should be considered by the structural engineer relative to piling because se-

but not less than

vere axial overloading of piles can occur under earthquake

conditions. In geographic areas where high vertical accelerations are possible, it may be advisable to consider another case of loading that codes do not now consider, namely, nor-

The deviation that should be allowed varies with the pile load and group size. A smaller tolerance is required fora single pile carrying a very high load. A larger tolerance can be allowed fora large group of piles under a structural mat. A tolerance of 3 in. (75 mm) in any direction is reasonable for normal pile usage . Marine work and large piles may require larger tolerances, , Generally, an overload of 10% on a pile due to deviation of the pile location does not require modifying the pile cap or group. Ifthis overload is exceeded, additional piles should be installed (and where necessary the pile cap modified) so that the center of gravity of the group remains substantially under that of the load, Sometimes piles driven off location can be pulled or pushed back into plan location, but this practice is not recommended. If this practice is permitted, the force used to move

the pile into proper position should be limited and carefully

controlled according to a lateral load analysis, considering the type and size of pile and the soil conditions. This is especially critical for precast piles used for trestle structures where a long moment arm can result in structural damage to the pile even with relatively low forces (Section 5.3.5). 2.4.2 Axial alignment tolerances -Deviations from required axial alignment can result from the pile driven off required alignment but with its axis remaining straight, the pile driven with its axis not on a straight line from pile head to tip, or a combination of these two with the pile bent and the tip off its plan location. Deviations from a straight line axis can take the form of a long sweeping bend or a sharp bend called a dogleg. The deviation of the pile axis from the specified alignment, whether vertical or battered, should be within the following tolerances: 'two rcent for embedded piles driven through sandy sails or soft clays; Four percent for embedded piles driven through difficult soils of nonuniform consistency. boulder-ridden soils, or batter piles driven into gravel; and A maximum of 2% of the total pile length in marine structures that have over half the pile length in water rather than soil. Piles driven outside of these tolerances s hould be reviewed by the engineer. The review should includ e consideration of horizontal forces and interference with other piles and may require review of the pile cap. For axial deviations from a straight lin e (bent piles), the allowable tolerance could range from 2 to 4% of the pile length, depending on subsoil conditions and type of bend, which could be sharp (excluding breaks in the pile) orswceping bends of varying radii. Experience and load tests have demonstrated that, in most cases, the pas sive soil pressures