Method Statement Document No: VIA/ELS/MS/001
For Date: 20.03.2018
Spun pile driving
Page 1 of 26
Method Statement
For
Spun pile driving for
Document No. :
Rev. No : 02
Prepared Date : 20.03.2018
Department :
Revision Control Table
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Method Statement Document No: VIA/ELS/MS/001
For Date: 20.03.2018
Spun pile driving
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Rev. Date Rev. No. Description of Revision Remarks
21/09/2017 00 First Issue
24/01/2018 01 Second Issue
20/03/2018 02 Third Issue
Contents
1. Introduction......................................................................................................................... 16
1.1. Purpose....................................................................................................................................16
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Method Statement Document No: VIA/ELS/MS/001
For Date: 20.03.2018
Spun pile driving
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1.2. Scope of Work.........................................................................................................................17
1.3. Work Sequence.......................................................................................................................18
2. General Approach for the construction...............................................................................19
3. Construction Time.............................................................................................................. 19
4. Material............................................................................................................................... 20
4.1. Concrete Spun Pile.................................................................................................................20
4.2. Structural Details.....................................................................................................................20
5. Pile Driving Equipment.......................................................................................................22
5.2. Crane Mounted BSP CX 110 Hammer................................................................................22
5.3. Junthan PM26 Pile Driving machine..........................................................................................25
6. Work Method...................................................................................................................... 26
6.1. Surveying.................................................................................................................................26
6.2. Driving of test pile......................................................................................................................26
6.3. Pile Driving Procedure............................................................................................................26
6.4. Positioning and Welding.........................................................................................................28
6.5. Verticality of Piles....................................................................................................................30
6.6. Verticality Correction of a pile................................................................................................31
6.7. Pile Termination criteria..........................................................................................................31
6.8. Testing of pile............................................................................................................................31
6.9. Pile cut off................................................................................................................................31
7. Safety................................................................................................................................. 32
Figure Control Table
Figure 1 - Proposed Project Location.........................................................................................................17
Figure 2-Work Sequence...........................................................................................................................18
Figure 3 Reinforcement Details.................................................................................................................21
Figure 4 Self-hanging System.....................................................................................................................23
Figure 5 Leader mounted system..............................................................................................................24
Figure 6 PM26 Pile Driving rig....................................................................................................................25
Figure 7 test pile location..........................................................................................................................26
Figure 8 Pile Driving arrangement.............................................................................................................27
Figure 9 Spun pile welding.........................................................................................................................28
Figure 10 Connection details of Welding Joint..........................................................................................29
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Method Statement Document No: VIA/ELS/MS/001
For Date: 20.03.2018
Spun pile driving
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Figure 11 Verticality Monitoring................................................................................................................30
Figure 12 Concrete pile Cutting.................................................................................................................32
Tabl
Table 1 Work Schedule..............................................................................................................................19
Table 2 Structural Properties.....................................................................................................................22
Table 3 BSP Hammer performance............................................................................................................23
Table 4 Juthan HHK-9A Hammer performance..........................................................................................25
Annexure
Annexures 1 Company profile CEPCO................................................................................................33
Annexures 2 Pile Driving equipment specifications...........................................................................34
Annexures 3 Pile Driving record sheet.................................................................................................34
Annexures 4 PDA Method Statement..................................................................................................37
Annexures 5 Static Load Test Method Statement (MLT)..................................................................38
Annexures 6 Organization Chart..........................................................................................................39
Annexures 7 Detailed Work Program...................................................................................................40
Annexures 8 Reference Drawings........................................................................................................41
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1.0 INTRODUCTION
It is proposed to expand the terminal building xxxxxxxxxxxxxxxxxxxxxx submitting a
proposal for installing 600mm diameter spun piles instead of bored piles given in the
original proposal by the designer. This revised method statement is submitted for driving
of spun piles considering enhanced pile capacity of 160MT (working load).
1.1 Purpose
This method statement covers the detailed method followed during spun pile
driving including safety precautions, machinery, men and documents related to
spun pile installation.
1.2 Work Scope
Approximately 1480 piles are to be installed according to the revised drawings
issued after enhancing the pile capacity for Proposed Terminal Building and CUC
building. The site location is shown in Figure 1.
Figure 1: Site location
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For Date: 20.03.2018
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2.0 Pre-driven activities
2.1 Surveying
After establishing the control points, ELS shall mark the piling points in
consultation with the client/ Engineer of the project. Pegs with markings shall be
used to mark the pile positions. An offset line shall be established facilitating to
re-locate the pile positions.
2.2 The spun piles
The spun piles used for this project shall be cast in Malaysia and imported to
Male. The outer diameter of the pile is 600mm and the wall thickness is 100mm.
For ease of driving, we will use an Oslo shoe, made of steel as shown in Figure 2 below.
Figure 2: Detail of the pile shoe used
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2.2.1 The pipe supplier:
M/S Concrete Engineering Product Berhad, Malaysia the company who has supplied the
Concrete spun pile for this particular project is well established public listed organization since
1983, they are fully certified with the requirement of SIRIM QAS Intranational and MS ISO
9001:2000 (quality management system for Manufacture of pre-tensioned spun concrete pile and
poles), the IKRAM QA Services ‘MS 1314: Part 4:2004 (Product certification for Class A, B and
C of precast pre- stressed spun concrete piles for 250mm to 1000mm diameters).
They have five factories located in Malaysia and their annual rated pile production capacity
approximate 1,030,000 tons.
CEPCO PHC Grade 80 Class B (Effective Pressure ≥ 5.0 N/mm2), 600mm diameter concrete
spun piles will be used for the project.
2.2.2 Structural Details of spun piles
The structural reinforcement details of CEPCO spun piles are showing in figure 3 and structural
properties are showing on Table 2
The Company profile of the supplier showing on Annexure-I
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For Date: 20.03.2018
Spun pile driving
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Figure 3: Reinforcement Details of spun piles proposed
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Table 1: Structural Properties of proposed spun piles
2.3 Welding
The estimated depth of pile is 12m. However, since the possibility of penetrating
some of the piles more than 12m is not impossible, we will order 30% of the pies
with 9m bottom and 6m top to make 15m total length involving one welded joint.
The spun piles of 9m bottom and 6m top will be used to make 15m piles. The
jointing will be done by welding.
Gas Metal Arc welding technique (MIG Welding) shall be used for welding.
1.2mm flux cored wire with an auto feeder unit shall be used for welding.
Welding process is a semi-automated system. A qualified welder shall be
employed for the welding process.
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3.0 Pile Driving Equipments
A crawler crane of 70-t capacity will be used to operate the pile driving hammer. In order to
lift maximum weight during pile driving will be about 25 tons.
Following Major Equipment are planned to use in the project
Crane Mounted BSP CX 110 Pile Driving Hammer
PM-26 (junthan) Pile Driving rig.
25t Mobile Crane
3.1 Crane Mounted BSP CX 110 Hammer
The hammer performance is showing in Table 02. The crane mounted operation of the hammer is
shown in Figure 4. The same hammer operated as a leader mounted system is shown in Figure 5.
Table 2: BSP Hammer performance
Model Ram Mass Max Impact Blow rate @ rated Operating Hydraulic Flow
Energy Energy pressure Required
Kg KNm bpm Bar L/min
CX 110 9000 106 36 250 215
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Figure 1: Self-hanging System
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Figure 2: Leader mounted system
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3.2 Junthan PM26 Pile Driving machine
Junthan PM26 Crawler mounted complete pile driving rig supposed to use to speedup the
pile driving process and the piling rig with powered by Cummins QSX 15tier 3 338 Kw
Engine. The HHK -9A Junthan Pile driving hammer is planned to use with the machine. The
Hammer performance is showing in Table 04. And the technical data of the machine showing
on Annexure 02-II. The Pile driving rig is showing in figure 06.
Table 1: Juthan HHK-9A Hammer performance
Model Ram Mass Max Impact Blow rate @
Energy rated Energy
Kg KNm bpm
HHK-9A 9000 105 40-100
Figure 3: PM26 Pile Driving rig
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For Date: 20.03.2018
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4.0 Driving Activity
4.1 Driving Machine
The pile shall be driven to final set using BSP CX 110 hydraulic hammer with
9MT ram weight. Details of the BSP CX110 hydraulic hammer are shown in
Appendix. The drop height can be changed as required upto 1.2m. However, as
per the results of test piles, we will be using a drop height of less than 0.5m for
pile driving. The Technical Data Sheets of the CX 110 hammer is shown in
Annexure 1.
4.2 Pile driving system
The pile driving system comprises of 9.0 MT hammer, strike plate, hammer
cushion, helmet and pile cushion to transfer the energy of hammer blow to the
pile head. The details of the hammer cushion and pile cushion are given below.
The schematic diagram of driving system is shown in Figure 7
Hammer Cushion
Diameter – 650
Height-210
Material- Synthetic Nylon cushion
Elastic modulus 2247.69 MPa
Pile cushion details
Diameter – 600mm
Thickness – 50mm
Material – Ply wood
Analysis done using GRL WEAP analysis showed that the hammer is quite sufficient to
drive the piles safely. An analysis done for new borehole 1 is given in Annexure 2. The
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For Date: 20.03.2018
Spun pile driving
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drop height of hammer can be raised to 1.0m whereas the analysis shows that a drop
height of 0.5m is sufficient to mobilize the required load.
GRL WEAP analysis done for a drop height of 0.5m shows that the driving stresses can
be maintained within acceptable limits. This has been seen while installing test piles and
dynamic load test as well.
4.3 Measures taken to avoid damage to the pile
Pile can get damaged during driving due to few reasons like,
1. exceeding the allowable tensile stress of pile material
2. exceeding the allowable compression stresses of pile material
3. Pile bending during driving
Following precautions have been taken to avoid damages due to above reasons.
Pile material is grade 80 concrete. This can withstand high compressive stresses during
driving. The allowable tensile and compressive stresses are given below.
Pre-stressed to 5.2 N/mm2.
Allowable dynamic pile stress in tension is given by;
fpe+0.25 (fc)0.5 where fpe = effective pre-stress of pile and = fc is 28 day compressive
strength of pile concrete.
Accordingly, allowable tensile stress = 7.44N/mm2.
Allowable compression is given by;
0.85 (fc) -fpe
Accordingly, allowable dynamic pile stress in compression = 62.8N/mm2
It was seen during installing the test piles that by maintaining the drop height at 0.5m,
the driving stresses can be maintained within the allowable limits.
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Bending of the pile during driving may occur if the hammer blow is not in the pile axis or
if attempted to make the pile vertical after driving to certain depth. This will be avoided
by making sure that the pile is made vertical before starting pie driving after positioning.
The pile cushion shall be checked periodically to make sure that it is not damaged due to
previous driving and will be replaced if it is observed that the pile cushion is not uniform
in thickness.
4.4 Pile Driving Procedure
After setting out the pile point, the 9m pile shall be transported to the
driving location.
During lifting, the pile shall be handled as per the guidelines by the
supplier.
The pile end with driving shoe shall be placed centering the pile location.
Pile shall be made vertical using the spirit level and plumb bob method
described in Section 4.0 below.
The drop height shall be maintained below 0.5m during driving to make
sure that the allowable driving stresses are not exceeded.
During driving pile driving record shall be recorded by the piling
supervisor. The piling supervisor would fill pile driving record when
driving is in progress and would be submitted to the consultant for
signature with signature of consultant’s representative at site.
5.0 Positioning of pile
The pile points shall be set out before commencing the piling work. A guide frame shall
be used to make sure that the pile bottom does not move any direction. The guide frame
shall be maintained in position until pile is driven to a depth that the pile bottom has no
way to move laterally.
6.0 Verticality of pile
To ensure a pile is truly vertical it is required to maintain verticality in two perpendicular
directions during driving. Therefore, a sensitive spirit level and plum bobs shall be used
during driving to maintain the verticality.
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6.1 Plumb Bob Method
To maintain the pile verticality a string with a plumb bob would be stretched at
the end of the fixed “L” angle. It is required to drive two “L” angles as shown in
Figure 8. To prevent wind induced swing of the plumb bob, the plumb shall be
immersed in a bucket of water. Two plumb bobs shall be used to monitor the pile
verticality at two perpendicular directions. Pile line can be aligned with these two
“L” angles conveniently.
1 ½” x 1 ½” angle iron
1 ½” x 1 ½” angle
iron
Approx.
2.0 m
Water bucket
Figure 8: Maintaining the pile verticality by plumb bob method
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6.2 Sprit Level Method
To maintain the verticality while driving it is required to place spirit level on two
adjacent vertical faces of pile & make sure they are vertical at the same time.
Figure 9 shows the spirit level method of checking the pile verticality.
Place Spirit level on vertical face of pile
A
D B
Figure 9: Maintaining pile verticality by spirit level method
Practically, to maintain the pile position as well as verticality two strings
stretched along the pile line (B-D direction) can be used conveniently & in the
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perpendicular direction (A-C direction) spirit level can be used to maintain the
verticality.
6.3 Verticality Correction of a pile
Pile driving would be started only after making sure that pile is vertical. This will
be done using the methods discussed in sections 5.2 and 5.2. If any tilt is observed
beyond 1 in 75, the leader of the pile rig would be adjusted to bring the pile to
vertical position before commencing driving.
.
7.0 Tubular Pile Jointing while diving
The top pipe shall be positioned on the bottom pile accurately. Then welding of top pipe
shall be done on horizontal plane as shown in Figure 10.
Figure 10: Welding the top most pile to middle pile at site
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8.0 Pile termination
As per the results of the four test piles driven at site, it was found that the piles driven to
final set 2.5mm per blow gave satisfactory test results. Therefore, all the piles will be
driven to a final set of 2.5mm per blow.
The rock level was encountered in all the additional investigations made before reaching
12.0m. It is expected that there will not be drastic changes in the coral rock profile.
However, if there are locations with deep rock level, piles will be still driven to final set
of 2.5mm per blow.
The pile driving records maintained during installation of test piles show that the rate of
penetration per blow is more than 10mm per blow in the overburden upto 11.0m. The rate
of penetration will gradually reduce after 11.0m and will reach 2.5mm per blow when it
reaches the rock level.
If any abnormal behavior is observed in any of the piles, that will be carefully studied and
reported to the client.
9.0 Pile cutting
After driving the piles, the pile cut off level shall be marked by the surveyor on pile. This
will be verified by the main contactors surveyor before commencing pile cutting.
Piles will be cut at the cut off level using cutting machine modified to cut circular piles.
Figure below shows a similar pile cutting machine modified to cut circular piles. Since
the pile to pile cap connection proposed does not consider connecting the tendons of the
pile to the pile cap, the pile with the tendons will be cot during the pile cutting process.
The pile to pile cap connection detail is shown in Figure 7.
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10.0 Pile as built drawing
Once the pile cutting is complete, as built survey will be done section wise and the as
built drawings shall be submitted. Coordinates showing the theoretical and actual
coordinates will be submitted with the deviations if any. The deviations if any will be
reported to the designer for review of the pile cap design.
11.0 Testing of Piles
11.1 High Strain Dynamic Load Test
High strain dynamic load test are done by applying a high energy impact on the
pile head to mobilize the soil resistance. During testing, pile head is monitored to
obtain the velocity and the force at the top of the pile. Since the applied load is
dynamic in nature, the measured acceleration and the velocity should be analyzed
and interpreted to obtain the static resistance and the static load-settlement
behavior. A schematic diagram of PDA test is shown in Figure 11. A detailed
method statement for dynamic load test will be submitted.
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Hammer
Monitoring the pile top
Data acquisition
using strain gauges and
and storing device
accelerometers
Mobilized pile resistance
due to the stress wave
Stress wave
propagation
passing though
Figure 5: Dynamic load test on pile, Schematic Diagram
Figure 5: Schematic diagram of PDA testing arrangement
Figure 11: Schematic arrangement of sensors for PDA test
11.2 Static load test
Static load test on piles shall be done on request on a selected pile to prove the
static capacity of pile. A separated detailed method statement for the static load
test shall be submitted before commencing the test. Basic set up of the static load
test is shown in Figure 12. A separate detailed method statement will be submitted
for the static load test
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Figure 12: Arrangement of static load test
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12.0 Sequence Of Piling
Mark 0.25 m interval on the
pile
Move the pile to the rig
Place the pile in the position
Check the Verticality and
position
Start driving (Fill
blow count record)
Continue driving up to
specified final set
Check the final set by giving 10 blows
and record the penetration. Repeat
the test for 3 times.
NO
If penetration at all 3
tests are equal or less
than the specific final
set
YES
Move to the next pile point
and repeat the same
procedure
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13.0 Safety Management
Since the activities related to the pile driving and load testing involve handling heavy
equipments and heavy loads, a proper safety management system is to be implemented at
site for related all the activities.
Safety precautions included checking the operational conditions of all the heavy
equipments used, supporting cables, pressure hoses and joints.
Safety helmets, boots and jackets are to be worn by all persons involved in the operation
and testing. Operation of all the machinery and equipments is to be done by operators
experienced in the relavent field.
Only the authorized persons who were aware of the work going on at site will be allowed
entering the site.
The adequacy of the beams used for preparing the reaction loading system of static load
test shall be calculated and proved before commencing the static load tests.
Any activity will not be proceeded if it any risk of doing it is identified. The following
general safety precautions shall be taken by all the work force.
All people would wear safety helmets, safety belts and safety shoes.
Skill well trained staff would operate equipments.
Site would be surrounded by safety tapes and un-authorized people would not be
allowed within the premises.
Workman compensation insurance would be available.
Plant & machinery insurance would be available.
All the welders are to wear the proper PPE before working
All the workers climbing above 1.5m to wear safety harness and other PPE
The risk assessment is attached to the end of this method statement
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14. Pile to pile cap connection detail
The proposed pile to pile cap connection detail is shown in Figure 7 below.
Prepared by:
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