APCC (WLL)

AL DHAFRA PIPELINE & CONTRACTING CO (WLL)

P.O. BOX: 2608, Abu Dhb! " #.A.E.
TEL: 02 6$2%&2% FAX: 02 6$$'6(6
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INTEGRATED 3ANAGE3ENT 454TE3
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(I4O &00' : 2000. I4O '(00' : '&&6 & OH4A4 '800' : '&&&)
HI4TOR5 OF CHANGE
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A.R. ANSARI
QA / QC Manager
01/10/2005
R)=!)>)7 & A--),0)7 B: : M.S. KUMAR
D)1!920!62 : Technica ! C"##ercia Manager
4!920u/) :
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N*) : ELIE 3 EL 3O#44A
D)1!920!62 : Par$ner%Managing &irec$"r
D0) : 01/10/2005
4!920u/) :
N*) : 4A3I ? ?HO#R5

D)1!920!62 : C"%'(ner/ Managing Par$ner
D0) : 01/10/2005
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Table of Contents
.............................................................................................................................................. 1
Table of Contents................................................................................................................... 2
1. Scope of Work:................................................................................................................... 3
2. Reference Documents:....................................................................................................... 3
3. Materials:............................................................................................................................ 3
Concrete:............................................................................................................................ 3
3.2 Steel Reinforcement:..................................................................................................... 3
3.3 Spacers:........................................................................................................................ 3
4.4 Shoel:.......................................................................................................................... !
4.! Temporar" Casin#:....................................................................................................... !
4.$ Tremie %ipe:.................................................................................................................. !
4.& Concrete %ump:............................................................................................................ !
4.' (ther )*uipment:.......................................................................................................... !
! Se*uence of +ctiities:........................................................................................................ !
!.1 ),caation an- %latform %reparation .if re*uire-/:........................................................$
!.2 Sure"in# an- Settin# (ut:........................................................................................... $
!.3 0nstallation of Temporar" Casin#:..................................................................................&
!.4 Drillin#:.......................................................................................................................... &
!.! 1abrication an- 0nstallation of Steel Ca#e:....................................................................'
!.$ Concretin#:.................................................................................................................... 2
!.& ),traction of Temporar" Casin#:.................................................................................13
!.' Documentation:........................................................................................................... 13
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1. Scope of Work:
The purpose of this working procedure is to detail various activities involved
in the execution of piling works using Temporary Casing by rotary Method.
2. Reference Documents:
Client/Consultants Specification and drawings
All applicable statutory authorities reuirements
All applicable !nternational Standards
!nstitution of Civil "ngineers Specification for #iling
Soil !nvestigation report
Approved #ile $esign
Approved Materials
Approved %ormats
All Applicable !MS &!ntegrated Management System' (eneral #rocedures
3. Materials:
Concrete
Steel reinforcement
Spacers
Tying )ire
All materials shall be in accordance with contract specification reuirements.
Concrete:
The ready mix concrete shall be supplied inconformity with the specifications.
The concrete mix design and the ready mix supplier to be approved by the
Consultants/Client prior to the start of any concreting works. *eady mix
concrete shall be supplied and tested in accordance with the Contract
Specifications and applicable international standards. The source of supply of
concrete shall not be changed without prior approval of the client/consultant.
A ualified independent approved laboratory shall carry out the testing of
concrete materials as per contract/specification reuirements.
3.2 Steel Reinforcement:
Mill certificates of the proposed steel reinforcement+ inconformity with the
specification reuirements shall be submitted for Consultants review and
approval prior to procurement. Approved steel reinforcement shall be
procured and stored in a manner to prevent contamination and damage of
reinforcement upon delivery to site. *einforcement shall be clean and free
from loose rust and loose mill scale at the time of fabrication, fixing in position
and subseuent concreting. The grade of the steel shall be as specified. All
bundles of the reinforcement shall be identified at the factory with durable
tags to allow checking of the uality control at site. All reinforcing bars shall
be bent cold in accordance with the relevant standard.
3.3 Spacers:
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!n order to ensure free flow of concrete in the pile bore through rebar cage, a
cover of -. mm shall be ensured by disk shaped spacers. The spacers shall
be fixed at regular intervals on the steel cage length in accordance with the
contract specification with the first set of spacers being attached one meter
from the bottom of the cage and the last set one meter from the top of the
cage. %our spacers for each row shall be inserted in the steel cage during
fabrication.
Spacers shall be durable, shall secure the reinforcing bars in their position
and shall not lead to corrosion of the reinforcement or spalling of concrete
cover.
3.4 Ting Wire:
!n order to form a rigid steel cage, the intersecting bars of the longitudinal and
helical reinforcement shall be interconnected together by an approved tying
wire, the ends of which shall be turned in to the interior of the pile.
4. !"uipment:
Surveying !nstruments
#iling *ig
Crane
Shovel
Temporary Casing
Tremie #ipe
Concrete #ump
/ther "uipment
4.1 Sur#eing $nstruments:
)e intend to use Theodolite, leveling staff, Tape and other normal surveying
instruments as reuired to set out the piling works on the site.
4.2 Piling Rig:
The piling rigs to be used are self0erecting purpose build drilling rigs &or crane
mounted drilling rigs'. The mast height of the piling rig is sufficiently long to
carry a telescoping 1elly bar of sufficient length to attain the depth of pile
reuired. The piling rig will be mounted on track0lying undercarriages
complete with tracks for stability. The piling rig will be fully maintained in good
working condition and will be capable of traveling in all weather conditions on
site. The piling rig is fitted with a drilling bucket of reuired diameter and will
be capable of drilling through any type of rock. $epending upon the diameter
and depth of the pile, piling rigs shall be chosen depending on their capacity
and mobili2ed accordingly.
4.3 %rane:
Crawler Cranes of 34 to 54 tons capacity shall be utili2ed to meet the pro6ect
reuirements.
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All cranes shall have safety flaps to ensure that the ob6ects do not fall from
the lifting hooks while lifting.
4.4 Shovel:
Shovel shall be utili2ed to move away the $ebris/mud coming out from pile
boring to an approved location within the site and after it becomes dry, the
debris shall be loaded on to the trucks and disposed in accordance with
concerned authorities reuirements.
4.5 Temporary Casing:
)e intend to use reuired diameter casings with minimum thickness of 7mm.
The length of the casing shall be ad6usted according to the site reuirement
depending on rock/hard stratum levels. Casing pro6ection shall be
approximately 84 to 34cm above the platform level and casing bottom level
shall be minimum 4..m below the rock/hard stratum level.
Temporary casings shall be free from distortion. They shall be of uniform
cross0section throughout each continuous length. $uring concreting they shall
be free from internal pro6ections and encrusted concrete, which might
adversely affect the proper formation of piles.
4.6 Tremie Pipe:
A steel pipe of diameter 59 or :9 or 79 fitted with a uick coupler at the top for
tight connection with the concrete pump shall be utili2ed.
Alternatively a tremie pipe of diameter 59 or :9 or 79 with hopper on top can be
utili2ed.
The si2e of the tremie pipe shall be chosen depending upon the pile diameter.
4.7 Concrete Pmp:
Concrete pump of reuired capacity, where reuired, will be used to pump the
concrete under pressure into the pile bore by means of a tremie pipe.
4.! "ther #$ipment:
)elding Machine
#ick0up ;us/<an
$rilling buckets of reuired diameter fitted with #engo teeth 5 =os min.
& Se"uence of 'cti#ities:
"xcavation and #latform #reparation
Surveying and setting out
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!nstallation of Temporary Casing
$rilling
%abrication and !nstallation of Steel Cage
Concreting
"xtracting of Temporary Casing
$ocumentation
5.% #&cavation an' Platform Preparation (if re$ire'):
Manual Trial pits/trench work prior to piling works shall be carried out in order
to identify the location of existing services within the site and take necessary
action as per the situation. =ecessary permissions shall be obtained from the
concerned departments. !n case any services exist within the site necessary
precautions shall be taken to protect the services.
#rior to the commencement of the piling works, if reuired, the existing
ground shall be excavated to the piling platform level and will be maintained
in a dry and safe condition.
5.2 Srveying an' Setting "t:
>ualified surveyor shall carry out the setting out of the pile center positions as
per approved shop drawings from the main reference point upon completion
of the excavation and platform preparation works.
The pile center points to be set out by steel pins, checked for position, and
then driven at least 8. cm below the working platform level/existing ground
level of the piling rig.
The setting out pins consist of steel reinforcing bar that will be driven slightly
below the surface of the platform so that they will not be disturbed by the
piling activities, the pins will be marked with a colored ribbon so that they can
be easily located/identified. The setting out of pile locations to be approved by
the "ngineer prior to commencement of drilling works.
Additional two reference points shall be provided outside the casing in order
to monitor the center point of casing during installation. %rom the center point
of the pile &marked by steel pin' two additional reference points at ?4
4
to each
other and at a certain distance approximately eual to @ m from outside face
of the casing shall be installed prior to installation of casing. Two templates
from these two additional reference points shall be used while driving the
casing in order to avoid deviation from the plan position.
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5.3 *nstallation of Temporary Casing:
Aocate the pile center point by hand excavation. !nstall additional two
reference points outside the casing, at ?4
o
to each other and at a certain
distance approximately eual to @ m from outside face of the casing prior to
installation of casing in order to monitor the center point of casing during
installation. Two templates from these two additional reference points shall be
used while driving the casing in order to avoid deviation from the plan
position. !nitially temporary casing of reuired diameter and reuired length
should be pitched and centrali2ed over the center point of the pile. #lumb and
twist the temporary casing into the ground using rotary head of the piling rig,
while checking the reference points for position as detailed above and
maintain the verticality by checking with a long hand held spirit level in two
perpendicular directions. $uring installation of casing care shall be taken to
ensure proper alignment over the pile location. The tolerance for verticality
will be @ in -.. The pile location shall not deviate from the plan position by
more than -. mm at cut0off level. The Aength of the temporary casing shall be
ad6usted in order to achieve minimum embedment of 4..m inside the
rock/hard stratum as reported in soil !nvestigation report.
Continue driving the temporary casing by twisting until embedded in to the
rock/hard stratum level by 4.. m or until refusal whichever is less to avoid any
possibility of collapse of borehole walls. The verticality and plumb shall be
checked during installation as detailed above. !n case of collapse of the soil
beneath the toe of the casing is observed, the casing shall be driven further
until collapse ceases. !n case if we are not able to continue the casing
installation by rotary method we shall pre0bore over the pile location and then
continue installation of casing. Temporary casing pro6ection shall be
approximately 84 to 34 cm above the platform level.
5.4 +rilling:
After installation of the casing the drilling rig shall be set over pile location and
the soil/rock will be drilled up to the predetermined/designed elevation. The
operator shall monitor the display on the piling rig monitor in order to achieve
the reuired drilling depth.
After completion of drilling, the bottom of the bore shall be cleaned with
bucket in order to remove drilling cuttings and loose materials from the bottom
of the borehole of the pile. A drilling/cleaning bucket, that tends to Bsweep9 the
sand and debris from the toe of pile, shall be used for this purpose.
$rilling shall be carried out with the use of temporary casing as a support for
maintaining the stability of the boring. The bottom level of casing shall be
embedded in the rock strata or hard strata by 4.. m in order to achieve the
stability.
The debris coming out from the pile boring shall be moved away from the
location of piles to an approved location within the site with the help of Shovel
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and left for a day. After it becomes dry, the debris shall be removed from the
site and disposed in accordance with concerned authoritiesC reuirements.
#iles shall not be bored so close to other piles, which have recently been
cast, and which contain workable or unset concrete that a flow of concrete
could be induced from or damage caused to any of the piles.
5.5 ,a-rication an' *nstallation of Steel Cage:
!n order to lift and place the steel cage without permanent distortion
reinforcement in the form of a rigid steel cage shall be assembled with helical
reinforcement in accordance with approved pile design drawings. Delical
reinforcement shall fit closely around the main longitudinal bars and the
intersecting bars shall be tied together by approved tying wire, the ends of
which shall be turned in to the interior of the pile.
!n order to ensure the free flow of concrete in the pile bore and through rebar
cage, a cover of -. mm will be ensured by disk shaped spacers.
The spacers shall be fixed at regular intervals on the steel cage length during
fabrication, in accordance with the Contract Specifications, with the first set of
spacers being attached one meter from the bottom of the cage and the last
set one meter from the top of the cage. %our spacers for each row shall be
inserted in the steel cage during fabrication.
All steel cages shall be inspected and cleared by the consulting "ngineer
prior to their installation. The length of the steel cage shall be ad6usted as per
reuirement. Main Aongitudinal rebar shall be continuous over the specified
pile length including the pro6ection above cut0off level or the available bar
length of @8m, which ever is less.
Epon arrival or 6ust prior to the arrival of concrete transit mixer to site, the
bottom level of the borehole shall be cleaned and measures shall be taken to
ensure that there is no accumulation of silt or other loose material at the base
of the boring. The bottom level of the borehole shall be verified prior to
installation of steel cage. Then ready made rebar cage shall be lifted up by a
Crawler Crane with a set of double wire ropes and then lowered in to the
borehole until reuired depth by maintaining in position with reuired cover by
circular spacers as approved prior to the placement of the tremie tube and
hanged from the casing top with the help of three bent up B S 9 hooks with
reuired pro6ection above cut0off level. "nsure the reuired cage length prior
to installation and check the top level of the rebar after installation of steel
cage.
The minimum cover at the toe level can also be achieved by hanging the
steel cage with these three bent up B S 9 hook supports placed around the
periphery of the casing and by checking the top level of steel cage with
reference to the top level of casing and by recording length of cage as shown.
The hooks can be placed either from inside the cage or from outside the
cage.
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5.6 Concreting:
The concrete mix design to be approved by Consultants prior to the start of
any concreting works. Trial mix test results shall be provided for consultants
review. Concrete shall be supplied and tested in accordance with the Contract
Specifications.
Approved ready mix concrete of specified grade for piling works shall be
procured from the approved supplier.
After installation of the steel cage as detailed in item &.&+ tremie pipe of
proper length with one end elbow fitted with uick clamp system shall be
placed inside the borehole through steel cage till its end touches the bottom of
the borehole. Then the tremie pipe is raised approximately 84 cm. The
elephant trunk of concrete pump will be brought to the elbow of tremie pipe
and fixed by uick clamp and then concrete will be pumped through the
tremie pipe. Concreting of the pile shall be done by the approved ready mix
concrete using high slump concrete as allowed by the specs, general codes
of practice and ;.S 7445. Concrete pump and the tremie pipe shall form part
of the delivery pipe. )hile concreting, the tremie pipe is raised by service
crane with wire ropes according to the filling of the pile taking care that the
end of the tremie pipe is always inside the pile concrete and it shall be at least
@ meter below the concrete top level. The concreting operation will be
continued until the concrete of the pile shall be brought up sufficiently far
above the reuired finish level to allow for slumping on withdrawal of the
casing and to ensure that all laitance and weak concrete rises above cut0off
level. After completion of casting the pile the tremie pipe will be withdrawn
totally and placed in another pile borehole and continue the above seuence.
After concreting any deviation from the theoretical concrete volume should be
recorded.
Alternatively a tremie of proper length with a hopper on top can be used and
concrete will be directly discharged from the ready0mix truck in to the tremie
hopper. The use of this method or the other previously detailed depends upon
the accessibility conditions and the availability of concrete pump at the time of
concreting.
>uality Control tests such as slump test, temperature of concrete, cube
testing etc shall be carried out in accordance with the contract specification
reuirements.
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Any empty boring left shall be backfilled with the excavated material. Also if
reuired, the platform is then back0filled to the casing top level in order to
allow the drilling rig to move over the casing without damaging them.
5.7 #&traction of Temporary Casing:
!mmediately after casting the pile, remove the hooks supporting the rebar
cage and extract the temporary casings by twisting and moving upwards while
the concrete within remains sufficiently workable to ensure that the concrete
is not lifted and that the resultant pile is continuous and of full section. $uring
extraction, a sufficient uantity of concrete shall be added to compensate the
slumping of concrete and maintained inside the casing in such a way that
during the course of casing extraction the bottom of the casing is always
below the concrete surface until the casing has lifted up to the reuired finish
level so as to overcome the pressure from external ground water or soil and
to ensure that no reduction in section or contamination of the pile takes place.
The concrete of the pile shall be brought up sufficiently far above the reuired
finish level to allow for slumping on withdrawal of the casing and to ensure
that all laitance and weak concrete rises above cut0off level. The concrete
final top level after withdrawing casing should be nominally as per the
reuirement of contract specifications and sub6ect to checking on site for
soundness.
Adeuate precautions to the satisfaction of the engineer shall be taken in all
cases where excess heads of water could occur as the casing is withdrawn
because of the displacement of water by the concrete as it flows into its final
position against the walls of the pile bore.
5.! +ocmentation:
#iling rig daily report and inspection check list shall be used to record the
details of piling activity for each day.
A#CC shall record the pile identification, pile location, design load, pile type,
platform level/existing ground level, pile toe level, casing length, casing top
level, concrete mix details etc as per contract reuirement.
%or site control and progress #iling rig daily report and !nspection check list
shall be produced giving all information on site progress and all relevant data
of each single Secant pile.
This documentation completely filled will be transmitted to the Consultants at
the end of the Secant piling works.
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