New Babil 400kV Substation Project

Document Title

Method Statement for Driven Precast Concrete Piles

Issue for review and Mohammed

EX-DE 001 23/11/2020
.W
Wahab.J
approval
Validity Rev.
Status number Prepared Checked Approved Contractor Company
Date Description
by by by Approval Approval
Revision Index
Company logo and business name Project name

Contract N. #####
New Babil 400kV Substation
Elsewedy Electric
Contractor logo and business name Location : Babil-Iraq

AL-Yamama Engineering Co. ltd.

Facility Name Location Scale Sheet of Sheets

New Babil 400kV Substation-Pilling works ONSHORE n.a. 1 of 25
Document Title Supersedes N.

Method of Statement for Driven Precast Concrete Piles n/a

Area Unit
32°29'01.3"N DMS
44°37'55.7"E
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CONTENT
1.......................................................................................................................................GENERAL
..........................................................................................................................................................3
2. KEY PERSONALS & ORGNIZATION CHART.......................................................................5
2.1 Piling Manager.................................................................................................................................5
2.2 Project Manager..............................................................................................................................5
2.3 Geotechnical Engineer.....................................................................................................................5
2.5 QA/QC Engineer..............................................................................................................................5
2.6 HSE supervisor................................................................................................................................5
2.7 Field Supervisor...............................................................................................................................6
3. DRIVING SYSTEMS...................................................................................................................7
3.1 Impact driving.................................................................................................................................7
3.2 Press-in piling...................................................................................................................................8
4. EQUIPMENT & MANPOWER...................................................................................................8
4.1 Equipment........................................................................................................................................8
4.2 Hammer selection............................................................................................................................9
4.3 Equipment that will use.................................................................................................................10
4.4 Manpower......................................................................................................................................11
5. WORK SEQUENCE TO DRIVING PC. PILES.......................................................................11
5.1 Preparation the work to driving the PC. piles:............................................................................11
5.2 Driving Procedure.........................................................................................................................14
5.3 Factors affecting installation......................................................................................................22
5.4 Penetration Limitations & pile set................................................................................................22
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1. GENERAL
Driven piles are the most commonly used deep foundation system for
transportation projects. Piles are typically installed in groups using an impact pile
driving hammer. Multiple pile types with various section properties are available to
resist almost any load demand. Pile lengths for some pile types can be easily
adjusted and spliced in the field to accommodate variations in subsurface
conditions. Reinforced concrete piles consider more susceptible to damage during
handling and driving because of tensile stresses compared to steel piles.
Advantages of reinforced concrete piles included their lower net compressive
stress during driving and under foundation loads, and a reduced danger of pile head
cracking. To reduce corrosion of the reinforced concrete joints, splices were
located below the ground surface, or if under water, the mudline. Segmental pile
sections were used to produce piles with varied lengths to accommodate variable
soil conditions and were easily transported to job sites.

Al Yamama is one of the largest and leader company in Piling Construction

Industry. Our major presence and activities are in southern part of Iraq. Al
Yamama Piling Division is an entity formed to focus on deep foundation & ground
Improvement works. We are a strong and professional Piling Contractor with
specialist team of geo-technical engineers and field staff with wide knowledge of
piling activities and associated acquirements including methods to execute and
supervise sophisticated works on agreed time schedules.
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The purpose of this plan is to demonstrate the methodology approach of New Babil
400kV Substation-Pilling works on how to carry-out the installation of the precast
concrete piles.
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Figure (1): Pile classification chart

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2. KEY PERSONALS & ORGNIZATION CHART

2.1 Piling Manager

Piling manager has the overall responsibility for all AYA.Co piling projects
and responsible for providing logistical and technical support for all piling
projects.

2.2 Project Manager

Construction Manager has the overall responsibility for implementing all
functions as Construction, Surveying, inspection, observation, monitoring and
Logging this Method Statement.

2.3 Geotechnical Engineer

Geotechnical engineer mainly responsible for preparing the construction
method of foundation project, assessment the soil condition and drivability, solve
any problem technical problems deal with soil and foundations.
2.4 Site Engineer
Site Engineer has direct responsibility for implementing the construction functions
in this Method Statement.

2.5 QA/QC Engineer

QA/QC Engineer has direct responsibility for implementing inspection in
this procedure. Also, together with the approved testing Laboratory have direct
responsibility manufacturing pies at AYA. batch plant.

2.6 HSE supervisor

HSE supervisor and officers will monitor and coordinate the work activity in
conjunction with the allocated activity supervisor. HSE Staff will not control or
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supervise the activity but act as support for the construction in identifying and
preventing unsafe acts on conditions.

2.7 Field Supervisor

Supervisor has overall responsibility for the implementation of civil works
in this specification. Supervisor shall arrange the manpower, equipment and
materials required for the implementation of the works, coordinate with HSE
officer and QA/QC Engineer involved in the tasks in accordance to the method
statement and reporting to the superintendent.

Piling Batch Plant

Manager Manager

Technical Project QA/QC

Support & QS Manager Engineer

Accountant- Delivery Production

Site Engineer
Purchases Team Team

HSE
Supervisor

Site
Supervisor

Machines
Operators

Riggers

Workers
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3. DRIVING SYSTEMS
The choice of a suitable driving system is of fundamental importance to
ensure successful pile installation with due regard to the safety of operatives and
environmental disturbance. The basic driving methods are:

3.1 Impact driving

This is the best method for driving piles into difficult ground or final driving
of piles to level in panel form. With a correctly selected and sized hammer, it is in
most conditions the most effective way of completing deep penetration into hard
soils. The downside is that it can be quite noisy and not suitable for sensitive or
restricted site. Show the figures below.

Figure (1) hydraulic hammer.

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3.2 Press-in piling

Otherwise known as silent vibration less hydraulic jacking. Machines of various
types are now widely used. This method is very effective in fine cohesive soils but
less so in dense coarse soils unless pre-drilling or jetting techniques are used. This
is the most effective method to use when installing piles in sensitive locations
where piling would have not been considered in the past. Length limitations are
given by soil conditions ,these techniques not available in Iraq.

4. EQUIPMENT & MANPOWER

4.1 Equipment
Piles are normally driven by impact type hammers. Typical driving
equipment consists of a crawler-mounted crane with a boom, leads, hammer, and
various accessories, each connected to act as a unit. The equipment serves to guide
and drive each pile accurately into its final position and must be strong enough to
withstand safely all loads imposed during the process. The crane and boom must
have adequate size, capacity and connections to handle the pile and the special
driving equipment, such as the hammer or extractor, leads, and accessories, safely.
Considerable engineering experience and judgement are necessary when
evaluating or specifying the suitability of driving equipment. Supplemental
information is normally available in the form of technical literature provided by the
equipment manufacturer. Only equipment anticipated to be detrimental to the pile,
soil, or soil-pile interaction should be excluded by the construction specifications.
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4.2 Hammer selection

Hammer selection may be the most important aspect of pile installation. In
some installations only one hammer type may be applicable for the pile-soil
combination, while for others several types may suitable. Evaluation must consider
the need to use pile penetration rate as the means to end driving, the ability to drive
the pile without structural damage or reducing soil capacity, the ability to obtain
penetration rates within the desired band, and the realization that some hammer
types may cause reduced capacities for identical pile lengths. In general, wave
equation analysis supplemented by engineering experience and judgement should
be the basis for hammer approval and criteria such as allowable driving stresses,
desired penetration rates, and any other data used as a basis for approval that are
clearly defined in the specifications.
Size selection for a particular hammer must consider the pile’s anticipated
driving resistance, ultimate capacity, pile stresses expected during driving, and pile
set-up. The hammer type and size used for production should always match that
used in the test program because a different hammer would most likely result in a
different capacity. The designer or contractor may designate a number of hammers
for the test program when warranted. For driven concrete piles, table (1) shown the
Suggested Minimum Hammer Energy - Impact Hammers (Taken from ARMY TM
5-849-1, May 1982)
Table (1): Minimum Hammer Energy - Impact Hammers
Pile capacity (ton) Minimum Hammer Energy (KN.m)
< 60 20.33
> 60 25.76
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4.3 Equipment that will use

Table (2) Equipment.

# Description No. Capacity Remarks

1 Hydraulic hammer 2 Up to 6 ton ram
2 Diesel hammer D25 2 76 KNm (max)

3 Mobile Crane 2 50 ton

7 Generator 2 100 KVA

8 Trailer 1 -

9 Welding Machine 2 -

10 Safety equipment - -

11 Fire extinguisher 10 or more Up to 5 kg

4.4 Manpower.
Table (3) Manpower.
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# Designation No. Remarks

1 Project Manager 1 Project Engineer
2 Site Engineer 1 Civil Engineer
3 Foreman 2 Chief Technician
4 Welders 1 Technician
6 HSE Officer 1 Technician
7 accountant 1
8 Cars Divers 3
9 Equipment 6
Drivers/Operators
10 Riggers 6
11 Surveyor 1 Technician
12 workers 8

5. WORK SEQUENCE TO DRIVING PC. PILES.

5.1 Preparation the work to driving the PC. piles:

- Set up barricades and sign boards around the area to prevent unwanted
personnel from entering the work area. Lights will be provided as per
night shift works (if necessary).

- Site engineer shall be planned for any work activity, if necessary.

- Prepare surveying work: the surveyor must be preparing all surveying

data that required for driving works as the project drawings, such as
coordinate, levels, distances…etc.

- Prepare blows log sheets for recording and evaluating pile set.
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- Safety staff must be supporting the require warning signs in the field,
safety team are must be readying to treat any injury by use first aid.

- Check all machines and equipment epically helmet of piling hammer,

the helmet consist of steel frame outside and combination of heavy
wood blocks and steel block , the wood block maintains pile head of
damages , the wood block must be replace from time to time because
its breaking and damaging during pile driving
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Figure (2): typical helmets.

Figure (3): wood block.

5.2 Driving Procedure

- The piling hammer shall be precisely located at the position where the
pile is to be driven ,normally set out by others .The Rebar safety cap
should be removed from the setting out pin by hand as late as possible
ahead of the hammer getting to the pin but before the rig is actually
positioned above the pin.
- The piling hammer mast shall be adjusted to the vertical position
checked in two places at 90o to each other.
- The first pile section shall be presented horizontally to the piling
hammer by crane in apposition as close to 90 as possible with the
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direction of movement to the hammer before being attached to the

winch by means of sling.
- Before hoisting the pile an exclusion zone shall apply of 1 m or
greater than the pile section from the hammer foot to prevent impact
from lateral movement. The second man shall retreat to a distance of
1m behind the pile toe in line with the direction of the pile section.

Figure (4) pile lifting to set inside the hammer helmet.

- Using the pile hoist rope, the pile section shall be lifted into a near
vertical position and the pile head located into pile helmet .The
Forman will ensure the steady unhindered progress of the hoist
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through The careful observation and control .During the hoist the
second man may enter the exclusion zone but until the pile section is
at the point of entering the helmet.
At this stage the second man may assisting maneuvering the pile
section in to the helmet .Should any persons enter the exclusion zone
,the second man de closer than described above the pile is likely to
collide with an obstruction , the Forman will immediately stop the
auxiliary hoist.

Figure (5) pile setting inside the hammer helmet.

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- The pile is lowered ,and the pile base is manually guided into the
hammer footplate which acts as a guide during the initial penetration
movement of the pile during driving .To prevent a trapping accident
,should the pile kick the rig must be clear of obstruction including
plant equipment and stores .Where less than 2m is available ,extra care
must be taken to ensure the pile does not kick out when repositioning.
- The pile shall be checked for verticality on achieving a penetration of
1m, adjustment shall be made for verticality if required.

Figure (6) check for verticality.

- All piles shall be driven to a predetermined set/design length, the

length of PC pile is standard (12 m), to reach for design length (24m)
should be use multi jointed piles, the principle work of its joint is
mechanically it consist of four steel plates install on corners side that
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connect piles together, the pile joint install manually by hand hammer
tool.
- There are many notes about pile joint must be consider:
1- The concrete faces and the collet socket and spigot of the two piles which
are to be joined shall be clean and detritus free.
2- Driving gasket is to be placed on the top of the lower segment.
3- The spigot is to be lowered into the collet socket.

Figure (7) pile jointing.

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Figure (8) pile joint installation.

- To prevent damage to the pile, care must be taken to ensure the

hammer blow is always axial to the pile, and the pile therefore struck
to its axis.

- The hoist rope is removed from the pile ,and the pile driving cycle
continued either at same location by the addition of further precast
pile section ,dependent upon the length and/or set specified for the
pile ,or at a new location.
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Figure (9) check for verticality for second piece of pile.

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Figure (10) driving the pile to reach to design depth.

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5.3 Factors affecting installation

• size, type, and length of pile.

• required driving capacity of the pile.

• inclination of the piles (vertical or battered).

• type of soil/rock into which the pile is to be installed.

• surrounding element (soil or water).

• uniformity of the soil strata from bent to bent.

• effective prestress in the pile.

• pile group arrangement.

• site location and accessibility (such as presence of surrounding structures,

potential to use larger equipment supported by floating barges as opposed to land-
based equipment).

• number of piles on the project and the construction schedule (economy of scale).

5.4 Penetration Limitations & pile set.

Penetration Limitations:
For impact hammers the rate of penetration is customarily defined as the
blow count per unit length of pile penetration. Blow counts are typically
recorded in the field on a per-foot basis until the pile approaches a
designated tip elevation or the end of driving. At that point the blow count is
usually recorded for each inch of penetration. Limiting penetration rates are
designated to prevent overdriving, which may cause structural damage to the
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pile, and to provide guidance for determining the relative capacity attained
during driving. Pile tip damage due to very difficult driving (commonly
referred to as refusal) is not readily detectable when the pile encounters an
obstruction or a hard bearing stratum prior to reaching the indicated tip
elevation. Therefore, the limiting penetration rates, or the criteria necessary
to determine limiting rates, should be specified. Rules of thumb, used to
avoid structural damage, derived through experience and generally accepted
by most engineers are listed in Table (4).

Table (4): Limiting Penetration Rates

Maximum Blow Count
Pile Type
(blows per inch)
Timber 3-4
Concrete 10
Steel Pipe 10 - 20
Steel -H 10 - 20

The Pile set

- In simple terms the final set is measure of physical performance (compared
with distance dropped)
- The required sets and anticipated pile design lengths shall be given to the
site foreman in writing prior to the commencement of pile construction.
- Set measurement on site is achieved by following steps blow.
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a) The competent machine operator is to mark the pile in an accessible point

i.e. the pile, frame, or cage, by whatever means, from a firm surface, such as
the rig foot.
b) The competent machine operator to retire to maximum distance possible for
safety.
c) Undertake the designated number of blows (usually10) at a given hammer
drop height(Cease operation)The competent machine operator is to turn to
the pile position and physically measure the depth of penetration
d) repeat the operation until desired set is achieved .Make pile entry on pilling
log sheet .

By the way we can get more accurate result to estimating pile set and stopping
driving process by using one of dynamic formulas , Hily’s formula is the most
common and widely use for estimating the pile set.

W ×H × η
R=
C
S+
2

.R : The ultimate driving resistance (pile bearing)

.W : weight of ram

.H : the height of the free fall the ram (mm) for signal acting use 90%

w+ p e2
ycneiciffe
η: wolb
fo ,(w >ep ) ,η=
w+p

P : pile weight and helmet weight

S : set per blow (mm)

.C : the sum of the temporary compression of pile , dolly and ground , as explain in table (5)
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e : the coefficient of restitution of the materials under impact =0.25 reinforce-concrete pile with
. halmet

Table (5): Temporary Compressions (mm)