Sicurezza AT000108 - E - Rev0

Instructions for the user
GENERAL WARNINGS FOR USE
DOCUMENT SOURCE LANGUAGE (ITALIAN)
READ AND UNDERSTAND THE INSTRUCTIONS IN THIS MANUAL

BEFORE USING THE MACHINE
IN CASE OF TRANSFER OF TITLE, THIS MANUAL MUST BE SUPPLIED WITH THE MACHINE
Document code - Edition Valid for machines (serial no.)
AT000108/E – Rev. 0 01/2005
SOILMEC S.p.A. 5819, Via Dismano I-47023 CESENA - ITALY

Tel. +39-(0)547-319111 - Fax +39-(0)547-318544
Web: http//www.soilmec.it - E-Mail: soilmec@soilmec.it
Soilmec respects the environment!
This manual has been printed on paper bleached
with (Cl2) chlorine-free products.
General warnings for use

Document code: AT000108/E - Rev.0 01/2005
No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means without
prior written permission from SOILMEC S.p.A.
In pursuing a policy of constant product development and update, SOILMEC S.p.A. reserves the right to make changes at any
time and without undertaking to give prior notice; therefore, also this publication may be subject to changes.
© Copyright 2005 SOILMEC S.p.A. - All rights reserved.
Printed in Cesena by the manufacturer.

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SOILMEC S.p.A. 5819, Via Dismano I-47023 CESENA - ITALY
Tel. +39-(0)547-319111 - Fax +39-(0)547-318544
Web: http//www.soilmec.it - E-Mail: soilmec@soilmec.it
DEALER OR LOCAL AUTHORISED ASSISTANCE CENTRE

Use this space to note the identification data of your Dealer or your nearest
Assistance Centre.
MEMORANDUM OF THE TECHNICAL DATA OF THE MACHINE

Use this space to note the identification data of your machine.
For a faster assistance, always specify the following data when contacting SOILMEC
After-Sales Service:
Machine type
Machine serial number
Year of manufacture
See chapter "IDENTIFICATION PLATES" in the Use and Maintenance Manual

General Warnings for Use AT000108/E Rev.0 01/2005
INTRO - page 1
PRESENTATION OF THE MANUAL

INTRODUCTION
This manual is published by SOILMEC to provide the drilling rigs’ operators with a basic overview
of the most common drilling techniques.
The document will deal with the most common problems an operator can have to face during work.
Of course, other precautionary measures may be necessary depending on the specific drilling
application.
The information in this manual must be regarded as complementary to those provided in the Use
an Maintenance manual supplied with each machine.
In addition to the respect of the instructions provided in this manual and all the others supplied with
the machine, you must also abide by any local and national regulations.
PURPOSE OF THE MANUAL

This manual has been drawn up to provide the operator with a series of warnings and general
information on how to correctly perform the main drilling techniques.
ManualeUtente_E.doc
AT000108/E Rev.0 01/2005 General Warnings for Use
INTRO - page 2
PERSONNEL WITH THE OBLIGATION OF CONSULTATION

In compliance with MACHINERY DIRECTIVE 98/37/EC and following amendments concerning the
optimised drafting of after-sales technical documentation, this manual is aimed in particular at
those who, regardless of their professional function at work, come into direct contact with the
machine or in any case have to operate in the area surrounding the same machine.
The personnel responsible are classified in the following key:
- Site manager
- Machine operator
- Maintenance/repair technician
- Riggers
- Operator given the task of driving the machine on the rack car
- Driver of the self-propelled crane or operator of the overhead crane
The manual deals with specific SUBJECTS and informs and trains the personnel responsible for
the machine specifically for the jobs they will be doing.
Therefore we recommend informing the above personnel and training them thoroughly before
letting them use the machine.
As it has already been mentioned in the Important Safety Notices at the beginning of the Use and
Maintenance manual supplied with the machine, no one should work on the machine unless they
have been specifically trained to do so and have read this manual beforehand.
This manual must be kept in the operator’s cab (in the document compartment behind the driver’s
seat) so it can be consulted at any time.
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INTRO - page 3
STRUCTURE OF THE MANUAL

The manual has been divided into specific SECTIONS (illustrated in the list below) which, at their
turn, are divided into CHAPTERS and SUB-CHAPTERS.
The SECTIONS of this manual are related to the different drilling techniques the SOILMEC
machines can perform.
• ENVISAGED USE OF THE KELLY EQUIPMENT

• ENVISAGED USE OF THE CFA EQUIPMENT
• ENVISAGED USE OF THE CSP EQUIPMENT
SYMBOLS USED IN THIS MANUAL

In the manual you’ll find a number of signal words that draw your attention to specific operations or
important safety messages.
These signal words are intended to alert you to the existence and relative degree of a hazard.
DANGER
The notices preceded by this symbol denote an extreme hazard exists. If proper precautions
are not taken, it is highly likely that you or others could be permanently injured (or killed).
WARNING
The notices preceded by this symbol denote a hazard exists. If proper precautions are not
taken you or others could be seriously injured. Additionally improper practices may result in
damage to the machine and reduce the safety standards for which it has been designed.
IMPORTANT
The notices preceded by this symbol draw the attention to important technical and/or
technological information that allows using the machine in a more efficient way. They also
draw the reader’s attention to all those operations for which SOILMEC After-Sales Service
must be contacted -i.e. when requiring ORIGINAL SPARE PARTS or TECHNICAL
ASSISTANCE.
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INTRO - page 4
REVISIONS
The information contained in this manual is based on the most up-to-date data available when it
goes into print.
Depending on the equipment and accessories that the machine can be equipped with there may
be some differences in some texts or illustrations without this being cause for dispute.
There may be variations in relation to a particular version of the machine at any time also if the
basic information is the same and still valid.
Nevertheless before starting any operation, make sure you have all of the information necessary
with particular reference to any revised technical publications available.
For any further information, please contact SOILMEC After-Sales Service.
UNITS OF MEASURE
The units of measure used in this manual are those of the INTERNATIONAL SYSTEM OF UNITS
(SI).
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INTRO - page 5
GENERAL INDEX
PRESENTATION OF THE MANUAL ............................................................................................... 1
INTRODUCTION ........................................................................................................................... 1
PURPOSE OF THE MANUAL ....................................................................................................... 1
PERSONNEL WITH THE OBLIGATION OF CONSULTATION .................................................... 2
STRUCTURE OF THE MANUAL .................................................................................................. 3
SYMBOLS USED IN THIS MANUAL............................................................................................. 3
REVISIONS ................................................................................................................................... 4
UNITS OF MEASURE ................................................................................................................... 4
GENERAL INDEX............................................................................................................................. 5
ENVISAGED USE OF THE KELLY EQUIPMENT ........................................................................... 7
WORK PHASES ............................................................................................................................ 8
TRAMMING ................................................................................................................................... 8
POSITIONING THE MACHINE.................................................................................................. 8
DRILLING ...................................................................................................................................... 9
TOOLS ....................................................................................................................................... 9
TYPICAL DRILLING CYCLE ....................................................................................................... 12
TEMPORARY CASING............................................................................................................ 13
DRILLING MUDS ..................................................................................................................... 14
CASING DRIVING ................................................................................................................... 15
CASING OSCILLATOR............................................................................................................ 15
HAMMER AND PERCUSSION TOOLS................................................................................... 16
LOWERING THE CAGE INTO THE HOLE.............................................................................. 16
CONCRETING ......................................................................................................................... 17
ALTERNATIVE USE.................................................................................................................... 17
OUT OF SERVICE .......................................................................................................................... 18
PARKING MODE (STRONG WIND, UNSTABLE TERRAIN, BREAKDOWNS).......................... 18
STABILITY WARNINGS .............................................................................................................. 18
WARNINGS FOR LOW TEMPERATURES................................................................................. 18
ENVISAGED USE OF THE CFA EQUIPMENT.............................................................................. 19
WORK PHASES .......................................................................................................................... 20
TRAMMING.............................................................................................................................. 20
POSITIONING THE MACHINE................................................................................................ 21
RIGGING ..................................................................................................................................... 21
DRILLING................................................................................................................................. 21
PULL-OUT PHASE - CONCRETING - AUGER CLEANING ................................................... 22
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INTRO - page 6
CLEANING THE HOLE ............................................................................................................23

LOWERING THE CAGE INTO THE HOLE ..............................................................................23
ALTERNATIVE USE ....................................................................................................................23
OUT OF SERVICE .......................................................................................................................... 24
PARKING MODE (STRONG WIND, UNSTABLE TERRAIN, BREAKDOWNS) ..........................24
STABILITY WARNINGS ..............................................................................................................24
WARNINGS FOR LOW TEMPERATURES .................................................................................24
ENVISAGED USE OF THE CSP EQUIPMENT .............................................................................. 25
WORK PHASES ..........................................................................................................................26
TRAMMING..............................................................................................................................26
POSITIONING THE MACHINE ................................................................................................27
RIGGING THE MACHINE ........................................................................................................27
DRILLING.................................................................................................................................27
CLEANING THE HOLE ............................................................................................................30
LOWERING THE CAGE INTO THE HOLE ..............................................................................30
ALTERNATIVE USE ....................................................................................................................31
FORBIDDEN USE .......................................................................................................................31
OUT OF SERVICE .......................................................................................................................... 32
PARKING MODE (STRONG WIND, UNSTABLE TERRAIN, BREAKDOWNS) ..........................32
STABILITY WARNINGS ..............................................................................................................32
WARNINGS FOR LOW TEMPERATURES .................................................................................32
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KELLY - page 7
ENVISAGED USE OF THE KELLY EQUIPMENT

All working phases involve some risks. Just to mention some of them:
• The accidental fall of objects such as cuttings, grout hose, bolts and other parts of the
machine despite the safety devices installed and regular checks and maintenance.
• The risk of crushing and pinching in moving parts of the machine such as tracks, turret,
mast and struts, drilling tool, auger cleaner etc. These parts cannot be protected by guards as
often such guards increase the risk instead of reducing it.
• The oscillation of suspended loads (e.g. reinforcing cages).
• The risk of crushing by other machines like the cutting loading shovel, the crane, the concrete
mixer, etc.
As a result, different dangerous zones exist all around the machine and some general
precautions must be taken.
1. Only personnel with a technical qualification and a level of training on safety are authorised to
enter the work area.
2. Only the machine operator can remain on the machine.
3. The access to the turret cover is only permitted in an emergency and for maintenance
operations with the machine standing still.
4. The machine operator must always pay attention to the personnel around the machine.
5. Remain in a dangerous area for the time strictly necessary.
6. The zone of maximum danger is within a radius of 4 metres from the auger for all the causes
listed above.
7. Another dangerous area with a radius of about 14 metres is the one exposed to the risk of fall
of the cage or the grout hose in the respective phases of use.
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KELLY - page 8
WORK PHASES
The machine has been designed for a specific application as explained below.
DANGER
Any use different from that envisaged by the manufacturer is expressly forbidden.
If the machine must be used for purposes other than those envisaged, a prior written approval
must be required to the manufacturer.
TRAMMING
The machine tramming is the operation during which the machine is moved from one working zone
to another on a more or less long and uneven route. During this phase tracks are operated
simultaneously, one at a time or in counter-rotation and the turret is rotated (if necessary).
Sometimes, to improve stability, it may be necessary to tilt the mast.
DANGER
The movement of these unprotected parts can result in risks of crushing and trapping. As a
result, only the machine operator can remain aboard the machine and all other people must
keep at a safe distance of at least 14 metres.
The work surface must be able to withstand the pressures on the ground produced by the
machine (see chapter “PERFORMANCE AND LIMITS OF USE” in section A of the Use and
Maintenance Manual supplied with the machine).
DANGER
Any ground collapse can result in a dangerous inclination of the machine and its
overturning.
The machine can also move on ramps or slightly sloped grounds. For the maximum admissible
slopes, please refer to chapter “PERFORMANCE AND LIMITS OF USE” in section A of the Use
and Maintenance Manual supplied with the machine.
DANGER
Exceeding the maximum admissible slopes can affect the stability of the machine and cause
it to overturn.
DANGER
The position of the kinematic unit and the mast are fundamental for the stability of the
machine. To avoid dangerous situations, strictly obey the instructions provided (see
“TECHNICAL DATA OF THE MAIN PARTS” and “PERFORMANCE AND LIMITS OF USE” in
Section A of the Use and Maintenance manual supplied with the machine.
We'd like to stress that tramming can be more dangerous than drilling as, in this phase, the mast
does not rest on the ground, the ground can be uneven or soft and the start and stop accelerations
can let the machine tip over.
POSITIONING THE MACHINE

The machine positioning consists in a series of small movements of the tracks and rotations of the
turret to align the drilling tool axis just above the stake indicating the drilling axis to be drilled.
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KELLY - page 9
The positioning phase also includes moving the mast to the vertical position.
DANGER
Also in this phase, it is extremely important that only the machine operator remains aboard
the machine. If you use the assistance of someone on the ground to align the tool with the
stake, these persons must remain within the working range of the machine only for the time
strictly necessary and in accordance with the general precautions indicated in points 1 - 7.
Keep clear of moving parts of the machine.
DRILLING
General information on the drilling equipment and tools:
TOOLS
Among the different types of drilling tools, we mention the augers and the buckets that are
produced in different versions.
Usually augers are used to drill dry soils as the presence of water tends to let the cuttings run off
during the pull-out phase.
The buckets, which are closed tools, retain cuttings better in presence of water.
The type of teeth and the shape of the tool must be chosen in relation to the type of soil.
Cuttings are emptied from the augers operating the spin-off function. Three-four seconds are
sufficient to centrifuge the drilled material.
DANGER
Cuttings are projected horizontally. People must keep clear of the area around the machine.
The buckets have a bottom that opens downwards letting the cuttings fall down. The bucket
opening is activated by lifting the Kelly so that it stops against the bucket striker flange placed
underneath the rotary, pressing the striker of the tool.
During drilling, operators have to remain in the area close to the machine only for checking or
replacing the tool.
Except for these two operations, operators must keep out of the dangerous zone around the
machine.
Checking the tool consists in verifying the teeth of the tool and refitting them immediately if they
are missing; or in verifying the wear of the teeth to decide whether or not they must be replaced.
These operations must be done with the tool stopped and under the supervision of the machine
operator.
The tool must be replaced in the case of breakage or if a different and more adequate tool must be
used.
Tools are wearable parts. As a result of this and despite a regular maintenance, they must be
replaced at regular intervals (4000-6000 operating hours).
Kelly or telescopic bar

The kelly bar is a telescopic drilling bar moved along the vertical axis by the rope of the main
winch. This rope is secured to the internal element of the kelly that supports the remaining outer
elements through a swivel element.
Unwinding the winch rope lets the kelly move down so the outermost telescope can rest on the
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KELLY - page 10
rotary table.
At this point the second telescope moves down and stops on the first one and so on.
Kelly can be supplied with 3, 4, 5 and 6 telescopes.
The rotation of the kelly is operated by the rotary head, and such rotation movement is then
transmitted to the tool fixed to the internal element of the kelly. The motion transmission occurs
thanks to special ribs welded on the kelly sections and sliding into special grooves located inside
the kelly terminals.
The swivel element placed between the rope and the kelly allows to keep the rope still while the
kelly is rotating.
WARNING
If the swivel gets stuck (due to a breakage of the bearings or a neglected maintenance) the
rope can break due to an excessive torsion, thus making it impossible to pull out the kelly.
Tools are wearable parts. As a result of this and despite a regular maintenance, they must be
replaced at regular intervals (4000-6000 operating hours).
Pull-down
In presence of hard soils where the tool penetration can be difficult despite the weight of the kelly
system, it is possible to use the pull-down system.
This consists of a hydraulic cylinder which lets the rotary table slide downwards and transmit the
kelly and the drilling tool an additional friction or mechanical crowd depending on the type of kelly
used.
Friction kelly
Friction crowd bars have rectilinear ribs that allow for a smooth sliding during the kelly down and
up movements.
The friction crowd is transmitted only when the tool is subjected to a quite continuous torsional
stress. If the teeth jump and slide on a hard soil layer, the crowd transmitted is negligible.
When drilling is carried out in presence of water, the suspended sand particles tend to settle at the
bottom between the kelly sections. When the kelly is moved up, water flows out through the special
draining apertures the sand that has settled down, is washed off.
WARNING
Keep the draining apertures clean. Failure to do so can result in a blockage of the kelly
telescopes and in a sudden fall of the kelly during the driving or pull-out phases.
Friction bars are simpler to use and maintain.
Mechanical locking bars

In this kind of kelly bars, the ribs have a number of steps that, during the clockwise rotation, allow
to fully transmit the pull-down crowd from the rotary head to the outermost telescope, from this to
the second telescope and so on.
The mechanical locks are placed at each end of the bar and in in-between positions corresponding
to a full stroke of the pull-down.
In order to pull out the kelly, it is necessary to unlock the mechanical locks by turning one turn
counter-clockwise with the tool resting at the bottom of the hole.
These bars are more difficult to be used, and are subjected to clogging, mechanical deformation
and wear.
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KELLY - page 11
As a result, we recommend using the mechanical locking bars in presence of hard layers, rocks
and gravel.
WARNING
If the axis to be drilled is shorter than the stroke of the kelly system used, the last telescope
won’t move out and the sand that settles down can block it once and for all. For this reason,
we recommend lowering the kelly to the ground in the horizontal position, moving the
telescopes out and removing this sand regularly (every week).
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KELLY - page 12
TYPICAL DRILLING CYCLE

Below you’ll find the description of a typical drilling cycle of a dry and stable soil, say the simplest
case. This will let you become familiar with the basic manoeuvres and the main controls of the
Soilmec machines, as well as the widely-adopted solutions.
The use of drilling mud, the direct casing driving and the use of the casing oscillator are explained
on next pages.
IMPORTANT
For the operations to be carried out to prepare the machine for work refer to section C in the
Use and Maintenance manual supplied with the machine.
Drilling consists of a number of cyclic operations:
• down-movement of the bar to let the tool rest on the ground
• drilling by letting the tool rotate until it is full of cuttings
• up-movement of the bar
• rotation of the turret to move the tool to the unloading position
• tool unloading
• rotation of the turret to re-align the tool with the drilling axis.
DANGER
All movements of the machine, the presence of mud and especially the unloading of the
cuttings are a danger for the personnel on the ground. The risk is even greater due to the
fact that the machine operator cannot see the entire manoeuvring area. The dangerous area
is indicated in chapter “RESIDUAL RISKS AND DANGEROUS AREAS” in section B of the Use
and Maintenance manual supplied with the machine. The jobsite personnel must keep out
of this area. Authorisation to access to this area can only be given by the machine operator
when the machine stands still.
The kelly bar is moved down by unwinding the rope of the main winch. The winch can be operated
at two different speeds during both up- and down-movements. In the absence of water, you can
use the fast speed (operating the relevant button on the control lever). In presence of water, we
recommend selecting the slow speed to avoid any “piston” effect and the possible collapse of the
excavation.
Drilling occurs by letting the tool rotate clockwise.
During drilling, we recommend releasing the rope of the main winch so as not to block the tool
travel. The Soilmec machines are equipped with a rope release control that is equivalent to a
brake. The rope layers are unwound only when the rope is pulled and for a length corresponding to
the pull action unlike what occurs when the winch rope unwinding control is operated (which result
in the complete unwinding of the rope).
Operate the feed pull-down (when no load is present, the rotary table can also be moved down at a
high speed).
When the tool is full, rotation stops and the kelly bar must be moved up by rewinding the rope of
the main winch.
In the case of use of mechanical locking bars, you have to do one counter-clockwise turn with the
tool at the bottom before starting pulling out.
DANGER
If the bar elements remain locked, two elements could be pulled out together and the kelly
could fall down or get damaged. This also subjects the rope and the swivel to a high stress.
If, as a result of this, the rope breaks, it can start moving out of control in the dangerous
area and injure any one standing in such area.
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KELLY - page 13
Once the tool is out of the hole mouth, rotate the turret operating the relevant control to empty the
same tool.
Operate the spin-off function to empty the tool and deactivate this function as soon as the tool is
empty.
DANGER
The tool spin-off, that is the fast rotation, projects the cuttings at a high distance. All people
on the ground must keep out of the tool unloading area, especially during this phase.
WARNING
We recommend not to reverse the rotation direction to slow down the tool. The rotary head
could get damaged.
If the tool used is a bucket, you have to lift the kelly to press down the striker under the bucket
striker flange so the tool bottom can open.
To re-close the bucket, lower the kelly down so the tool bottom closes, then raise the tool above
the ground.
Operate the turret back-rotation control to re-align the turret with the drilling axis.
To avoid that cuttings can fall down from the bucket from a high height , we recommend lowering
the rotary table by means of the pull-down system (right control lever 1 forwards). Once the bucket
has been emptied, the rotary must be moved back to the starting position in correspondence of the
bar lock disengaged.
WARNING
If the steps of a lock are not in the correct position, the contact zone can be very small and
the ribs can be crushed. This results in wear and metal burrs that affect the correct
operation of the drilling bar. For this reason, we recommend placing the rotary table 15 cm
above the lock that has been disengaged.
DANGER
Drilling is done at a short distance from the crawler tracks of the machine. The hole could
collapse and the machine could overturn.
For the ground pressures and the admissible slopes of the work surface, please consult chapter
“PERFORMANCE AND LIMITS OF USE” in Section A of the Use and Maintenance manual
supplied with the machine.
Below you’ll find some other notes which, although they are partly beyond the purpose of this
manual, offer an exhaustive picture of the possible applications of the machine.
TEMPORARY CASING
In order to avoid a collapse of the hole mouth, it is a common practice to drive a length of tube with
a higher diameter than the tool into the new hole for some metres.
• The first method for driving a temporary casing consists in starting drilling for roughly 3 metres,
widen the hole 10 to 20 cm with the special tool fitted on the tool, and drive the temporary
casing into the soil by pushing it down with the bucket striker flange or the tool.
• The second method, which is recommended if the soil collapse can occur at a deeper depth, is
driving a long casing using a casing oscillator and a crane before starting drilling the hole.
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KELLY - page 14
• The third method, most suitable for this kind of machines, consists in using conventional casing
tubes complete with joints and shoe with notches.
In this case, the small bucket striker flange, placed under the rotary head, is replaced with the
larger casing driver plate on which the first 1.5m casing element (called landing collar) is welded.
Rotation and thrust allow to drive the casing elements into the soil, after they have been connected
to the landing collar.
WARNING
For this technique, we recommend using casings with tongues able to transmit the
maximum torque of the rotary head without having to mount fixing devices. In this way, it
will be possible to drive the casing placing the landing collar on it and turning the same
without having to reach a dangerous height to couple the joint.
On request, Soilmec can supply a joint with tongues and fixing conical screws.
DANGER
The connection between casing element and landing collar must be done at a dangerous
height. As a result, we recommend using remotely controlled or automatic fixing systems to
avoid operating at high heights from the ground.
WARNING
The connection of a new casing element with the one already driven can be done with the
service rope using slings, shackles or hooks of adequate capacity. Manual locking/unlocking
at a high height must be avoided. For these operations, the use or an aerial platform or of
remotely controlled devices is compulsory.
In all these cases, it is necessary to pull out the tool above the temporary casing inlet in order to
remove the cuttings.
DRILLING MUDS
In order to avoid any collapse of the hole walls, it is possible to use drilling muds (bentonite,
polymers) that develop a hydrostatic thrust and a water-proof effect and contrast, in this way, the
inflow of groundwater, geostatic thrusts and the collapse of the hole walls.
The mud must be above the groundwater or, even better, level with the hole mouth.
For this reason, a small tank with earth walls is prepared all around the hole and filled at regular
intervals by a centrifugal pumps to compensate any loss of mud.
WARNING
In these cases, we recommend moving the drilling bars slowly to avoid “piston” effects. The
tool pulled out of the hole must be left on the mouth of the same so that mud can fall down
before cuttings are removed.
DANGER
Holes filled with drilling muds are hardly visible. Additionally, the mud dispersed all around
makes the ground slippery. As a result of this, you could slip adnd fall into a drilled hole. For
this reason, we recommend placing barriers or other visible signs all around the drilling
area.
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KELLY - page 15
CASING DRIVING
With the third method described for realizing a temporary casing, the various casing elements can
be driven by emptying them with the tool at regular intervals. This lets you reach depths of 15-20
metres without having to resort to a casing oscillator. This method is called direct casing driving.
Driving a casing prevents any collapse of the excavation and avoids the use of mud. The water
inside the hole must be at least level with the groundwater.
The use of the casing guarantees a perfect straight excavation. Casing driving is recommended in
presence of rocky fragments or erratic blocks which would let the drilling bars move out of the
envisaged drilling axis and get damaged.
WARNING
To move the tool out of the casing outlet, the length of the kelly (with telescopes in) must be
compatible with the one of the casing and of the mast (please refer to chapter “
DESCRIPTION AND TECHNICAL DATA” in section A in the Use and Maintenance manual
DANGER
While handling and connecting the casing elements, riggers could be crushed by the load or
be injured (risk of amputation of fingers, hands or upper limbs). During these operations,
we recommend using personal protective devices and proceed with extreme caution.
DANGER
The connection between casing element and landing collar must be done at a dangerous
height. As a result, we recommend using remotely controlled or automatic fixing systems to
avoid operating at high heights from the ground.
WARNING
For this technique, we recommend using casings with tongues able to transmit the
maximum torque of the rotary head without having to mount fixing devices. In this way, it
will be possible to drive the casing placing the landing collar on it and turning the same
without having to reach a dangerous height to couple the joint.
On request, Soilmec can supply a joint with tongues and fixing conical screws.
WARNING
The connection of a new casing element with the one already driven can be done with the
service rope using slings, shackles or hooks of adequate capacity. Manual locking/unlocking
at a high height must be avoided. For these operations, the use or an aerial platform or of
remotely controlled devices is compulsory.
CASING OSCILLATOR
The front part of the undercarriage can be equipped with a special frame to connect, move and
operate a casing oscillator.
IMPORTANT
For the use of this accessory part, please refer to the relevant manual.
With the direct casing driving, the rotation exerted on the casing is the continuous type; with the
casing oscillator, the rotation is automatic and alternated.
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KELLY - page 16
The removal of the soil from the casing interior and the weight of the casing oscillator let the casing
enter the soil.
DANGER
The oscillation movement of the casing oscillator is automatic. As a result, you could be
crushed or remain trapped between the oscillator and the crawlers or between moving parts
of the oscillator. When the casing oscillator is running, people must keep in the clear.
DANGER
While loading and connecting the casing elements, riggers could be crushed by the load or
be injured (risk of amputation of fingers, hands or upper limbs). During these operations,
we recommend using personal protective devices and proceed with extreme caution.
WARNING
The use of the service rope for loading the casing elements with these elements resting on
the ground in the horizontal position allow to secure the sling and connect the casing
elements on the ground and minimise the risks for the riggers. In this case the sling and the
service rope must be placed to the side of the casing and be slackened so that the different
coupling elements can be reached from the ground while the casing is driven into the soil. If
the sling is long enough, once it has been slackened, it can be detached from the service
rope and remain attached to the casing during the drilling or driving phase.
HAMMER AND PERCUSSION TOOLS

When the base of the pile must be driven into a rocky stratum or when intermediate rocky strata
must be drilled through, we recommend using percussion tools to move, break or crush such hard
strata.
Percussion tools are let fall down for one or more metres to increase their impact force.
The auxiliary winch of the Soilmec machines can be switched from the controlled descent mode to
the free fall mode, on request.
The free fall function must be activated with the relevant switch protected by the lockable cover
placed behind the driving cab. Once the free fall function has been switched on, it can be operated
with the two controls located in the driving cab.
DANGER
The accidental activation of the free fall function lets the load suspended from the service
rope move without control, thus resulting in serious risks for the personnel standing
underneath. As a result of this, it is compulsory to deactivate this function with the relevant
switch when its use is not necessary.
WARNING
For the use of the rope of the auxiliary winch, please refer to the relevant load capacity table (see
chapter “PERFORMANCE AND LIMITS OF USE” in section A of the Use and Maintenance
manual supplied with the machine).
LOWERING THE CAGE INTO THE HOLE

Once the hole bottom has been cleaned, attach the service rope to the top of the cage moved near
the machine with an adequate lifting equipment.
ManualeUtente_E.doc
KELLY - page 17
Once the area has been cleaned, the cage is first placed in vertical position and aligned with the
hole before being lowering into the same.
DANGER
Due to the fragility of the cage structure, the cage could break in the point of attachment of
the slings and fall down. Before moving the cage, check that its structure is intact.
WARNING
For the use of the rope of the auxiliary winch, please refer to the relevant load capacity table
in the Use and Maintenance manual supplied with the machine.
The mud with suspended sandy particles is replaced with clean mud only when the cage is down in
the hole.
CONCRETING
For concreting operations, we recommend using a service crane or the rope of the auxiliary winch
installed on the machine.
Concreting is usually done by means of a tube-jet unit consisting of a funnel at the top and a
number of elements that reach the bottom of the hole.
In order to avoid that the first concrete pumped into the hole can be washed out, a ball of foamed
polystyrene (or an inflated ball) is placed at the top of the tube before starting filling it. The ball
acts as a water/concrete separator and floats in the hole.
Tube and pile are filled until the two liquid columns (internal and external) are in balance. Vertical
movements of the tube improve filling. Afterwards, the lengths of the tube-jet units are removed
one at a time and the blank space is filled with concrete.
During this phase, it is also necessary to pull any casing elements out of the hole in relation to the
hardening times to avoid that such elements can remain blocked down into the hole.
WARNING
For the use of the rope of the auxiliary winch, please refer to the relevant load capacity table
in the Use and Maintenance manual supplied with the machine.
ALTERNATIVE USE
Drilling can also be done into a temporary casing driven by a vibrator (blind holes, unstable
formations).
ManualeUtente_E.doc
KELLY - page 18
OUT OF SERVICE
PARKING MODE (STRONG WIND, UNSTABLE TERRAIN,
BREAKDOWNS)
There are conditions when it may be necessary to leave the machine out of service and without
surveillance for longer or shorter periods of times.
Mechanical breakdown
Site-stoppages for organisational reasons
Bad weather conditions (strong wind, rain, low temperature, etc.)
In these situations dangerous conditions may arise due to the slow subsidence of pistons
(stabilisers, mast struts, boom struts, etc.) and the consequent movement of parts of the machine
causing it to overturn.
Also strong wind or unstable terrain due to rain or floods can make the machine unstable.
Very low temperatures can damage parts of the machine.
STABILITY WARNINGS
Choose a stable supporting surface (cement, rock, ground in relief, working platforms made of
wood, metal bases)
Refer to the instructions in the chapter “ENVIRONMENTAL LIMITS” in the Use and
Maintenance Manual supplied with the machine to define the mode and configuration the
machine can be left in.
Use braces in the case of particularly bad environmental conditions. Please contact Soilmec
After-Sales Service for the methods of application (recommended on crane towers which would
be costly to dismantle and this would also take a long time).
WARNINGS FOR LOW TEMPERATURES

Maintenance Manual supplied with the machine to define the method of use and the different
ways of storing the machine.
ManualeUtente_E.doc
CFA - page 19
ENVISAGED USE OF THE CFA EQUIPMENT
• The accidental fall of objects such as cuttings, grout hose, bolts and other parts of the
machine despite the safety devices installed and regular checks and maintenance.
• The risk of crushing and pinching in moving parts of the machine such as tracks, turret,
mast and struts, drilling tool, auger cleaner etc. These parts cannot be protected by guards as
often such guards increase the risk instead of reducing it.
• The oscillation of suspended loads (e.g. reinforcing cages).
• The risk of crushing by other machines like the cutting loading shovel, the crane, the concrete
mixer, etc.
As a result, different dangerous zones exist all around the machine and some general
precautions must be taken.
12. Remain in a dangerous area for the time strictly necessary.
listed above.
ManualeUtente_E.doc
CFA - page 20
WORK PHASES
DANGER
TRAMMING
DANGER
DANGER
overturning.
DANGER
it to overturn.
DANGER
ManualeUtente_E.doc
CFA - page 21

DANGER
WARNING
Positioning the machine with the rotary connected to the concrete pump by the hose can be
dangerous. An excess tension of the hose can result in a machine overturning.
RIGGING
Rigging a drilling rig consists in lowering the footpad to the ground, aligning the mast, cleaning the
grout outlet and fitting the drillbit cap to the drilling tool.
IMPORTANT
These phases require the presence of the riggers within the zone of maximum danger.
As a result, it is compulsory to:
• previously check the presence of cuttings which could fall down
• remain in the area for the time strictly necessary
• rig only a stationary machine under the supervision of the machine operator.
DANGER
The riggers must pay maximum attention during the lowering of the mast footpad. Feet at
risk!
DRILLING
The continuous flight auger is moved vertically by multipart reeving of the main rope.
For a proper drilling, it is essential to avoid a "corkscrew" penetration of the auger in the ground as
this will let the tool stall after a few metres. It is recommended to let the auger advance in a
continuous way and for short lengths so that cuttings can detach from the hole walls and move out
of the hole without clogging the space between the auger turns.
WARNING
Do not raise the auger during drilling so as not to loose the drillbit cap and fill the inlet with
cuttings.
ManualeUtente_E.doc
CFA - page 22
Usually drilling does not require the presence of personnel in the vicinity of the machine, except for
two operations.
Once the tool has been driven into the ground for one metre, the openable guide at the base of the
auger must be opened by hand. This operation must be done with the tool stopped and under the
supervision of the machine operator.
The cuttings moving up along the auger come out of the drilling hole. Their removal from the
ground must be done with an excavator with cab equipped with the FOPS protections.
DANGER
Except for these two operations, people must keep clear of the dangerous zone.
WARNING
We'd like to draw the reader's attention to the fact that, during drilling, soil is removed from
the area under the mast footpad. A gradual yielding of the ground during this phase, as a
result of the drilling operations, could let the machine tip over. For this reason, a special
sensor has been installed on the mast footpad to sense the pressure reduction under the
pad and alert the machine operator who must promptly operate the footpad controls and
bring the machine back to safety conditions.
PULL-OUT PHASE - CONCRETING - AUGER CLEANING

After drilling, the auger and the cuttings are moved out of the hole and concrete is pumped into the
hole. For a proper concreting, it is necessary to avoid abrupt up-movements of the excavated
cuttings. In fact, this would not allow for the immediate filling of the open space created under the
drillbit. This open space could be refilled with the soil collapsing creating a filling discontinuity.
Concrete shall be pumped in continuously and the pull-out speed shall be adequate to the filling
speed. It is advisable to use a control instrument and proceed in accordance with the relevant
instructions.
During the pull-out phase, cuttings are moved out of the hole and must be removed to avoid
dangers resulting from their fall from a high height.
DANGER
Blocks of clay and big stones falling down from the auger can lead to lethal injury. When
drilling grounds with blocks of clay and stones, remove the debris from the auger during the
pull-out phase using, for instance, a loader or a shovel.
Soilmec supplies a rotating cleaner which slides along the auger flights and remove cuttings even if
the auger is not running.
It is advisable:
1. to keep the cleaner to max 3-4 metres above the ground to avoid any projection of cuttings
2. not to dip the cleaner into the cutting heap to avoid soiling the part of auger already cleaned
3. The cutting heap should be removed constantly during the pull-out phase.
ManualeUtente_E.doc
CFA - page 23
DANGER
The cleaner moves and turns. To avoid any risk of crushing and injury, keep clear of its
working range during operation.
DANGER
During pumping, the hose is subject to shakes and pressure peaks which could loosen the
nuts. As a result, some parts could fall down. Pay a special attention to this hose. Always
connect the different parts of the hose one with the other and with the machine using some
steel ropes or safety chains.
CLEANING THE HOLE

After the pull-out phase, remove any cuttings from the surface all around the hole with the loader.
Remove any concrete residues from the hole mouth with a shovel before lowering the cage down
into the hole.

While cleaning the hole mouth, it is possible to attach the service rope to the top of the cage
moved near the machine with an adequate lifting equipment.
hole by the machine, then lowered down into the hole by gravity.
In order to help the final lowering phase, the special bell vibrator can be used.
DANGER
The suspended cage can swing and injure the personnel. The machine operator and the
riggers must pay maximum attention!
DANGER
The weight of the cage must not exceed the load capacity rating of the auxiliary winch. The
length of the cage must not exceed the maximum permissible height.
DANGER
ALTERNATIVE USE
• Drilling can also be done into a temporary casing driven by a second machine (blind boring,
unstable formations).
• On a sufficiently firm ground, drilling with the continuous flight auger can also be done by
pulling out the auger without casting pumped concrete.
Filling can be done in a subsequent phase with a second machine (sand drains and sandwich
drains).
• For the execution of gas hoisting shafts (waste disposal site), the concreting phase is replaced
by the laying of a filtering tube sealed to the ground.
ManualeUtente_E.doc
CFA - page 24
OUT OF SERVICE
BREAKDOWNS)
STABILITY WARNINGS
wood, metal bases)

Refer to the instructions in the chapter “ENVIRONMENTAL LIMITS” in the Use and Maintenance
Manual supplied with the machine to define the method of use and the different ways of storing
the machine.
ManualeUtente_E.doc
CSP - page 25
ENVISAGED USE OF THE CSP EQUIPMENT

The CSP (Casing Secant Pile) equipment has been designed to bore vertical holes with a
continuous flight auger housed inside a casing.
Typical applications:
- Secant pile walls, say partially overlapped (secanted) piles of cast in-situ concrete. The rigid
casing ensures the straightness of the excavation which, otherwise, would tend to deviate from
the hard area to those with softer soil or concrete.
- Augered piles in particularly unstable soils. The casing protects against collapse during drilling.
- Augered piles in underground streams. The casing protects against concrete washout.
- Piling or drilling with restricted vertical tolerances.
The drilling equipment consists of two rotaries,

- the top rotary operates the continuous flight auger,
- the bottom rotary operates the casing.
The first is a normal rotary table for CFA; the second one has an integral passage for the auger
retrieval.
- The accidental fall of objects such as cuttings, casing, bolts and other parts of the machine
despite the safety devices installed and regular checks and maintenance.
- The risk of crushing and pinching in moving parts of the machine such as tracks, turret, mast
and struts, drilling tool, auger cleaner etc. These parts cannot be protected by guards as often
such guards increase the risk instead of reducing it.
- The oscillation of suspended loads (e.g. reinforcing cages).
- The risk of crushing resulting from other machines in the worksite like the loader, the crane, the
concrete mixer etc.
As a result, different dangerous areas exist all around the machine and some general
precautionary measures must be taken.
5. Remain in a dangerous areas for the time strictly necessary.
listed at the beginning of the paragraph.
ManualeUtente_E.doc
CSP - page 26
WORK PHASES
IMPORTANT
TRAMMING
DANGER
DANGER
overturning.
DANGER
it to overturn.
DANGER
ManualeUtente_E.doc
CSP - page 27

DANGER
WARNING
Positioning the machine with the rotary connected to the concrete pump by the hose can be
dangerous. An excess tension of the hose can result in a machine overturning.
RIGGING THE MACHINE

Rigging a drilling rig consists in lowering the footpad to the ground, aligning the mast, cleaning the
grout outlet and fitting the drillbit cap to the drilling tool.
IMPORTANT
These phases require the presence of the riggers within the zone of maximum danger.
As a result, it is compulsory to:
• previously check the presence of cuttings which could fall down
• remain in the area for the time strictly necessary
• rig only a stationary machine under the supervision of the machine operator.
DANGER
The riggers must pay maximum attention during the lowering of the mast footpad. Feet at
risk!
DRILLING
The continuous flight auger is moved vertically by four part reeving of the main rope.
The casing is moved vertically by two part reeving of the service rope acting on a sliding cradle.
During driving, the cradle is moved down to the mast base, clamped in this position by two
hydraulic bolts and used as a transmission block of the service rope. This rope comes down from
the cathead along one side, runs around a pulley in the cradle and moves up again to the casing
driver. Here, it runs around a pulley fixed under the rotary and moves back to the cradle where a
second pulley guides it back to the cathead.
During retrieval, the sliding cradle rests on the casing driver and the rope moves down from the
cathead through the cradle and up to the cathead from the opposite side. The passages through
the intermediate pulleys do not interfere with the pull-out function.
The normal rotation direction of the casing is counter-clockwise, say contrary to the rotation
direction of the auger which allows cuttings to move out of the hole.
ManualeUtente_E.doc
CSP - page 28
DANGER
The rotation of both rotaries in the same direction to maximum torque can result in serious
damage to the machine parts, especially the mast.
WARNING
If the casing driver rotates in the same rotation direction of the auger rotary, cuttings can
accumulate and form a sort of plug that prevents any subsequent removal.
The lower outlet of the casing is equipped with teeth like a corer. These teeth are designed to
rotate counter-clockwise during drilling.
WARNING
If the casing rotates clockwise, the teeth may get damaged or come out of their special
supports.
The integrity of the teeth is of the utmost importance for the excavation speed on rock,
concrete and casehardened layers.
For a proper drilling, it is essential to avoid a "corkscrew" penetration of the auger in the ground as
this will let the tool stall after a few metres. It is recommended to let the auger advance in a
continuous way and for short lengths so that cuttings can detach from the hole walls and move out
of the hole without clogging the space between the auger turns.
Usually drilling does not require the presence of personnel in the vicinity of the machine, except for
two operations.
Once the tool has been driven into the ground for one metre, the openable guide at the base of the
auger (if present) must be opened by hand. This operation must be done with the tool stopped and
under the supervision of the machine operator.
The cuttings moving up along the auger come out of the casing outlet. Their removal from the
ground must be done with an excavator equipped with cab in accordance with the FOPS
regulations.
IMPORTANT
Except for these two operations, people must keep clear of the dangerous zone.
With the auger cleaned, cuttings are initially conveyed to the auger inside the casing. After that,
when almost half of the cased section has been excavated (e.g. 8 metres if the casing is 16 m),
cuttings begin to fall down out of the upper outlet of the casing.
DANGER
Cuttings fall from a significant height that can be highly dangerous for the people standing
close to the drilling area. Stones can rebound and project splinters. As a consequence, the
area around the excavation site comprised within a radius of 8 metres must be regarded as
an interdicted area.
Part of these cuttings can remain attached to moving or fixed parts of the auger forming dried
sediments which may hinder the following operation of the auger cleaner or the up-movement of
the cuttings themselves.
IMPORTANT
After every working cycle, when the cleaner is close to the ground, remove all sediments and
clean the auger.
ManualeUtente_E.doc
CSP - page 29
WARNING
We'd like to draw the reader's attention to the fact that, during drilling, soil is removed from
the area under the mast footpad. A gradual yielding of the ground during this phase, as a
result of the drilling operations, could let the machine tip over. For this reason, a special
valve keeps the mast on the ground. Riggers must be very careful to the movement of the
mast.
PULL-OUT PHASE - CONCRETING - AUGER CLEANING

The procedure envisaged and recommended for casting is to pump concrete by pulling out only the
auger with the casing driven in the soil. In this way, the complete auger passes through the cleaner
and most cuttings are removed. The casing will be driven out only after concreting. If casing and
auger are driven out simultaneously, most cuttings will remain on the auger.
DANGER
If the cuttings remain on the auger, during next excavation they will come out of the casing
outlet at a high height and the danger of fragment projection will increase.
DANGER
The weight of the cuttings on the auger can affect the machine stability during tramming.
For a proper concreting, it is necessary to avoid abrupt up-movements of the excavated cuttings. In
fact, this would not allow for the immediate filling of the open space created under the drillbit. This
open space could be refilled with the soil collapsing creating a filling discontinuity. Concrete shall
be pumped in continuously and the pull-out speed shall be adequate to the filling speed. It is
advisable to use a control instrument and proceed in accordance with the relevant instructions.
During the pull-out phase, cuttings are moved up to the casing top and must be removed to avoid
dangers resulting from their fall from a high height.
DANGER
Before driving out the casing, be sure that there are no cuttings on the casing driver or the
auger cleaner. These cuttings could fall down from a high height during the cage laying and
preparation. Remove such cuttings, if necessary.
The cutting heap should be removed constantly during the pull-out phase.
DANGER
Blocks of clay and big stones falling down from the auger can lead to lethal injury. When
drilling grounds with blocks of clay and stones, remove the debris from the auger during the
pull-out phase using, for instance, a loader or a shovel.
Soilmec supplies a rotating cleaner which slides along the auger flights and remove cuttings even if
the auger is not running.
It is advisable:
4. to keep the cleaner to max 3-4 metres above the ground to avoid any projection of cuttings
5. not to dip the cleaner into the cutting heap to avoid soiling the part of auger already cleaned
ManualeUtente_E.doc
CSP - page 30
6. The cutting heap should be removed constantly during the pull-out phase.
DANGER
The cleaner moves and turns. To avoid any risk of crushing and injury, keep clear of its
working range during operation.
DANGER
During pumping, the hose is subject to shakes and pressure peaks which could loosen the
nuts. As a result, some parts could fall down. Pay a special attention to this hose. Always
connect the different parts of the hose one with the other and with the machine using some
steel ropes or safety chains.
CLEANING THE HOLE

After the pull-out phase, remove any cuttings from the surface all around the hole with the loader.
Remove any concrete residues from the hole mouth with a shovel before lowering the cage down
into the hole.

To lay the cage into the casing, two systems have been envisaged:
Driving into the concrete jet after pulling out the casing and removing the machine as it occurs with
the CFA.
Unscrewing of the casing from the lower rotary and laying of the cage into the casing. In this case,
concrete is poured through a contractor tube-jet and the casing is driven out subsequently using
the machine.
WARNING
In the second case, the operator given the task of removing the casing must work under the
special roofing fixed to the lower rotary in order not to get injured due to the fall of cuttings.
While cleaning the hole mouth, it is possible to attach the service rope to the top of the cage
moved near the machine with an adequate lifting equipment.
hole by the machine, then lowered down into the hole by gravity.
In order to help the final lowering phase, the special bell vibrator can be used.
DANGER
The suspended cage can swing and injure the personnel. The machine operator and the
riggers must pay maximum attention!
DANGER
The weight of the cage must not exceed the load capacity rating of the service winch. The
length of the cage must not exceed the maximum permissible height.
DANGER
ManualeUtente_E.doc
CSP - page 31
ALTERNATIVE USE
On a sufficiently firm ground, drilling with the continuous flight auger can also be done by pulling
out the auger without casting pumped concrete.
Filling can be done in a subsequent phase with a second machine (sand drains and sandwich).
For the execution of gas hoisting shafts (waste disposal site), the concreting phase is replaced by
the laying of a filtering tube sealed to the ground.
FORBIDDEN USE
It is expressly forbidden to use the machine for:
- Lifting and handling loads
- Loading and unloading trucks
- Moving cuttings exerting a thrust
- Pushing or pulling jobsite equipment
and in general, using the machine for purposes other than those envisaged and described in the
two previous paragraphs.
ManualeUtente_E.doc
CSP - page 32
OUT OF SERVICE
BREAKDOWNS)
STABILITY WARNINGS
wood, metal bases)

Maintenance Manual supplied with the machine to define the method of use and the different
ways of storing the machine.
ManualeUtente_E.doc

Sicurezza AT000108 - E - Rev0

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Instructions for the user

GENERAL WARNINGS FOR USE

DOCUMENT SOURCE LANGUAGE (ITALIAN)

READ AND UNDERSTAND THE INSTRUCTIONS IN THIS MANUAL

Document code - Edition Valid for machines (serial no.)

AT000108/E – Rev. 0 01/2005

SOILMEC S.p.A. 5819, Via Dismano I-47023 CESENA - ITALY

General warnings for use

© Copyright 2005 SOILMEC S.p.A. - All rights reserved.

Printed in Cesena by the manufacturer.

DEALER OR LOCAL AUTHORISED ASSISTANCE CENTRE

MEMORANDUM OF THE TECHNICAL DATA OF THE MACHINE

Machine serial number

See chapter "IDENTIFICATION PLATES" in the Use and Maintenance Manual

PRESENTATION OF THE MANUAL

PURPOSE OF THE MANUAL

PERSONNEL WITH THE OBLIGATION OF CONSULTATION

STRUCTURE OF THE MANUAL

• ENVISAGED USE OF THE KELLY EQUIPMENT

SYMBOLS USED IN THIS MANUAL

CLEANING THE HOLE ............................................................................................................23

ENVISAGED USE OF THE KELLY EQUIPMENT

POSITIONING THE MACHINE

Kelly or telescopic bar

Friction bars are simpler to use and maintain.

Mechanical locking bars

TYPICAL DRILLING CYCLE

HAMMER AND PERCUSSION TOOLS

LOWERING THE CAGE INTO THE HOLE

WARNINGS FOR LOW TEMPERATURES

ENVISAGED USE OF THE CFA EQUIPMENT

POSITIONING THE MACHINE

PULL-OUT PHASE - CONCRETING - AUGER CLEANING

CLEANING THE HOLE

LOWERING THE CAGE INTO THE HOLE

WARNINGS FOR LOW TEMPERATURES

ENVISAGED USE OF THE CSP EQUIPMENT

The drilling equipment consists of two rotaries,

POSITIONING THE MACHINE

RIGGING THE MACHINE

PULL-OUT PHASE - CONCRETING - AUGER CLEANING

CLEANING THE HOLE

LOWERING THE CAGE INTO THE HOLE

WARNINGS FOR LOW TEMPERATURES

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