THE CONSTRUCTION AND COMPLETION OF BORED

PILE WORKS OF BRIDGE 042 AND BRIDGE 044 FOR

EAST COAST RAIL LINK PROJECT SECTION 3

ADVANCE GEOTECHNICS SDN BHD

METHOD STATEMENT

BORED PILE CONSTRUCTION

AG/MSM/BP
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BORED PILING WORKS

Formation of Borehole

Set out pile position

Pile positions set by Main contractor’s licensed surveyor, before commencement of piling.
The existing ground level at the pile position will be measured and recorded.

Set boring unit

Prior to boring, the following steps will be carried out:

• Offset surveyed pile position in two perpendicular directions by placing 2 offset

markers at appropriate distances from the pile position, to facilitate the installation of
temporary steel casing. The offset distance will be such that these markers will not be
disturbed during installation process.

1.0~1.5m

Reference
marker 1
Steel
casing

Pile center

Reference
marker 2

ISOMETRIC VIEW
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BORED PILING WORKS

Pile center
1.0~1.5m

Reference
marker 1

1.0~1.5m Steel
casing

Reference
marker 2
PLAN

• Level the platform for the boring rig by placing steel plates.
• Check the verticality of the Kelly Bar of a boring rig, by banks-man prior
commencement of boring.
• Position the boring rig at the designated location to commence boring works.

3.2 Commence boring with auger

• Temporary casing shall be installed into ground upon reaching rock or firm soil strata.
• Commence boring, boring shall continue until it has reached the design pile toe level.
• Collect soil sample from the ground level to the pile toe level at every 3m interval and
at each and every soil interface, record the corresponding excavation depth.
• Soil sample collected shall be kept inside transparent plastic bag with clear labelling
of pile reference, size, depth and date with permanent marker for future reference.
• Stabilize borehole by filling the borehole with drilling fluid or lengthen the temporary
casing to the depth where collapsible soft soil layer can be protected from falling.
• Cease boring works when the designated level has been achieved.
• The designated level is usually the design pile toe level shown in the
construction drawing.
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BORED PILING WORKS

Typical schematic illustration showing borehole using combination of

both short temporary steel casing with stabilising fluid

Opening for
Overflowing if
Stabilising
Steel Plate
Fluid/Water is used Earth Bund
1m above G.L.
Ground Level
Soil Layer 1
(Typically G.W.T Slurry Collection
Backfilled)

Soil Layer 2
(Soft collapsible soil
layer)
Bentonite
Slurry

• Stabilizing fluid shall be used only when the length of temporary casing inserted is
shorter than the depth of collapsible soil and when the possibility of groundwater
seepage is high especially during the granite or rock drilling process.
• Pump the water/stabilizing fluid such as polymer or bentonite into the borehole as
soon as the bored length exceed the length of temporary casing or the groundwater
starting to seep into the borehole before continuing boring works.
• Maintain the level of stabilizing fluid at the ground level by constant pumping.
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BORED PILING WORKS

Typical schematic illustration showing borehole using only temporary steel

casing

Steel Plate

1m above G.L.
Ground Level
Soil Layer 1
(Typically G.W.T
Backfilled)

Soil Layer 2
(Soft collapsible soil
layer)

Soil Layer 3
(Strong Soil
Layer)

• Dry hole is formed when there is no groundwater seepage or the temporary steel
casing installed is deeper than the collapsible soil.
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BORED PILING WORKS

Verticality Check during Temporary Casing Installation and Boring Works

During the course of boring, the following will be performed:

• Check the casing position during and after placing of the casing, prior to boring work.
• Check the verticality of casing during installation, using plumb-lines method from two
perpendicular directions.
• Adjust or extract the casing if in any direction is deviated, and re-installed until the
plumb-line is in verticality with the side of the casing.
Pile Position
Spirit Ruler

Plumb

• Take and record the top level of temporary steel casing to enable measurement of
pile depth.
• Measuring tape tied to a weight shall be lowered down using hand to the base of
borehole touching the perimeter of borehole and compare with the casing perimeter at
the top to check verticality of the bored hole.
• Limit the maximum allowance in eccentricity of steel casing to 1:75 mm.
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BORED PILING WORKS

Drilling Tools

• Soil drilling shall be performed by a combination of the use of drilling tools, i.e.
Soil auger, Soil bucket and cleaning bucket.

Auger – For normal drilling into soil

Soil or rock bucket – For drilling through Soil, rock/ granite

Cleaning bucket – For removing loose soil at the base of the borehole
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BORED PILING WORKS

Cleaning of Base
• Clean the base of the borehole to remove any loose, disturbed or remoulded soil with
a cleaning bucket.
• Measure the depth from the base of the borehole to the top of the temporary steel
casing.
• Confirm the depth of the borehole with Consultant’s representative (RE or COW).
• If the groundwater seepage is less than 300mm, a bag of cement will be poured into
the borehole and it shall be casted as dry condition.
• In the event that groundwater seepage is more than 300mm, the borehole shall be
casted as tremie condition.

Clean-Up
Bucket
Design Toe Level

3.6 Installation of Reinforcement Cage

• A number of reinforcement cages are required for construction of the bored piles. The
temporary steel casing shall be used as a support for lapping the reinforcement cages
during installation.
• The lapping joint for the stirrups shall be 50mm (tap welded) and 300mm (without
weld).
• Fabricated steel cages with internal links at interval 3.0m shall be stored at steelyard
without substantial load on top and to prevent shape deformation.
• Weld main bars with main links at the top of the reinforcement cage to hold the main
bars and main links together for lifting purposes during installation.
• Hook the wire sling with shackles onto the main links.
• Use concrete spacers (eg. Plastic wheel spacer) to ensure the reinforcement cage is
in correct positioning and to achieve a concrete cover of 75mm.
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BORED PILING WORKS

• The spacers shall be placed at not more than one metre below the top of the
reinforcement cage and not more than 4.0m interval along the main reinforcement.
Temporary Steel Casing

Plastic Wheel Spacer

Cut-Off-Level

Reinforcement Steel Cage

3m

Concrete Spacer

Plastic Wheel Spacer

• Hold the reinforcement cage at the temporary steel casing top (for lapping) by
inserting a T25 or equivalent material across the main link and rest it on the top of the
casing.
• Dislodge the wire sling with the shackles from the main links.
• Repeat the above procedure for other reinforcement cages.

For last reinforcement cage

• Support the reinforcement cage on the temporary steel casing with the short rebar
(same procedure as lapping).
• Dislodge the wire sling with shackles from the main links.
• Hoist the hangers (made up of a hook at the top and different lengths of the
reinforcement depending on depth of the cut-off level of the bored pile) to the
reinforcement cage.
• Hoist and lower the hangers together with the reinforcement cages to the designated
depth.
• Suspend the reinforcement cages at the designated depth by hooking the hanger
onto the temporary steel casing at the top. This is to secure the reinforcement cage in
position and maintain the verticality of the reinforcement cage during concreting works.
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BORED PILING WORKS

Tap weld
Steel hooks

T16 rod OR

12m Steel cage

Steel Casing

• Reinforcement cage is tap welded or steel hooked to the steel casing to prevent the
cage from floating up during concreting.

Concreting of Bored Pile in

In Tremie Condition
• Use a tremie pipe of diameter of minimum 200mm for concreting bored.
• Join the sections of the tremie pipe prior to lowering it into the borehole. Lower the
tremie pipe into the borehole until approx. 150 mm above toe level to facilitate flow of
concrete.

Tremie Condition

Tremie Pipe
Steel Support
(For tremie pipe)
Ground Level
Concrete
Stabilising Fluid

Reinforcement Cage

300mm
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BORED PILING WORKS

• Pour concrete into the borehole via a hopper attached to the top section of tremie
pipe. The concrete slump for tremie method shall be between 100 to 150mm.
• Withdraw the tremie pipe from the borehole as the concrete level rises. This is to
facilitate the flow of concrete. However, it is important to note that the tremie pipe is to
be embedded not less than 2m below the concrete level.

Ground Level

2m

• Dismantle the tremie pipe from the top, section by section.

• Pump the stabilising fluid back to the storage pond by a submersible pump when the
stabilising fluid is displaced by the volume of concrete. However, it is important to note
that the pumping rate of the stabilising fluid shall not be exceeding extensively from the
discharging rate of the concrete.
• The level of stabilizing fluid shall be maintained at an appropriate level to prevent
collapse of the borehole during concreting works.
• The concrete shall be over-casted by at least 500mm above the cut-off level of the
pile to allow weak concrete to be removed during hacking stage.
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BORED PILING WORKS

In Dry Condition

• When the borehole is in dry condition, direct discharge of concrete will be carried out.
• Concrete will be discharged through a short conical hopper fixed to a short length of
tremie pipe not less than 6.0m.
• The hopper shall be placed centrally over the bored hole to direct the concrete
discharge from the ready-mix concrete truck.
• The concrete shall be over-casted by at least 300mm above the cut-off level of the
pile to allow weak concrete to be removed during hacking stage.

Dry Condition

Ground Level
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BORED PILING WORKS

Extraction of Casing and Backfill

• Carry out the extraction of temporary steel casing using a vibro-hammer (if
necessary) immediately after the casting work.
• Backfilled the empty borehole above the pile cut-off level with bored out soil.
• Remove the suspension beam or setting frame after backfilling.

Pile Hacking

Pile Excavation
The pile excavation will be planned and carried out by main-con, as per their master work
program.
The excavation will be followed by piling contractor for pile hacking work.
Main-con will inform piling contractor upon completion of excavation pile cap work.
After excavation completed, main-con will provide and mark pile cut-off level (COL) on
each pile for piling contractor for pile trimming.

Pile Hacking

BORED PILE HACKING PROCEDURES

1. After bored pile installation complete, pile cutting will commence based on main
contractor’s schedule.
2. The pile cutting will require mobilization of air compressor breaker, and other
mandatory cutting equipment or tools.
3. In general, building contractor will cast lean concrete prior to the pile cutting. The pile
is then cut based on cut off level marked by main contractor.
4. Pile will be hacked and trimmed off by manual hacking with air compressor breaker
until cut-off level.
5. For pile with reinforcement lap length, the pile will be hacked to expose the
reinforcement and the reinforcement length uncovered will comply with the minimum
lap length.
6. Main contractor to provide firm and safe base for worker working in the excavation
area including dewatering and shoring for deep excavation.
7. Main contractor to confirm the schedule in advance for the purpose of manpower and
equipment preparation.
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BORED PILING WORKS

Pile Remedial work (if any)

If the pile concrete under cast below piles COL, insufficient starter bar or sunken steel
cage condition, the attached remedial work proposal below shall be complied on site.
An inspection after pile remedial work completed shall be carried out by clerk of work,
main-con supervisor and piling contractor supervisor.
Below are illustrations of pile rectification works;

Case 1: Remedial Work for Bored Piles casted below cut-off level
(Build up pile)

Extended started bar

Cut-Off-Level Join / lap main

rebars & fixed links
by welding
by welding. Required weld
length, Lw (refer to
Poor concrete to be table in case 2)
hacked away.

Stage 1
Stage 2

Concreting in progress
(Grade 35 concrete)

Install temporary
casing & cast
concrete Build-up pile
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BORED PILING WORKS

Case 2: Remedial Work for Bored Piles with insufficient length of starter bars at cut-off
Stage 3 level
Stage 4

Re-bar with insufficient length Extended

starter bar
Joint Detail
(refer to Detail a)
C.O.L

Stage 1 Stage 2

Welding Length
Required weld length, Lw = yield load / weld strength
= 0.87(fy)(As) / 0.7(s)(215)(80%) N/mm2

where,
fy = yield strength of steel (N/mm2)
As = cross sectional area of bar (mm2)
s = fillet weld length (mm)
Site welding strength pw = 215 N/mm2 shall be reduced to 80% as per code CP 65
requirement.

Detail a

A1
Where,
A1 + A2 > Total weld length, Lw
B

A2
Lw, required welding length
(refer to the table below)
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BORED PILING WORKS

Steel, fy = 460 N/mm2 Weld length required, Lw (in mm)

Fillet weld Weld Bar diameter, D (mm)
leg strength 12 16 20 22 25 28 32
2
(mm) (N/mm )
5 600.00 80.0 140.0 220.0 260.0 330.0 420.0 540.0
6 720.00 70.0 120.0 180.0 220.0 280.0 350.0 450.0
7 840.00 60.0 100.0 150.0 190.0 240.0 300.0 390.0
8 960.00 50.0 90.0 140.0 160.0 220.0 260.0 340.0
10 1080.00 50.0 80.0 120.0 150.0 190.0 230.0 300.0
12 1200.00 40.0 70.0 110.0 130.0 170.0 210.0 270.0

Steel, fy = 460 N/mm2 Weld length required (for both-sides welding), Lw (in mm)
Fillet weld Weld Bar diameter, D (mm)
leg strength 12 16 20 22 25 28 32
2
(mm) (N/mm )
5 600.00
40 70 110 130 165 210 270
6 720.00
35 60 90 110 140 175 225
7 840.00
30 50 75 95 120 150 195
8 960.00
25 45 70 80 110 130 170
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BORED PILING WORKS

Case 3: Remedial Work for Bored Piles with sunken steel cage
(Steel cage below cut-off level)

Steel cage below COL

Extended starter bar

Join / lap main
Re bars & fixed links
by welding
COL by welding. COL

Joint Detail
(refer to Detail
Concrete to be hacked a)
away & expose at
least 7 of rebar cage

Stage 1 Stage 2

Concreting in progress
(Grade 35 concrete)

COL COL
Build up
Install temporary
casing & cast concrete

Stage 3 Stage 4
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BORED PILING WORKS

Case 5: Remedial Work Bored Piles with Sunken Steel Cage

(Steel cage below Cut-Off Level)

Holes drilled into

bored pile with
anchorage length,
L
Steel cage below
COL COL COL
L

Stage 1 Stage 2

Reinforcement bars inserted

into drilled holes which are
grouted with Hilti RE-500 as
per manufacturer’s
recommendation.
COL

Stage 3
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BORED PILING WORKS

Case 5: Remedial Works For Bored Piles with Sunken Steel Cage
(Steel cage below Cut-Off Level)

Holes drilled into

bored pile with
anchorage length,
L
Steel cage below
COL COL COL
L

Stage 1 Stage 2

Reinforcement bars inserted

into drilled holes which are
grouted with non-shrink grout
or epoxy concrete (anchorage
length using epoxy concrete
COL shall refer to manufacture
specification)

Design Anchorage Bond Stress:

fb = Fs / ( x D x L) where fb = Bond stress

Fs = Force in the bar (f y x bar area)
D = Bar diameter
L = Anchorage length

Design Ultimate Anchorage Bond Stress:

Stage 3
fbu = B(fcu)1/2 where fbu = Design ultimate bond mix
fcu = concrete design mix
B = Coefficient for rebars
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BORED PILING WORKS

Values of bond coefficient (B) table:

Bar Type
Values of bond coefficient, B

Compression
Tension
Bar
B
a
r
Round bars 0.28 0.35
Type 1: deformed 0.40 0.50
bars
Type 2: deformed 0.50 0.63
bars
Fabric 0.65 0.81

Steel bar anchorage length table:

Steel, fy = 460 Length of bar, L (mm)
2
N/mm
Bond coeff. B = 0.63 Bar diameter, D (mm)
fcu (N/mm2) 12 16 20 22 25 28 32
30 400.00 540.00 670.00 740.00 840.00 940.00 1070.00
35 380.00 500.00 620.00 680.00 780.00 870.00 990.00
40 350.00 470.00 580.00 640.00 730.00 810.00 930.00
45 330.00 440.00 550.00 600.00 690.00 770.00 880.00
65 272.00 363.00 453.00 499.00 567.00 634.00 725.00

Steel, fy = 250 Length of bar, L (mm)

2
N/mm
Bond coeff. B = 0.63 Bar diameter, D (mm)
fcu (N/mm2) 12 16 20 22 25 28 32
30 220.00 290.00 370.00 400.00 460.00 510.00 580.00
35 210.00 270.00 340.00 370.00 420.00 470.00 540.00
40 190.00 260.00 320.00 350.00 400.00 440.00 510.00
45 180.00 240.00 300.00 330.00 370.00 420.00 480.00
65 148.00 197.00 247.00 271.00 308.00 345.00 394.00