Professional Documents
Culture Documents
Method Statement
for
Anchored - Bored Pile - Shotcrete
Retaining Wall System
A. Wondimu
Addis Ababa
June, 2006.
ANCHORED-BORED PILE – SHOTCRETE
RETAINING WALL SYSTEM
Maritime Building, Addis Ababa, Ethiopia
TABLE OF CONTENTS
1 General Overview ............................................................................................................. 1
1.1 Methodology................................................................................................................ 1
1.2 Site Details................................................................................................................... 1
2 Construction Methodology ............................................................................................... 2
2.1 Site preparations and Setting out ................................................................................. 2
2.1.1 Site preparations ................................................................................................ 2
2.1.2 Setting out.......................................................................................................... 2
2.2 Reinforced – Concrete bored cast insitu piles ............................................................. 2
2.2.1 Construction Sequence ...................................................................................... 2
2.2.2 Description of Equipment.................................................................................. 4
2.3 Excavation (Earth works) ............................................................................................ 6
2.4 Reinforced shot-crete membrane................................................................................. 6
2.4.1 Construction Sequence ...................................................................................... 6
2.4.2 Description of Equipment.................................................................................. 7
2.5 Construction sequence of grouted temporary anchors ................................................ 8
2.5.1 Drilling of anchor bore hole .............................................................................. 8
2.5.2 Temporary Grouted anchor units..................................................................... 10
2.5.3 Installation and Post-Grouting........................................................................ 10
2.5.4 Anchor proof testing and locking .................................................................... 12
2.5.5 Details of Equipment ....................................................................................... 12
3 Material Specifications ................................................................................................... 14
3.1 Piling.......................................................................................................................... 14
3.1.1 Concrete........................................................................................................... 14
3.1.2 Reinforcement Steel ........................................................................................ 14
3.2 Anchor Unit ............................................................................................................... 14
3.2.1 Anchor tendons................................................................................................ 14
3.2.2 Grout Mix ........................................................................................................ 14
3.3 Shotcrete .................................................................................................................... 14
3.3.1 Dry Mix ........................................................................................................... 14
3.3.2 Reinforcement Steel ........................................................................................ 15
4 Quality Control / Quality assurance................................................................................ 16
4.1 Piling.......................................................................................................................... 16
4.2 Anchors...................................................................................................................... 16
4.3 Shotcrete .................................................................................................................... 17
5 List of Equipments.......................................................................................................... 18
6 List of Key personnel...................................................................................................... 19
7 Annex.............................................................................................................................. 20
7.1 Daily activity report................................................................................................... 20
7.2 Pile log sheet.............................................................................................................. 21
7.3 Anchor installation sheet ........................................................................................... 22
7.4 Anchor stressing forms.............................................................................................. 23
ANCHORED-BORED PILE – SHOTCRETE
RETAINING WALL SYSTEM
Maritime Building, Addis Ababa, Ethiopia
1 General Overview
1.1 Methodology
The construction of a vertical retaining wall with BAUER anchored bored pile wall-shotcrete
membrane system is a step wise construction technique that produces a safe optimized
excavation pit ready for subsequent substructure works. The detailed construction steps
include:
1. Careful setting out of the centre line of the bored pile with a high level of accuracy
using appropriate surveying techniques.
2. Installation of reinforced bored cast – insitu piles along the periphery of the plot as
set out above.
3. Excavation of the site in equal lifts. While retaining the void between two adjacent
bored piles with reinforced shotcrete membrane
4. Installation of tie back temporary grouted anchor that support the bored piles
(reinforced concrete piles).
The excavation, shotcrete works and the installation of anchors activities are repeated until
the designed excavation level is attained.
The outcome of the above is a clean level working space for the next construction step- the
substructure works. Each of the above steps has been described in detail in the following
sections of this statement of methods.
The proposed site is located in Mexico Area bordering in the old Maritime building opposite
Telecommunication Centre.
In order to create the working space for the underground works, it is necessary to retain the
all the boundaries of the plot. Due close proximities of the existing old Maritime building and
the Insurance building, extra caution has to be implemented while installing the anchoring
systems on these directions.. The total retaining wall to be constructed is nearly 270 mL.
The Methods and steps detailed in subsequent sections describe the installation a temporary
retaining structure until the eventual transfer of loads to the eventual to be constructed
permanent systems.
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ANCHORED-BORED PILE – SHOTCRETE
RETAINING WALL SYSTEM
Maritime Building, Addis Ababa, Ethiopia
2 Construction Methodology
In addition a central working space also has to be cleared and leveled for stores steel
fabrication anchor fabrication, etc.
Once axis of the plot lines is cleared and leveled, the locations of the pile centers will be
carefully surveyed and staked by a qualified surveyor. However it will be the client who will
provide the coordinates of the corners of plot. Using the coordinates provided, pile centre
locations can be calculated for all piles.
Corners piles and intermediate piles will then be carefully setout with a surveying instrument
with a high level of accuracy. These pile points will serve as reference axis for the piles to be
installed; hence will be properly secured and protected from any instructions.
Using two reference piles, intermediate piles can easily be pegged knowing the distance
offset to each pile centre. Once located, the pile centre is marked by driving a 25cm steel
reference peg. This point is then clearly identified with color marking and covered with
protection to prevent any accidental damages.
1. Once the pile centers have been marked (2.1.2) the drilling rig BG -11 or equivalent will
be positioned at the drilling location. The mast of the rig will be checked by the drilling
foreman for verticality in two perpendicular directions with the help of a spirit level. At this
stage two additional mutually perpendicular references will be marked for the pile to be
drilled.
2. A short –temporary casing will be driven while maintaining the fixed distance to the
established references above. Figure 1 depicts the step by step pile installation process.
3. Bore hole excavation will proceed with the aide of the lockable telescopic Kelly bar
mounted on the mast of the drilling rig. Once toe level is reached, the bore hole will be
cleaned to free from loose debris.
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ANCHORED-BORED PILE – SHOTCRETE
RETAINING WALL SYSTEM
Maritime Building, Addis Ababa, Ethiopia
4. A reinforcement cage fabricated on site consisting of main and helical steel bars will be
lowered into the bore.
5. Concreting will proceed with tremie method. The short temporary casing will then be
extracted and the pile top leveled.
The installation of the short temporary casing will be conducted while simultaneously
checking its verticality and location from the equidistant perpendicular references. The
drilling of the borehole will proceed with the appropriate drilling tools. Meanwhile changes in
stratigraphy are carefully recorded by a qualified staff and will then be submitted in a format
as per Annex 7.2.
A weighted measuring tape shall be used to measure borehole depth. The borehole will be
excavated to the required design depth.
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ANCHORED-BORED PILE – SHOTCRETE
RETAINING WALL SYSTEM
Maritime Building, Addis Ababa, Ethiopia
The ready mixed piling concrete will be supplied at the piling location with transmixers.
Tremie concreting method will be utilized to provide a well compacted pile.
Tremie tubes in fixed length sections are jointed using compiling heads to reach the
approximate depth of the pile. At the joints grease and sealing 0-rings will give a water tight
connection to prevent ingress of ground water should it be present.
Concrete is poured directly from the mixer-truck into the hopper and eventually the borehole
via the already lowered tubes. If ground water is present, a Styrofoam chip or plastic ball
plug is used within the tremie pipe to prevent segregation of concrete at water – concrete
contact.
Tremie tubes are removed in sections as concreting progresses noting the concrete depth .
If ground water in present section can only be removed if the bottom of the tubes is
embedded minimum 1.5m into fresh concrete. For dry boreholes on the other hand, a
maximum drop height of 2.0m has to be ascertained prior to removing any tremie tubes.
Once fresh concrete has reached the ground level, the short temporary casing will be
removed and the concrete topped up to bring to the ground level. Once again if water is
present in the borehole contaminated concrete shall be over flushed to yield good concrete at
the pile top.
The drilling tool accessories will vary depending on the type soil to be excavated. Our
experienced operator will decide on the type of tool to be used in the progress of drilling.
Figure 2: Shows the details of Bauer drilling rig BG – 11.
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ANCHORED-BORED PILE – SHOTCRETE
RETAINING WALL SYSTEM
Maritime Building, Addis Ababa, Ethiopia
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ANCHORED-BORED PILE – SHOTCRETE
RETAINING WALL SYSTEM
Maritime Building, Addis Ababa, Ethiopia
Excavation will continue in successive lifts to coincide with the shotcrete and anchor
installation activities. This activity will be carried out with a conventional excavator with the
vertical faces between adjacent piles at the retaining wall done manually. Subsequent lifts
will continue once anchors have been installed at that level.
The following section details the shotcreting and anchor installation activities.
anchor
max. a = 2.50 m
water proofing
A reinforcement wire mesh consisting of longitudinal and horizontal bars is securely fixed to
the wall before shotcrting. The shotcrete is then applied to the wall by using compressed air
and water mixed at the nozzle. The compressed air shoots the designed dry mix – a blend of
designed proportions of specifically graded aggregate with ordinary Portland cement. Figure
4 shows the shotcreting activity in progress.
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ANCHORED-BORED PILE – SHOTCRETE
RETAINING WALL SYSTEM
Maritime Building, Addis Ababa, Ethiopia
The combination of impact and water mixing at the nozzle create a highly compacted rigid
wall mass. This activity is repeated to the required excavation level.
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ANCHORED-BORED PILE – SHOTCRETE
RETAINING WALL SYSTEM
Maritime Building, Addis Ababa, Ethiopia
The anchor installation process involves (Figure 6 shows pictorially the construction steps).
1. Cutting through the reinforced concrete pile to be supported at the prescribed design
angle
2. Drilling of the borehole using appropriate tools to suit the site soil conditions.
3. The fabricated anchor unit is inserted into the borehole and the whole filled with
cement suspension.
4. Post grouting of anchor follows to enlarge the grout mass.
5. After curing the grout mass has cured the anchor is tensioned to the design load.
The detailed retaining system design provides the levels at which the anchors are to be
installed for each individual pile. The BAUER site Engineer clearly marks the anchor levels,
guides the anchor foreman on each individual anchor inclination, borehole depth etc. In
general, a tabular anchor installation schedule is prepared containing pertinent information
such as pile no., number of anchor layer, inclination angle for each anchor layer, borehole
depth, anchor unit length and anchor loads. Such schedule not only controls the degree of
accuracy on the construction process but it also expedites the installation task as the work at
hand will be clear to all site management. As anchor installation is usually on the critical path
of he construction schedule, due consideration is given to achieve the targeted minimum
daily production rates.
Once the anchor level has been marked and checked against the design, the anchor drilling
unit (UBW 06) is positioned at the pile location. The boom of the anchor drilling unit is then
adjusted to the prescribed drilling inclination. Once confirmed, coring through the reinforced
concrete pile will resume followed by the borehole installation task.
Several (drilling) tools and techniques are currently available. However the optimal method
for the specific type of soil encountered will be selected based on the site experience. For
instance the continuous flight auger method is best suited for soil matrix. For consolidated
soils and soft rocks, the use of roller type bits fixed at the end of extendable drilling rods
tends to yield high production rates. On the other hand, if hard rock formations are
encountered the use of pneumatic type down the hole hammer may be required.
After the borehole has been completed to the design depth the fabricated anchor unit is
carefully lowered into the borehole. A detachable grout pumping hose is also lowered
together with the unit.
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ANCHORED-BORED PILE – SHOTCRETE
RETAINING WALL SYSTEM
Maritime Building, Addis Ababa, Ethiopia
1. Borehole is drilled
using hammer,
rotary, circulation
or continuous flight
auger
2. Anchor tendon is
inserted
with the borehole
filled with cement
suspension
4. Secondary
grouting
5. Tensioning
After the cement
grout has set the
anchor is tensioned
to the calculated
load and secured
6. Completed
anchor
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ANCHORED-BORED PILE – SHOTCRETE
RETAINING WALL SYSTEM
Maritime Building, Addis Ababa, Ethiopia
Once lowered into the borehole, the primary grouting hose fitted directly to the grout pumping
unit (KP-60) which is in turn connected the slurry mixer (ZM), will pump a pure cement slurry
suspension from the bottom of the borehole up displacing any ground water should it be
present. Pumping stops as the slurry reach the top of the bore. The detachable hose is then
removed to be used for installation of other anchor units.
After allowing the initial set of the grout mass (approximately 4-5 hrs depending on the soil
conditions), clean water is pumped via the secondary grouting ducts at the required pressure
to crack the grout mass thereby enabling post grouting activities. Post grouting activities will
normally resume after 24 hrs. A cement slurry of 0.4 - 0.45 water cement ratio is carefully
pumped via each individual duct while recording the slurry consumption and pumping
pressure. Post grouting normally continues 2 - 3 days until the back pressure of about 50-60
bars is attained.
At the completion of post grouting, a curing period of about 10-14 days is maintained prior to
pre-stressing the anchors to their design loads.
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ANCHORED-BORED PILE – SHOTCRETE
RETAINING WALL SYSTEM
Maritime Building, Addis Ababa, Ethiopia
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ANCHORED-BORED PILE – SHOTCRETE
RETAINING WALL SYSTEM
Maritime Building, Addis Ababa, Ethiopia
Before anchors are locked at 0,8 of the design working load, temporary anchors are
individually tested up to 1,25 times the working load. At this stage the anchor elongation at
each load is recorded and checked against acceptable standard set forth. The sample report
produced is attached in Annex 7.4. With the aide of a hydraulic jack specially designed for
this purpose, anchors are tested and finally locked having fulfilled the required criteria.
The protruding anchor strands will then be cut and the anchor head capped to yield a
completed anchor.
1. UBW – 06
2. Grout Pump KP – 60
3. Mixer Unit ZM- Mixer
4. Stressing hydraulic Jack
UBW 06
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ANCHORED-BORED PILE – SHOTCRETE
RETAINING WALL SYSTEM
Maritime Building, Addis Ababa, Ethiopia
KP 60
ZM 1
Mixer capacity
Mixing [m³; m³/h] 0,165; 5,00
Dimension L/B/H [m] 1,00/1,00/1,75
Gross weight [t] 0,31
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ANCHORED-BORED PILE – SHOTCRETE
RETAINING WALL SYSTEM
Maritime Building, Addis Ababa, Ethiopia
3 Material Specifications
3.1 Piling
3.1.1 Concrete
Piling concrete should have a high workability (slump) in the range of 180 -220 mm. The
concrete should flow unhindered through the tremie tubes.
A typical Design mix for piling concrete
• Class C-25
• Maximum W:C 0.45 – 0.50
• Slump 180 -220mm
• Minimum cement : 370 – 380 Kg/m3 (O.P.C)
• Maximum Aggregate : 16mm
• Supper plasticizer / Retarder to achieve high workability at low w:c ratio.
3.3 Shotcrete
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ANCHORED-BORED PILE – SHOTCRETE
RETAINING WALL SYSTEM
Maritime Building, Addis Ababa, Ethiopia
PERCENTING MIX
SIEVE PROPORTION ACTUAL
SIZE % PASSING 30% 25% 45% GRADING LIMIT LIMIT LIMIT
(MM) M.AGG SAND DUST M.AGG SAND DUST SAMPLE 1 2 3
8 100 100 100 30 25 45 100 100 100 100
4 3.89 100 100 1.167 25 45 71.167 85 74 61
2 0.93 72.88 100 0.279 18.22 45 63.499 71 57 36
1 0.61 0 100 0.183 0 45 45.183 57 42 21
0.5 0 0 53.4 0 0 24.03 24.03 39 26 14
0.25 0 0 12.34 0 0 5.553 5.553 21 11 5
0.125 0 0 2.27 0 0 1.0215 1.0215
0.075 0 0 0 0 0 0 0
100
90
80
70
PERCENT PASSING (%)
60
50
40
30
20
10
0
0.01 0.1 1 10 100
GRAIN SIZE (mm)
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ANCHORED-BORED PILE – SHOTCRETE
RETAINING WALL SYSTEM
Maritime Building, Addis Ababa, Ethiopia
4.1 Piling
The installation of piles will be in accordance with section 2.1 of this method statement. To
ensure quality, all steps of the pile installation process are carefully recorded. Such records
are provided by the Piling Supervisor to be checked by the site in charge before final
submittal to Engineer on the Pile Drilling and concreting Record attached in Annex 7.2. The
record includes the following data:
• pile number
• pile date of completion
• pile diameter
• Working platform level
• pile design cut off level
• pile toe level
• concrete top level
• reinforcement cage details (length and bars diameters)
• pile concrete length
• pile bored length
• ground water table
• drilling time and piling rig in use
• concreting time, concrete details and ticket no.
• concrete cube Nos.
Any unexpected drilling condition encountered will be noted briefly in the records, and
brought to the attention of the Engineer immediately.
Cubes are taken regularly to ensure the quality of the concrete delivered to the piles.
4.2 Anchors
The installation of anchors will be in strict accordance with section 2.5. Anchor installation
records are produced by the supervisor for each anchor installed. The records detail
information pertinent to anchor installation as listed below:
• anchor number
• anchor drilling date
• anchor diameter, angle of inclination
• primary grouting , nos. mixes
• secondary grouting , nos. mixes and back-pressure
An anchor stressing report is also produced for each anchor. This report ensures our clients
as to the performance of our installed anchors. The report as per attached sample in Annex
7.4, contains information on the load response behavior of the anchor. The installed anchors
can be given a seal of approval if the set criteria based on DIN 4125 is met.
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ANCHORED-BORED PILE – SHOTCRETE
RETAINING WALL SYSTEM
Maritime Building, Addis Ababa, Ethiopia
4.3 Shotcrete
Once again, under guidance from the outlined procedures, the supervisor ensures total
compliance to the detailed steps and requirements outlined in section 2.4. The gradation of
the aggregate used is periodically checked to ensure that it is with in the set limits. In
addition, cubes for compressive strength tests shall be taken to ensure the design
requirements.
At the site, the daily consumption volumetric (m3) of dry mix is carefully recorded and
checked against the area of wall covered. Ideally, the maximum wastage of mix will be less
than approximately 40 – 45%. However for poor quality of blends, the over consumption
tends to be on the high side. Hence, carefully kept records can also assist as they tend to
give a good indication of the quality of the mix.
Based on site experience, periodic check of the mix quality ensures the delivery of high
quality compact wall mass as well as preventing the unnecessary wastage of dry mix.
The daily actively report Annex 7.1 compiles information such as area shotcreted and
consumption of dry mix for that particular day.
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ANCHORED-BORED PILE – SHOTCRETE
RETAINING WALL SYSTEM
Maritime Building, Addis Ababa, Ethiopia
5 List of Equipments
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ANCHORED-BORED PILE – SHOTCRETE
RETAINING WALL SYSTEM
Maritime Building, Addis Ababa, Ethiopia
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ANCHORED-BORED PILE – SHOTCRETE
RETAINING WALL SYSTEM
Maritime Building, Addis Ababa, Ethiopia
7 Annex
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ANCHORED-BORED PILE – SHOTCRETE
RETAINING WALL SYSTEM
Maritime Building, Addis Ababa, Ethiopia
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ANCHORED-BORED PILE – SHOTCRETE
RETAINING WALL SYSTEM
Maritime Building, Addis Ababa, Ethiopia
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ANCHORED-BORED PILE – SHOTCRETE
RETAINING WALL SYSTEM
Maritime Building, Addis Ababa, Ethiopia
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