Small Diameter Spun Piles

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 Questions & Answers

Small Diameter Spun Piles

Manufacturer
GREEN CORE SDN BHD (207018-M)
16, Jalan PJS 9/3A
Bandar Sunway
46150 Petaling Jaya
Email: greencoresdnbhd@gmail.com
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DESIGN & DESIGN CONCEPT

• What are Small Diameter Spun Piles?

• Small Diameter Spun Piles are Grade 80 and Grade 90spun concrete piles
manufactured by Green Core Sdn Bhd.
• Small Diameter Spun Piles are manufactured with sizes from 180mmφ,
210mmφ and 235mmφ.
• The structural carrying capacities of the Small Diameter Spun Piles are 391
kN, 600 kN and 715 kN respectively.
• The working loads of these Small Diameter Spun Piles are 300 kN, 560 kN
and 680 kN respectively. These working loads were carefully selected and will
ultimately depend on the soil conditions and the depths they are required to be
installed into.
• Small Diameter Spun Piles are produced to replace reinforced concrete piles
with dimensions of 150mm x 150mm, 200mm x 200mm & 250mm x 250mm.
These reinforced concrete piles produced from Grade 45 concrete were
designed to carry 200 kN, 400 kN and 60 kN.
• Small Diameter Spun Piles are made in the same way as the larger spun piles
and the pile is prestressed before they are made.
• Small Diameter Spun Piles are registered for patent with MyIPO as PI
2017702702.

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• History of Spun Concrete Piles in Malaysia.

• Spun Concrete Piles were first produced in Penang for the first Penang Bridge
in the late 1970s.
• Spun Concrete is a Japanese technology and had been used in spun concrete
poles for electricity transmission as later to foundation piles.
• When the Penang Bridge was completed, the spun pile making machinery was
sold to a group of Malaysian engineers who form Industrial Concrete Products
Sdn Bhd (ICP). ICP is still the largest manufacturer of spun concrete piles and
they control around 60% of the Malaysian market.
• Concrete Engineering Products Sdn Bhd (Cepco) was later set up in Sg Petani.
• Both ICP and Cepco were listed on Bursa Saham Malaysia but ICP had now
been privatized by IJM Corp. Bhd.
• In the 1990s, three other spun concrete piles manufacturers were set up but
Perlis Concrete and Percon-Wika folded. Only Petropipe-Daido Concrete Sdn
Bhd survived but was later taken over by Cepco.
• The last few years saw the setting up of two new spun pile companies, namely
Eng Beng Piling Sdn Bhd and Sunway Spun Piles Sdn Bhd, a subsidiary of the
Sunway Group.
• Only Sarawak Concrete Sdn Bhd produces spun concrete piles in East
Malaysia.

• Market size for Spun Concrete Piles in Malaysia

• In 2014, CIDB estimated the size of the precast piles (spun concrete piles,
reinforced concrete piles, steel H-Piles) is estimated to be worth
RM1,300,000,000.00.
• Spun concrete piles has a 55% share of this market which is worth RM 700
million while the market size for reinforced concrete piles is worth RM
600million.
• Spun piles are produce in sizes larger than 250mm diameter worldwide. So
spun concrete piles are competing with and winning the competition for larger
sizes of piles, meaning than the market size for larger reinforced concrete piles
are worth RM150,000,000.00 for while currently available spun piles capture
RM 700 million worth of piles.
• The market for the small reinforced concrete piles with sizes of 150mm x
150mm, 200mm x 200mm & 250mm x 250mm has no competition from spun
concrete piles and are worth RM 450, 000, 000.00. That is a huge market in
itself. These estimates were taken from CIDB where the figures were from
tender awards given out by JKR. Nearly all of JKR building projects and small
bridges, retaining walls and drains were using these smaller reinforced
concrete piles. The potential market size for our small diameter spun piles to

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 replace these piles is easily RM650 million if we include the Government and
private sectors. That was in 2014 as we did not update the figures since 2017.
• It proves spun concrete technology is more superior than reinforced concrete
pile technology in terms of design in working loads and ease of handling and
installation.
• Currently, most of the housing projects consisting of double storeys and single
storey buildings use the smaller reinforced concrete piles as their foundations.
Office structures, factories, infrastructure works like drains also use these
small reinforced concrete piles. There is a perpetual market for smaller piles as
housing projects, factories and factory renovations are being launched non-
stop.
• Our aim at Green Core Sdn Bhd is to replace part of this market for smaller
reinforced concrete piles with our Small Diameter Spun Piles where these
small spun piles will provide a cost effective alternative to the older
technology of using reinforced concrete piles.

• Where are Small Diameter Spun Piles used?

• As their name suggests, Small Diameter Spun Piles are used in low rise
projects where the column loadings are low. Small Diameter Spun Piles can
also take lateral loadings, so they can be used in project with lateral loadings
like retaining walls and signboards.
• Mosques and places of worship
• Single and double storey houses
• Shops up to 4 storeys
• Apartments and condominiums up to 8 storeys
• Production and flatted factories up to 5 storeys
• Warehouses & stores
• Transmission towers for telecommunications
• Transmission towers for Tenaga Nasional Bhd and SESCO
• Bridges for housing estates and “kampongs”
• Hypermarkets and supermarkets
• Offices up to 8 storeys
• Government offices including schools
• Hospitals and clinics
• Road and highway embankments
• Foundations for drains and retaining walls up to 6m high.
• Water tanks & oil tanks

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This above list of structures would constitute about 80% of the value of the Malaysia
construction industry. In fact, most of the Government spending on JKR projects would
require the use of Small Diameter Concrete Piles. Our focus to successfully penetrate the
market is to get SIRIM certification of Small Diameter Concrete Piles to enable us to be
approved for JKR projects. That is our main target market.

• Technical Comparison between Small Diameter Spun Piles and Reinforced Concrete
piles:-
• Small Diameter Spun Piles are manufactured using Grade 90 concrete and the
spinning technique produce denser and consistent grade of concrete as
compared with the vibrated concrete technology. Vibration of concrete used in
150mm x 150mm reinforced concrete piles is totally inefficient as the 150mm
bed is too shallow to be vibrated effectively. The top manufacturers uses
vibrating table while most still use the vibrating poker. As a result, the
concrete is not vibrated to filled in the end plates completely and resulting in
poor workmanship. These gaps between the endplates and concrete will cause
cracking of the piles when they are driven.
• Spinning technology ensures that the concrete is evenly spread along the
whole length of the pile. The gaps between the end plates and the
reinforcement are always filled with concrete.
• Small Diameter Spun Piles, being made from Grade 90 concrete are more
durable during handling. The piles are also prestressed, so their threshold for
breaking during handling is greater than that for reinforced concrete piles.
Being resistant to breakages during handling, Small Diameter Spun Piles can
be exported to neighbouring countries. A large portion of the turnover for ICP
and Cepco derives from their export to neighbouring countries. ICP had
exported to Canada and New Zealand.
• Being made from higher grade of concrete, Small Diameter Spun Piles can
carry heavier column loads. This higher capacity to carry heavier working
loads puts them at an advantage over reinforced concrete piles. For example,

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 the 150mm x 150mm reinforced concrete piles are designed to carry 20 tons of
loads only while our 180mmφ Small Diameter Spun Piles can carry at least 30
tons in the same soil conditions and driven to the same depth. That is a 50%
higher carry capacity but at less than 20% in costs.
• Being circular, it is easier during installation to rightly align the piles. Every
piling contractor will prefer to install circular piles rather than square piles. It
is not only easy to align the piles within a pile group but also to the global axis
of the project.
• The Grade 90 concrete that made the Small Diameter Spun Piles are usually
added with a small amount of fly ash, a by product cementitious material from
the burning of coal or heavy fuel in a furnace. The fly ash will protect the
concrete from sulphate attacks from sea water. So the Small Diameter Spun
Piles and other spun concrete piles are better suited for use in a marine
environment than reinforced concrete piles.
• With many current projects in hilly areas needing pre-drilling of the soil
before the installation of piles, circular piles have an advantage over the
square reinforced concrete piles. It is easier to drill smaller diameter holes than
the larger one. So our Small Diameter Spun Piles have an advantage over the
currently available spun concrete piles as well. (picture below)

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 • While 150mm x 150mm concrete piles have a maximum length of only 6m,
our 180mmφ SDSP can be produced in length of up to 7.5m. That means
lesser number of joints for a driven pile. Lesser pile joints are better for the
design of the pile as joints are usually a source of technical problems
encountered for piled foundations.
• Our Small Diameter Spun Piles are steam cured. Steam curing the Small
Diameter Spun Piles means that the piles can be demoulded after 4 hours in
the steam chamber. Steam curing hastens the gain of strength in high grades of
concrete and the piles can be used within 3 days of production. That means
steam curing allow the Small Diameter Spun Piles to achieve Grade 90 in 3
days while the current production method for reinforced concrete piles can
only do that after 11 days. Even so, the concrete making up the reinforced
concrete is Grade 45.

• Competitiveness and Commercial Viability.

• We cannot be cheaper than reinforced concrete piles when it comes to the

production of the Small Diameter Spun Piles. The current production methods
for small sizes reinforced concrete piles calls for mass production method.
Many sets of moulds are laid with reinforcements and then filled and vibrated.
They are then left to dry in the sun. Demoulding takes place at least 4 days
from the date of casting these piles. The piles are then left to “aged” in outdoor
yards. Quality control, in regards to stacking and curing is lacking. Rejections
of the final products are high due to poor workmanship and supervision.
• Therefore the profit margins are low. Breakages during installation on site are
common. Usually, it is the cracking of the pile heads, caused by having a gap
between the concrete the steel end plates. That is due to poor workmanship.
The costs of the production increases as replacement piles for those broken
during driving would be required.
• Our production method ensures that there is very little rejection of the Small
Diameter Spun Piles. Every pile is produced individually so quality is assured.
• Every Small Diameter Spun Pile is steam cured. The steam curing ensure
rapid achievement of concrete design strength, ensuring that each and every
Small Diameter Spun Pile sent to site is ready for driving/installation.
• With little rejection, the costs of production will be maintained constant, thus
ensuring no disruption of project schedules.
• The Malaysian construction industry is subjected to the fluctuations of steel
prices. Prices of steel bars, at RM1, 700 a year ago is currently hovering at
RM3, 300. That uncertainty will definitely send the prices of piles sky high or
that the reinforced concrete pile manufacturer absorbs the additional costs of
steel price increase.

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 • For a 150mm x 150mm reinforced concrete pile, the steel content of the main
pile body is 18 kg per 6m length while our SDSP 180mmφ has only 9 kg of
steel content.
• Our concrete content is only 0.08m³ for a 6m pile while the 150mm x 150mm
reinforced concrete pile has a concrete content of 0.135m³ yet the SDSP
180mmφ can carry minimum 30 tons while the 150mm x 150mm reinforced
concrete pile can carry only 20 tons. This shows the efficiency on design of
spun concrete piles and their advantage over reinforced concrete piles.
• Being lighter, more Small Diameter Spun Piles can be transported in a long
trailer than reinforced concrete piles. This will reduce transportation costs and
thus make the Small Diameter Spun Piles more competitive.
• Reinforced concrete pile manufacturers always pride themselves that they are
able to produce reinforced concrete piles on site. This cannot be done by the
current batch of spun concrete pile manufacturers. Not any more. Green Core
Sdn Bhd has innovated and modified current spinner beds to allow us to
produce our Small Diameter Spun Piles on site. We can compete on even
terms those sizable projects that require site casting. It’s more competitive to
cast piles on site rather than relying transporting them from factories which
could be located a long distance away.
• With our spinning and steam curing method, we can definitely be more
competitive than reinforced concrete piles as our production cycle is 6 hours
rather than the 3 days required for the reinforced concrete moulds to be turned
around. That means we do not need many, many sets of steel moulds to
produce as many piles as the reinforced concrete pile manufacturers. Steel
moulds are costly to make and maintain.
• Piled foundations using our Small Diameter Spun Piles will definitely be
competitive. The higher working loads of the Small Diameter Spun Piles as
compared with the smaller sizes of reinforced concrete piles will ensure less
number of piles to be used. Smaller pile caps are required if our Small
Diameter Spun Piles are used. Less number of piles means lower costs for the
project, thus saving developers a lot of money.
• Overall, this would mean cost savings in time and money as fewer piles would
be rejected as compared with reinforced concrete piles.

How do you justify the selected working loads for the Small Diameter Spun Piles?

• The recommended working loads for the 180mmφ, 210mmφ and 235mmφ Small
Diameter Spun Piles are 30 tons, 60 tons & 68 tons respectively.
• The Small Diameter Spun Piles are prestressed piles, meaning that these piles had
been subjected to a compressive force during their manufacture.
• With the addition of the prestress, the concrete is in compression, meaning that it will
take a higher loading.

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 • The structural strength of the Small Diameter Spun Piles can be calculated from this
compression and the pile concrete area, which works out to 391kN, 600kN & 715kN
respectively. That means there will be concrete failure in the pile when the
compressive forced from the axial loadings exceed 391kN or 39 tons. The concrete
failure loads for the 210mmφ x 60mm is 600kN or 60 tons while the concrete failure
load for the 235mmφ x 60mm pile is 715kN or 71 tons.
• But structural loads of the pile (the ability of the pile to carry loads without
overstressing the pile) do not control the working loads of pile.
• The main criteria for governing the pile working loads falls on the types of soil and
the founding strata. This is called the geotechnical capacity of the pile.
• The ability of a pile to carry the load it is subjected to depends on the types of soil
(cohesive or cohesion less) the pile has been drive through as well as the type of
bedrock at the founding strata.
• The portion of resistance to the axial loads carried by the length of the pile is called
the skin friction will the portion of the end point of the pile is the end bearing.
• The summation of the skin friction and the end bearing is the working load. A safety
actor is between 2 to 3 is usually used in the geotechnical calculations for the working
loads.
• The recommended working loads for the Small Diameter Spun Piles are 300kN,
580kN & 680kN for the 180mmφ, 210mmφ and 235mmφ respectively.

Pile Size Structural Capacity kN Recommended Working Load

kN
1 180mmφ x 55mm 391 300
2 210mmφ x 60mm 601 580
3 235mmφ x 60mm 715 680

What is new in the Small Diameter Spun Piles?

• New concrete mix design. Previously, small diameter spun concrete piles are
not manufactured here in Malaysia nor any part of the world including Japan.
In fact, the Japanese specifications allow the 300mm diameter as the smallest
size spun piles. Then 250mm diameter spun piles became popular but that was
the smallest size produced.
• Our superplasticizers are provided by the GCP group which allows us to
achieve high strength of up to 90Mpa concrete strength with optimum cement
content.

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• The obvious reason for the lack of smaller size piles could be the concrete mix
design. Previous generation of plasticizers used in high grade concrete tend to
have a low water: cement ratio, thus making the concrete mix very dry. That
would be no good for small diameter spun piles.
• With the newer class of plasticizers in the market, we have a “high flow”
concrete which allow us have high grade concrete with high workability. This
enable us to produce
• With this high flow concrete as formulated by Ir. Tiam Ah Chew, we at Green
Core Sdn Bhd are able to produce Small Diameter Spun Piles with little
rejection rate.
• We also included the X-Cross, a unique cross shaped reinforcement bar
welded perpendicular to the reinforcement cage of the pile. The X-Cross
strengthens the Small Diameter Spun Piles and increases their resistance to the
jacking force or vibrating force during installation. These are spaced at 1.0m
centres.
• We also increased the thickness of the skirting plates around the ends of the
spun piles. The width of the skirting plate had also been widened. The wider
steel skirting plate allows the pile to be gripped by the jaws of the
vibrohammer should the pile installation requires the use of a vibrohammer.
• We use 5 nos. of 4.5mm prestressing strands instead of 4 nos. The use of 5
strands enables the pile to be prestressed evenly.

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 • With our prestressing, the effective prestress on the piles of our 180mmφ,
210mmφ & 235mmφ are 6.20 N/mm², 3.88 N/mm² & 3.32 N/mm²
respectively.
• The structural carrying capacities of the Small Diameter Spun Piles are 391
kN, 601 kN and 715 kN respectively.
• The working loads of these Small Diameter Spun Piles are 300 kN, 580 kN
and 680 kN respectively. These working loads were carefully selected and will
ultimately depend on the soil conditions and the depths they are required to be
installed into.
• Our Small Diameter Spun Piles are light, weighing from 204 kg, 407kg &
475kg respectively for the 180mmφ, 210mmφ & 235mmφ piles per 6m length.
• They therefore require relatively light hammers and small piling machines.
They will need only to use 1.5-3.0 tons to be driven into any types of soil
found in Malaysia. That would mean that the relatively fast and mobile IPH
hammer with a 3 tonne hammer can be used to drive these piles instead of
using the heavy and cumbersome P207 piling crane. Setting up and
mobilization costs would be reduced.

• Manufacturing of Small Diameter Spun Piles.

• To produce a small diameter spun piles, a steel mould of the corrected size is
used.
• The steel mould of the pile for a fixed length of pile is placed two spinning
beds placed across the factory floor. The length of the mould will determine
the length of the pile to be produced.
•

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• The two sets End plates are to be specially machined as if they are being used
for normal spun piles.
• The end plates are 10mm thick, thick enough to withstand the prestressing
force of 5 nos. of strands being prestressed at the same time
•

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• Prestressing strands. These strands are made for prestressing purpose and made from very
high grade steel with an allowable tensile strength of 650N/mm².
• The 4 nos. starter bars of the pile, which had been welded to the steel end plates, are
placed inside the mould. The spiral links, which form the lateral reinforcement for the
spun piles are then stretched across the pile mould. Pre marked distances will determine

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 the spacings for the spiral links. Once they are stretched across the inside of the mould,
they are welded to the steel plate. The welding ensures that the spiral links will stay in
place in the pile.
• The X-Crosses are welded onto the spiral links. This is a new feature and found only in
Small Diameter Spun Piles

• The 5 strands are pulled across the length of the moulds and fixed to the end plates. With
holes, specially drilled through the steel plates, the strands are threaded through these
holes.
• The 5 strands are then pulled individually. Each strand is slotted through the prestressing
jack and pulled. Once the designated tensional force has been achieved, the strand is
wedged against the steel end plate that will later form part of the pile.

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•
• Prestressing jack
• Wedges.
• Once the placing of spiral steel cage, X-Crosses, end plates had been done and checked,
concrete is poured into the steel moulds. The exact amount of wet concrete is poured into
the mould.
• Once the full amount of concrete is poured in, the lid of the mould is closed.
• The spinning beds are started and the steel mould is spun for about twenty minutes. Once
that had been done, the steel mould with the already finished spun concrete pile is
removed from the spinner beds and is placed immediately in the curing steam chamber
whether they are left for a further 4 hours.
• The steam cured the concrete and after 4 hours, the concrete would have achieved at least
Grade 40 concrete. At this stage, the finished product could be removed from the steel
mould. The steel mould is cleaned and steel mould oil is used to maintain a clean surface.
• The spun pile, now removed from the mould is then moved to the stockyard where they
are allowed to cure for another 2 days. By then the concrete would have achieved at least
Grade 70 concrete and would be allow to be sent to the site. We have completed the
production cycle for the spun pile.
• For production of Small Diameter Spun Piles, our production cycle is 6 hours from
setting up the steel mould still demoulding the finished spun concrete piles.

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Installation of Small Diameter Spun Piles

Drop hammer & Hanging leaders

• Piles, big or small sizes, are installed using the percussion method (hydraulic
hammers, diesel hammers or drop hammer and pile injection method.
• Our Small Diameter Spun Piles has an added feature in the skirting at the pile joints.
This skirting allows the Small Diameter Spun Piles to be installed by the use of
vibrohammers.
• For Small Diameter Spun Piles, the hammer weights vary from 1.0 tonnes for the
180mmφ to 3.0 tonnes for the 210mmφ spun pile.
• For the 180mmφ & 210mmφ, the piling hammer used can be a drop hammer or the
IPH. IPHs are converted excavated with a small hydraulic hammer attached.
• The use of a drop hammer or a hanging leader is used mainly for small sized piles on
very difficult to access sites like slopes, or in the median of a road.
• Efficiency of the drop hammer is usually less than 85% and the hammer weight is a
maximum of 3 tonnes. The piling hammer is usually 1.5 tons and is suitable to drive
up to 210mmφ piles

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IPH or excavator based hydraulic hammer

• IPH or International Piling Hammer is a Malaysian invention and had been

exported to the neighbouring countries. Initially, the hammer weights used
varies from 1-2 tons only but lately, the inventors had manufactured 7.0 tons
IPHs.
• IPHs are very versatile and mobile. They were modified from used excavators,
the excavator being modified to a piling machine while retaining the base unit.
• They are used for small section piles, namely 150mm x 150mm & 200mm x
200mm reinforced concrete piles. These IPHs can be adapted to drive our
Small Diameter Spun Piles at a very low cost.

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• These IPH hammers are efficient and silent. Their efficiency is at least 90%
efficient. Most of our Small Diameter Spun Piles will be driven by these IPHs.

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Hydraulic Hammers.

• Hydraulic hammers will be use to drive the 235mmφ SDSP as their working
loads are 70 tons. We can still use 3.5 tons IPHs and these are getting common
nowadays.
• The base crane of the hydraulic hammers is heavy (up to 30 tons) and
cumbersome. Mobility is not as good as those IPHs but their hammer
efficiency can be up to 95%.
• Moving these machines and operating them are costly and their cost to a
project is high.
• The rate of piling is also slower as compared with the IPHs.

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Pre Augering

• While pre-augering for preboring for the installation for a reinforced concrete pile or
spun pile is only part of the installation method, it is common nowadays in the
industry.

• Piles on ground conditions where the hard layer is near to the ground surface, needs to
be predrilled/pre-augered/or prebored first to achieve sufficient pile length. Often, a
hard layer with SPT >25 overlays soft ground strata below it. At that SPT>25, it is
difficult for the pile to penetrate. Hard driving will put stresses on the pile which
ultimately damages the pile. The solution is to prebore a hole beyond the hard layer.
The pile is then installed into that bored hole and is driven to set using conventional
methods.

• The Small Diameter Spun Piles are circular so that the predrill holes can be chosen to
be slightly bigger than the diameter of the pile. It is difficult to choose a predrill
diameter for the square reinforced concrete piles.

• It is relatively easy to drill small diameter holes for our Small Diameter Spun Piles
and many machines are available.

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Pile Injection Method.

• Pile injection method is common nowadays as we are building structures

closer to existing buildings or residence. Pile injection method for pile
installation eliminates the nuisance of construction noises. This is the
preferred pile installation method by the Local Authorities.
• Most project sites in towns and cities all over Malaysia are using this pile
injection method
• Pile injection machine varies in capacities of 60 tons to the mammoth 1400
tons. The 1400 tons machine can inject spun concrete piles with diameter up to
800mm. The Small Diameter Spun Piles will require the use of the basic
machines.

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 • We added the X-Cross & widened the skirting so that our Small Diameter
Spun Piles can be installed using this method.

• Structural Design of Small Diameter Spun Piles.

• Small Diameter Spun Piles are precast, prestressed concrete piles. The Grade
90 concrete is poured into a mould where the whole mould is spun. Spinning
the mould with the concrete inside will compact the concrete. The concrete
made with this spinning process is more consistent than vibrated concrete.
• A prestressing force is applied to each of the five prestressing strands for the
piles. When the concrete hardens, the prestressing strands are cut. The
contraction of the prestressed is taken up by the concrete or “transfer” to the
concrete. The concrete is compressed, adding to the ability of the concrete to
take more compressive loads.
• The prestressing allows the small surface of the concrete to carry a large load.
The working loads of the piles can be summarized as below:-

SMALL DIAMETER SPUN CONCRETE PILES SPECIFICATIONS

self Concrete Minimum Cracking Axial Recommended
Pile
Pile Wall weight Characteristic Effective Bending Working Working
Nominal
Ref. Diameter Thickness Strength Prestress Moment Load** Load
mm mm kN/m N /mm² N /mm² kNm kN kN

SD
180 55 0.38 90 5.5 47 391 300
180

SD
210 60 0.81 90 4.00 73 601 580
210

SD
235 60 1.47 90 3.32 100 715 680
235

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 • Specifications for the Production of Small Diameter Spun Piles

The Small Diameter Spun Piles (SDSP) is designed to BS 8004- 1986- British Standard Code of Practice
for Foundations and MS 1314 for Prestressed Concrete Piles.

Constituent Materials: British Standards are quoted below. Other equivalent Standards, where
applicable are acceptable.

Cement BS 12:1996 /MS 522/MS 1227/MS 1389 Ordinary Portland Cement

Aggregates BS 882 : 1992 /MS 30 Sand / 20mm Aggregates

Prestressing Steel BS 5896 /MS 1138 /JIS G 3137 Prestressing tendons

High tensile Bar BS 4449 : 1997/MS 144 & MS 146 Longitudinal reinforcement Bars
Cold Drawn Wire BS 4461 : 1978 Lateral Reinforcement

Mild Steel Plate BS EN 10026 : 1993 End Plates, Grip Plate ( Grade S275 )

Admixture BS 5075-3 : 1985 Super Plasticizer

Pile Head Connections to Pile Caps

After installation of the Small Diameter Spun Piles, these piles are cut using a diamond saw
at the cut off level. The cut is check to ensure a level and clean cut. After inspection, the pile
head is clear clean of debris.

An end cap of the appropriate size is placed over the cut pile. There are 4 numbers of 9mmφ
holes on the end cap. A concrete drill is used to 8mm diameter holes into the concrete body
of the spun pile. Similarly, there are another 4 numbers of holes sides of the end plates and
8mm diameter holes are similarly drilled into the side of the pile. Into these holes are
inserted 8mm diameter hot dipped galvanized bolts with washers to tighten the bolts to the
end plate. That should hold the end plate firmly to the pile.

There are 5 starter bars of 8mm diameter welded to the top of the end plates. The starter
bars are 350mm long. The starter bars will provide a bond between the pile and the pile cap.
The end of each starter is bent into an L-shape and the whole length of the leg is welded to
the end plate.

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