METHOD STATEMENT FOR INSTALLATION OF PRECAST REINFORCED

CONCRETE PILES USING HYDRAULIC INJECTION SYSTEM

PROJECT :- CADANGAN PEMBINAAN IBU PEJABAT POLIS DAERAH SIPITANG,
SABAH
1. PURPOSE
The purpose of this method statement is to establish guidelines and
requirements for the installation of 300mm x 300mm EC piles to the foundations
for the Police Headquarters. This method statement is not meant to be
exhaustive, sufficient only to define stages and processes.
2. REFERENCE

BS 8004 : 1986 Code of Practise For Foundations

The main function of bearing piles is to transfer the load to lower levels of the
ground which are capable of sustaining the load with an adequate factor of
safety and without settling at the working load by an amount detrimental to the
structure that they support. Piles derive their carrying capacity from a
combination of friction along their sides and end bearing at the pile point or
base. The former is likely to predominate for piles in clays and silts and where
long sockets are formed in soft rocks. The latter applies to piles terminating in a
stratum such as compact gravel, hard clay or rock.
Piles should be installed to the prescribed depth, resistance or set per blow
without damage to the pile shafts or the bearing stratum and records of the
installation process should be maintained.
The load should be applied concentrically with the axis of the pile.
3. The System
The ZYC Injection System is an innovative hydraulic injection piling system which
is free of noise, vibration and pollution. The system allows for a smooth, simple
and rapid pile installation process while adhering to the most stringent
environmental protection requirements. It is generally more cost effective than
conventional piling systems and is more suitable when piling adjacent to
sensitive structures or in urban areas where a clean noise-free and vibration-free
piling system is essential. The system ensures that piles are installed with a high
level of accuracy and a 100% quality check on all injected piles since each pile is

subjected to twice the working load, effectively individually load testing each
pile. The guesswork and uncertainty associated with conventional piling systems
is therefore eliminated.
The system is able to install a wide range of square pile sizes from 125mm x
125mm to 400mm x 400mm and spun piles from 300mm to 600mm diameter. It
can be easily manoeuvred around site and with its wide base and low centre of
gravity it is suitable for various types of ground conditions. It is easily
dismantled for transportation and is generally of low maintenance.
The system is also able to handle individually cast pile lengths exceeding 12m,
thus reducing the number of welded joints within a pile length.
4. The Machine
The ZYC Injection Machine utilises a system for installing piles using the
clamping-type pile driving mechanism, which is the main working mechanism to
clamp and drive the piles into the ground. It consists of hydraulic cylinders for
driving the piles, a pile clamping box, and hydraulic cylinders for clamping the
piles.
The ZYC Hydraulic Injection machine comprises:
a) Main body of the machine mounted with crane and operation room on
top.
b) Pile driving cylinders and horizontal beam.
c) Longitudinal moving mechanism.
d) Horizontal moving mechanism.
e) Matching weight and matching weight beam.
f) Steel dead weights.
The components are delivered by trailers to site where they are assembled using
mobile crane.
A copy of the ZYC Hydraulic Injection machine brochure is enclosed.
The Proposed Injection Machinery for this project consists of 1 No. ZYC320B-B
(320 tonnes) for installation of 300mm x 300mm piles
5. The Pile Loading
The ZYC Injection System injects the piles with a continuous and evenly applied
loading up to a load of twice the specified working load, with the load held for
30 seconds after no further penetration has been observed.
Concrete Pile (for this project)
300mm x 300mm Piles Design Load 1050 kN

A certain quantum of piles within this particular project will not be able to be
installed with the conventional centre mechanism loading system due to the
constraints of the site. Therefore, a side piling attachment will be utilised. This is
basically the same as the centre piling mechanism, with clamping system and
installation method identical, although the pressure loading capability is reduced
due to the eccentricity of the overall machine weight.
For general information purposes, the total weight of the machine with all
counterweights may be 100 tonnes. However, from experience and machinery
maintenance view points, the machine is only loaded to about 80 Tonne. Since
side piling is only able to utilise 50% of the load for pressure injection, the
maximum load that may be applied when side piling is undertaken will be 400
kN.
6. Platform / Access
All platforms and access at or to the piling locations shall be provided by the civil
works contractor. The proposed platform levels shall be approved prior to survey
setting out.
The ground conditions are to be examined for suitability for the stability and
movement of the piling rig, and conditions corrected as deemed necessary. Steel
plates shall be provided if necessary for the even distribution of the weight of
the machine.
7. Setting Out
Based on the design layout of the piles, the positions of the piles are set out on
site and pegs installed by a competent surveyor engaged by the main contractor.
These set out pegs are checked for correctness before the piling operation
commences. Due to the high accuracy of set up and positioning of the machine
prior to driving, the normal tolerance of 75mm deviation of the pile from
required position can easily be attained.
8. Delivery of Piles
All required piles will be delivered by trailer and offloaded by 25 Tonne mobile
crane.
The piles will be stored on firm, flat ground, with timber supports between
subsequent layers, to avoid any undue bending in the piles.

9. Driving Method
The driving method ensures that the works are conducted with the minimum of
noise and disturbance, and with minimum damage to the pile being injected.
Each pile will be driven continuously until the specified set and/or depth has
been reached.
The driving method is by means of clamping and injecting the piles into the
ground with the following steps:
a. At first, the pistons of two (2) pile driving cylinders are withdrawn to
raise the pile-driving box to the high position.
b. The pre-cast pile is lifted and placed into the centre of the pile-driving
box.
c. The pile-driving cylinders from four (4) directions are then engaged to
clamp the pile tight.
d. Then by manipulating the hand lever of the pile-driving valve, the piledriving cylinders are extended to produce pressure to drive the pile
into the ground.
e. Once the pile has been driven into the ground, the pile driving
cylinders release the pile and return to steps (a), (b), (c) and (d) again
until the pile has been fully driven into the ground.
The piles are therefore driven into the ground vertically, without any forcible
corrections, thereby adhering to the requirement for the finished pile to be
within the maximum deviation from the vertical of 1 in 75.
In some soils the vertical and lateral displacement or heave resulting from
subsequent piling may carry with it piles that have already been installed. This
may cause end bearing piles to be lifted off their bearing stratum. If lifting is
suspected, careful levelling from a datum unaffected by the piling should be
made on the heads of piles already driven before and after driving subsequent
piles. Risen piles which depend largely on end bearing and which are capable of
being redriven should be redriven to the specified resistance.
10. Pile Meter and Load Meter
As the pile is being injected into the ground, both the injected pressure (Mpa)
and the corresponding load (KN) can be read instantly from the Pressure Meter
and Load Meter in the control room.

A table of injection pressure (Mpa) and the corresponding load (KN) tabulated by
the machine manufacturer is herein enclosed for reference.
11. Pile Installation Record
A pile installation record form is enclosed. For every pile installed, a record is
kept of the load bearing in KN throughout the length of installed pile at intervals
of 0.5m. The piles will be marked to show the depth of penetration in 0.5m
intervals.
Any unexpected driving conditions will be noted in the record.

12. Pile Jointing

Each pile extension subsequent to initial pile is jointed using a full perimeter VButt weld, with the verticality of the extension pile checked prior to welding.
The upper and lower end plates are cleared of any undesired material and
seated. Any concrete laitance is then removed by hand hammer and the joint
area cleaned using wire brush. Welding is then undertaken using an AC Arc
Welder utilising 4mm welding rods.
13. Cutting of Pile Head
Upon excavation to required level and provision of blinding concrete as working
surface within the pilecap, breaking of the piles to cut off level will be
performed. This is done by first vertical cutting into the sides of the protruding
pile using a petrol driven concrete saw, followed by breaking of the concrete
using compressed air driven concrete breakers. All debris is then removed from
within the pilecap, and the resultant protruding reinforcement bars prepared for
inclusion within the pilecap reinforcement cage.
The concrete is normally stripped to a level such that the remaining concrete will
project 50mm to 75mm into the pilecap. The pile reinforcement should be
exposed for a length sufficient to permit it to be bonded into the pilecap.