C156 Preliminary Tension Test Pile T1 T2 Rev 0

CONTRACT156:DESIGN, CONSTRUCTIONAND COMPLETION OFSTATIONANDASSOCIATED TUNNELS ATMARINASOUTHFORNORTH SOUTHLINEEXTENSION
METHODSTATEMENTFOR PRELIMINARYTENSIONTESTPILET1ANDT2BY REACTIONPILEMETHOD

PreparedBy:
METHODSTATEMENTFOR PRELIMINARYTENSIONTESTPILET1AND T2BYREACTIONPILEMETHOD CONTRACT156:NORTHEASTLINE EXTENSION
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TableofContents
1. Introduction 1.1 SummaryOverviewforPreliminaryPileT1andT2 2. References 2.1 References 3. SiteOrganisationChartforPreliminaryTestPileConstructionandTesting 4. MethodologyofPreliminaryTestPileConstructionandInstallation 4.1 ListofPlantandEquipmentforPreliminaryTestPileConstruction 4.2 BoringandInstallationofPreliminaryTestPile 4.2.1 SettingOut 4.2.1.1 PileLocationbySurvey 4.2.1.2 Setboringunit 4.2.2 InstallationofTemporaryCasing 4.2.3 DebondingofPreliminaryTestPileT1andT2 4.2.3.1 PreparationofDebondingCasing 4.2.3.2 InstallationofDebondingCasing 4.2.4 BoringofPreliminaryTestPile 4.2.5 CleaningandDesandingofBoreholes 4.2.5.1 BaseCleaningbyBucket 4.2.5.2 DesandingofBentoniteSlurry 4.2.6 IndependentVerticalityandDepthMonitoring 4.2.7 InstallationMonitoringInstrumentationforPreliminaryTestPile
4.2.7.1 4.2.7.2 VibratingWireStrainGauge(VWSG) TellTaleRodExtensometer
4.2.8 PreliminaryTestPileSteelReinforcementCage
4.2.8.1 4.2.8.2 FabricationofReinforcementCage SiteDeliveryofReinforcementCage
5. TensionLoadTestMethodology 5.1 ListofPlantandEquipmentforTensionTestSettingUp 5.2 MethodologyofTensionLoadTestAssemblyandSettingUp 5.2.1 InstallationofReactionPiles 5.2.2 AssemblingWorksforTensionLoadTest 6. TestingEquipment 7. MeasuringMovementofPile 8. ProtectionofTestingEquipment ----------C 156 NORTH EAST LINE EXTENSION BORED PILING WORKS
4.2.8.3 InstallationofReinforcementCage 4.2.9 ConcreteInstallation 4.2.9 HBeamInstallationbyPlungeInMethod
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TableofContents,contd
9. Records 10. LoadingSequence 11. ScheduleforPreliminaryTestPileT1andT2Construction
12. SafeWorkProcedures
Appendix
AppendixA LocationandReferenceBoreholeforPreliminaryTestPileT1andT2 AppendixBSiteOrganisationChartforPreliminaryTestPileConstructionand Testing AppendixCDebondingCasingDetailandDebondingMaterialBituthene3000Product DetailandSpecification AppendixDIllustratedSequencefortheDebondingCasingInstallation AppendixETypeofBentoniteTestandProcedures AppendixFKodenDrillingMonitorBrochuresandPhoto AppendixGPreliminaryTestPileT1andT2InstrumentationandReinforcementDetail Drawing AppendixHVibratingWireStrainGaugesTechnicalSpecification AppendixISequenceofBoredPileReinforcementCageTandemLifting AppendixJRecordingSheet AppendixKHBeamColumnDesignCalculation AppendixLDiagrammaticSequenceforHBeamColumnInstallation AppendixMReactionPileDesignCalculation AppendixNTensionTestSetttingUpLayoutDrawingforPreliminaryTestPileT1andT2 AppendixOLoadingSequenceforPreliminaryTestPileT1andT2 AppendixPTentativeScheduleforPreliminaryTestPileConstructionandTesting TensionLoadTest AppendixMRiskAssessment

----------C 156 NORTH EAST LINE EXTENSION BORED PILING WORKS
1. Introduction
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Contract 156 North East Line Extension comprises of design, construction and completion of a 1.6km long, fully underground rail transit system with one non civil defence MRT station and associated tunnels. The C 156 project site interface with Marina Coastal Expressway project 482 and483project. ThismethodstatementpresentsthemethodologyoftensiontestforthePreliminaryTestPileon T1andT2byusingReactionPileMethod.
1.1 SummaryOverviewforPreliminaryPileT1andT2
Preliminary test pile T1 and T2 which have being selected and approved by the Engineer and Authorityforthetensiontest.Theintentiontestloadforthepreliminarytestpilewillbe 3 x WL, WorkingLoad,and,Table1showsthetabulatedtestloadforT1andT2piles. PileRef T1 T2 Table1.T1andT2pilesummarytable Theobjectiveofthetestaretoestablishtheultimateskinfrictionduetoupliftforceimposedonthe pilebasedonthedesignloadatestablishedsocketingdepthonOldAlluviumlayer.Theproposed locationforthePreliminaryTestPileT1andT2installationwillbeonthereferenceboreholes,and, theaforesaidlocationandboreholesdetailscanbereferredinAppendixA. PileDia. (mm) 1200 1200 Pile Length (m) 45.21 50.6 Borehole Ref NS/023 NS/015 Working Load,WL (kN) 4,035 4,049 PSF (kN) Debonded Debonded TestLoad, 3xWL+PSF (kN) 12,105 12,147
3.
References
2.1 References
WSH(Construction)Regulations2007 ProjectSafetyManual RiskAssessment SingaporeCodeofPractice,CP4 LTAsMaterial&WorkmanshipSpecificationClause5.7 CivilDesignCriteriaForRoadandRailTransitSystemsClause6.5.1~6.5.5 CodeofPracticeFoundationBritishStandard8004;1986
3.
SiteOrganisationChartforPreliminaryTestPileConstructionandTesting
ThesiteorganisationchartforthePreliminaryTestPileconstructioncanbereferredinAppendixB.
4. MethodologyofPreliminaryTestPileConstructionandInstallation
Themethodologyforthepreliminarytestpileconstructionandinstallationcoversonthefollowing;
i. ii. iii.
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ListofPlantandEquipment BoringandInstallationofPreliminaryTestPile TensionTestAssemblyandTestingMethodology
4.1 ListofPlantandEquipmentforPreliminaryTestPileConstruction
TheplantandequipmenttobedeployedforthePreliminaryTestPileT1andT2constructionare listedintheTable2. No 1 2 3 4 5 6 7 8 9 Table2.ListofPlantandMachineriesforPreliminaryTestPileConstruction. EquipmentDescription BoringRig HydraulicCrawlerCrane HydraulicExcavator BentoniteSilo Desander WeldingMachine SandPump TremiePipe Vibrohammer Capacity BG30 100tons 7m 75m 100m/hr 500Amp 15hp 100meter 10tons Units 1 1 1 3 1 2 2 1 1
4.2 BoringandInstallationofPreliminaryTestPile
TheinstallationproceduresforthePreliminaryTestPilecoveronthefollowing; i. SettingOutofPileLocationbySurvey ii. InstallationofTemporaryCasing iii. InstallationofDebondingCasing iv. BoringofPreliminaryTestPile v. CleaningandDesandingofBoreholes vi. InstallationofMonitoringInstrumentsforPreliminaryTestPile vii. VerticalityCheck viii. SteelReinforcementCageInstallation ix. ConcreteInstallation x. HBeamInstallationbyPlungeInMethod
4.2.1 SettingOut 4.2.1.1 PileLocationbySurvey
Pile positions set by piling contractors surveyor, and checked by Resident Surveyor, before commencementofpiling.Theexisting groundlevelat the pilepositionwillbe measuredand recorded.
METH HODSTATE EMENTFOR R PRE ELIMINARY YTENSIONTESTPILET1AND T2BYR REACTIONPILE P METH HOD CONTRAC CT156:NORTHEASTLINE EXTENSION
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4.2.1.2 Setboring gunit

Priortob boring,thefo ollowingstep pswillbecarriedout: O Offsetsurveye edpilepositi ionintwope erpendicular rdirectionsb byplacing2 offsetmarke ersat i. ap ppropriated distancesfrom mthepilepo osition,tofac cilitatethein nstallationoftemporary steel ca asing. The offset distanc ce will be su uch that thes se markers will w not be disturbed du uring in nstallationpr rocess. ii. Leveltheplatformfortheboringrigby yplacingsteelplates. rticalityoftheKellyBaro ofaboringri ig,bybanks manpriorco ommenceme entof iii. Checkthever boring. theboringrigatthedesig gnatedlocati iontocomm menceboringworks,and,Figure1sho ow Positiont thesettin ngoutboredpileposition npriorcomm mencementofboringwor rks.
Figure e1.SettingO Outpileposit tionbysurve ey.
4.2.2 In nstallationofTempor raryCasing g

i. Preboredtot thesizeofouterdiamete ertemporary ycasingatth hesetoutpi ilepositiontothe mto2mwh hichevercom mesfirstgove ernedbythe existinggro oundwaterle evel depthof1.5m romexistinggroundlevel l. fr nstalltempor rarycasingin ntogroundb byvibroham mmer,and,Figure2show wsthetempor rary In ca asinginstalla ation.
ii.
casinginstall lationbyvibrohammer Figure2.Temporaryc
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iv.
IncontroltheverticalityofPreliminaryTestpileduringboringworks,atemporarycasing willbedrivenintothegroundatminimumtoadepthofexceedingtheFilllayerormoreif requires. Thetopoftemporarycasingwillberaisedabovethegroundatrequiredleveltoattainthe trenchstabilityatFactorofSafety1.4.Thetrenchstabilitycalculationforeverytestpilewill besubmittedinseparatesubmission.
4.2.3 DebondingofPreliminaryTestPileT1andT2
In the proposed Preliminary Test Pile T1 and T2 design consideration, the piles requires to be debondedfromFillLayeruptoTopofOldAlluviumLayer.Themainobjectiveofdebondingisto eliminateanyshaftresistancecontributionfromsoilparameterlayerduringtheloadingofthetest pilebytensionotherthanfromOldAlluviumlayeronly.Thegeneralsequenceforthedebonding worksentailsareasfollows; i. PreparationofDebondingCasing ii. InstallationofDebondingCasing
ThemethodproposedforthedebondingofPreliminaryTestPileT1andT2isbydebondingcasing method. The material and preparation works involved prior installation of the debonding casing areasfollows; i. Provide1200mminternaldiametercasingwith10mmthickandthedebondinglengthwill beprovideduptothetopofOAlayer. ii. ThecasingwillbewrappedallroundwithproposedBituthene3000debondingmembrane thatprovidessmoothsurfacethatcreatesadebondingeffectforthepile. iii. In additional measures to prevent the inflow of concrete into the annular space during concrete placing, 5 layers of 1200mm x 25mm thick polystyrene plug will be installed at 500mm above the bottom of the debonding casing. The polystyrene will be continuously wrappedwiththedebondingmembranetopreventanydamagetothepolystyreneduring debondingcasinginstallation. Thedebondingcasingdetailandtheproposeddebondingmaterial,Bituthene3000productdetail andspecificationcanbereferredinAppendixC.
4.2.3.1 PreparationofDebondingCasing
4.2.3.2 InstallationofDebondingCasing
Thesequencesfordebondingcasinginstallationareasfollows; i. Installed1500mmdiameteroutertemporarycasinginaccordancetotheearlierexplained section4.2.2. ii. Precede boring works from ground level up to 500mm above the top of OA level with 1500mmdiameterboringtools.
iii. iv.
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v. vi. vii.
Installed the 1200mm internal diameter debonding casing up to the final 1500mm diameterborehole. Gradually press down the debonding casing with kelly bar by applying control pressure untilthetoeofthedebondingcasingreachthetoporatminimum300mmabovethetopof OldAlluviumlayer. The1200mmdiameterdebondingcasingwillbesecurelyweldedontotheoutertemporary casing. Changethedrillingtoolsfrom1500mmdiameterto1200mmdiameterandcontinueboring totherequireddesigntoelevel. Theillustratedsequenceforthedebondingcasinginstallationcanbereferredin Appendix D.
4.2.4 BoringofPreliminaryTestPile
The boring worksprocedure for thepreliminarytest pile T1 and T2 willbe in accordance to the Approved Method Statement for Bored Pile Construction. Bentonite slurry will be used as the stabiliser fluid for the whole boring process. In addition to the works, various suitable types of boringtools willbeused,and,soil bucketorcleaningbucket willbe deployedasthe generalsoil conditioninC156areprimarilyconsistsofclayandsand. ThegeneralguidelinesfortheboringworksforthePreliminaryTestPileareasfollows; i. ThebentoniteslurrylevelwillbemaintainedattherecommendedleveltabulatedandPE endorsedTrenchStabilityCalculationduringtheboringworks. ii. Soilsamplingfortheboreholewillbecollectedat2mintervalfromexistinggroundlevelup tothefinalfoundinglevel.Thesoilsamplecollectedwillbestoredinsoilsamplingbagwith clearlylabelledbyindicatingthepilereferenceno,dateanddepthofthesamplecollected, The complete set of soil sample of individual bored pile will be kept in the proper soil samplestorageareaprepared. iii. TheboredholewillbemeasuredwithgraduatedmeasuringreinforcednylonMilliontape.
4.2.5 CleaningandDesandingofBoreholes
ThecleaningofthecompletedPreliminaryTestPilewillbethecombinationof; i. Basecleaningbybucket,and, ii. Desandingofbentoniteslurry.
4.2.5.1 BaseCleaningbyBucket
i.
ii.
Clean the base of the borehole to remove any loose, disturbed or remoulded soil with a cleaningbucket. Measurethedepthfromthebaseoftheboreholetothetopofthetemporarysteelcasing
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ConfirmthedepthoftheboreholewithQPSssiterepresentative.
4.2.5.2 DesandingofBentoniteSlurry
The bentonite in the borehole which contains soil particles in suspension is pumped from the bottom of the trench by lowering of tremie pipe with submersible pump for desanding. This processwillcarryoutafterthefinalfoundinglevelhasbeingachievedandcountercheckbyQPSs siterepresentative. The submersible pump which securely is attached to the tremie pipes is lowered to the depth at interval 30m depth. This method is to sequence the bentonite replacement every 30m depth by replacing the first 30m bentonite with contains heavy suspended sand particles with fresh/treatedbentonite.Thispreferencemethodistoreducetheoverloadpumpingeffecttothe submersiblepump.Increasedofthepumpdepthnext30mwillbetakeneffectafterthesandorsoil particles coming out from the desander mesh screen is minimal. This process will continue by extendingthetremiepipefurtheruntilthesubmersiblepumpstoebaseis500mmabovethefinal foundingtoelevel. Upon completion of the desanding works, the bentonite slurry will be extracted out from the boreholesbyusingbentonitesamplerwhichisshownbelowinFigure3.
Figure3.Bentonitesampler
Thetypebentoniteteststhatshouldbecarriedoutontodeterminethebentoniteslurryextracted fromboreholesare; i. Viscosity ii. Density iii. PH iv. SandContent The details and test proceduresfor the individual test mentionedcanbe referredin Appendix E. ResultsfromthetestsshallcompliedwiththeLTAsM&WSpecificationClause5.3.2Table5.4.The extractionfromtheclauseistabulatedandshownonTable3below.
Properties Viscosity Density PH SandContent

RangeofResults (atSingaporeTemperature) 30 90sec 1.02~1.35g/cm3 9.0 12.0 Lessthan5% TestMethod
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Marshconemethod Muddensitybalance PHindicatorpaperstrips SandContentKit
Table3.BentoniteTestCriteria. 4.2.5 IndependentVerticalityandDepthMonitoring Itisutmostimportanttheverticalityofpiletobemaintainwithinthetoleranceduringtheboringfrom groundleveluptothefinalfoundinglevel.Attheendofdesandingworks,theKodendrillingmonitor DM 682 or 684 will be utilised to provide an additional and independent quality assurance on pile verticality.ThetechnicalbrochureandphotosofKodendrillingmonitorisenclosedinAppendixF.
4.2.6 InstallationMonitoringInstrumentationforPreliminaryTestPile
Monitoring instrumentation will be installed on Preliminary Test Pile T1 and T2. The type of monitoringinstrumentsthatwillbeinstalledonpreliminarytestpileT1andT2are; i. VibratingWireStrainGauges,and, ii. Telltalerods. TellTalerodsandVibratingWireStrainGaugeswillbeinstalledinT1andT2atpredetermined levelsbasedontheapproveddesign.Asrequires,thetelltalerodswillbeassembledat; i. TopofOldAlluvium. ii. PileToe InthePreliminaryTestPileT1,Thedetaillayoutforthepositionandlevelforthetwomentioned monitoringinstruments,withinclusiveofreinforcementdetailforthePreliminaryTestPileT1and T2,canbeclearlyreferredinAppendixG. 4.2.6.1 VibratingWireStrainGauge(VWSG) Thevibratingwireprincipleofmeasuringthestrainisbasedonthefactthatthenaturalfrequency ofvibrationofthetautwire,restrainedatbothends,varieswiththesquarerootofthetensionin thewire.EachoftheVWSGwillbeinstalledbytyingtotheT13x1000mmreinforcementbarand securelyspotweldedtothemainreinforcementbar.ThewiresensorisplacedontopoftheVWSG beforepottingtheassemblyinepoxyinarubberhose.ThesignalcablesforalltheVWSGwillbe routedtothetopofthepileandconnectedtothedataloggerfordatareadings. The Vibrating Wire Strain Gauges will be installed at predetermined level based on the Engineer/Authoritysapproveddesignat2mintervalfromtopofOldAlluviumuptotoelevel. ThetypeandtechnicalspecificationfortheproposedVSWGcanbereferredinAppendixH.
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4.2.6.2 TellTaleRodExtensometer Telltalerodextensometerassemblyconsistsofa6mmdiameterstainlesssteelrodwhichattached toafixedanchorpointinthepile,and,placedwithinaprotective13mminternaldiameterGIpipes. As the pile undergoing tension during loading, the inner steel rod remains free in the protective steel pipe. Two Linear Vertical Displacement transducers will be used will to monitor the movementofthetelltaleextensometers.TheGIpipeswillbesecurelytiedinpositiontothesteel reinforcement cage with galvanised wire or cable tie. The GI pipes will be further sealed from cementinclusionatthebottomwithendcapandmaskingtapeonthetop. 4.2.7.1 FabricationofReinforcementCage TheContractC486BoredPilesreinforcementcagewillbeprefabricatedinthefactoryandwillbe clearlymarkedforidentificationpriorconcretingworks.Thereinforcementcagewillbefabricated inaccordancetotheApprovedConstructionDrawing.Internaltransferwillbeprovidedifdeemed necessary. 4.2.7.2 SiteDeliveryofReinforcementCage The delivery of reinforcement cage to site will be 5 days in advance prior the boring of the PreliminaryTestPile.ThislagtimeisforthemonitoringinstrumentationVWSGandTelltale installation works. The reinforcement cage will be stored at the nearest location to the bored location, provided, the reinforcement cage is raised above the ground by placing 4x4 timber below.Astoppershouldbeprovidedbymeansofchamferedtimbertopreventthereinforcement cagefromrollover.
4.2.7 PreliminaryTestPileSteelReinforcementCage
4.2.7.3 InstallationofReinforcementCage
TheinstallationoftheBoredPilereinforcementcageisexplainedasfollows; i. WeldmainbarswithmainlinksatthetopofthereinforcementcageanduseUclipstohold themainbarsandmainlinkstogetherforliftingpurposesduringinstallation. ii. Hookthewireslingwithshacklesontothemainlinks. iii. Usethespreaderbeams(withwiresling)tohoistthereinforcementcageandlowerintothe borehole. iv. Theboredpilereinforcementcagewilltandemliftedbysinglecrane.AppendixIshowsthe typicaltandemliftingmethod. v. Use concrete spacers of similar concrete grade as the bored pile to ensure the reinforcementcageisincorrectpositioningandtoachieveaconcretecoverof75mm. vi. Hold the reinforcement cage at the temporary steel casing top (for lapping) by inserting T40rebaracrossthemainlinkandrestitonthetopofthecasing. vii. Detachtheshackleswiththewireslingfromthemainlinks.
viii. ix. x. xi. xii. xiii. xiv. xv. xvi. xvii.
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HoistthesubsequentreinforcementcageandlapthereinforcementcagesusingUclipsat alternatemainbars. Place additional Uclips at the section of the reinforcement cages where the main lifting pointislocated,ifnecessary. Repeattheaboveprocedureforotherreinforcementcages. Forlastreinforcementcage, Supportthereinforcementcageonthetemporarysteelcasingwiththeshortrebar(same procedureaslapping). Dislodgethewireslingwithshacklesfromthemainlinks. Hoistthehangers(madeupofahookatthetopanddifferentlengthsofthereinforcement dependingondepthofthecutoffleveloftheboredpile)tothereinforcementcage. Useuclipsorweldthehangerstothestarterbarofthereinforcementcage. Hoistandlowerthehangerstogetherwiththereinforcementcagestothedesignateddepth. Suspendthereinforcementcagesattheminimumof100mmabovethefinalfoundingdepth 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 duringconcretingworks.
4.2.8 ConcreteInstallation
TheconcreteplacingfortheboredpilewillconformtotheM&WSpecificationClause5.2.2.6.The proceduresandsequenceofconcreteplacementaresummarisedasfollows; i. Useatremiepipeofdiameterofminimum250mmandforconcretingboredpile. ii. Jointhesectionsofthetremiepipepriortoloweringitintotheborehole. iii. Lowerthetremiepipeintotheboreholeuntil300mmabovetheleveltofacilitateflowof concrete. iv. Placetheamountofvermiculiterequiredtohaveanapproximateheightof400mminthe tremiepipe. v. Place the vermiculite in the tremie pipe prior to discharging the concrete. This is to separatetheconcreteandthestabilizingfluid,bentoniteslurryduringtheinitialplacingof concrete. vi. Pourconcreteintotheboreholeviaahopperattachedtothetopsectionoftremiepipe.The concrete slump for tremie method shall be between 175225mm with minimum 4 hours and6hoursretardation. vii. Measure and record the concrete level in the borehole when discharging concrete from each truck, and, the measured depth will be recorded in the concreting record sheet as attachedinAppendixJ.
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ix.
x. xi.
xii.
xiii.
xiv.
The actual concrete level measured will be plotted in the depth versus concrete volume graphwhichattachedin AppendixJ,and,theactualconcretevolumelinesshallcompares withthetheoreticalconcretevolumeline. Tremie pipe will be withdrawn from the borehole as the concrete level rises. This is to facilitatetheflowofconcrete.However,itisimportanttonotethatthetremiepipeistobe embeddednotlessthan3mbelowtheconcretelevel. Dismantlethetremiepipefromthetop,sectionbysection. Pump the bentonite slurry back to the storage silos by a submersible pump when the bentonite slurry is displaced by the volume of concrete. However, it is important to note thatthepumpingrateofthebentoniteslurryshallnotbeexceedingextensivelyfromthe discharging rate of the concrete. The level of stabilizing fluid, bentonite slurry shall be maintained at an appropriate level to prevent collapse of the borehole during concreting works. TerminatetheconcretingworkswhentheconcretelevelinthePreliminaryTestPileonce fresh good quality concrete overflows from casing top. Topping up of concrete should follows after the temporary casing extraction as the concrete level might drop at depth belowthecasingtop. Thetemporarycasingwillbeextractedoutbyusingvibrohammeruntiltheremaining 2 meter length casing sink into the ground. It is important that the leftin casing is kept withintoleranceduringtheprocess. Any vibration or boring works is to be avoided at minimum distance of 5 times pile diameterfromanewlycastedpilewithin24hoursaftercasting.
IntheproposedPreliminaryTensionTestPile,HBeamwillbecastedintothepreliminarytestpile toprovideananchoringtothepileduringincrementofload.TheHBeamisdesignwithsufficient bonding length with additional shear studs installed to withstand the ultimate testing load. The numbers and coverage length requires for the shear stud will based on the endorsed design calculationasattachedinAppendixK. ThesequencesfortheHBeaminstallationbyplungeinmethodareasfollows; i. The concrete casting will proceed continuously until good quality fresh concrete overflowsoutfromthecasingtop. ii. Withdrawthetremiepipesfromtheboreholesandtopuptheconcreteuptothecasing toplevelifnecessary. iii. Theoutertemporarycasingwillbeextractedfromthegroundbyusingvibrohammer. iv. ItisimportantthatthetopportionPreliminaryTestPileshouldbecoverwithcanvasor plasticsheetingduringthetemporaryoutercasingextraction,thisistoavoidanysoilor muddropintonewlycastedconcreteonthetestpiletop.
4.2.9 HBeamInstallationbyPlungeInMethod
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vi.
vii. viii.
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Oncethetemporaryoutercasinghadbeingremoved,HBeamwillbeliftedupbytandem lifting and plunge into thePreliminary Test Pile and embedded into therequireddepth basedonthesubmittedEngineersdesigncalculation. During the HBeam installation, the verticality and positioning of the HBeam will be solely control by the HBeam casing guide which have preinstalled into the top of the steelcage.ThedetailoftheHBeamguidecasingcanbereferredinAppendixGandI. TheHbeamwillsecurelysupportandweldedtothetemporarysupportingbeam. Properbarricadessurroundingthetestpileshallbeprovidedtopreventanyinterference tothetestpile. ThediagrammaticsequencefortheHbeaminstallationcanbereferredinAppendixL.
5. TensionLoadTestMethodology
5.1 ListofPlantandEquipmentforTensionTestSettingUp Table2showsthelistofPlantandEquipmentforTensionTestSettingUpWorks.

No 1 2 3 4 5 6 No 7 8 9 10 11 12 Table2.ListofPlantandEquipmentforTensionLoadSettingUpWorks Thecalibrationcertificatesformonitoringapparatuswillbesubmittedinseparatesubmission. EquipmentDescription HydraulicCrawlerCrane WeldingMachine GeneratorSet HydraulicJack LoadCell DialGauge EquipmentDescription DumpyLevel HydraulicPump LinearVerticalDisplacementTransducers MainGirderBeam BearingPlate TiltingPlate Capacity 80tons 500Amp 50kVA 1000 1000 Mitoyo Capacity Sokkia Enerpac Units 1 2 2 2 2 2 Units 1 1 2 2nos 4pcs 2pcs
5.2 MethodologyofTensionLoadTestAssemblyandSettingUp
IntheproposedTensionLoadTestforPreliminaryTestPileT1andT2,HBeamwhichhadbeing castedtogetherwiththetestpilewillprovideanchoringtothepreliminarytestpileduringtension
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loading process, and, the reaction piles installed at each opposite sides will resist the resultant compressionloadfromthemaingirderbeamduringloading. ThemaingeneralpreparationworksfortheTensionLoadTestAssemblyareasfollows; i. InstallationofReactionPiles ii. AssemblingWorksforTensionLoadTest
5.2.1 InstallationofReactionPiles
Two reaction piles of sufficient capacity will be installed either side of the test pile to resist the resultant compressionloads. These pileswill be concretedup to minimum 1mabovethe ground level and willbearagainstthereactionbeam.Thereactionpileswillbeinstalledatdistance of 3 timesthepreliminarytestpilediameter. Atfinalpreparation, asteel bearing plate willbesetcentrally on top of the reaction pile and the maingirderwillbeplacedontopofthebearingplate. The required pile diameter size, reinforcement detail and pile length for the reaction pile can be referredinAppendixM.
5.2.2 AssemblingWorksforTensionLoadTest
Thesequencesofassemblingtensionloadtestsetupareasfollows; i. Asuitableplatformwillbepreparedoverthe workingareaofthetest. Thiswillaidthe stabilityandaccurateassemblyofthetestsetup. ii. The main reaction beam(s) are then carefully aligned and levelled to ensure that the beampileheadloadingpointsareinthesameverticalaxis. iii. Placedthetwomainreactionbeamsparalleleachatoppositepositionwithaspaceofminimum 100mmfromedgeofthemainreactionbeamstotheedgeoftheHBeam,and,securelylayon theReactionPilewhichoverlainwith4steelbearingplate. iv. Transfer frame will be welded to the HBeam based on the proposed Professional Engineer design. v. Placehydraulicjackunderthetransferframewithanallowanceforloadcellinstallation. vi. Tiltingplateswillbeplacedontopoftheloadcellstoprovideequilibriumbalanceduringthe loadingprocess. The details setup for the proposed tension load test is attached in Appendix N, and, the Main ReactionBeamdesigncalculationwillbesubmittedinseparatesubmission.
6. TestingEquipment The Hydraulic Jack, pump, hoses, couplings and other apparatus to be operated under hydraulicpressureshallbecapabletowithstand3timesthemaximumworkingpressure ----------C 156 NORTH EAST LINE EXTENSION BORED PILING WORKS
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without leakage. All measuring instruments used in the test shall be calibrated and certified.
Figure4.DualJackmethodsforthePreliminaryTensionTestPile.
Hydraulic Jack
i. ii. iii.
Figure5.PlanviewofdualjackarrangementsforPreliminaryTensionTestPile ThepumpunitshallbeconnectedtotheHydraulicJacks. As the same pump unit is used, the pressure applied to the two jacks should be equal. TheloadappliedtothetestpileisthereforethesumoftheproductoftheJackRam Areaandthepressureapplied.
7. MeasuringMovementofPile LevellingMethod Movement of pile shall be measured with a levelling instrument. As shown in Figure 6 below, 2 scale rulers shall be welded on the steel plate (which is on top of the pile) diagonallyoppositesides.Initialreadingsfromthescalerulersandthebenchmarksshall berecorded. ----------C 156 NORTH EAST LINE EXTENSION BORED PILING WORKS
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Figure6.Rulerinstalledformeasuringthepileheadmovement DialGaugeMethod Twodialgaugeswillbesupportedbyrebarthatweldedtothepreliminarytestpilecasing asinFigure7.
Figure7.Installationofdialgaugesonpilehead 8. ProtectionofTestingEquipment All testing equipment shall be protected from unnecessary disturbance prior to and throughout the load test. This is achieved by using safety tape to tape around the perimeteroftheloadtestarea.Aguard/workershallbeinchargeoftheprotectionofthe pilethroughouttheloadtest. ----------C 156 NORTH EAST LINE EXTENSION BORED PILING WORKS
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9. Records ThesettlementdatacollectedduringthetestingperiodwillberecordedintheSettlement RecordingsheetwhichisattachedinAppendixJ. 10. LoadingSequence Loading Sequence for the Preliminary Test Pile shall be complied with LTAs M&W Specificationclause5.7.145.1.18.3,and,theloadingsequenceforPreliminaryTestpile T1andT2canbereferredatAppendixO. 11.ScheduleforPreliminaryTestPileT1andT2Construction ThetentativescheduleforthePreliminaryTestPileConstructionandTestingisattached inAppendixP. 12. SafeWorkProcedures
Ensured that Daily Tool Box Meeting with related topics concerning the works is conductedforalltheworkersinvolvedontheworks. EnsuredthatalltheworkersareequippedwithproperPersonalProtectiveEquipment or PPE (Safety Boots, Safety Vest, Safety Helmet, Safety Glass, and Ear Plug for hacking works, Hand Glove, Dust Mask for hacking works, Safety Harness for workingatheightmorethan3meter). EnsuredthattheSiteEngineers,SafetySupervisorandSiteForemanareinformedon theriskinvolvedontheworksandthenecessarysafetypreventiontobetakenas statedintheRiskAssessmentwhichisattachedinAppendixQ. Ensuredthatproperworkingplatformsandsafetyharnessareprovidedsecurelyfixed tothebaseandattachedtolifelineatallthetimeduringtheworks. Ensuredthattheexcavatedtrench/holesareproperlybarricadedandsecurelycover whendeemednecessary. EnsuredthattheLiftingGearsarecheckforanydefectsandcolourcodedin accordancetothecoloursmonth. Ensuredthatthedesignatedtestareaaresecurelycordonedandonlyauthorized personnelallowedtoenter. EnsuredthatRiskAnalysishasbeingproperlyaddressedoridentifyontheparticular highriskactivitybeforeprecedingthetask. Safeingressandegressshouldbeproperlydemarcatedforemergencyexitpurposes.
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APPENDIX
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AppendixA

LocationandReferenceBoreholeforPreliminaryTestPile T1anT2

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AppendixB

SiteOrganisationChartforPreliminaryTestPile ConstructionandTesting

CONTRACT156NORTHEASTLINEEXTENSION SITEORGANISATIONCHARTFORPRELIMINARYTESTPILECONSTRUCTION
MainContractor: SongTaeWon DesignManager HP:92344488 Construction YounManHyun ConstructionManager HP:92344499 Analysis HsanWynn GeotechnicalEngineer
AndyKang SeniorEngineer HP:91738975
SubContractor:
SongJuHun ProjectManager HP:91384320 PhangKianKok TechnicalManager HP:91683932 ParkInHo ConstructionManager HP:83765209
GeoEngConsultants DRNgTionGuan P:65466318
TinAungTun SeniorEngineer HP:81688954
Ramasamy SafetySupervisor HP:92439604
ConcretingTeam
BoringTeam
TestPile SettingUp Team

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AppendixC

DebondingCasingDetailandDebondingMaterial Bituthene3000ProductDetailandTechnical Specification

Grace Below Grade Waterproofing
BITUTHENE 3000 AND BITUTHENE LOW TEMPERATURE
Self-adhesive, rubberized asphalt/polyethylene waterproofing membranes for basements and sub-structures

Bituthene 3000 and Bituthene Low Temperature are self-adhesive, rubberized asphalt/polyethylene waterproofing membranes used in basements and sub-structures. Waterproofhigh hydrostatic head resistance Cross laminated filmprovides dimensional stability, high tear strength, puncture and impact resistance Cold appliedno flame hazard; self-adhesive overlaps ensure continuity Chemically resistantprovides effective external protection against aggressive soils and ground water Flexibleaccommodates minor settlement and shrinkage movement Controlled thicknessfactory made sheet ensures constant, non-variable site application Wide application window Bituthene Low Temperature surface and ambient temperatures between 25F (-4C) and 60F (16C) Bituthene 3000 surface and ambient temperatures at 40F (5C) or above
Description
Ripcord split release on demandfaster application in the straight-aways, ease of membrane positioning in detailed areas Bituthene is ideal for waterproofing concrete, masonry and wood surfaces where in-service temperatures will not exceed 130F (54C). It can be applied to foundation walls, tunnels, earth sheltered structures and split slab construction, both above and below grade. (For above grade applications, see Above Grade Waterproofing Bituthene 3000 and Bituthene Low Temperature.) Bituthene is 116 in. (1.5 mm) thick, 3 ft (0.9 m) wide and 66.7 ft (20 m) long and is supplied in rolls. It is unrolled sticky side down onto concrete slabs or applied onto vertical concrete faces primed with Bituthene Primer WP-3000, Primer B2 or Primer B2 LVC. Continuity is achieved by overlapping a minimum 2 in. (50 mm) and firmly rolling the joint.
Advantages
Use
Hydroduct 220 on Hydroduct Tape Bituthene WP-3000, Primer B2 or Primer B2 LVC Bituthene 3000 Hydroduct Coil 600
Product Advantages Waterproof Cross laminated film Cold applied Chemically resistant Flexible Controlled thickness Wide application window Ripcord split release on demand
Bituthene 3000 reinforcement
Footing
Bituthene Liquid Membrane termination or Bituthene Mastic Bituthene Liquid Membrane fillet
Drawings are for illustration purposes only. Please refer to graceconstruction.com for specific application details.
Bituthene is extremely flexible. It is capable of bridging shrinkage cracks in the concrete and will accommodate minor differential movement throughout the service life of the structure. Safety, Storage and Handling Information Bituthene products must be handled properly. Vapors from solvent-based primers and mastic are harmful and flammable. For these products, the best available information on safe handling, storage, personal protection, health and environmental considerations has been gathered. Material Safety Data Sheets (MSDS) are available at graceconstruction.com and users should acquaint themselves with this information. Carefully read detailed precaution statements on product labels and the MSDS before use. Surface Preparation Surfaces should be structurally sound and free of voids, spalled areas, loose aggregate and sharp protrusions. Remove contaminants such as grease, oil and wax from exposed surfaces. Remove dust, dirt, loose stone and debris. Concrete must be properly dried (minimum 7 days for normal structural concrete and 14 days for lightweight structural concrete). If time is critical, Bituthene Primer B2 or Bituthene Primer B2 LVC may be used to allow priming and installation of membrane on damp surfaces or green concrete. Priming may begin in this case as soon as the concrete will maintain structural integrity. Use form release agents which will not transfer to the concrete. Remove forms as soon as possible from below horizontal slabs to prevent entrapment of excess moisture. Excess moisture may lead to blistering of the membrane. Cure concrete with clear, resin-based curing compounds which do not contain oil, wax or pigment. Except with Primer B2 or Primer B2 LVC, allow concrete to thoroughly dry following rain. Do not apply any products to frozen concrete. Repair defects such as spalled or poorly consolidated areas. Remove sharp protrusions and form match lines. On masonry surfaces, apply a parge coat to rough concrete block and brick walls or trowel cut mortar joints flush to the face of the concrete blocks. Temperature Apply Bituthene 3000 Membrane only in dry weather and at air and surface temperatures of 40F (5C) and above. Apply Bituthene Low Temperature Membrane only in dry weather and when air and surface temperatures are between 25F (-4C) and 60F (16C). Apply Bituthene Primer WP-3000 in dry weather above 40F (5C).
Application Procedures
Priming Apply Bituthene Primer WP-3000 by spray or roller at a coverage rate of 500600 ft2/gal (1215 m2/L). Allow to dry one hour or until concrete returns to original color. Apply Bituthene Primer B2 by a lambs wool roller at a coverage rate of 250350 ft2/gal (68 m2/L). Allow primer to dry one hour or until tack-free. Apply Bituthene Primer B2 LVC by a lambs wool roller at a coverage rate of 325425 ft2/gal (7.510 m2/L). Allow primer to dry one hour or until tack free. Dry time may be longer in cold temperatures. Reprime areas if contaminated by dust. If the work area is dusty, apply membrane as soon as the primer is dry. Do not apply any primer to Bituthene membrane. Corner Details The treatment of corners varies depending on the location of the corner. For detailed information on Bituthene Liquid Membrane, see separate product information sheet. At wall to footing inside corners Option 1: Apply membrane to within 1 in. (25 mm) of base of wall. Treat the inside corner by installing a 34 in. (20 mm) fillet of Bituthene Liquid Membrane. Extend Bituthene Liquid Membrane at least 212 in. (65 mm) onto footing, and 212 in. (65 mm) onto wall membrane. Option 2: Treat the inside corner by installing a 34 in. (20 mm) fillet of Bituthene Liquid Membrane. Apply 12 in. (300 mm) wide strip of sheet membrane centered over fillet. Apply wall membrane over inside corner and extend 6 in. (150 mm) onto footing. Apply 1 in. (25 mm) wide troweling of Bituthene Liquid Membrane over all terminations and seams within 12 in. (300 mm) of corner. At footings where the elevation of the floor slab is 6 in. (150 mm) or more above the footing, treat the inside corner either by the above two methods or terminate the membrane at the base of the wall. Seal the termination with Bituthene Liquid Membrane. Joints Properly seal all joints with waterstop, joint filler and sealant as required. Bituthene membranes are not intended to function as the primary joint seal. Allow sealants to fully cure. Pre-strip all slab and wall cracks over 116 in. (1.5 mm) wide and all construction and control joints with 9 in. (230 mm) wide sheet membrane strip.
Apply Bituthene Primer B2 in dry weather above 25F (-4C). (See separate product information sheet.)
Application on Horizontal Surfaces (Note: Preprufe pre-applied membranes are strongly recommended for below slab or for any application where the membrane is applied before concreting. See Preprufe product information sheets.) Apply membrane from the low point to the high point so that laps shed water. Overlap all seams at least 2 in. (50 mm). Stagger all end laps. Roll the entire membrane firmly and completely as soon as possible. Use a linoleum roller or standard waterfilled garden roller less than 30 in. (760 mm) wide, weighing a minimum of 75 lbs (34 kg) when filled. Cover the face of the roller with a resilient material such as a 12 in. (13 mm) plastic foam or two wraps of indoor-outdoor carpet to allow the membrane to fully contact the primed substrate. Seal all T-joints and membrane terminations with Bituthene Liquid Membrane at the end of the day. Protrusions and Drains Apply membrane to within 1 in. (25 mm) of the base of the protrusion. Apply Bituthene Liquid Membrane 0.1 in. (2.5 mm) thick around protrusion. Bituthene Liquid Membrane should extend over the membrane a minimum of 212 in. (65 mm) and up the penetration to just below the finished height of the wearing course. Vertical Surfaces Apply membrane in lengths up to 8 ft (2.5 m). Overlap all seams at least 2 in. (50 mm). On higher walls apply membrane in two or more sections with the upper overlapping the lower by at least 2 in. (50 mm). Roll all membrane with a hand roller. Terminate the membrane at grade level. Press the membrane firmly to the wall with the butt end of a hardwood tool such as a hammer handle or secure into a reglet. Failure to use heavy pressure at terminations can result in a poor seal. A termination bar may be used to ensure a tight seal. Terminate the membrane at the base of the wall if the bottom of the interior floor slab is at least 6 in. (150 mm) above the footing. Otherwise, use appropriate inside corner detail where the wall and footing meet. Membrane Repairs Patch tears and inadequately lapped seams with membrane. Clean membrane with a damp cloth and dry. Slit fishmouths and repair with a patch extending 6 in. (150 mm) in all directions from the slit and seal edges of the patch with Bituthene Liquid Membrane. Inspect the membrane thoroughly before covering and make any repairs. Drainage Hydroduct drainage composites are recommended for both active drainage and protection of the membrane. See Hydroduct product information sheets.
Protection of Membrane Protect Bituthene membranes to avoid damage from other trades, construction materials or backfill. Place protection immediately in temperatures above 77F (25C) to avoid potential for blisters. On vertical applications, use Hydroduct 220 Drainage Composite. Adhere Hydroduct 220 Drainage Composite to membrane with Hydroduct Tape. Alternative methods of protection are to use 14 in. (6 mm) asphalt impregnated board or 1 in. (25 mm) extruded polystyrene. Such alternatives do not provide positive drainage to the system. Adhere protection board with an adhesive or Hydroduct Tape. In mud slab waterproofing, or other applications where positive drainage is not desired and where reinforced concrete slabs are placed over the membrane, the use of 14 in. (6 mm) hardboard or 2 layers of 18 in. (3 mm) hardboard is recommended. Insulation Always apply Bituthene membrane directly to primed or conditioned structural substrates. Insulation, if used, must be applied over the membrane. Do not apply Bituthene membranes over lightweight insulating concrete. Backfill Place backfill as soon as possible. Use care during backfill operation to avoid damage to the waterproofing system. Follow generally accepted practices for backfilling and compaction. Backfill should be added and compacted in 6 in. (150 mm) to 12 in. (300 mm) lifts. For areas which cannot be fully compacted, a termination bar is recommended across the top termination of the membrane. Placing Steel When placing steel over properly protected membrane, use concrete bar supports (dobies) or chairs with plastic tips or rolled feet to prevent damage from sharp edges. Use special care when using wire mesh, especially if the mesh is curled.
Approvals Warranty
City of Los Angeles Research Report RR 24386 U.S. Department of Housing and Urban Development (HUD) HUD Materials Release 628E Five year material warranties covering Bituthene and Hydroduct products are available upon request. Contact your Grace sales representative for details. Support is provided by full time, technically trained Grace representatives and technical service personnel, backed by a central research and development staff.
Technical Services
Supply
Equipment by others:
Bituthene 3000 or Bituthene Low Temperature Roll weight Palletization Storage Ancillary Products Bituthene WP-3000 Bituthene Primer B2 Bituthene Primer B2 LVC Bituthene Liquid Membrane Hydroduct Tape Bituthene Mastic
3 ft x 66.7 ft roll (200 ft2) [0.9 m x 20 m (18.6 m2)] 83 lbs (38 kg) gross 25 rolls per pallet Store upright in dry conditions below 95F (+35C). 5 gal (18.9 L) pail/24 pails per pallet 5 gal (18.9 L) pail/48 pails per pallet 5 gal (18.9 L) pail/48 pails per pallet 1.5 gal (5.7 L) pail/100 pails per pallet or 4 gal (15.1 L) pail/24 pails per pallet 1 in. x 200 ft (2.5 cm x 61.0 m) roll/6 rolls per carton Twelve 30 oz (0.9 L) tubes/carton or 5 gal (18.9 L) pail/36 pails per pallet
Soft broom, utility knife, brush or roller for priming
Physical Properties for Bituthene Membrane

Property Color Thickness Flexibility, 180 bend over 1 in. (25 mm) mandrel at -25F (-32C) Tensile strength, membrane, die C Tensile strength, film Elongation, ultimate failure of rubberized asphalt Crack cycling at -25F (-32C), 100 cycles Lap adhesion at minimum application temperature Peel strength Puncture resistance, membrane Resistance to hydrostatic head Permeance Water absorption
Typical Value Dark gray-black 116 in. (1.5 mm) nominal Unaffected 325 lbs/in.2 (2240 kPa) minimum 5,000 lbs/in.2 (34.5 MPa) minimum 300% minimum Unaffected 3000: 4 lbs/in. (700 N/m) Low Temp: 5 lbs/in. (880 N/m) 9 lbs/in. (1576 N/m) 50 lbs (222 N) minimum 200 ft (60 m) of water 0.05 perms (2.9 ng/m2sPa) maximum 0.1% maximum
Test Method ASTM D3767method A ASTM D1970 ASTM D412 modified1 ASTM D882 modified1 ASTM D412 modified1 ASTM C836 ASTM D1876 modified2 ASTM D903 modified3 ASTM E154 ASTM D5385 ASTM E96, section 12water method ASTM D570
Footnotes: 1. The test is run at a rate of 2 in. (50 mm) per minute. 2. The test is conducted 15 minutes after the lap is formed and run at a rate of 2 in. (50 mm) per minute at 40F (5C). 3. The 180 peel strength is run at a rate of 12 in. (300 mm) per minute.
www.graceconstruction.com
For technical assistance call toll free at 866-333-3SBM (3726)

We hope the information here will be helpful. It is based on data and knowledge considered to be true and accurate and is offered for the users consideration, investigation and verification, but we do not warrant the results to be obtained. Please read all statements, recommendations or suggestions in conjunction with our conditions of sale, which apply to all goods supplied by us. No statement, recommendation or suggestion is intended for any use which would infringe any patent or copyright. W. R. Grace & Co.Conn., 62 Whittemore Avenue, Cambridge, MA 02140. In Canada, Grace Canada, Inc., 294 Clements Road, West, Ajax, Ontario, Canada L1S 3C6. This product may be covered by patents or patents pending. BIT-210F Printed in U.S.A. 9/08 Copyright 2007. W. R. Grace & Co.Conn. FA/LVI/1M Bituthene, Preprufe, Ripcord and Hydroduct are registered trademarks of W. R. Grace & Co.Conn.
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1. Product Name Bituthene Waterproofing Systems Hydroduct Drainage Composites 2. Manufacturer Grace Construction Products 62 Whittemore Avenue Cambridge, MA 02140 (866) 333-3SBM (3726) Fax: (617) 498-4311 www.graceconstruction.com 3. Product Description BASIC USE Bituthene waterproofing systems and Hydroduct drainage composites are used in positive-side waterproofing applications over concrete, masonry and wood surfaces. They are used in new construction and retrofit applications. Typical applications include foundation walls, tunnels, earth sheltered structures, and split slab construction such as plaza areas and parking decks. Interior uses include mechanical rooms, laboratories and kitchens. COMPOSITION & MATERIALS The Bituthene waterproofing systems consist of several waterproofing membranes and compatible accessory products and are complemented by the use of the appropriate Hydroduct drainage composite. The Bituthene membranes are available in rolls, interwound with a disposable silicone treated release sheet. The volatile organic compound (VOC) content of all Bituthene membranes is 0 g/L. Bituthene System 4000 Waterproofing Membrane is a factory made composite with a thickness of 0.060" (1.5 mm) consisting of 0.004" (0.1 mm) of cross-laminated polyethylene film and 0.056" (1.4 mm) of selfadhesive rubberized asphalt. It is specifically formulated for use with the Bituthene System 4000 Surface Conditioner and compatible accessory products. Bituthene System 4000 Surface Conditioner is a water based surface conditioner specifically formulated to prepare concrete, masonry and wood surfaces for the System
SPEC-DATA and MANU-SPEC are registered trademarks of Reed Elsevier Inc. The ten part SPEC-DATA format conforms to the editorial style of The Construction Specifications Institute and is used with their permission. The manufacturer is responsible for technical accuracy. 2007 Reed Construction Data. All Rights Reserved.
Grace Construction Products 4000 Waterproofing Membrane. Its VOC content is 125 g/L. Bituthene 3000 and Bituthene Low Temperature Membranes are factory made composites with a thickness of 0.060" (1.5 mm). These products consist of 0.056" (1.4 mm) of self-adhesive rubberized asphalt and 0.004" (0.1 mm) of cross-laminated, high density polyethylene film. Hydroduct drainage composites consist of dimpled, high impact polystyrene cores and filter fabrics designed to provide positive drainage and membrane protection. The VOC content of all Hydroduct products is 0 g/L. Hydroduct 220 Drainage Composite is used for vertical applications over Bituthene waterproofing membranes. Hydroduct 660 Drainage Composite is used for all horizontal applications. Hydroduct 200 is intended for areas which are not waterproofed. Hydroduct 225 Drainage Composite incorporates a molded polyvinyl chloride core and is intended for areas requiring heat or hydrocarbon resistance. COMPATIBILITY Apply waterproofing membrane directly to structural surfaces. Bituthene membranes can be used over EPS wall forming systems if the additional guidelines in Technical Letter 18, Insulated Wall Forming Systems, are followed. Bituthene membranes are compatible with aged asphalt and coal tar products. Bituthene membranes are incompatible with creosote, pentachlorophenol, linseed oil and materials containing polysulfide polymer. The rubberized asphalt component of Bituthene membranes is not compatible with flexible PVC or rubber sheet membranes. Do not apply Bituthene membranes over materials containing petroleum solvents, fuels or oils. Joint sealants containing solvents must be fully cured prior to Bituthene membrane application. Refer to Technical Letter 10, Chemical Compatibility with Other Materials. Bituthene membranes are compatible with appropriate Hydroduct drainage composites. Bituthene membranes are not compatible with certain types of prefabricated drainage systems that damage waterproofing membranes when exposed to soil pressures. ACCESSORY MATERIALS Architectural and Industrial Maintenance Regulations limit the VOC content in products classified as Architectural Coatings. Refer to Technical Letters on manufacturers website for the most current list of allowable limits. Bituthene Primer WP-3000 is a water based latex primer used to prime all concrete, masonry and wood surfaces. Its VOC content is 110 g/L. Bituthene Primer B2 is a black, rubber based primer in solvent used to prime all concrete, masonry and wood surfaces. In addition, its patented formulation promotes the adhesion of Bituthene membranes to green concrete and damp surfaces. Its VOC content is 440 g/L. Bituthene Deck Prep Surface Treatment is a low viscosity, 2-component, asphalt-modified coating used to smooth and level rough decks prior to installing the Bituthene waterproofing membrane. Its VOC content is 10 g/L. Bituthene Liquid Membrane is a 2-component, cold applied trowel grade waterproofing material used to flash corners, form fillets and detail hard-to-reach areas. Its VOC content is 10 g/L. Bituthene Mastic is a rubberized asphalt based mastic used to seal membrane terminations. Its VOC content is 200 g/L. Hydroduct Tape is a 2-sided, highly aggressive adhesive tape that is specially formulated to adhere Hydroduct drainage composites or expanded or extruded polystyrene protection board to the membrane. Its VOC content is 61 g/L. LIMITATIONS Do not apply Bituthene membranes in areas where they will be permanently exposed to sunlight, weather or traffic. Bituthene membranes are not recommended as pond liners or as tank liners except when installed between 2 concrete slabs. Bituthene strips over joints in T-beam structures will not provide complete waterproofing. For these structures, 9" (225 mm) strips over properly cured and sealed joints, followed by membrane coverage over the entire surface, are required for a complete waterproofing system. Bituthene membranes are not intended to be used as a roofing underlayment or flashing material. Use of tile set in thinset mortar is not recommended on surfaces waterproofed with Bituthene membranes unless approved by thinset mortar manufacturer.
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All Hydroduct drainage composites should be promptly covered. Do not leave drainage exposed to sunlight for more than 2 weeks. Motor vehicles, construction equipment and other trades should not be allowed directly on the drainage composites. Protect Bituthene membranes from UV or site damage immediately after installation or 24 hour flood test. Backfilling or installation of the wearing course should be completed as soon as possible. 4. Technical Data APPLICABLE STANDARDS ASTM International ASTM C366 Standard Test Methods for Measurement of Thickness of Sandwich Cores ASTM C836 Standard Specification for High Solids Content, Cold Liquid-Applied Elastomeric Waterproofing Membrane for Use with Separate Wearing Course ASTM D412 Standard Test Methods for Vulcanized Rubber and Thermoplastic Rubbers and Thermoplastic ElastomersTension ASTM D570 Standard Test Method for Water Absorption of Plastics ASTM D882 Standard Test Method for Tensile Properties of Thin Plastic Sheeting ASTM D903 Standard Test Method for Peel or Stripping of Adhesive Bonds ASTM D1621 Standard Test Method for Compressive Properties of Rigid Cellular Plastics ASTM D1876 Standard Test Method for Peel Resistance of Adhesives (T-Peel Test) ASTM D1970 Standard Specification for SelfAdhering Polymer Modified Bituminous Sheet Materials Used as Steep Roofing Underlayment for Ice Dam Protection ASTM D3767 Method A - Standard Practice for Rubber-Measurement of Dimensions ASTM D3776 Standard Test Methods for Mass Per Unit Area (Weight) of Fabric ASTM D4491 Standard Test Methods for Water Permeability of Geotextiles by Permittivity ASTM D4533 Standard Test Method for Trapezoid Tearing Strength of Geotextiles ASTM D4632 Standard Test Method for Grab Breaking Load and Elongation of Geotextiles ASTM D4716 Standard Test Method for Constant Head Hydraulic Transmissivity (InPlane Flow) of Geotextiles and Geotextile Related Products
Grace Construction Products ASTM D4751 Standard Test Method for Determining Apparent Opening Size of a Geotextile ASTM D4833 Standard Test Method for Index Puncture Resistance of Geotextiles, Geomembranes, and Related Products ASTM D5385 Standard Test Method for Hydrostatic Pressure Resistance of Waterproofing Membranes ASTM E96 Standard Test Methods for Water Vapor Transmission of Materials ASTM E154 Standard Test Methods for Water Vapor Retarders Used in Contact with Earth Under Concrete Slabs, on Walls, or as Ground Cover APPROVALS City of Los Angeles Research Report RR 24386 U.S. Department of Housing and Urban Development (HUD) HUD Materials Release 628E Miami Dade, NOA 03-0630.04 SPECIFICATIONS American Railway Engineering Association Chapter 29-2-4 Federal Construction Guide Specification FCGS-07111 General Service Administration (GSA) GSAPBS 07115 National Railroad Passenger Corporation (Amtrak) Section 7.02 AIA MASTERSPEC Section 07100 U.S. Army Corps of Engineers CEGS-07111 U.S. Department of the Navy NFGS-07111 U.S. Department of Veterans Affairs H-08-1 Section 07113 PHYSICAL PROPERTIES Bituthene waterproofing membranes conform to the physical property and typical values listed in Tables 1 and 3. Hydroduct drainage composites conform to the physical property and typical values in Table 2. 5. Installation SAFETY Bituthene products must be properly handled. Vapors from the solvent based primer and mastic are harmful and flammable. For these products, the best available information on safe handling, storage, personal protection, health and environmental considerations has been gathered and is available on Material Safety Data Sheets (MSDS). All users should acquaint themselves with this information. Carefully read detailed precaution statements on product labels and MSDS before use, or contact Grace Construction Products. STORAGE & HANDLING Protect all materials from rain and physical damage. Do not double stack pallets of membrane on the jobsite. Provide tarpaulin cover on top and all sides, allowing for adequate ventilation. Store membrane where temperatures will not exceed 90 degrees F (32 degrees C) for extended periods. In low temperature conditions, the membrane should be stored above 40 degrees F (5 degrees C) to promote good adhesion. Store all products in a dry area away from high heat, flames or sparks. Store only as much material at point-of-use as required for each days work. PREPARATORY WORK Surface Condition Concrete must be smooth, monolithic and free of voids, spalled areas, loose substrate and sharp protrusions, dirt and debris, and must contain no visible coarse aggregate. Repair defects such as spalled or poorly consolidated areas. Use Bituthene Deck Prep Surface Treatment to smooth and level rough concrete decks. Remove sharp protrusions and form match lines. Curing Concrete must be cured a minimum of 7 days for normal structural concrete and 14 days for lightweight structural concrete. If concrete is placed over a nonvented metal deck, the required curing time is doubled. Use form release agents that will not transfer to the concrete. Remove forms as soon as possible from below horizontal slabs to prevent entrapment of excess moisture. Excess moisture can lead to blistering of the membrane. Cure concrete with clear, resin based curing compounds containing no oil, wax or pigment. Allow concrete to thoroughly dry following rain. On masonry surfaces, apply a parge coat to rough concrete block and brick walls or trowel-cut mortar joints flush to the face of the concrete blocks. Cure time and drying time for concrete and masonry surfaces may be reduced by using Bituthene Primer B2. TEMPERATURE Apply Bituthene System 4000 Membrane only in dry weather when air and surface temperatures are above 25 degrees F
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(-4 degrees C) Apply Bituthene 3000 Membrane only in dry weather when air and surface temperatures are above 40 degrees F (5 degrees C) Bituthene Low Temperature Membrane can be used at temperatures above 25 degrees F (-4 degrees C) and up to 60 degrees F (16 degrees C) Cover the membrane immediately in temperatures above 77 degrees F (25 degrees C) to reduce potential for blistering Apply Bituthene System 4000 Surface Conditioner and other accessory products not listed below in dry weather above 25 degrees F (-4 degrees C) Apply Bituthene Primer WP-3000 in dry weather above 40 degrees F (5 degrees C) Do not apply products to frozen concrete APPLICATION Surface Conditioner Bituthene System 4000 Surface Conditioner is supplied ready to use. Do not dilute with water or solvents. Spray surface conditioner uniformly to substrate at a rate of 300 ft2/gal (7.5 m2/L). Use appropriate sprayer and nozzle. Allow surface conditioner to dry completely and thoroughly prior to membrane application. The surface conditioner is considered dry when the substrate returns to its original color. To test for dryness, rub small conditioned area by
TABLE 1 PHYSICAL PROPERTIES OF BITUTHENE MEMBRANES

Property & Test Method Color Thickness, ASTM D3767, Method A Low temperature flexibility, ASTM D1970 Resistance to hydrostatic head, ASTM D5385 Lap adhesion at minimum application temperature, width, ASTM D1876, Modified Tensile strength, membrane, ASTM D412 (Die C), Modified Tensile strength, film, ASTM D882, Modified Elongation, ultimate failure of rubberized asphalt, ASTM D412, Modified Cracking cycling, 100 cycles, ASTM D836 Peel strength, width, ASTM D903, Modified Puncture resistance, membrane, ASTM E154 Permeance, maximum, ASTM E96 Water Method Water absorption, 72 hr, ASTM D570 Bituthene System 4000 Membrane Gray-black 0.060" (1.5 mm) nominal Unaffected at -45F (-43C) 231' (70 m) min 5.0 lb/in (880 N/m) 325 psi (2240 kPa) min 5000 psi (34.5 MPa) min 300% min Unaffected at -25F (-32C) 9.0 lb/in (1576 N/m) 50 lb (222 N) min 0.05 perms (2.9 ng/(Pa s m ))
2
Grace Construction Products hand. Wet conditioner will ball up under the fingertips. Let dry until conditioner cannot be rubbed off. If conditioned areas are not covered that day, recondition the area if there is significant dust or dirt contamination. Primer Apply Bituthene Primer WP-3000 by spray or roller at a coverage rate of 500 - 600 ft2/gal (12 - 15 m2/L). Allow to dry 1 hour or until concrete returns to original color. Apply Bituthene Primer B2 by lambs wool roller at a coverage rate of 250 - 350 ft2/gal (6 - 8 m2/L). Allow primer to dry 1 hour or until tackfree. Dry time may be longer in cold temperatures. Reprime areas if contaminated by dust. If the work area is dusty, apply membrane as soon as the primer is dry. Surfaces treated with Deck Prep Surface Treatment do not require conditioning or priming. Metal does not require priming but must be clean, dry and free of loose paint, rust or other contaminants. Use Bituthene Primer B2 for damp or green substrates. Do not apply primer or surface conditioner to membrane. Corners The treatment of corners varies depending on the location of the corner. At wall-to-footing inside corners: Option 1 - Apply membrane to within 1" (25 mm) of base of wall. Treat the inside corner by installing a 3/4" (19 mm) fillet of Bituthene Liquid Membrane. Extend liquid membrane at least 3" (75 mm) onto wall membrane Option 2 - Treat the inside corner by installing a 3/4" (19 mm) fillet of Bituthene Liquid Membrane. Apply 12" (300 mm) wide strip of membrane centered over fillet. Apply wall membrane over inside corner and extend 6" (150 mm) onto footing. Apply 1" (25 mm) wide troweling of Bituthene Mastic or Bituthene Liquid Membrane over all terminations and seams within 12" (300 mm) of corner At footings where the elevation of the floor slab is 6" (150 mm) or more above the footing, treat the inside corner either by one of the above methods or terminate the membrane at the base of the wall. Seal the termination with Bituthene Mastic or Bituthene Liquid Membrane. At plaza deck-to-wall inside corners: Option 1 - Apply membrane on wall and deck to within 1" (25 mm) of corner. Treat the inside corner by installing a 3/4" (19 mm) fillet of Bituthene Liquid Membrane. Extend Bituthene Liquid Membrane at least 3" (75 mm) onto deck membrane and 3" (75 mm) onto wall membrane. Terminate
Bituthene 3000 Membrane Dark gray-black 0.060" (1.5 mm) nominal Unaffected at -25F (-32C) 200' (60 m) min 4.0 lb/in (700 N/m) 325 psi (2240 kPa) min 5000 psi (34.5 MPa) min 300% min Unaffected at -25F (-32C) 9.0 lb/in (1576 N/m) 50 lb (222 N) min 0.05 perms (2.9 ng/(Pa s m ))
2
Bituthene Low Temperature Membrane Gray-black 0.060" (1.5 mm) nominal Unaffected at -45F (-43C) 200' (61 m) min 5.0 lb/in (880 N/m) 325 psi (2240 kPa) min 5000 psi (34.5 MPa) min 300% min Unaffected at -25F (-32C) 9.0 lb/in (1576 N/m) 50 lb (222 N) min 0.05 perms (2.9 ng/(Pa s m2)) 0.1% max
0.1% max
0.1% max
SHEET WATERPROOFING
07 13 00
top of membrane wall flashing with Bituthene Mastic, Bituthene Liquid Membrane or termination bar Option 2 - Apply membrane on deck to within 1" (25 mm) of corner. Treat the inside corner by installing a 3/4" (19 mm) fillet of Bituthene Liquid Membrane. Extend Bituthene Liquid Membrane at least 3" (75 mm) onto wall and membrane Option 3 - Apply membrane on deck to within 1" (25 mm) of corner. Treat the inside corner by installing a 3/4" (19 mm) fillet of Bituthene Liquid Membrane. Apply membrane flashing sheet on wall, over fillet and 6" (150 mm) onto deck membrane. Apply 1" (25 mm) wide troweling of Bituthene Mastic or Bituthene Liquid Membrane over all terminations and seams within 12" (300 mm) of corner. Terminate top of membrane wall flashing with Bituthene Mastic, Bituthene Liquid Membrane or termination bar In planters, reflecting pools and fountains, apply membrane on wall and deck to within 1" (25 mm) of corner. Treat the inside corner by installing a 3/4" (19 mm) fillet of Bituthene Liquid Membrane. Extend Bituthene Liquid Membrane at least 3" (75 mm) onto deck membrane and 3" (75 mm) onto wall membrane. Terminate top of wall membrane with Bituthene Liquid Membrane or termination bar. For wall to wall inside corner, apply 12" (300 mm) membrane strip centered on corner.
TABLE 2 PHYSICAL PROPERTIES OF HYDRODUCT DRAINAGE COMPOSITES

Property & Test Method Drain core Thickness, ASTM C366-B Compressive strength, ASTM D1621 (modified) Flow, 1.0 gradient, 37.9 kPa load, ASTM D4716 0.433" (11 mm) 15,000 psf (732 kN/m2) 16 gal/min/ft (0.003 L/min/m) 0.433" (11 mm) 21,000 psf (1025 kN/m2) 16 gal/min/ft (0.003 L/min/m) 0.433" (11 mm) 15,000 psf (732 kN/m2) 16 gal/min/ft (0.003 L/min/m) 0.433" (11 mm) 21,000 psf (1025 kN/m2) 16 gal/min/ft (0.003 L/min/m) Hydroduct 220 Hydroduct 660 Hydroduct 200 Hydroduct 225
Grace Construction Products Press membrane tightly into corner to ensure full contact. Cover the treated corner with a full sheet of membrane to ensure 2-ply coverage. For outside corners, apply 12" (300 mm) membrane strip centered on corner. Cover the treated corner with a full sheet of membrane to ensure 2-ply coverage. Joints Properly seal all joints with waterstop, joint filler and sealant as required. Bituthene membranes are not intended to function as the primary joint seal. Allow sealant to fully cure. Prestrip all slabs and wall cracks over 1/16" (1.6 mm) wide and all construction and control joints with 9" (225 mm) wide membrane. Drains At drains, apply a collar of membrane which extends 6" (150 mm) beyond the drain opening. Apply full coverage of membrane over the collar. Cut out the drain opening so the membrane extends under the clamping ring. Place a bead of Bituthene Mastic or Bituthene Liquid Membrane between the membrane and clamping ring. An alternate method is to apply Bituthene Liquid Membrane 0.090" (2.3 mm) thick so that it extends under the clamping ring and overlaps the deck membrane at least 3" (75 mm). Install clamping ring after Bituthene Liquid Membrane has cured. Application to Horizontal Surfaces Apply membrane from the low point to the high point so that laps shed water. Overlap all seams at least 2 1/2" (64 mm). Stagger all end laps. Roll the entire membrane firmly and completely as soon as possible. Use a linoleum roller or standard water-filled garden roller less than 30" (762 mm) wide, weighing a minimum of 75 lb (34 kg) when filled. Cover the face of the roller with a resilient material such as a 1/2" (13 mm) plastic foam or 2 wraps of indoor/outdoor carpet to allow the membrane to fully contact the primed substrate. Seal all T-joints and membrane terminations with Bituthene Mastic or Bituthene Liquid Membrane at the end of the day. For required testing of horizontal applications, see Flood Testing. Application to Vertical Surfaces Apply membrane in lengths up to 8' (2 m). Overlap all seams 2 1/2" (64 mm) minimum. On higher walls, apply membrane in 2 or more sections with the upper overlapping the lower by at least 2 1/2" (64 mm). Roll membrane with a hand roller. Terminate the membrane at grade level. Press the membrane firmly to the wall with the butt end of a hardwood tool such as a hammer handle, or secure into a reglet. A termination bar may be used to secure the top termination. Failure to use heavy pressure at terminations can result in a poor seal. Terminate the membrane at the base of the wall if the bottom of the interior floor slab is at least 6" (150 mm) above the
Filter fabric Apparent opening size, ASTM D4751 Permittivity, ASTM D4491 Tensile strength, ASTM D4632 Weight, ASTM D3776 Mullen Burst, ASTM D3786 Puncture, ASTM D4833 100 US sieve (150 micron) 150 gal/min/ft2 (6110 L/min/m2) 110 lb (485 N) 4.0 oz/yd (136 N/m )
2 2
100 US sieve (150 micron) 80 gal/min/ft2 (3250 L/min/m2) 230 lb (1020 N) 8.0 oz/yd (270 g/m )
2 2
100 US sieve (150 micron) 150 gal/min/ft2 (6110 L/min/m2) 110 lb (485 N) 4.0 oz/yd (136 g/m )
2 2
40 US sieve (380 micron) 100 gal/min/ft2 (4074 L/min/m2) 290 lb (1291 N) 6.0 oz/yd2 (203 g/m2) 480 psi (3304 kPa) 105 lb (720 N)
215 psi (1480 kPa) 65 lb (285 N)
690 psi (4753 kPa) 162 lb (720 N)
215 psi (1430 kPa) 65 lb (285 N)
SHEET WATERPROOFING
07 13 00
footing. Otherwise, use appropriate inside corner detail where the wall and footing meet. Seal all laps within 12" (300 mm) of all corners with a troweling of mastic. Apply a troweled bead of Bituthene Mastic or Bituthene Liquid Membrane to all vertical and horizontal terminations at the end of each workday. Protrusions and Penetrations Apply membrane to within 1" (25 mm) of the base of the protrusion. Apply Liquid Membrane 0.090" (2.3 mm) thick around the protrusion. Extend Bituthene Liquid Membrane over the sheet membrane at least 3" (75 mm) and up the protrusion to just below the finished height of the wearing course (for horizontal applications) or for a minimum of 6" (150 mm) for vertical applications. FLOOD TESTING Flood test all horizontal applications with a minimum 2" (50 mm) head of water for 24 hours. Mark any leaks and repair when the membrane is dry. Before flood testing, be sure the structure will withstand the dead load of the water. For well-sloped decks, segment the flood test to avoid deep water near drains. Conduct the flood test 1 day after completing the application of Bituthene waterproofing system. Immediately after flood test is completed, and all necessary repairs made, install Hydroduct 660 Drainage Composite to protect the Bituthene membrane from traffic and other trades. MEMBRANE REPAIR Patch tears and inadequately lapped seams with membrane. Slit fishmouths and repair with a patch extending 6" (150 mm) in all directions from the slit and seal edges of the patch with Bituthene Mastic. Inspect the membrane thoroughly before covering and make any repairs. PROTECTION Protection of Membrane Protect Bituthene membranes to avoid damage from other trades construction materials or backfill. Place protection immediately in temperatures above 77 degrees F (25 degrees C) to reduce potential for blistering. On horizontal applications, use Hydroduct 660 Drainage Composite for protection. Adhere as necessary to membrane with Hydroduct Tape. Alternate methods are to use 1/8" or 1/4" (3 or 6 mm) asphaltic hardboard. When reinforced concrete slabs are placed over the
Grace Construction Products membrane, use Hydroduct 660 Drainage Composite or 1/4" (6 mm) hardboard or 2 layers of 1/8" (3 mm) hardboard. On vertical applications, use Hydroduct 220 Drainage Composite. Adhere Hydroduct 220 to membrane with Hydroduct Tape. Alternative protection methods are to use 1" (25 mm) expanded polystyrene or 1/4" (6 mm) extruded polystyrene that has a minimum compressive strength of 10 lb/in2 (69 kN/m2). If 1/4" (6 mm) extruded polystyrene protection board is used, backfill should not contain sharp rock or aggregate over 2" (50 mm) in diameter. Adhere polystyrene protection board with Hydroduct Tape or compatible adhesive. Cover any exposed Bituthene membrane with weather resistant flashing such as copper, aluminum or neoprene. Install Hydroduct 660 Drainage Composite or alternate protection the same day the membrane is applied or immediately after a 24 hour flood test. No waiting before backfill or application of wearing course is necessary. Placement of Backfill Use care during backfill operation to avoid damage to waterproofing and drainage system. Follow generally accepted practice for backfill and compaction. Backfill should be added in 6" - 12" (150 - 300 mm) lifts. For bermed areas that cannot be fully compacted, a termination bar is recommended across the top termination of the membrane. In general, backfill or the final wearing course should be placed as soon as possible after installation of the membrane. Placement of Reinforcing Steel When placing reinforcing steel over properly protected membrane, use concrete bar supports (dobies) or chairs with plastic tips or rolled feet to prevent damage from sharp edges. Use special care when using wire mesh, especially if the mesh is curled. 6. Availability & Cost AVAILABILITY A network of distributors carries Bituthene waterproofing systems and Hydroduct drainage composite products for delivery to project sites. COST Bituthene waterproofing systems and Hydroduct drainage composites are competitively priced. For specific information, contact a local distributor or a Grace Construction Products representative. 7. Warranty Five year material warranties covering Bituthene and Hydroduct products are available upon request. Contact the manufacturer for further information. 8. Maintenance None required, if installed in accordance with manufacturers recommendations. 9. Technical Services Support is provided by full-time, technically trained Grace representatives and technical service personnel, backed by a central research and development staff. 10. Filing Systems Reed First Source Additional product information is available from the manufacturer.
SHEET WATERPROOFING
07 13 00
Grace Construction Products
W. R. Grace & Co.-Conn. hopes the information here will be helpful. It is based upon data and knowledge considered to be true and accurate and is offered for the users consideration, investigation and verification, but we do not warrant the results to be obtained. Please read all statements, recommendations or suggestions in conjunction with our conditions of sale, which apply to all goods supplied by us. No statement, recommendation or suggestion is intended for any use which would infringe any patent or copyright. W. R. Grace & Co.-Conn., 62 Whittemore Avenue, Cambridge, MA 02140. In Canada, W. R. Grace & Co. Canada, Ltd., 294 Clements Road, West, Ajax, Ontario, Canada L1S 3C6. Bituthene and Hydroproduct are registered trademarks of W. R. Grace & Co.-Conn. Dens-Glass Gold is a registered trademark of the Georgia-Pacific Corporation. This product may be covered by patents or patents pending. Copyright 2005 W.R. Grace & Co.-Conn. BIT-012W Printed in U.S.A. 11/05 AFS/LI/6M
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AppendixD

SequenceofDebondingCasingInstallation

Prepared by:
Page:
Project: Contract 156 - North East Line Extension

Stage 1 1, Pre-boring works
SEQUENCE OF DEBONDING CASING INSTALLATION

Stage 3: 1. Continue boring out the soil based on the outer temporary casing diameter from ground level up to 500mm above the top of OA layer.
1 of 2
Fill Layer
Bentonite
Fill Layer
Kallang Formation 500mm OA Layer
Kallang Formation
OA Layer
Stage 2: 1. Installtemporary outer casing by vibro hammer. until the depth based on trench stability calculation
Stage 4: 1. Install the Preliminary Test Pile debonding casing 500mm above the OA layer.
Fill Layer
Temporary Outer Casing
Install 1200mm debonding casing
Fill Layer
Kallang Formation
Kallang Formation 500mm
OA Layer
OA Layer
Prepared by:
Page:
Project: Marina Coastal Expressway Contract 486

Stage 5 1. Press down the 1200mm debonding casing into Kallang Formation layer 500mm by using kelly bar.
SEQUENCE OF DE-BONDING CASING INSTALLATION

Stage 7 1. Desanding of Preliminary Test Pile Stage 9: 1. Install H-Beam into Preliminary Test Pile by plunge-in method
2 of 2
H-Beam
To desander
Fill Layer
Fill Layer
Fill Layer
Polystrene Plug
Debonding casing Casing Kallang Formation 500mm
Debonding Casing Polystrene Plug Kallang Formation
Debonding Casing Kallang Formation
OA Layer OA Layer OA Layer
Stage 6 1. Continue boring works with 1200mm boring tools up to design toe level
Stage 8 1. Lowering of reinforcement cage and casting of Preliminary Test pile.
Stage 10: 1. Install Reaction Piles. 2. Assembling the tension test set up. 3. Conduct Tension loading test.
Upward Jackin Downward Force Downward Force
Fill Layer
Fill Layer
Fill Layer
Reaction Pile
Polystrene Plug
Debonding casing Casing Kallang Formation
Debonding Casing Polystrene Plug Kallang Formation Kallang Formation
Concrete OA Layer Design Toe Level OA Layer OA Layer
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AppendixE TypeofBentoniteTestandProcedures
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TESTINGFORSPECIFICGRAVITY
MudBalance
Themeasurementofspecificgravity(ordensity)onuntreatedmud,givesasimpleindication onamountofsuspendedparticlesinmud TheMudBalanceconsistsofthreecomponents: 1) Thebalancingrule,whichcomprisesthemudcup,theriderslidingalongthegraduatedsca le,theknifeedgethatrestsonthefulcrumandlevelbubble. 2) Thelidforthemudcup. 3) ThebasewithVnotchfunctionsasthefulcrum TestProcedure 1) Checkthatinstrumentiscleananddry. 2) Removethelidandfillthecupwiththesampletobetested. 3) Replacethelid.Checkthatitsitssnugly.Observethesurplusoutflowthroughtheholeint helid.Lackingofoutflowmayindicateinsufficientmudincup. 4) Holdingthelidinplacewithafingeroverthehole,cleantheexteriorofmudbalance. 5) Placethebalancewiththeknifeedgesittingonthefulcrum. 6) Slidetherideralongthegraduatedscaleuntiltheinstrumentisinequilibrium,asthespirit levelwillindicate. 7) ReadtheSpecificGravityscalebytheedgeoftheridernearesttothefulcrum. 8) Washanddrytheinstrumentcheckingthattheholeinthelidisclear. ----------C 156 NORTH EAST LINE EXTENSION BORED PILING WORKS

THEMARSHFUNNELTEST
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MarshFunnel TheMarshFunnelTestKitconsistsofthefollowingcomponents: 1) TheMarshFunnel. 2) Ameasuringcupmarkedtoread946ml(1.U.S.Quart). 3) Astopwatch. Thestandardfunnelusedtotestclearfreshwaterwillgiveareadingof26seconds. TestProcedure 1) Checkthatthefunneloutlettubeisclearandthattheequipmentiscleananddry. 2) Holdormountthefunnelinanuprightpositionandplacearodorfingertoplugtheoutlet whilefilling. 3) Fillthetestsampleintothefunnelthroughthescreentilltheamountofslurryreachedthe undersideofthescreen. 4) Subsequentlyplacetheemptymeasuringcuponlevelplatformundertheoutletnozzle. 5) Start the stopwatch simultaneously while the rod or finger is removed to commence the flowofslurryintothecup. 6) Recordthetimestakenforflowofslurryfrommarshfunneltofill1U.S.quart;normally indicatedinmeasuringcupwithmarkingaroundtherimofcup.

TESTFORSANDCONTENT
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SandContentKit In the drilling industry, excessive sand content elevates the risk of drilling tools becoming "sandedin" if circulation stopped while the bit is within the bottom of bore hole, aside from addingtodragandwearonmovingpartsandtransportingpipelines. Inthefoundationindustry,excessivesandcontentelevatestheriskofslurryentrapment duringtheprocessoftremieconcretewhenupwarddisplacementofslurryishinderedbythe heaviersandparticles,asidefromaddingtodragandwearonmovingpartsandtransporting pipelines. TheSandContentTestKitmeasuresthevolumetricquantityofparticlesretainedonmesh200 sieves. Thetestkitconsistsofthefollowingcomponents: 1) Ataperedglassmeasuringtubewithvolumetricpercentgraduations. 2) Amesh200sievesetinanopenendedtube. 3) Afunneltofitthesievescreenandaidthetransferofwashedsandbackintothemeasurin gtube. TestProcedure 1) Checkthatthetestkitiscleanandfreefromdefects. 2) Pourtestsampleintotheglasstubeuntilitfillstothemarklabelled"MUDTOHERE"or10 0%marking. 3) Addwaterintoglasstubeandthumboverthemouthoftheglasstubewhileshakingconte nttodispersesandfromslurrygel. 4) Pourthecontentfromglasstubeontomesh200screen.Addmorewatertothetubeandw ashoutallcontentfromthetubeontothescreen. 5) Tipmorewaterthroughthescreenandtapthesideofthescreenwithasticktoencourage flowthroughthescreen,ifnecessary.(DoNOTstirormashthematerialonthescreen. ----------C 156 NORTH EAST LINE EXTENSION BORED PILING WORKS
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6) Capthefunneloverthesandretainingscreenandplacetheglasstubeattipoffunnel. 7) Inverttheassemblyandtipsomecleanwaterviatheoppositesideofsandscreentowash thesandintothetube. 8) Readthesandlevelandrecordthevolumetricpercentofsandcontentintestsample. 9) Washanddrytheinstrumenttakingcaretocleanbutnotdamagethemesh200screen.

TESTINGTHEpHVALUES
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PHPaper ThepHvalue,orHydrogenIondetermination,isverifiedinthefieldusingpHindicatorpapers orpHmeter.ApHvalueof7isneutral.pHvaluesbeloworabove7,shallrespectivelyindicate theacidicandalkalinenatureoftestsample. HighpHvalueinslurryisindicativeofcementiousinclusion,whilelowpHvaluemayindicate thepresenceofsaltinslurry,normallybroughtabouttowardsseaward,organicoratsalt depositedenvironment. Obtaining pH values by means of visual verification on indicator paper may give rise to subjective judgement amongst individuals, besides the tinting of colours introduced through dippinginslurry,whichmaynotatalltimebelightlycoloured. The pH value by means of pH meter eliminates subjective judgment. The sensitive nature of thiselectronicdeviceshallrequirecleansingimmediatelyafteruse,aswellasperiodicalchecks throughdipsinneutralizingsolution.Preventivemeasureisnecessarytoavoidshortcircuiting thedevicebyoversubmerginginslurry.Forthepurposeofclarity,thepHmeterisnominated.

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AppendixF KodenDrillingMonitorBrochuresandPhoto
SPECIFICATIONS
Recorder Unit
Standard Configuration
Recorder unit
Ultrasonic
Drilling Monitor
DMR-602 (DM-602) DMR-604 (DM-604) Power supply DMT-000 (Built into Recorder unit) DMT-001 DMT-002 DMT-003 DMW-001A (DM-602) Winch unit DMW-002A (DM604) Connecting cable CW-558 AC power cable CW-71 Spare parts kit Operation manual 93170152 Brief operation for DM-602 card for DM-604 250 x 20 mm (A3-560) Included in a vinyl bag Included in a vinyl bag Output connector: D-Sub 25 pin 2 2 2
Contained in an aluminum box Contained in an aluminum box For 100 VAC, contained in an aluminum box For 110 VAC, contained in an aluminum box For 220 VAC, contained in an aluminum box For 440 VAC, contained in an aluminum box With a sensor unit and cable With a sensor unit and cable With 15-pin connectors With 3-pin connectors Included in Recorder unit Contained in Recorder unit Contained in Recorder unit Contained in Recorder unit
47 kg 47 kg 10 kg 10 kg 10 kg 12 kg 121 kg 121 kg 10 m 10 m 1 set 1 1 1
DM-602/604
Koden promotes intelligent foundation work.
Spare Parts List
Measuring system Recording system DM-602 DM-604 Recording paper Measuring range Shift 0% (radius) 50% 100% Paper Constant speed feed Synchronized 1/40 rate with the depth 1/50 1/100 1/200 Measuring accuracy Depth mark PC display and storage Power supply protection circuit Power supply Power consumption
Recording paper DMP-250 Recording stylus DMS-001 Current feed stylus DMS-002
Optional Item
Operating temperature
Ultrasonic echo sensing system Direct recording in two directions (X-X' or Y-Y') Direct recording in four directions (X-X' and Y-Y') Electrosensitive recording paper 250 mm x 20 m (DMP-250) 0.5 m 1.0 m 2.0 m 4.0 m 0 to 0.5 m 0 to 1.0 m 0 to 2.0 m 0 to 4.0 m 0.25 to 0.75 m 0.5 to 1.5 m 1.0 to 3.0 m 2.0 to 6.0 m 0.5 to 1.0 m 1.0 to 2.0 m 2.0 to 4.0 m 4.0 to 8.0 m 7.5 mm/min, 15 mm/min, 30 mm/min and 60 mm/min 25 mm/m of sensor up/down movement 20 mm/m of sensor up/down movement 10 mm/m of sensor up/down movement 5 mm/m of sensor up/down movement 2% at full scale A depth mark is printed every 1 m and depth is automatically printed numerically every 5 m Serial data output provided (RS 232C cable: option) Equipped with two built-in non-fuse breakers (2 A and 8 A), a leakage breaker (20 A) and an overvoltage protection circuit 100 VAC, 50/60 Hz 110 VAC, 50/60 Hz 220 VAC, 50/60 Hz 440 VAC, 50/60 Hz 500 VA 700 VA 700 VA 700 VA (At 100 VAC) (At 110 VAC) (At 220 VAC) (At 440 VAC) -10C to +50C (14F to 122F)
RS 232C output port CW-384
Winch Unit
Up/down speed Up/down movement distance Bottom and casing sensing system Operating temperature
0 to 20 m / min 100 m maximum Automatic sensing by limit switch -10C to +50C (14F to 122F)
DIMENSIONS AND WEIGHT

Winch Unit
DMW-001A (DM-602) DMW-002A (DM-604)
740 (29 9/64) 700 (27 9/16)
Recorder Unit
DMR-602 (DM-602) DMR-604 (DM-604)
590 (23 15/64)
445 (17 33/64)
75 (2 61/64)
465 (18 10/32)
840 (33 5/64)
345 (13 37/64)
465 (18 5/16)
90 (3 9/16)
90 (3 9/16)
Sensor unit
45 (1 49/64)
1390 (54 3/4)
660 (26)
Weight: 57 kg (126 lb) (for 100/110/220 VAC) 59 kg (130 lb) (for 440 VAC)
1050 (41 11/32)
400 (15 3/4)
Unit: mm (inch)
Weight: 121 kg (267 lb)
Design and specifications are subject to change without notice.
To ensure proper and safe use of the equipment, please carefully Safety precaution read and follow the instructions in the Operation Manual.
750 (29 17/32)
Deeper excavation measurement in high accuracy Clear recording even in slurry contaminated with dirt and sand High quality excavation work reducing time and cost
Tamagawa Office: 2-13-24 Tamagawa, Ota-ku, Tokyo, 146-0095 Japan Tel: +81-3-3756-6501 Fax: +81-3-3756-6509 Uenohara Office: 5278 Uenohara, Uenohara-shi, Yamanashi, 409-0112 Japan Tel: +81-554-20-5860 Fax: +81-554-20-5875
For details, please contact:
www.koden-electronics.co.jp
06.10 PDF
overseas@koden-electronics.co.jp
www.koden-electronics.co.jp
The DM-602/604 helps improve the quality of a drilled hole and reduces working time and cost!
Main controls/switches
RANGE switch
Used for switching the measuring range (radius) in four steps of 0.5 m, 1 m, 2 m and 4 m (Photograph shown is DM-604 operation panel)
General
GAIN switch
Used for switching the gain control method to AUTO or MANUAL
CALIBRATION control
Used for calibrating the distance between the sensor and the wall face to the actual measured distance.
STC control (outer control)

Used for adjusting or eliminating irregular reflections near the oscillation line.
GAIN control (inner control)

Used for adjusting the receiving gain.
Recent progress and development in foundation engineering has resulted in great strides in excavation techniques. By using artificial slurry of high density and specific gravity, deeper excavation has been made possible. The DM602/604 series Drilling Monitor system has been developed in compliance with the users needs arisen from the recent construction environment to accurately measure and record the shape of a drilled hole of greater depth. It can be easily positioned and set up for measurement to provide quick and accurate recordings of excavations. The DM602/604 series Drilling Monitor provides the following advantages. Helps improve the quality of a drilled hole and reduces working time and cost. Provides on site records of the perpendicularity of drilled holes and the shape of cross sections in high accuracy. Provides numerical measurement data that can be easily imported into various Windows applications (Excel, Word, PowerPoint, etc.) for work reports, etc. (Option)
DEPTH RESET switch

Used to reset the depth record to 0 m.
SPEED/DEPTH display window

Used to display the speed and the depth of the sensor.
Features
External Power Supply Input POWER switch with circuit breaker WINCH connector Voltage meter POWER connector Non-fuse breaker RECORDER POWER switch UP/STOP/DOWN switch
MANUAL MARK switch

As long as it is set to ON, the manual mark is recorded on the recording paper.
PAPER SPEED switch (MENU) WINCH UP/DOWN SPEED control

Used for selecting sensor movement between up, down or stop. Used for controlling the sensor up or down speed (turning it to the right increases the speed). Used to change the paper speed in 4 steps in CONSTANT and PROPORTIONAL speed modes.
DRILLING HOLE MARK WIDTH switch

Used for setting the reference value (diameter) of the drilling hole on the wall face (in cm).
DATA PRINT/RECORD START & STOP switch

Used to start and stop recording as well as print text data.
The DM-602/604 supplies clear records of a drilled hole even in slurry, heavily contaminated with dirt and sand. The DM-602/604 supplies clear and precise records thanks to its unique signal processing technique that discriminates wall echoes from the noise. The DM-602/604 has the facility to cancel the oscillation line echo that often prevents very close echo recordings. The sensor device is automatically controlled to stop at the casing and at the bottom of the hole. An emergency return function is also included. Depth range mark, depth mark, drilled hole mark, date, time, etc. can be printed on the recording paper. Limit switches are provided to avoid possible wire breakage or entanglement of the wire and cable. The recorded result can be output to an external PC via a built-in RS 232C output port. (Option) A non-fuse circuit breaker is used for circuit protection, eliminating the need for cumbersome fuse replacement at the construction site.
X X'
Recording Examples
Y' YX' X
DM-602
DM-604
Drilling hole mark Wall face Depth mark (in 1-meter intervals) Depth mark (in 5-meter intervals)
The winch unit and recorder unit on site
Recording the echo of a drilled hole
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KODENPhotos
SettingofKodenRecorderbeforewithdrawingthesensorfromthetrenchbottom
RealtimeprintingontrenchverticalitybyKodenRecorder
KodensWinchUnit
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AppendixG PreliminaryTestPileT1andT2Instrumentationand ReinforcementDetailDrawing

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AppendixG PreliminaryTestPileT1andT2Instrumentationand ReinforcementDetailDrawing

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VibratingWireStrainGaugesTechnicalSpecification

AppendixH
VW embedment strain gages
51.5(Gage Length)
1235 1230 1240 1243
[ Model : 1235 ] 158 77(Gage Length) [ Model : 1230 ] 158 153(Gage Length) [ Model : 1240,1243 ]
19.8 19.8
1245
[ Model : 1245 ]
255 250(Gage Length)

19.8
[Dimension]
Description
VW Embedment strain gages are composed of a stainless steel tube with flanges at either end. Inside the tube is a steel strip near by the plucking coil that is held in tension between the ends of the tube. Strain in the concrete applied on the flanges is transmitted to the tube and a steel strip, changing in the tension of the strip. When the strip is plucked near by the plucking coil, it vibrates at its resonant frequency changed. This signal is transmitted to the VW readout unit. The readout unit processes the signal and displays a reading. The gage is equipped with a lightning protection to protect the sensor from electrical shock and a temperature device to compensate for temperature variations.
Applications
The model 1240 VW Embedment strain gage is designed to measure strain in reinforced concrete and mass concrete. The rosette block is used to mount 2~4 VW Embedment strain gage on steel members in four directions to measure the magnitude, distributed direction and trend of strain. The enclosure for no stress strain gages is used to verify difference of strain between no stress and loading conditions, and to find the trend of stress after embedded in dams and embankments. The model 1230 VW Embedment strain gage is useful for measuring strain toward tangential and radial directions in tunnel shotcrete. The model 1235 of the super small sized is applicable usefully when mock-tested with the gage of 51.5mm or there is the limit on the condition of establishment. The model 1243 is useful if being applicable in testing the concrete file improving steel as manufactured with the structure for high temperature able to were endurable at 200. The model 1245 as the gage with 250mm shows the excellent performance more than normal type model since the seal or compression is great big at the prestressed concrete.
Features
High stability and reliability Not affected by cable length and resistance Potted high graded epoxy to prevent against impact on the connecting cable. Extremely measured strain 300m H2O waterproof Built-in temperature device Built-in lightning protection device Employed permanent anti-corrosive materials Automated measurement is possible
Recommendation
Measured data of model 1230 is converted it into stress by multiplying conversion factor. It is important that they is installed with VW shotcrete cells to monitor changes in stress for rocks for radial stress if is possible. In embedment of model 1230 composed of a tangential and radial cell, the radial cell of them must be installed so that it ensures good physical contact between the cell and the surrounding rock.
The products contained in this catalogue can be changed without any notification for improving the products.
www.aceinstrument.com / acens@naver.com
VW embedment strain gages
Model Sensor element Range Resolution Accuracy Nonlinearity Coefficient of linear expansion Operating temperature Built-in temperature device Temperature device range Temperature device accuracy Gage length Gage factor Materials Built-in lightning protection device Weight Signal cable
1230 (Shotcreat) VW Type 3,000 microstrain 0.5 microstrain 0.1 FSR 0.5 FSR 1110
-6
1235 (Miniature)
1240 (Standard)
1245 (Long gage)
1243 (High temperature)
/ -29220 Optional : RTD( 2k) RTD : -45~100 RTD : 0.7 153 mm 3.304 250 mm 153 mm
-40~105 Standard : Thermistor (3k) Thermistor : -30~80 Thermistor : 1 77 mm 0.7756 51.5 mm 0.3911
Special stainless steel 300 series, High grade epoxy potting Gas tube arrester (Frequency output lines) 0.2 kg 0.3 kg 0.2 kg 2 4.5 mm, 0.24 mm 4C shielded PVC cable 5 m 2 5 mm, 0.25 mm 4C shielded silicon or Teflon shielded PVC cable 5m for Model 1243
The Readout
The VW Embedment strain gages output the equivalent frequency signal to inclination, with equivalent voltage to temperature of a Thermistor or RTD. It is connected to the system such as the VW readout units, data loggers to be data logging and data acquisition system to monitor readings. Ace's Readout unit ACE-800 (VW Palm size readout) ACE-1000 (VW Data recorder) Ace's Auto data acquisition system ACE-1100 (VW Mini logger) ARF-100 (RF Data acquisition system) We provide other companys data acquisition system (CR-10, DR515 etc.) after consulting the kind, amount of sensor, installing sites, operating manual or system.
Ancillary Equipments Universal terminal box (Model 7012/7024) Rosette block for four directions Enclosure case kit for no stress strain gages Mounting bracket for shotcrete
Mount Bracket for Rosette Block VW Shotcrete Gage (Model 1240)
Ordering Information
Keeping VW readout unit Cable length (Standard 5 meters)
[4-Direction Rosette Block]
[ Bracket for tunnel ]
[Installation kit of No-stress strain gage]
Signal Cable
Wiring or Tapping Arc Welding or Wiring

150
Enclosure Case Kit

500
Cement
VW Embedment Strain Gage
Reinforced bar
VW Embedment Strain Gage
200
Styrofoam
Bracket
[Kit of Model 1230]
[Installation in reinforced concrete]
[Installation kit of No-stress strain gage]
The products contained in this catalogue can be changed without any notification for improving the products.
www.aceinstrument.com / acens@naver.com
ForApproval REV0
AppendixI SequenceofBoredPileReinforcementCageTandemLifting
ForApproval REV0
AppendixJ RecordingSheet
PROJECT :
Date :
BORED PILE RECORD

a) PILE REF. NO. b) TOP OF CASING LEVEL (m) c) EXISTING GRD LEVEL (m) d) CUT-OFF LEVEL (m) e) BLIND BORING (m) f) PILE TOE LEVEL (m) g) PILE DIAMETER (mm) : : : : : : : h) WORKING LOAD (T) I) DEPTH FROM EGL (m) j) CON'C LENGTH (m) k) PAY LENGTH (m) l) CASING LENGTH (m) m) BORING RIG ID : : : : : : DENSITY VISCOSITY pH VALUE : : : POLYMER TEST
REMARKS
Initial
Before concreting / / /
BORING RECORD
COMMENCEMEN TIME DEPTH : DESCRIPTION COMPLETION : Reinforcement Cages : (m) Length : T.O.C. F.C.L.
GENERAL INFORMATION
C.O.L.
Rebar :
Min. Lap :
Links :
Method: Tremie / Dry Grade:
Theoretical Volume :
Actual Volume :
TOE LEVEL
% Overbreak :
Verticality
Pile Base Level
Overcast :
Time : SUBCONTRACTOR REPRESENTATIVE H MAIN CONTRACTOR REPRESENTATIVE QPS / PE (TERS) REPRESENTATIVE
Time :
NAME :
NAME :
NAME :
PROJECT :
Date :
BORED PILE CONCRETING RECORD

a) PILE REF. NO. b) DIAMETER (mm) c) DATE CAST d) TIME CAST : : : : e) TIME COMPLETE f) CONCRETE SUPPLIER g) CONCRETE GRADE : : :
CASTING TIME TRUCK No. START FINISH SLUMP (mm)
TEST CUBE TAKEN (nos)
VOLUME (m3)
ACCUM. VOLUME (m3)
THEORETICAL DEPTH OF CONCRETE (m)
ACTUAL DEPTH OF CONCRETE (m)
TREMIE PIPE ________ LENGTH (m) TOTAL LENGTH
TEMPERATURE ()
REMARKS
CUT
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
REMARKS :
SUBCONTRACTOR REPRESENTATIVE
MAIN CONTRACTOR REPRESENTATIVE
SQPS / PE (TERS) REPRESENTATIVE
NAME :
NAME :
NAME :
PROJECT : C907
Pile Reference No: Inspection Checklist for Reinforcement Cage Cage 1 (Top) Cage 2 Cage 3 Cage 4 Cage 5 Cage 6 (Bottom)
Date: Remark
S/n Process Description o 1 Cages Identification 2 3 4 5 6 7 8 9 Cage Length & Size Nos and Size of Rebars Lap Length Sufficient Equal Spacing of Main Bars Equal Spacing of Shear Links Nos. of U-Bolts Proper Tightening of U-Bolts Proper fixing of wire to rebars
10 Cage Cleanliness 11 150mm Inclinometer Reservation Tubes 12 50mm Sonic Logging Pipes 13 Plunge-In Column Type 14 Others
Please indicate: Enough / O.K. = Not Enough = X (To add / adjust) Not Applicable = Nil Checked By: Checked By: Checked By:
Sub-Con Representative
Main-Con Representative
QPS / PE (TERS) Representative
CONCRETING CHART Project:

Tremie Pipe
Panel No:
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Date:
T1
T2
T3
Depth (meters)
18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280
Concrete volume (cubic metres) Comments
Signed as a correct record Tuksu E&C Samsung E&C OPS Represntative Signature Signature Signature Date Date Date
BENTONITE TEST RECORD

PROJECT: Section: DATE: PILE No: Sheet Number BENTONITE AS SUPPLIED TO THE PILE TYPE OF TEST Density Marsh Viscocity pH Fluid Loss (30mins) Max. Filter Cake Thickness Sand Content UNITS g/cm ml mm %
3
ALLOWABLE LIMITS FRESH 1.02 30 - 36 8 - 10 N/A N/A N/A RE-USED 1.02 - 1.30 30 -90 8 - 12 N/A N/A N/A
ACTUAL RESULTS FRESH RE-USED
seconds
BENTONITE IN PILE PRIOR TO PLACING CONCRETE TYPE OF TEST Density Marsh Viscocity pH Fluid Loss (30mins) Max. Filter Cake Thickness Sand Content Comments: UNITS g/cm ml mm %
3
ALLOWABLE LIMITS FRESH 1.02 30 - 36 8 - 10 30 1.0 0.5 RE-USED 1.02 - 1.10 30 -90 8 - 12 40 3.0 3
ACTUAL RESULTS FRESH RE-USED
seconds
NOTE: Figures shown (.) are to be used unless otherwise specified
Prepared by Tuksu Engineering & Construction Name: _____________________ Signed _________________ Date ________________
Checked and Verified by Client's Representative (Samsung E&C) Name: _____________________ Checked and Verified by QPS Name: _____________________ Signed _________________ Date ________________ Signed _________________ Date ________________
PILE LOAD TEST RECORDS

Contract No Pile Group/No Date Installed Date Time Load (Tons) % Project: Type of Pile Penetration TBM Reading 1 2 A Scale Reading B C A Difference B C Average A (mm) Pile Size Working Load Test Load Dial Gauge B C Average D (mm)
Page:_______of______
Remark
TUKSU Engineering & Construction's Site Representative
Samsung E&C 's Site Representative
QPS' Site Representative
Name & Date
Name & Date
Name & Date
ForApproval REV0
AppendixK HBeamColumnDesignCalculation
GeoEng Consultants
C 156 MCE 486 Temporary Services of Bore PilePiling Construction NorthWorks Southand Line Extension - Bored Works
Scrap Bin Design Check TENSION TEST PILE T1 & T2

REACTION PILE, PLUNGE COLUMN &
TRANSFER BEAM DESIGN
Document No:
GECPL/DOC-3162/GN/10.089
Submitted to: Tuksu Engineering and Construction (s) Ltd.
Revision: -
Date: th January 2010 819th March 2010
23 New Industrial Road #04-05 Century Industrial Building Singapore 536209 Tel: 6546-6318 * Fax: 6546-6319 * E-mail: geoeng@singnet.com.sg
PRELIMINARY TENSION TEST PILE SET UP
1.0 INTRODUCTION
The report details the design of reaction pile, pilecap, plunge column and transfer beam for tension pile test set up for site C 156. There are 2 number of tension piles that will be tested, which are tension pile C1 and C2. Both tension pile is 1200mm diameter and the maximum tension test load is 12,147 kN. The tension pile information is attached in the report.
2.0 DESIGN
The reaction for the tension load test will be provided by 2 nos of 1.5m diameter compression bored pile installed with 8m socket into OA layer. The test pile will be pulled up using plunge column and the loads will be transferred to tansfer beam and main beam. Note that the main beam for this pile test will be designed in a separate report.
(B) C. DESIGN OF TRANSFER FRAME ARRANGEMENT

1. Forces Maximum test load Factor of safety Factored design load Q
m
12500 1.4 17500
kN kN
2. Material and Dimensions Section: 356x406x634kg/m py D (mm) 474 B (mm) 424 T (mm) 77 pw 325 t (mm) 48 250 N/mm2 r (mm) 15.2 N/mm2 (S355) Iy (cm4) 98200 Zy (cm3) 4640 Sy (cm3) 7108
Yield strength A (cm2) 806 Weld strength
Class 42 electrode
Section to Column Weld Weld size Weld length = D+B-4r-t Plates Plate yield strength Plate thickness Plate width
s1 lw
40 789.2
mm mm
pyp tp bp
335 50 498
N/mm2 mm mm
(S355)
Plate to Section and Section Flange to Column Weld Full single partial penetration butt welds. So for flange to column weld check not necessary as they are same size same member. Plate to section needs to check by taking weld to be parent member strength as plate is thinner. 3. Design Check - Shear Shear force on each section Shear area Shear capacity Fv Av Pv 8750 65296 12733 OK > Fv kN mm2 kN = Q/2 = 2TB =0.6pyAv
4. Design Check - Moment Load centroid from edge Moment Moment capacity of section Moment capacity of plates Moment capacity of welds Total moment capacity x M Mc1 Mc2p Mc2w Mc 400 3500 1810 3954 2342 4152 OK > M mm kNm kNm kNm kNm kNm
= Qx/4 = py. min (1.2Zy, Sy) = py. (B+tp).(tpbp) =0.7pw.s1lwB = Mc1.+ min(Mc2p, Mc2w)
5. Design Check - Plate to Section Butt Weld Combined moment of inertia Force on welds Resistance of butt welds Ic Fw Pw
4 238060.81 cm 10.85 kN/mm 16.25 kN/mm OK > Fw
= Iy + tpbp.(B+tp)2/4 = Fvbptp(B+tp)/4Ic = pytp
(C) D. PLUNGE IN COLUMN

1. Forces Test pile diameter Bored concrete cube strength Maximum test load Factor of safety Factored design load 2. Section Axial Capacity Section yield strength Section area Capacity D fcu Q
m
1500 40 12500 1.4 17500
mm N/mm2 kN kN
py A PT
325 806 261950 OK > Q
N/mm2 cm2 kN
(S355) = pyA
3. Headed Stud Shear Connector Diameter of studs Overall height of studs Nos. of vertical rows Nos. of studs per flange per row Nos. of studs on both sides of web Total nos. of studs Vertical spacing of studs Lateral spacing of studs Effective extent of stud bond Nominal static strength Design static strength Total capacity from studs
d h nz nf nw N sz sx L Qk Qu NQu
25 100 23 3 0 138 150 150 3300 168 134 18492 OK > Q 3547500 577500 4125000 20625 OK > Q
mm mm
mm mm mm kN kN kN
OK >5d OK >4d = (nz-1)sz =0.8Qk
OK <600mm
Flange stud concrete shear area (flange) Flange stud concrete shear area (web) Total shear area Concrete shear resistance
Acv Vr
mm2 mm2 mm2 kN
= 2(2h+(nf-1)sx+1.5d)L = 2(2h+(nw-1)sx+1.5d)L = 0.8fcu1/2Acv where 0.8fcu1/2 <= 5N/mm2
4. Pile Rebar Bond Rebars nos. Layer 1 Layer 2 n T T d Lb fb Pb 35 40 25 47.2 2550 3.16 41820 OK > Q mm mm N/mm2 kN
Equivalent diameter Bond length Bond unit capacity Bond capacity
=L-D/2 (where D is pile dia) =0.5fcu1/2 =nfb dLb
ForApproval REV0
DiagrammaticSequenceforHBeamColumnInstallation

AppendixL
Prepared by:

Stage 1 1. Concreting of working test pile.
Sequence of H-Beam Installation by Plunge-In Method

Stage 2 1. Continue concreting works by allowing the concrete to overflows out from the casing. 2. Concrete placing will be stop until visible sign of good quality concrete overflows out from the casing. Stage 3 1. Extract out the tremie pipe from the borehole.
Page 1 of 2
Placing concrete by tremie method
Placing concrete by tremie method
Pumping of displaced bentonite slurry

Allowed concrete to overflow until appearance of good quality concrete Allowed concrete to overflow until appearance of good quality concrete Temporary Outer Casing
Concrete
Temporary Outer Casing Inner De-bond Casing
Inner De-bond Casing
Inner De-bond Casing
Bentonite Slurry
Bentonite Slurry
Bentonite Slurry
MC Layer
MC Layer
MC Layer
Preliminary Test Pile
Prepared by:

Stage 4
Sequence of H-Beam Installation by Plunge-In Method

Stage 5 1. Lift and installed the H-Beam guide by the temporary guide frame. 2. Plunge the H-Beam to the depth based on the design embedment depth. 3. Securely weld the H-Beam into the position.
Page 2 of 2
1. Lift and installed the H-Beam guide by the temporary guide frame. 2. Plunge the H-Beam to the depth based on the design embedment depth.
H-Beam Plunging the HBeam into the Preliminary Test Pile through the guide casing
H-Beam
Pre-Installed Guide Casing
Inner Debond Casing
Required embedment depth for H-Beam based on PE Design Calculation
ForApproval REV0
AppendixM
ReactionPileDesignCalculationandReinforcementDetail
GeoEng Consultants
C 156 MCE 486 Temporary Services of Bore PilePiling Construction NorthWorks Southand Line Extension - Bored Works
Scrap Bin Design Check TENSION TEST PILE T1 & T2

REACTION PILE, PLUNGE COLUMN &
TRANSFER BEAM DESIGN
Document No:
Submitted to: Tuksu Engineering and Construction (s) Ltd.
Revision: -
Date: th January 2010 819th March 2010
23 New Industrial Road #04-05 Century Industrial Building Singapore 536209 Tel: 6546-6318 * Fax: 6546-6319 * E-mail: geoeng@singnet.com.sg
PRELIMINARY TENSION TEST PILE SET UP
1.0 INTRODUCTION
The report details the design of reaction pile, pilecap, plunge column and transfer beam for tension pile test set up for site C 156. There are 2 number of tension piles that will be tested, which are tension pile C1 and C2. Both tension pile is 1200mm diameter and the maximum tension test load is 12,147 kN. The tension pile information is attached in the report.
2.0 DESIGN
The reaction for the tension load test will be provided by 2 nos of 1.5m diameter compression bored pile installed with 8m socket into OA layer. The test pile will be pulled up using plunge column and the loads will be transferred to tansfer beam and main beam. Note that the main beam for this pile test will be designed in a separate report.
GeoEng Consultants
PROJECT:
C 156
Sheet No.: Date: Designed By:
of
REF:
Tension Pile Test Set Up Check
Checked By:
Tension test pile Information: Tension pile diameter = Tension working load = M ax tension test load = 1200 mm 4,049 kN 12,147 kN
(A) Reaction Pile & Pilecap Design: Reaction pile diameter No of reaction pile fcu Penetration length into OA, l M ax Tension test load Tension test load Load taken by reaction pile = = = = = 1500 2 40 8 12,147 mm N/mm2 m kN = = = 12,147 kN 12,147 / 2 6,074 kN
(i) Structural capacity Check Pile structural capacity = = = M IN (7.5M pa OR 0.25fcu) x Ab 7.5 x 1000x pi x 1.5^2 / 4 13,254 kN > 6,074 kN
(OK!)
(ii) Geotechnical capacity Check By considering only OA layer contribute to pile geotechincal capacity, pile penetrates 8m into OA layer, [Note: Using the borehole with worst soil profile (NS 015) , top of OA layer is at RL41.2m] Avearge SPT N value Pile skin friction = = = = = = = = = = = = 65 pi x D x l x fs pi x 1.5 x 8 x 2(65) 4900 kN 50 N 50 x 100 5000 kN 4900 + 5000 9,900 kN 1.5 9,900 / 6,074 1.63 > 1.5
(Note: fs = 2N)
Pile end bearing
(SPT N at toe of pile = 100)
Pile geotechnical capacity
M in Geotechnical FOS Geotechnical factor
(OK!)
Nominal steel reinforcement area, As= 0.5% Ac: Hence provide nominal rebar of 20T25 full length for the reaction pile, with links T10-250
PROJECT: C156 REF: PILECAP FOR REACTION PIL DESIGNED BY: GN CHECKED BY: TG
GeoEng Consultants (S) Pte Ltd 23 New Industrial Road #04-05 Century Industrial Building Singapore 536209 TEL: 6546 6318 FAX: 6546 6319
PILECAP DESIGN
PILE TYPE B (mm) H (mm) Min. Rebar 0.13%BH As min (mm2) As /bar bar dia (mm) no. bar req no. bar prov As prov Spacing Bored pile 2400 (both sides) 1200 3744 491 25 8 12 5890 T25-205
Design Information : Reaction pile diameter= Number of pile = fcu = 1500 1 40 mm for each pilecap N/mm2
PILE CAP Dimension
D (mm) 1200
C (mm) 1200
H (mm) 1200
Bottom Rebar 'X' 'Y' T25-200 T25-200
Binder 'Z' T13-150
Hence prov ide T25-200 at bottom of pilecap f or both directions and links of T13-150.
ForApproval REV0
AppendixN
TensionTestSettingUpLayoutDrawingforPreliminaryTestPileT1 andT2
ForApproval REV0
AppendixO MainReactionBeamDesignCalculation
ForApproval REV0
SeparateSubmission
ForApproval REV0
AppendixP
LoadingSequenceforPreliminaryTestPileT1andT2
Pile No. Pile Diameter Working Load Maximum Test Load 1st Cycle Load Cycle Number 1st Cycle Load (% of WL) % of NSF
: : : (WL)*(3.0) + (NSF)*(1.0) :
T1 1200 4035 12105.0
mm kN kN
NSF:
0 KN
Load (kN)
Time
2nd Cycle
3rd Cycle
0% 0% 25% 50% 75% 100% 75% 50% 25% 0% 0% 0% 0% 0% 25% 75% 100% 125% 150% 125% 100% 75% 25% 0% 0% 0% 0% 0% 25% 50% 75% 100% 125% 150% 175% 200% 225% 250% 275% 300% 300% 250% 200% 150% 100% 50% 0% 0%
0% 100% 100% 100% 100% 100% 100% 100% 100% 100% 0% 0% 0% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 0% 0% 0% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 0% 0%
0 0 1008.75 2017.5 3026.25 4035 3026.25 2017.5 1008.75 0 0 0 0 0 1008.75 3026.25 4035 5043.75 6052.5 5043.75 4035 3026.25 1008.75 0 0 0 0 0 1008.75 2017.5 3026.25 4035 5043.75 6052.5 7061.25 8070 9078.75 10087.5 11096.25 12105 12105 10087.5 8070 6052.5 4035 2017.5 0 0
0855 0900 1000 1100 1200 1800 1810 1820 1830 1930 0855
Minimum Holding Period 60 mins 60 mins 60 mins 60 mins 6 hrs 10 mins 10 mins 10 mins 10 mins 60 mins 10 mins 10 mins 10 mins 6 hrs 60 mins 6 hrs 10 mins 10 mins 10 mins 10 mins 10 mins 60 mins 10 mins 10 mins 10 mins 10 mins 10 mins 10 mins 60 mins 60 mins 60 mins 60 mins 60 mins 60 mins 60 mins 24 hrs 10 mins 10 mins 10 mins 10 mins 10 mins 10 mins
Day
Action
900 1500 1600 2200 2210 2220 2240 2250 2350 0855 900 1000 1100 1200 1300 1400 1500 1600 1700
900 1000 1100 1400 1600 1700 1800
Take initial reading Leave until settlement < 0.25mm/hr Leave until settlement < 0.25mm/hr Leave until settlement < 0.25mm/hr Leave until settlement < 0.25mm/hr Maintain for 6 hours Leave until rebound < 0.25mm/hr Leave until rebound < 0.25mm/hr Leave until rebound < 0.25mm/hr Leave until rebound < 0.25mm/hr Leave until rebound < 0.25mm/hr Take final reading Take initial reading Leave until settlement < 0.25mm/hr Leave until settlement < 0.25mm/hr Leave until settlement < 0.25mm/hr Maintain for 6 hours Leave until settlement < 0.25mm/hr Maintain for 6 hours Leave until rebound < 0.25mm/hr Leave until rebound < 0.25mm/hr Leave until rebound < 0.25mm/hr Leave until rebound < 0.25mm/hr Leave until rebound < 0.25mm/hr Leave until rebound < 0.25mm/hr Take final reading Take initial reading Leave until settlement < 0.25mm/hr Leave until settlement < 0.25mm/hr Leave until settlement < 0.25mm/hr Leave until settlement < 0.25mm/hr Leave until settlement < 0.25mm/hr Leave until settlement < 0.25mm/hr Leave until settlement < 0.25mm/hr Leave until settlement < 0.25mm/hr Leave until settlement < 0.25mm/hr Leave until settlement < 0.25mm/hr Leave until settlement < 0.25mm/hr Leave until settlement < 0.25mm/hr Maintain for 24 hours Taking reading Leave until rebound < 0.25mm/hr Leave until rebound < 0.25mm/hr Leave until rebound < 0.25mm/hr Leave until rebound < 0.25mm/hr Leave until rebound < 0.25mm/hr Leave until rebound < 0.25mm/hr Taking Final Reading after 6 hrs
Testing Criteria Testing shall be continued until the maximum test load has been reached or when settlement exceeds 10% of pile diameter (CDC A5-6.5.1).
Pile No. Pile Diameter Working Load Maximum Test Load 1st Cycle Load Cycle Number 1st Cycle Load (% of WL) % of NSF
: : : (WL)*(3.0) + (NSF)*(1.0) :
T2 1200 mm 4049 kN 12147.0 kN
NSF:
0 KN
Load (kN)
Time
2nd Cycle
3rd Cycle
0% 0% 25% 50% 75% 100% 75% 50% 25% 0% 0% 0% 0% 0% 25% 75% 100% 125% 150% 125% 100% 75% 25% 0% 0% 0% 0% 0% 25% 50% 75% 100% 125% 150% 175% 200% 225% 250% 275% 300% 300% 250% 200% 150% 100% 50% 0% 0%
0% 100% 100% 100% 100% 100% 100% 100% 100% 100% 0% 0% 0% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 0% 0% 0% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 0% 0%
0 0 1012.25 2024.5 3036.75 4049 3036.75 2024.5 1012.25 0 0 0 0 0 1012.25 3036.75 4049 5061.25 6073.5 5061.25 4049 3036.75 1012.25 0 0 0 0 0 1012.25 2024.5 3036.75 4049 5061.25 6073.5 7085.75 8098 9110.25 10122.5 11134.75 12147 12147 10122.5 8098 6073.5 4049 2024.5 0 0
0855 0900 1000 1100 1200 1800 1810 1820 1830 1930 0855
Minimum Holding Period 60 mins 60 mins 60 mins 60 mins 6 hrs 10 mins 10 mins 10 mins 10 mins 60 mins 10 mins 10 mins 10 mins 6 hrs 60 mins 6 hrs 10 mins 10 mins 10 mins 10 mins 10 mins 60 mins 10 mins 10 mins 10 mins 10 mins 10 mins 10 mins 60 mins 60 mins 60 mins 60 mins 60 mins 60 mins 60 mins 24 hrs 10 mins 10 mins 10 mins 10 mins 10 mins 10 mins
Day
Action
900 1500 1600 2200 2210 2220 2240 2250 2350 0855 900 1000 1100 1200 1300 1400 1500 1600 1700
900 1000 1100 1400 1600 1700 1800
Take initial reading Leave until settlement < 0.25mm/hr Leave until settlement < 0.25mm/hr Leave until settlement < 0.25mm/hr Leave until settlement < 0.25mm/hr Maintain for 6 hours Leave until rebound < 0.25mm/hr Leave until rebound < 0.25mm/hr Leave until rebound < 0.25mm/hr Leave until rebound < 0.25mm/hr Leave until rebound < 0.25mm/hr Take final reading Take initial reading Leave until settlement < 0.25mm/hr Leave until settlement < 0.25mm/hr Leave until settlement < 0.25mm/hr Maintain for 6 hours Leave until settlement < 0.25mm/hr Maintain for 6 hours Leave until rebound < 0.25mm/hr Leave until rebound < 0.25mm/hr Leave until rebound < 0.25mm/hr Leave until rebound < 0.25mm/hr Leave until rebound < 0.25mm/hr Leave until rebound < 0.25mm/hr Take final reading Take initial reading Leave until settlement < 0.25mm/hr Leave until settlement < 0.25mm/hr Leave until settlement < 0.25mm/hr Leave until settlement < 0.25mm/hr Leave until settlement < 0.25mm/hr Leave until settlement < 0.25mm/hr Leave until settlement < 0.25mm/hr Leave until settlement < 0.25mm/hr Leave until settlement < 0.25mm/hr Leave until settlement < 0.25mm/hr Leave until settlement < 0.25mm/hr Leave until settlement < 0.25mm/hr Maintain for 24 hours Taking reading Leave until rebound < 0.25mm/hr Leave until rebound < 0.25mm/hr Leave until rebound < 0.25mm/hr Leave until rebound < 0.25mm/hr Leave until rebound < 0.25mm/hr Leave until rebound < 0.25mm/hr Taking Final Reading after 6 hrs
Testing Criteria Testing shall be continued until the maximum test load has been reached or when settlement exceeds 10% of pile diameter (CDC A5-6.5.1).
ForApproval REV0
AppendixQ
TentativeScheduleforPreliminaryTestPileConstructionand TestingTensionLoadTest
TENTATIVE WORK PROGRAMME FOR PRELIMINARY TEST PILE CONSTRUCTION AND TESTING
ID 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Task Name Duration Start Finish -1 Tue 6/1/10 93 days March 1 2 3 4 April 5 May 6 7 8 9 10 11 12 13
CONTRACT 156 - NORTH SOUTH LINE EXTENSION

June July 14 15 16 17 18 19 Construction and Testing for Preliminary Test Pile
Construction and Testing for Preliminary Test Pile Design Submission Method Statement for Kentledge Test Method Statement for Tension Test PE Design Submission for works related to Preliminary Test Pile Mobilisation and Setting Up Mobilisation and Setting Up for PTP Construction Preliminary Test Pile By Kentledge Method Installation of Preliminary Test Pile Installation of PTP C1 Installation of PTP C2 Assembling and Testing of Preliminary Test Pile by Kentledge PTP C1 PTP C2 Preliminary Test Pile By Tension Preliminary Test Pile By Tension Method Installation of PTP T1 Installation of PTP T2 Assembling and Testing of Preliminary Test Pile by Tension PTP T1 PTP T2 Mobilisation and Demobilisation Demob from PTP C1 and T1 and Mob to PTP C2 Demob from PTP C2 and Mob to PTP T2
93 days
Mon 3/1/10
28 days 6 days 10 days 21 days
Mon 3/1/10 Mon 3/1/10 Sun 3/7/10 Mon 3/8/10
Sun 3/28/10 28 days Sat 3/6/10 6 days Tue 3/16/10 Sun 3/28/10 21 days
Design Submission Method Statement for Kentledge Test
PE Design Submission for works related to Preliminary Test Pile Construction
21 days 21 days
Mon 3/15/10 Mon 3/15/10
Sun 4/4/10 Sun 4/4/10
21 days 21 days
Mobilisation and Setting Up Mobilisation and Setting Up for PTP Construction
49 days 18 days 2 days 2 days 19 days 3 days 3 days 51 days 21 days 2 days 2 days 21 days 2 days 2 days 17 days 7 days 7 days
Mon 4/5/10 Mon 4/5/10 Mon 4/5/10 Wed 4/21/10 Wed 5/5/10 Wed 5/5/10 Fri 5/21/10 Mon 4/12/10 Mon 4/12/10 Mon 4/12/10 Sat 5/1/10 Wed 5/12/10 Wed 5/12/10 Mon 5/31/10 Wed 4/14/10 Wed 4/14/10 Sat 4/24/10
Sun 5/23/10 Thu 4/22/10 Tue 4/6/10 Thu 4/22/10 Sun 5/23/10 Fri 5/7/10 Sun 5/23/10 Tue 6/1/10 Sun 5/2/10 Tue 4/13/10 Sun 5/2/10 Tue 6/1/10 Thu 5/13/10 Tue 6/1/10 Fri 4/30/10 Tue 4/20/10 Fri 4/30/10
49 days 18 days 2 days Installation of Preliminary Test Pile Installation of PTP C1 2 days Installation of PTP C2 19 days 7 days setting up + 2 days test PTP C1 7 days setting up + 2 days test 51 days 21 days 2 days Installation of PTP T1 2 days
Preliminary Test Pile By Kentledge Method
Assembling and Testing of Preliminary Test Pile by Kentledge
PTP C2 Preliminary Test Pile By Tension
Preliminary Test Pile By Tension Method
Installation of PTP T2 21 days Assembling and Testing of Preliminary Test Pile by
7 days setting up + 2 days test PTP T1 7 days setting up + 2 days test 17 days 7 days Mobilisation and Demobilisation Demob from PTP C1 and T1 and Mob to PTP C2 7 days Demob from PTP C2 and Mob to PTP T2
PTP T2
Task Split
Progress Milestone
Summary Project Summary
External Tasks External Milestone
Deadline
Page 1
ForApproval REV0
AppendixR
RiskAssessment
RISK ASSESSMENT FORM PRELIMINARY TEST PILE CONSTRUCTION

Company: Worksite: Process/ Location: Work scope : Samsung Engineering and Construction Approved by: (Name, designation) (Date) Tuksu Engineering & Construction, Ltd. C156 North South Line Extension PTP T1 and PTP T2 Preliminary Test Pile Construction Park Hong Shin Project Manager Youn Man Hyun Construction Manager Tuksu Engineering & Construction Conducted by: (Names, designations) (Date) Last Review Date: Song Ju Hun (Project Manager) Park In Ho (Construction Manager) Ramasamy (Safety Co-ordinator) Next Review Date:
Safety Supervisor
S/No
Description of Work Activity
Hazards Identified
Initial Risk Index
Proposed Control Measures
Residual Risk Index
Remarks
F
a) Traffic accident during transportation. 1 Mobilization & Demobilization b) Injuries or fatalities cause by collapse of equipment or material 2
S R
3 6 a) Provide watchman / traffic warden to control traffic. b) Ensure that equipments are properly rigged by experienced rigger, inspect all sling and wire rope.
F
2 2
S
2 2
R
4 4 Site foreman Lifting sup.
a) Accidental movement of crane &/ or its components due to certain controls not moved to neutral position 2 3 6
a) Crane operator to be currently registered with MOM on the same type / class of crane he operates and must be in good health. b) Check all controls are returned to neutral position or locked beforehand. c) Submit crane manufacturers manual, valid LM & LA / LG certificates prior to mobilization to main contractor for verification & acceptance d) Carry out daily pre-operation checks 2 2 4 Site foreman Lifting sup.
Powering / Starting up of crane b) Failure of crane systems / components
e) Quarterly maintenance by mechanic for crane on site. f) 6 monthly inspection by Approved Person (AP) for crane on site g) Prepare & submit Permit to work for any lifting operation
S/No
Hazards Identified
Initial Risk Index
Residual Risk Index
Remarks
F
a) Fire
S R
a) Overloading causes overheating and fires.
F
2 b) Maintain all electrical equipment. a) Qualified electrician is allowed to carry out all electrical connections. b) All electrical switchgears must be well insulated, isolated and connected to earth. c) Conduct regular inspection of electrical connections and equipment, properly recorded. d) All temporary electrical inspected by Licensed Electrical Worker (LEW). a) Hand gloves, ear plugs and goggles must be worn as required. b) Conduct tool box meeting on proper use of tools. c) Follow manufacturers instruction on proper usage. a) Boring Rigs with LM certificate must be submitted and confirmed by main contractor prior to commencement of work. b) Conduct daily check by operator and regular inspection and maintenance by mechanic. c) Maintenance tag shall be pasted on the piling rig. Only competent personnel shall operate the piling rig and shall submit his valid operators certificate to main contractor. a) Licensed cable detection survey to be conducted before trial trench. b) Trial trench to be carry out along sheet pile and king posts locations c) To ensure sufficient clearance between utilities ands CBP. a) Provide PEs Design & calculations for crane access and provide firm and stable platforms or steel plates / hardcore. 2
S
2
R
4 Const. Manager LEW HSE sup.
b) Electric shocks/explosion/burns 3
Usage of generator
Hand and Power Tools 4
Personal Injuries 1 3 3
Site foreman
a) Defective piling Rigs
5a
General: Piling works
b) Unqualified Piler
Const. Manager Lifting sup. Operator
c) Damage to underground utilities
5b
Moving of Piling /Boring Rig
a) Toppling of Piling/ Boring Rig due to soft ground b) Property Damage
b) Weekly checking on the crane access by site engineer and banks man to guide machinery c) Conduct daily tool box meeting.
Const. Manager Lifting sup. Operator
S/No
Hazards Identified
Initial Risk Index
Residual Risk Index
Remarks
F
a) Piling Rig moving parts injuring workers 2
S R
2 4 a) Ensure workers stay clear of rig during piling/ boring. b) Conduct regular tool box meeting; ensure that guards are placed at appropriate areas. a) Provide PE endorsed calculation on trench stability. b) Ensure the bentonite level in the borehole maintained as per the trench stability calculation 6 c) Ensured sufficient bored earth beside the borehole for immediate backfilling during collapsed. a) Provide sufficient casing length beyond the Fill layer b) Ensure the borehole attended by banks man full time for 4 during the boring works c) Planning for the boring works so that the borehole is not left unattended for period of more than 2 days. a) Conduct tool box meeting to workers on all safe practices of lifting operation shall be observed with the followings: b) Valid certificate of lifting gear and appliances with main contractor code must be provided prior to use. c) Ensure all connections are securely fastened. d) Provide appointed and qualified Lifting supervisors, rigger and signalman during lifting operations. e) Wear safety Helmets 6 f) Workmen should not stand under the hoisting path. g) Crane operator to have a clear view on the operation area. h) Lifting supervisor is brief to be present to oversee the hoisting operation at all times and check for valid LG and defects. I) Implement Lifting Permit j) Cordon of lifting area k) Provide Lifting Plan for critical lift and in public areas a) Workmen appointed to guide the moving truck during reversing b) Vehicle driver to ensure that nobody is standing behind 4 the vehicle while reversing c) Provide sufficient lightings at the path of the reversing vehicle in the night.
F
1
S
2
R
2 Const. Manager Lifting sup. Operator
5c
Boring Works
b) Collapsed of Borehole
Const. Manager/ Site Engineer
c) Sudden drop of bentonite level
Const. Manager/Site Engineer
a) Struck by Lifting object
Const. Manager/Site Engineer/ Site Foreman/ Lifting sup. Operator
5d
Bore Piling concreting work and Lifting Operations
b) Hit by moving concrete truck.
Lifting sup. Site foreman
c) Tremie Pipe Choked
a) Ensured that all tremie pipe connection are water tight an sealing tape. b) Ensured that the tremie pipes are regulary check for dent defects 1 c) Ensure that the concrete slump is at the requires workabi and reject the dry slump if necessary d) Provide steel strainer on tremie hopper to filter any object than 50mm.
Constr. Manager/ Site Engineer/Site Foreman
S/No
Hazards Identified
Initial Risk Index
Residual Risk Index
Remarks
F
5d Bore Piling concreting work and Lifting Operations c) Workers falling into the Borehole a) Ultraviolet radiation 2
S R
2 4 a) Ensure all bored casing into ground must be protruded at least 600mm to 1meter above ground. b) Effective barricades and displayed of danger signs must be provided immediately if casing is to leave overnight. a) Use approved eye protection equipment and apron b) Use screens to protect other personnel a) To ensure all electrode holders, welding cables, cable connectors and other welding equipment are properly insulated and ensure all welding sets fitted with an effective low voltage shock prevention device. b) No person is permitted to carry out arc welding in wet condition. c) Qualified electrician must carry out all connections on electrical powered equipment. a) Ensure substandard materials not used on site. b) Certified welders to be deployed and conduct welding tests.
F
1 1
S
2 3
R
2 3
Site engineer Site foreman Operator
2 2
3 3
6 6
b) Potential electrical hazard sparks causing injury
Site foreman Welder
Cutting & welding of bore casing and reinforcement cage
c) Substandard materials and welding works
Const. Manager Site engineer
Note: F Frequency of Occurrence; S Severity of Hazard; R Risk Index TABLE 1 : ACCIDENT FREQUENCY
Likelihood Frequent Probable Occasional Remote Improbable
Rating 5 4 3 2 1
Description Likely to occur repeatedly Likely to occur more than once Could possibly occur Unlikely to occur Extremely unlikely to occur based on judgement and where possible, supported by industry experience
TABLE 3:
RISK INDEX MATRIX
Severity (S) Likelihood (L) Accident Frequency Category (5) (4) (3) (2) (1) Frequent Probable Occasional Remote Improbable
Accident Severity Category (4) Catastrophic 20 16 12 8 4 (3) Major 15 12 9 6 3 (2) Serious 10 8 6 4 2 (1) Minor 5 4 3 2 1
TABLE 4: Risk Index 1-2 3-5
DEFINITION OF RISK INDEX Description Acceptable Moderately Acceptable Definition Further action may not be necessary Further action is to be taken where reasonably practicable to do so. Management attention is required. A careful evaluation of the hazards should be carried out to ensure that the risk level is reduced to as low as is practicable within a defined period of time. Interim risk control measures, such as administrative controls, may be implemented. Immediate management intervention is required before work commences. Very high risk level must be reduced to at least Medium Risk before work commences. There should not be any interim risk control measures and should not be overly dependent on personal protective equipment or appliances. If need be, the hazard should be eliminated before work commences.
6-11
Not acceptable
12-20
Strictly Not acceptable
Risk Assessment Form - Preliminary Tension Load Test by Reaction Method

Company: Worksite: Process/ Location: Work scope : Samsung Engineering and Construction Approved by: (Name, designation) (Date) Tuksu Engineering Conducted by: & Construction, Ltd. (Names, designations) (Date) C156 North South Line Extension PTP T1 and PTP T2 Preliminary Tension Load Test by Reaction Method Park Hong Shin Project Manager Last Review Date: Youn Man Hyun Construction Manager Song Ju Hun (Project Manager) Park In Ho (Construction Manager) Ramasamy (Safety Co-ordinator) Next Review Date:
Safety Supervisor S/No Description of Work Activity Hazards Identified Initial Risk Index Proposed Control Measures Residual Risk Index Remarks
F
a) Traffic accident during transportation. b) Injuries or fatalities cause by collapse main girder beam during setting up. 2
R
a) Provide watchman / traffic warden to control traffic. b) Ensure that equipments are properly rigged by experienced rigger, inspect lifting gear. c) Conduct separate tool box for the Tension test Pile setup personnel daily basis. d) Ensure that the main girder beam lain flat on the supporting/reaction pile. e) Temporary strut the main girder beam by welding a tie bar to the adjacent main girder beam.
Site foreman/ Lifting Supervisor./Site Engineer
Tension Load Test Setting Up
a) a) Injuries cause by movement and swinging of crane b) Injuries or death due to fall from height 2 2 4 b) c) d) e)
Provide proper warning signage behind the crane to alert personnel Provide safety barrication around the crane. Ensure that the no workers or vehicle beside the swinging direction of the crane. Ensured that the workers are equipped with safety harness and hooked to the H-Beam columns life line. Conduct separate tool box for the Tension Test Pile set-up personnel on daily basis.
Site foreman/ Lifting Supervisor/Rigg er\/Signalman
Proposed Control Measures Description of Work Activity

a)
Hazards Identified
Buckling of Girder beam/Transfer Frame/H-Beam Column which caused injury to workers and testing personnel
Initial Risk Index
Residual Risk Index
Remarks
S/No
F
2
S
2
R
a)
F
b) c) d) Provide Professional Engineer calculation on Safety Factor of Girder beam at ultimate loading case. Restrict entry to unauthorised personnel by barricading the test area. Keep the test personnel within the safe distance from the test area. The test arrangement should comply with the approved tension test set-up. 2
S
1
R
2
Tension Load Test Setting Up
Construction Manager/Site Engineer/Site Foreman 2 1 2
e)
Bursting of hydraulic hose or coupling
a)
b)
Ensured that the hydraulic hose need the coupling section is securely tied to the connection point with rope. Replace the unacceptable/deteriorate condition hydraulic hose Hand gloves, ear plugs and goggles must be worn as required. Conduct tool box meeting on proper use of tools. Follow manufacturers instruction on proper usage.
a)
Personal Injuries during set up. 3 2 6
a)
b) c)
Note: F Frequency of Occurrence; S Severity of Hazard; R Risk Index TABLE 1 : ACCIDENT FREQUENCY
Likelihood Frequent Probable Occasional Remote Improbable
Rating 5 4 3 2 1
Description Likely to occur repeatedly Likely to occur more than once Could possibly occur Unlikely to occur Extremely unlikely to occur based on judgement and where possible, supported by industry experience
TABLE 3:
RISK INDEX MATRIX
Severity (S) Likelihood (L) Accident Frequency Category (5) (4) (3) (2) (1) Frequent Probable Occasional Remote Improbable
Accident Severity Category (4) Catastrophic 20 16 12 8 4 (3) Major 15 12 9 6 3 (2) Serious 10 8 6 4 2 (1) Minor 5 4 3 2 1
TABLE 4: Risk Index 1-2 3-5
DEFINITION OF RISK INDEX Description Acceptable Moderately Acceptable Definition Further action may not be necessary Further action is to be taken where reasonably practicable to do so. Management attention is required. A careful evaluation of the hazards should be carried out to ensure that the risk level is reduced to as low as is practicable within a defined period of time. Interim risk control measures, such as administrative controls, may be implemented. Immediate management intervention is required before work commences. Very high risk level must be reduced to at least Medium Risk before work commences. There should not be any interim risk control measures and should not be overly dependent on personal protective equipment or appliances. If need be, the hazard should be eliminated before work commences.
6-11
Not acceptable
12-20
Strictly Not acceptable

C156 Preliminary Tension Test Pile T1 T2 Rev 0

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CONTRACT156:DESIGN, CONSTRUCTIONAND COMPLETION OFSTATIONANDASSOCIATED TUNNELS ATMARINASOUTHFORNORTH SOUTHLINEEXTENSION

METHODSTATEMENTFOR PRELIMINARYTENSIONTESTPILET1ANDT2BY REACTIONPILEMETHOD

METHODSTATEMENTFOR PRELIMINARYTENSIONTESTPILET1AND T2BYREACTIONPILEMETHOD CONTRACT156:NORTHEASTLINE EXTENSION

4.2.8.3 InstallationofReinforcementCage 4.2.9 ConcreteInstallation 4.2.9 HBeamInstallationbyPlungeInMethod

METHODSTATEMENTFOR PRELIMINARYTENSIONTESTPILET1AND T2BYREACTIONPILEMETHOD CONTRACT156:NORTHEASTLINE EXTENSION

----------C 156 NORTH EAST LINE EXTENSION BORED PILING WORKS

METHODSTATEMENTFOR PRELIMINARYTENSIONTESTPILET1AND T2BYREACTIONPILEMETHOD CONTRACT156:NORTHEASTLINE EXTENSION

----------C 156 NORTH EAST LINE EXTENSION BORED PILING WORKS

METHODSTATEMENTFOR PRELIMINARYTENSIONTESTPILET1AND T2BYREACTIONPILEMETHOD CONTRACT156:NORTHEASTLINE EXTENSION

ListofPlantandEquipment BoringandInstallationofPreliminaryTestPile TensionTestAssemblyandTestingMethodology

4.2.1 SettingOut 4.2.1.1 PileLocationbySurvey

----------C 156 NORTH EAST LINE EXTENSION BORED PILING WORKS

ForApp proval REV0

4.2.1.2 Setboring gunit

Figure e1.SettingO Outpileposit tionbysurve ey.

4.2.2 In nstallationofTempor raryCasing g

casinginstall lationbyvibrohammer Figure2.Temporaryc

METHODSTATEMENTFOR PRELIMINARYTENSIONTESTPILET1AND T2BYREACTIONPILEMETHOD CONTRACT156:NORTHEASTLINE EXTENSION

----------C 156 NORTH EAST LINE EXTENSION BORED PILING WORKS

METHODSTATEMENTFOR PRELIMINARYTENSIONTESTPILET1AND T2BYREACTIONPILEMETHOD CONTRACT156:NORTHEASTLINE EXTENSION

ThecleaningofthecompletedPreliminaryTestPilewillbethecombinationof; i. Basecleaningbybucket,and, ii. Desandingofbentoniteslurry.

----------C 156 NORTH EAST LINE EXTENSION BORED PILING WORKS

METHODSTATEMENTFOR PRELIMINARYTENSIONTESTPILET1AND T2BYREACTIONPILEMETHOD CONTRACT156:NORTHEASTLINE EXTENSION

----------C 156 NORTH EAST LINE EXTENSION BORED PILING WORKS

Properties Viscosity Density PH SandContent

METHODSTATEMENTFOR PRELIMINARYTENSIONTESTPILET1AND T2BYREACTIONPILEMETHOD CONTRACT156:NORTHEASTLINE EXTENSION

Marshconemethod Muddensitybalance PHindicatorpaperstrips SandContentKit

----------C 156 NORTH EAST LINE EXTENSION BORED PILING WORKS

METHODSTATEMENTFOR PRELIMINARYTENSIONTESTPILET1AND T2BYREACTIONPILEMETHOD CONTRACT156:NORTHEASTLINE EXTENSION

----------C 156 NORTH EAST LINE EXTENSION BORED PILING WORKS

viii. ix. x. xi. xii. xiii. xiv. xv. xvi. xvii.

METHODSTATEMENTFOR PRELIMINARYTENSIONTESTPILET1AND T2BYREACTIONPILEMETHOD CONTRACT156:NORTHEASTLINE EXTENSION

----------C 156 NORTH EAST LINE EXTENSION BORED PILING WORKS

METHODSTATEMENTFOR PRELIMINARYTENSIONTESTPILET1AND T2BYREACTIONPILEMETHOD CONTRACT156:NORTHEASTLINE EXTENSION

----------C 156 NORTH EAST LINE EXTENSION BORED PILING WORKS

METHODSTATEMENTFOR PRELIMINARYTENSIONTESTPILET1AND T2BYREACTIONPILEMETHOD CONTRACT156:NORTHEASTLINE EXTENSION

5.1 ListofPlantandEquipmentforTensionTestSettingUp Table2showsthelistofPlantandEquipmentforTensionTestSettingUpWorks.

----------C 156 NORTH EAST LINE EXTENSION BORED PILING WORKS

METHODSTATEMENTFOR PRELIMINARYTENSIONTESTPILET1AND T2BYREACTIONPILEMETHOD CONTRACT156:NORTHEASTLINE EXTENSION

METHODSTATEMENTFOR PRELIMINARYTENSIONTESTPILET1AND T2BYREACTIONPILEMETHOD CONTRACT156:NORTHEASTLINE EXTENSION

METHODSTATEMENTFOR PRELIMINARYTENSIONTESTPILET1AND T2BYREACTIONPILEMETHOD CONTRACT156:NORTHEASTLINE EXTENSION

Figure6.Rulerinstalledformeasuringthepileheadmovement DialGaugeMethod Twodialgaugeswillbesupportedbyrebarthatweldedtothepreliminarytestpilecasing asinFigure7.

METHODSTATEMENTFOR PRELIMINARYTENSIONTESTPILET1AND T2BYREACTIONPILEMETHOD CONTRACT156:NORTHEASTLINE EXTENSION

----------C 156 NORTH EAST LINE EXTENSION BORED PILING WORKS

METHODSTATEMENTFOR PRELIMINARYTENSIONTESTPILET1AND T2BYREACTIONPILEMETHOD CONTRACT156:NORTHEASTLINE EXTENSION

METHODSTATEMENTFOR PRELIMINARYTENSIONTESTPILET1AND T2BYREACTIONPILEMETHOD CONTRACT156:NORTHEASTLINE EXTENSION

----------C 156 NORTH EAST LINE EXTENSION BORED PILING WORKS

METHODSTATEMENTFOR PRELIMINARYTENSIONTESTPILET1AND T2BYREACTIONPILEMETHOD CONTRACT156:NORTHEASTLINE EXTENSION

----------C 156 NORTH EAST LINE EXTENSION BORED PILING WORKS

AndyKang SeniorEngineer HP:91738975

SongJuHun ProjectManager HP:91384320 PhangKianKok TechnicalManager HP:91683932 ParkInHo ConstructionManager HP:83765209

GeoEngConsultants DRNgTionGuan P:65466318

TinAungTun SeniorEngineer HP:81688954

Ramasamy SafetySupervisor HP:92439604

TestPile SettingUp Team

METHODSTATEMENTFOR PRELIMINARYTENSIONTESTPILET1AND T2BYREACTIONPILEMETHOD CONTRACT156:NORTHEASTLINE EXTENSION

DebondingCasingDetailandDebondingMaterial Bituthene3000ProductDetailandTechnical Specification

----------C 156 NORTH EAST LINE EXTENSION BORED PILING WORKS

Grace Below Grade Waterproofing

BITUTHENE 3000 AND BITUTHENE LOW TEMPERATURE

Self-adhesive, rubberized asphalt/polyethylene waterproofing membranes for basements and sub-structures

Bituthene 3000 reinforcement

Physical Properties for Bituthene Membrane

For technical assistance call toll free at 866-333-3SBM (3726)