Concrete Sheet Pile Construction Methodology

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FREY-FIL CORPORATION FFC

Rev. No. Rev. Date
INFRA MANAGEMENT SYSTEM 00
CONCRETE SHEET PILE CONSTRUCTION Page Document No.
1 of 15
METHODOLOGY M17-CIV-007-ABP-004
Construction of Abusag Bridge Location

Baggao - Dalin - Sta. Margarita Road
Baggao, Cagayan
DEPARTMENT OF PUBLIC WORKS AND HIGHWAYS

Contract ID: 18B00053
ct Name: 001 - ENSURE SAFE AND RELIABLE NATIONAL ROAD SYSTEM BRIDGE
-REPLACEMENT OF PERMANENT WEAK BRIDGES ABUSAG BRIDGE (B04258LZ) &
APPROACHES Along Baybayog - Baggao - Dalin - Sta. Margarita Road Baggao,
Cagayan
Location of the Contract: Baggao - Dalin - Sta. Margarita Road Baggao, Cagayan
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CONCRETE SHEET PILE CONSTRUCTION

METHODOLOGY
Revision and Approval Block

Re Prepared By Verified By Approved By Noted By
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Print Date: 05/Jun/2020
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Rev. No. Rev. Date
2 of 15

Baggao, Cagayan
CONTENT
1. Introduction…………………………………………………………………………………………3
2. Preliminary works………………………………………………………………………………….3
3. Construction implementation……………………………………………………………………..4
4. Construction of detour roads……………………………………………………………………..6
5. Construction of craneway road & bridge and platform………………………………………...6
6. Earthworks………………………………………………………………………………………….7
7. Bored piling activities……………………………………………………………………….……..8
8. Construction of piers and abutments……………………………………………………………
13
9. Girder fabrication and installation……………………………………………………………….13
10. Construction of bridge slab including sidewalks………………………………………….……15
11. Construction of backwall, wingwall and retaining wall………………………….
……………..15
12. Slope protection works for abutments………………………………………………….
……….16
13. Construction of approach slab and PCCP………………………………………….
…………..17
14. Construction of u-ditch drainage line……………………………………………………………17
15. Construction of railings, guardrail and traffic signage…………………………………………
17
16. Construction of lighting post pedestal and
fixtures…………………………………………….18
17. Road marking and
painting……………………………………………………………………….18
18. Material testing and quality control………………………………………………………………
19
19. Attachments……………………………………………………………………….……………21-
34
a. Attachment A (Method Statement for Pile Dynamic Test)
b. Attachment B (Method Statement for Pile Dynamic Test)

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3 of 15

Baggao, Cagayan
General Consideration
Precast concrete piles shall be of the design shown on the Plans. Prestressed concrete piles shall
be prestressed as prescribed in item 406, Prestressed Concrete Structures. The piles shall be cast
separately and concrete in each pile shall place continuously. The completed piles shall be free from
stone pockets, honeycombs, or other defects, and shall be straight and true to the form specified.
The forms shall true to line and built of metal, plywood or dressed lumber. A 25mm chamfer strip
shall be used in all corners. Form shall be water-tight and shall not be removed until at least twenty-
four (24) hours after the concrete is placed.
Piles shall cure and finished in accordance with item 405, structural Concrete and 406,
Prestressed Concrete Structures.
Cylinder specimens shall be made and tested in accordance with item 405. Piles shall not be
moved until the tests indicate that the concrete has attained a compressive strength of at least 80%
of the design 28-day compressive strength and they shall not be transported or driven until design
28-day compressive strength has been attained.
If testing equipment is not available, as in isolate areas, piles shall not be moved until after
fourteen (14) days after casting and shall not be transported or driven prior to 28 days after casting.
If high early strength cement is used, piles shall not be moved, transported or driven prior to 7 days
after casting.
When concrete piles are lifted or moved, they shall be supported at the points shown on the
plans; if not shown, they shall be supported at the quarter points.

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4 of 15

Baggao, Cagayan
Introduction
Precast concrete sheet piles were designed to stabilize the road embankment to prevent further
lateral movements of earth due to vehicular loads on the road. Analysis and design of the sheet pile
system are presented. Construction aspects related to handling, installing and finishing works at site
are highlighted.
Today, due to the increasing number of vehicles used on roads, more roads are being
constructed to cater for the massive traffic volume. They are now built across rivers, hills and
mountains in order to link countries, cities or districts. For the roads built adjacent to river on soft
ground, there is always problem caused by the road users. The major problem is the settlement of
road embankment near to river. Fig. 1, shows the slip circle occurring at the affected area with the
signs of lateral movements of earth towards the river.
Maintenance works such as backfilling and resurfacing the settled road have always been carried
out. However, such measures are found to be not effective in the long run. In order to solve this
problem, a new Precast Concrete Sheetpile System was developed.

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5 of 15

Baggao, Cagayan
Precast Concrete Sheetpile System The development of reinforced concrete since late of 18th
century by Francois Hennebique has brought the innovation to current concrete structures [1]. One
of the current trend is to prefabricate components which is cost effective and short in construction
period. Taking full advantage of the great features of precasting techniques, use of precast concrete
sheetpile has been attempted as a solution to road embankment. The basis of the above idea is that
precast concrete flexible retaining wall in sheet pile form as shown in Fig.2, is able to provide
protection to the road embankment effectively. The lateral earth pressure from road embankment
and river bed has significant effect on the requirement of strength and stiffness of the precast
concrete sheetpile. Therefore, adequate designed length of sheetpile is necessary in order to make
the whole system functioning effectively.
Description of Projects
The above road embankment protection using precast concrete sheetpile has been presented by the
contractor and further approved by the DPWH regional office for the construction of Slope
protection structure for both alignment A & B considering much higher degree of structural stability
to support embankments and a solution for those affected residence that was within the right of way
acquisition along the project area.
Project Location: The project site is located Baggao - Dalin - Sta. Margarita Road Baggao, Cagayan
The road embankment is the only main road to the nearby town of Jitra.
Below are some site constraints when carrying out the work:
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6 of 15

Baggao, Cagayan
1. Alignment A (approaches and Bridge)

(a) Additional provision of Detour road along the Alignment is highly recommended before closing
the road going to approaches. Plans and computation must be submitted to DPWH for evaluation
and approval prior to commencement of the work.
(b) The existing PCCP road can only be blocked after opening the completed temporary access road
and construction can only proceed after settlement of road ROW. Issues with the affected residence
within the road ROW must be settled first to provide smooth execution of the construction most
specially in the 1st approach of the bridge as shown in the plans.
(c) Acquisition of limits for detour road must be properly surveyed w/ plans & presented to DPWH
for approval and notice to proceed initial phase of construction.
(d) Other physical obstructions must be settled first by the DPWH construction and Legal
department.
(e) Limited space for stacking stocks of precast concrete sheet pile.
(f) Minimum disturbance and vibration work when piling is less applicable due to existence of
electrical cables and residence area nearby.
Alignment B (Road going to Annayatan-right & Tallang-left)

(a) All obstruction such as century trees, electrical post, residence perimeter fence, existing drainage
system, culverts, road barriers etc. must be properly documented and present to DPWH for further
evaluation. Additional variation (if applicable) will be discussed accordingly.
(b) Provision of Detour Roads are highly recommended before closing the existing road on both
directions. No works shall proceed if construction safety considerations are not properly deployed
on the project site. Plans & computation must be submitted to DPWH for evaluation and approval
before any commencement of work.
(c) Minimum disturbance and vibration work when piling are less applicable to the nearest electrical
post location.

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Rev. No. Rev. Date
7 of 15

Baggao, Cagayan
Construction Sequence
1. Survey Staking
Provide proper stake-out reference as basis in the clearing and grubbing limits and reference of
alignment subject for trenching works.
2. Initial clearing and grubbing

To provide clear working area and identify obstruction along the alignment of Concrete Sheet Pile.
This includes the clearing and grubbing prior to the construction of Detour Road

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8 of 15

Baggao, Cagayan
3. Construction of Detour Road

Before closing the main existing road, provide a well graded and properly maintained detour road
for temporary access while working on the embankment protection structure. Affected area by the
detour road must be properly restored as is for the benefits of the land owners after the completion
of the entire project considering the project is already accessible to receive traffics. Detour Road
maintenance is only effective within the project duration or usage duration stated in the proposal of
Detour road. Detour Road to be converted into barangay/street road will depend to the final inputs
of the local government unit and DPWH. Road signs for must also properly deployed for road
safety. Refer separate reference presented for detour roads on both alignment A and alignment B.
4. Demolition, removal & hauling of existing obstruction

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9 of 15

Baggao, Cagayan
Before commencement of trenching works intended for concrete sheet pile, identifying obstruction
subject for removal must be properly evaluated and presented to DPWH for work order request and
approval. Debris like concretes can be used as embankments for detour roads if only allowed by the
department.
5. Preparation of Equipment
All needed equipment must be on the site works as possible to provide continues and smooth
operation in the working area.
6. Unloading and re-stacking of Concrete Sheet Pile near and within the provided area
Precast concrete sheet pile were cast in factory and delivered to site for installation by trailer and
unloaded to the designated place using mobile crane as shown in Fig. 10. Location of stacking area
must be easily for the crane to reach out for lifting and carrying it on the assigned pile location.
Figures 10. Lifting of precast concrete sheetpile from trailer to storage area in site

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Rev. No. Rev. Date
10 of 15

Baggao, Cagayan
7. Excavation Works
Excavate for placement and construction of structures and backfill structures.
After securing alignment with proper limit reference, area is now ready to receive trenching
works. Designed depth of trench must be strictly followed and supervised and make sure
operators to provide properly excavated trench before setting the piles. If found out the soil
structure is weak, the immediate supervisor engineer assigned will provide quick action to
address the situation before letting his/her personnel continue the work. Provision of wall
support is highly recommended if necessary specially those locations near the existing
residence within the working area.
Excavation and trenching are among the most hazardous construction operations. OSHA
defines an excavation as any man-made cut, cavity, trench, or depression in the earth’s surface
formed by earth removal. A trench is defined as a narrow underground excavation that is
deeper than it is wide, and is no wider than 15 feet (4.5 meters).
Dangers of Trenching and Excavation

Cave-ins pose the greatest risk and are much more likely than other excavation related
accidents to result in worker fatalities. Other potential hazards include falls, falling loads,
hazardous atmospheres, and incidents involving mobile equipment. Trench collapses cause
dozens of fatalities and hundreds of injuries each year.
Protect Yourself
Do not enter an unprotected trench! Trenches 5 feet (1.5 meters) deep or greater require a
protective system unless the excavation is made entirely in stable rock. Trenches 20 feet (6.1
meters) deep or greater require that the protective system be de-signed by a registered
professional engineer or be based on tabulated data prepared and/ or approved by a
registered professional engineer.
Protective Systems
There are different types of protective systems. Sloping involves cutting back the trench wall
at an angle inclined away from the excavation. Shoring requires installing aluminum hydraulic
or other types of supports to prevent soil movement and cave-ins. Shielding protects workers
by using trench boxes or other types of supports to prevent soil cave-ins. Designing a
protective system can be complex because you must consider many factors: soil classification,
depth of cut, water content of soil, changes due to weather or climate, surcharge loads (eg.,
spoil, other materials to be used in the trench) and other operations in the vicinity.

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Rev. No. Rev. Date
11 of 15

Baggao, Cagayan
Competent Person
OSHA standards require that trenches be inspected daily and as conditions change by a
competent person prior to worker entry to ensure elimination of excavation hazards. A
competent person is an individual who is capable of identifying existing and predictable
hazards or working conditions that are hazardous, unsanitary, or dangerous to employees and
who is authorized to take prompt corrective measures to eliminate or control these hazards
and conditions.
Access and Egress

OSHA requires safe access and egress to all excavations, including ladders, steps, ramps, or
other safe means of exit for employees working in trench excavations 4 feet (1.22 meters) or
deeper. These devices must be located within 25 feet (7.6 meters) of all workers.
General Trenching and Excavation Rules
 Keep heavy equipment away from trench edges.

 Keep surcharge loads at least 2 feet (0.6 meters) from trench edges.
 Know where underground utilities are located.
 Test for low oxygen, hazardous fumes and toxic gases.
 Inspect trenches at the start of each shift.
 Inspect trenches following a rainstorm.
 Do not work under raised loads.

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Rev. No. Rev. Date
12 of 15

Baggao, Cagayan
8. Installation of Concrete sheet pile

a. Positioning of Concrete sheet pile - Before setting of concrete sheet pile, a guide frame/beam is
placed on the ground to set out the position of the concrete sheet pile wall.
b. Installation of First Concrete Sheet Pile

– The piling rig lifts up the first sheet pile and set it to the assigned location. The engineer must
monitor the designed top elevation of the concrete sheet pile and make sure the guide is firmly installed
to provide proper vertical alignment.
c. Installation of second Concrete sheet pile

– the piling rid lift up the second sheet pile and set it to the assigned location and this time to sheet
piles must be interlocks with the 1st driven concrete sheet pile. Process b & c repeats till the
installation of sheet pile is completed within the length of the guide frame/guide beam.
d. Pouring of Sand-Cement Mortar
– before removing of guide frame/ guide beam, concrete sheet pile base shall firm and stable to
assure no possible dislocation or movement at the end tip of driven sheet pile. Sand-cement mortar
should be composed of cement, sand, and water, be well-mixed, and have the proper consistency to
obtain a dense, homogenous lining that will adhere firmly to the substances surface. After curing of
Sand-cement mortar proper backfilling and 95% compaction shall be applied.
e. Backfilling and compaction
The stabilized volume shall be backfilled with select granular backfill. The maximum compacted
thickness of any layer shall not exceed 150mm. all subsequent layers shall be spread and compacted
in a similar manner.

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13 of 15

Baggao, Cagayan
The backfill materials shall be compacted until a uniform density of not less than 95 mass
percent of the maximum dry density determined by AASHTO T 99 Method C is attained, at a
moisture content determined by Engineer to be suitable for such density. Acceptance of compaction
may be based on adherence to an approved roller pattern developed as set forth in item 106,
Compaction equipment and Density Control Strips.
During the progress of the work, the engineer shall make density tests of compacted material in
accordance with AASHTO T 310 or other approved field density tests. If, by such tests, the
Engineer determines that the specified density and moisture conditions have not been attained, the
contractor shall perform additional work as may be necessary to attain the specified conditions.
At least one group of three (3) in-situ density tests shall be carried out for each 500 m of each
layer of compacted fill.
Backfilling shall be even on all sides of the structure, and each layer shall be extended to the
limits of the excavation or to natural ground.
Backfill shall be placed in such a manner as to avoid any damage or disturbance to the concrete
sheet pile wall or misalignment of the structure. Any damaged or disturbed during backfill
placement shall either be removed or replaced at the contractor’s expense or corrected, as directed
by the Engineer.
Backfill shall not be placed against concrete less than 7-days old of unit 80 percent of the design
strength is achieved. An acceptable lightweight mechanical or vibratory compactor shall be used
within one (1) meter of the wall face.
f. Installation of Anchorage System

Concrete Sheet pile with designed tie rods shall be properly installed most specially to an actual
condition with exposed height from natural grade line (NGL) of more than 2.1m or as per approved
drawings and specifications (refer approved details of tie rods).
g. Chipping Works
Before start chipping of a depth 300mm on top of installed concrete sheet pile, make sure the
attachment of each sheet pile, anchorage system, the backfilling and compaction are surely 100%
stable and structurally intact so that no detaching of said sheet pile while personnel are doing heavy
chipping works prior to the construction of capping beam. The Engineer and the contractor shall
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14 of 15

Baggao, Cagayan
properly monitor the works to avoid excess chipping and make sure reinforcements are exposed at a
depth provided a locking system when installing rebars for the beam.
h. Installation of Capping Beam

As per designed, the capping beam size is 450mm x 300mm in cross section and structurally
reinforced. Provided with properly installed concrete forms, cast in place concrete shall have
corresponding samples to undergo testing procedures as per DPWH standard of monitoring strength
of casted concrete. The contractor shall not remove the guide frames/guide beams until the curing
duration of concrete or as per the instruction of immediate supervisors and Engineers including
removal of forms.
i. Road way Embankments

As directed by the Project Engineer, continues backfilling for embankment shall be on the
next phase after completion of concrete sheet pile structure. The same process under backfilling and
compaction shall govern considering DPWH standard of Earthworks, subbase, and base course
requirements before the setting and construction of PCCP surface course.
j. Drainage and Slope Protection Structures

Remaining riprap slope protection Structure shall be constructed as per DPWH approved drawings,
standard & specifications, and procedures. The Capping beam shall be free of any filling materials
and shall be cleaned out while and after doing riprap works. Drain Pipes shall be installed as per
approved plans and locations considering the standard of DPWH in the installation of the said
pipes. If coring works will be applied, the contractor shall provide tools and equipment that is suited
to do heavy coring in the concrete sheet pile walls. The pipe shall be installed with designed slope
and must be grouted to make provide intact connection with the sheet pile wall.
Submitted by:
TEODORICO A. GUICO
Project Manager, FREY-FIL CORPORATION

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Concrete Sheet Pile Construction Methodology

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Document Reference

FREY-FIL CORPORATION FFC

Construction of Abusag Bridge Location

DEPARTMENT OF PUBLIC WORKS AND HIGHWAYS