Doc. Title Method Statement of Piling Works for Buildings TOA-TOYO JOINT VENTURE

Doc. No CM - MS – BW - 002 Rev. No. 0 Date July,2010Construction of Port Facilities and Buildings for Cai Mep International Container Terminal

CAI MEP INTERNATIONAL CONTAINER TERMINAL

METHOD STATEMENT OF PILING WORKS FOR BUILDINGS

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Doc. Title Method Statement of Piling Works for Buildings TOA-TOYO JOINT VENTURE

Doc. No CM - MS – BW - 002 Rev. No. 0 Date July,2010Construction of Port Facilities and Buildings for Cai Mep International Container Terminal

TABLE OF CONTENTS

1. General…………………………………………………………… 2

2. Scope of Works…………………………………………………... 2

3. Reference Technical Specification ………………………………. 2

4. Reference Drawings……………………………………………..... 2

5. Specification of Piling Machine…………………………………... 2

6. Piling Schedule……………………………………………………. 2

7. Equipment and manpower list…………………………………… 2

7.1. Equipment………………………………………………………… 3

7.2. Labors…………………………………………………………….. 5

8. General Flow Chart Of Piling Work……………………………… 6

9. Piling Procedure…………………………………………………... 7

10. Piling by Diesel Hammer…………………………………………. 8

10.1 Driving Lower Segment PHC Pile………………………………... 8

10.2 Splicing Work……………………………………………………... 9

10.3 Driving Upper Segment PHC Pile……………………………….... 9 11. Pile Driving Record………………………………………………. 10 12. Pile Dynamic Analyzer…………………………………………... 11

13. Quality Control………………………………………………….... 11

13.1. Inspection of Fabrication ……………………………………….... 11

13.2. Inspection of Welding Work……………………………………... 11

14. Safety Control…………………………………………………...... 12

15. Appendixes……………………………………………………….. 13

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Doc. Title Method Statement of Piling Works for Buildings TOA-TOYO JOINT VENTURE

Doc. No CM - MS – BW - 002 Rev. No. 0 Date July,2010Construction of Port Facilities and Buildings for Cai Mep International Container Terminal

1. General :

This Method Statement for PHC and the solid pile, piling work procedure of

buildings for CAI MEP INTERNATIONAL CONTAINER TERMINAL

PROJECT is to demonstrate the process of driving these piles in compliance with

all the required specifications, standards, and proper construction procedures

governing the pile driving works for the building foundation of the project.

2. Scope Of Works :

Execution and supply of PHC and square solid piles, setting piles location before

driving, driving and all necessary engineering works could be categorized as

follows:

Type of piles are PHC pile type A, (Ø 600 mm, Ø500mm), and 400mmx400mm

solid square piles.

3. Reference Technical Specifications :

Technical Specification: Part 4B, Division 2 – Piling Works for Buildings.

4. Reference Drawing List :

Attached in Appendix B

5. Specification and Certificate of Piling Machine

Specification of piling machine and crane operation certificate:

Attached in Appendix C

6. Piling Schedule :

Attached in Appendix E

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Doc. Title Method Statement of Piling Works for Buildings TOA-TOYO JOINT VENTURE

Doc. No CM - MS – BW - 002 Rev. No. 0 Date July,2010Construction of Port Facilities and Buildings for Cai Mep International Container Terminal

7. Equipment & Manpower List:

7.1. Equipment to Be Used:

The Equipment to be used for pile driving works is summarized in Table 7.1

Table 7.1 List of Equipment

No Equipment Specification Quantity Capacity

1 Diesel Pile Hammer KOBELCO K35/K25 1 5T

2 Diesel Pile HammerKOBELCO

K35/DELMAG D 251 5T

3 Diesel Pile Hammer HERA3500/D25C 1 5T

4 Diesel Pile HammerKOBELKO K45/KB60

MITSUBISHI MB 701 4.5T,6T,7T

5 Crane Truck Model: LS78 1 35T6 Crane Truck Model: DH 350 1 35T7 Theodolite Japan Made 04 100% precise8 Survey Equipment US Made 1 100% precise9 Automatic Level Japan Made 2 100% precise

TOTAL→ 13

7.2. Labors To Be Deployed:

Labors and/or trades to be deployed for PHC piling work is summarized in

Table 7.2Page 4

Doc. Title Method Statement of Piling Works for Buildings TOA-TOYO JOINT VENTURE

Doc. No CM - MS – BW - 002 Rev. No. 0 Date July,2010Construction of Port Facilities and Buildings for Cai Mep International Container Terminal

Table 7.2- List of labors

Description Quantity Remark

Engineer 3

Foreman 3

Piling operator 3

Workers 12

Welders 6

Surveyor 4

Crane operator 2

TOTAL→ 33

8. General Flow Chart Of Piling Work:

General Flow Chart:

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Doc. Title Method Statement of Piling Works for Buildings TOA-TOYO JOINT VENTURE

Doc. No CM - MS – BW - 002 Rev. No. 0 Date July,2010Construction of Port Facilities and Buildings for Cai Mep International Container Terminal

9. Piling Procedure

PHC Piles D600mm, D500mm and Solid 400mmx400mm will be plant

fabricated and transported to the site by a Trailer truck and by barge. They will be

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Mobilization of Piling Machine

Delivery of PHC Pile by Barge & Trailer Truck for Building

Lifting the lower segment PHC pile by Crane then mount Diesel Hammer

Driving the lower segment PHC pile

Confirm the bearing capacity by evaluating penetration during driving

Lifting the upper segment PHC pile and Splicing

Driving the upper PHC pile(Middle/Top)

Finish

Doc. Title Method Statement of Piling Works for Buildings TOA-TOYO JOINT VENTURE

Doc. No CM - MS – BW - 002 Rev. No. 0 Date July,2010Construction of Port Facilities and Buildings for Cai Mep International Container Terminal

supported by bedding timbers placed directly under the positions of lifting hooks

(Shown in Figure 1).

Piles will be stored carefully on flat ground within the temporary yard and a

maximum of three (3) layers per stock pile is required.

Pile markings should be carried out to every pile segments to check the rough

penetration per hammer blow. Bottom segment piles will be marked at every 1.0m

pitch, middle segments, and top segments will be marked every 20cm pitch.

Material delivery dockets, receipts and physical inspection report shall be

submitted to the Engineer.

TRUCK CRANE

TRAILER PHC PILE

0. 2L 0. 2L 0. 6L

Figure 1: Transportation of PHC Pile

PHC PILE TIMBER 0. 2L ER

0. 2L 0. 2L

Figure 2: Storage of PHC Pile

10. Piling By Diesel Hammer :

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Sand Bag Sand Bag

Doc. Title Method Statement of Piling Works for Buildings TOA-TOYO JOINT VENTURE

Doc. No CM - MS – BW - 002 Rev. No. 0 Date July,2010Construction of Port Facilities and Buildings for Cai Mep International Container Terminal

The piles will be driven by diesel hammer. The driving will be stopped after

confirming the bearing capacity. (Shown in Figure 2)

CENTER LINE OF PILE

SURVEYER

TRANSIT/PLUMB BOB

PILE DRIVER

SURVEYER

PILE UNDER DRIVING

DIESEL

HAMMER

G N I V I R D

N O I T C E R I D

TRANSIT/PLUMB BOB

Figure 2: Pile Driving

10.1. Driving Lower Segment PHC Pile:

Crane will lift up the lower segment PHC Pile near the piling machine. The PHC

pile will be held along leader of diesel hammer. Lifting position shall be 0.2L of pile

length. ( lower than cracking moment)

The pile position will be adjusted by moving the leader until its top coincides with

the hammer then mount the cap on the pile top. Before start driving, vertical position

of the pile will be checked carefully by total station or theodolite to confirm its

verticality.

10.2. Splicing Work:

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Doc. Title Method Statement of Piling Works for Buildings TOA-TOYO JOINT VENTURE

Doc. No CM - MS – BW - 002 Rev. No. 0 Date July,2010Construction of Port Facilities and Buildings for Cai Mep International Container Terminal

Prior to splicing, welding surfaces will be cleaned and free from rust, oil, water

and other foreign elements that would affect welded joints.

After driving lower segment, the upper segment will be lifted by piling machine,

set above the lower segment coincide their centers directly and aligned vertically

then fixed the clamp to maintain its alignment. Inclination tolerance shall be

checked by split level, and it should be less than 1.0cm/1.0m)

. Splices will be made by butt welding, using arc welding performed 2G position

and in accordance to WPS (Welding Position Standard) for welding.

Visual and NDT inspection check will be conducted to every welding joint done.

Figure 3

10.3Driving Upper Segment PHC Pile:

Top segment shall be driven after obtaining the PDA test results for correction

factor from Hailey’s formula

Driving will be complete after confirming the sufficient bearing capacity, from

Hailey’ s formula shown below with reference to PDA Test results.

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PILE DRIVER

DIESEL HAMMER

HELMET

LOWER PILE

1) DRIVING OF LOWER PILE 2) CLEANING OF PILE HEAD 3) SPLICING 4) RESUMING OF DRIVING

UPPER PILE

Doc. Title Method Statement of Piling Works for Buildings TOA-TOYO JOINT VENTURE

Doc. No CM - MS – BW - 002 Rev. No. 0 Date July,2010Construction of Port Facilities and Buildings for Cai Mep International Container Terminal

If it is found that the bearing capacity is still insufficient obtained from

rebound record against design, the pile should be extended and re-driven until the

bearing capacity is reached.

Ru = 9.81 (Ef.MR.H) x MR + e 2 .MP

S+0.5(C1+C2+C3) MR + MP

= A In which:

Ru : Ultimate Resistance, KN

MR: Weight of ram, Kg

H : Drop height of hammer, mm

Ef : Efficiency of fall of hammer

MP: Weight of pile + helmet, Kg

e : Coefficient of restitution [ e = (S+{C₁+C₂+C₃}÷2 x PDA)/(Ef x MR x H) ]

C1: Elastic deformation of pile, mm

C2: Elastic deformation of ground, mm

C3: Elastic deformation of pile head cushion, mm (here C3 = 2 mm).

S : average penetration, in mm per blow for at least the last 10 blows

RP: Correction Factor (RP = S.L.T. / A)

(Use rebound record- Attached Appendix F)

The result of Pile driving and bearing capacity shall be confirmed by the

Engineer and the records of pile installation shall be submitted to the Engineer.

In case the pile tip can not reach the design level due to unforeseen hard layer,

this matter will be reported to the Engineer.

If piles cannot be driven to the design level but has already attained the required

bearing capacity, the driving shall be stopped in accordance to specification and

Engineer’s instruction to avoid buckling or cracking of the pile.

Pile head treatment shall be done after getting Engineer’s approval.

11. Pile Record:

Before final setting of the piles, the rebound shall be recorded.

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x RP

Doc. Title Method Statement of Piling Works for Buildings TOA-TOYO JOINT VENTURE

Doc. No CM - MS – BW - 002 Rev. No. 0 Date July,2010Construction of Port Facilities and Buildings for Cai Mep International Container Terminal

The pile driving is deemed completed after confirmation of the sufficient bearing

capacity against design. Bearing capacity for all piles will be calculated with

formula.

12. Pile Dynamic Analyzer (PDA)

Pile Dynamic Analysis will be conducted to confirm the pile capacities and to

decide the correction factor of Hiley’s formula. PDA test provides more

information, about Skin resistance distribution, Toe resistance, simulated static

load-settlement relationship, pile integrity, stresses in the pile during the blow.

PDA test shall be conducted by Engineer

13. Quality Control

13.1. Inspection of Fabrication

Before fabrication PHC and square Pile materials such as, cement, sand, gravel,

reinforcing bars, tendon wires and etc, will be inspected on Factory before

fabrication, and finished product will again be inspected before delivery to the site.

The inspection report shall be submitted before piles will be delivered on site.

When PHC and square piles arrives on site/stockyard, these will be inspected

again for its, physical conditions, quantity and quality in accordance with

specification or standards listed below:

- Length tolerance: ±3%

- Outside diameter tolerance: +7mm/-4mm

- Wall thickness tolerance: +unspecified/-0mm

- Cracking: no crack

The quality control and inspection report will be submitted to the Engineer.

13.2. Inspection of Welding Work.

Prior to the welding, the grooved face and its adjacent areas shall be completely

free from oil, paint, oxide, water and all other foreign materials.

Welding rod will be stored in a dry and humid place to keep its required

temperature. Only welding rod approved by the Engineer will be used on the

splicing of pile.

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Doc. Title Method Statement of Piling Works for Buildings TOA-TOYO JOINT VENTURE

Doc. No CM - MS – BW - 002 Rev. No. 0 Date July,2010Construction of Port Facilities and Buildings for Cai Mep International Container Terminal

Piles are jointed with their end plates evenly around its diameter, welding must

be carried out in accordance with manufacture’s instruction and must be checked

before driving resumes. Piles welding splice will be tested by NDT test. Basically

all weld joints shall be tested by NDT but reducing option will be proposed

depending on the quality of test obtained on the previous welded joints. (Refer to

attached form in Appendix F)

(1) Crack Inspection of Welding

There shall be no cracks in or near the weld beads. The inspection shall be carried

out by visual and Non Destructive test (NDT).

(2) Inspection of Bead Surface and Shape

Visual inspection of bead surface and shape shall be done by the process listed

below.

a. Pits on bead surface

Butt joints shall be free of weld pits on the bead surface.

b. Flatness of bead

There shall be no height difference exceeding 3mm within 25mm length of a bead.

c. Undercut

The depth of undercut shall not exceed 0.3mm.

d. Overlap

There shall be no overlap.

During driving, the pile head will be protected by helmet of cast steel or mild

steel fitted closely around the pile. Packing (cushion) timber, covering the head of

pile, will be placed on the pile and will be replaced as often as necessary to prevent

damage to the piles.

14. Safety Control:

Prior to commencement of any activities, the contractor will ensure all safety

work practices and requirements for the different operations and are made

informed and strictly complied at all times.

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Doc. Title Method Statement of Piling Works for Buildings TOA-TOYO JOINT VENTURE

Doc. No CM - MS – BW - 002 Rev. No. 0 Date July,2010Construction of Port Facilities and Buildings for Cai Mep International Container Terminal

The following steps are strictly checked before and during working.

1. Equipment and machine efficiency checking prior to operation.

2. Grand condition

3. Tool box meeting

15. Appendices:

Appendix A: Organizational Chart

Appendix B: Ref. Drawings List

Appendix C: Specification and Certificate of Piling Machine

Appendix D: Fabrication Schedule

Appendix E: Pile Driving Schedule

Appendix F: Pile Driving & Welding splicing Form

Appendix G: Checklist for PHC Pile Manufacturing

Appendix H: Inspection and Test PLan

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Doc. Title Method Statement of Piling Works for Buildings TOA-TOYO JOINT VENTURE

Doc. No CM - MS – BW - 002 Rev. No. 0 Date July,2010Construction of Port Facilities and Buildings for Cai Mep International Container Terminal

Appendix A: Organizational Chart

Item No Title Numbers Remarks

1 Site Manager 2

2 Engineer/Safety 3

3 Foreman 3

4 Operator 3

5 Welder 6

6 Worker 12

7 Surveyor 4

Total→ 33

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TOA-TOYO JV

Site Manager

Engineer & Safety

Pile TransportationTeam

Piling Rig-2Team-2

Piling Rig-1Team-1

Doc. Title Method Statement of Piling Works for Buildings TOA-TOYO JOINT VENTURE

Doc. No CM - MS – BW - 002 Rev. No. 0 Date July,2010Construction of Port Facilities and Buildings for Cai Mep International Container Terminal

Appendix B:

Ref. Drawing List:

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Doc. Title Method Statement of Piling Works for Buildings TOA-TOYO JOINT VENTURE

Doc. No CM - MS – BW - 002 Rev. No. 0 Date July,2010Construction of Port Facilities and Buildings for Cai Mep International Container Terminal

Appendix C:

Specification and Certificate of Piling Machine

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Doc. Title Method Statement of Piling Works for Buildings TOA-TOYO JOINT VENTURE

Doc. No CM - MS – BW - 002 Rev. No. 0 Date July,2010Construction of Port Facilities and Buildings for Cai Mep International Container Terminal

Appendix D:

Pile Fabrication Schedule

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Doc. Title Method Statement of Piling Works for Buildings TOA-TOYO JOINT VENTURE

Doc. No CM - MS – BW - 002 Rev. No. 0 Date July,2010Construction of Port Facilities and Buildings for Cai Mep International Container Terminal

Appendix E:

Pile Driving Schedule

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Doc. Title Method Statement of Piling Works for Buildings TOA-TOYO JOINT VENTURE

Doc. No CM - MS – BW - 002 Rev. No. 0 Date July,2010Construction of Port Facilities and Buildings for Cai Mep International Container Terminal

Appendix F:

Pile Driving & Welding splicing Form

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Doc. Title Method Statement of Piling Works for Buildings TOA-TOYO JOINT VENTURE

Doc. No CM - MS – BW - 002 Rev. No. 0 Date July,2010Construction of Port Facilities and Buildings for Cai Mep International Container Terminal

Appendix G:

Checklist for PHC Pile Manufacturing

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Doc. Title Method Statement of Piling Works for Buildings TOA-TOYO JOINT VENTURE

Doc. No CM - MS – BW - 002 Rev. No. 0 Date July,2010Construction of Port Facilities and Buildings for Cai Mep International Container Terminal

Appendix H:

Inspection and Test Plan

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