TP10

Penang Second Bridge
Marine Bridge Substructure

Construction
Spun Pile
Main Span Pilecap Construction
by
Ir. Cheng Kim Bong

Senior Resident Engineer
MMSB Consult Sdn. Bhd.
Content
Penang Second Bridge Alignment

Type Of Piles
Summary of Piles
Pile Testing Locations
Pile Testing of Spun Pile, Steel Pile & Bored Pile
Spun Pile
Spun Pile Detail
Spun Pile Length
Spun Pile PDA Test
Spun Pile Test For BHT11 (P163)
Mobilization Factor of Spun Pile
Pile Head Damage Analysis
Validation of Spun Pile
Penang Second Bridge
Penang Second Bridge Alignment
Type Of Piles
P0-P11 : Spun Pile

P12-P23 : Steel Pile
Approach Span
P000
Batu Maung
P023
P24-P27 :
Bored Pile
Main Span
P024
P027
P28-P43 : Steel Pile P145-P282 : Spun Pile

P44-P144 : Spun Pile P283-P292 : Bored Pile
Approach Span
P028
P144
Approach Span
P145
P292
Batu Kawan
Summary of Piles
Description
Passed Pile
(Nos.)
Rejected Pile
(Nos.)
Total Pile
(Nos.)
Steel Pile (1.6m)
368
368
Spun Pile (1.0m)
5158+19*
10
5168+19*
Bored Pile (2.3m-2.0m)
66
66+1 (P26-20 rejected)
Bored Pile (1.5m)
80
80
* 19 nos. replacement spun piles P107-07 A & B, P102-12 A & B, P061-13 A & B,
P120-04 A & B, P122-07A & B, 8A, P137-7A & 7B, P193-21A & B, P9-17
A&B, P280-R15 A&B
Pile Testing Locations
BHT8
BHT9
BHT10
BHT7
BHT6
BHT4
BHT3&5
BHT2
BHT11
BHT1
BHT12
Pile Testing On Spun Pile, Steel Pile & Bored Pile

Pile Test
No.
Chainage
Location
(near to)
Pile Type
Working
Load (kN)
Total Test
Done
Total
Passed
Not
Conclusive
O-Cell Test
BHT 3
CH 9+700
P161
1.2m Steel Pile
5,800
O-Cell Test
BHT 7
CH 2+688
P33
1.6m Steel Pile
8,100
O-Cell Test
BHT 9
CH 1+981
P25
2.3~2.0m
Bored Pile
25,500
MLT & PDA
BHT 1
CH 15+900
P273
1.0m Spun Pile
3,800
MLT & PDA
BHT 2
CH 11+700
P197
1.0m Spun Pile
3,800
MLT & PDA
BHT 5
CH 9+700
P161
1.0m Spun Pile
3,840
MLT
BHT 4
CH 3+500
P48
1.0m Spun Pile
3,800
MLT & PDA
BHT 6
CH 3+530
P48
1.2m Spun Pile
4,600
MLT & PDA
BHT 3
CH 9+700
P161
1.2m Steel Pile
5,800
MLT & PDA
BHT 11
CH 9+818
P163
1.0m Spun Pile
3,720
Statnamic
CH 11+028
P185-L08
1.0m Spun Pile
3,100
Statnamic
BHT 11
CH 9+818
P163
1.0m Spun Pile
3,720
MLT & (Statnamic

on Anchor Pile)
BHT 12
CH 16+913
P292
1.5m Bored Pile
8,000
MLT & (Statnamic

on Anchor Pile)
BHT 8
CH 1+368
P15
1.6m Steel Pile
7,210
Statnamic
CH 3+548
P49-R15
1.0m Spun Pile
3,410
Statnamic
CH 1+980
P25-09
2.0m Bored Pile
27,200
SPUN PILE
Spun Pile Detail
ICP Spun Pile Sectional Details

Revised pile shoe
detail as per next
slide
SEE DETAIL X
Spun Pile Detail
Pile Shoe Details
DETAILS OF PILESHOE
Spun Pile Detail
Extension Joint
Spun Pile Detail
Extension Joint
Spun Pile Detail
4 Lifting Points of Spun Pile
L1
L2
L3
L4
L5
L= Pile Length L1 = 0.05L L2 = 0.28L L3 = 0.31L L4 = 0.23L L5 = 0.13L

* Average Pile Length is about 58.5m
Spun Pile Length
Design Pile Length vs Actual Pile Length

Difference Between Design Pile Length & Actual
Pile Length
Description
Spun Pile
(1.0m)
Total Pile
(Nos.)
0 to 2m
2 to 5m
> 5m
5187
4744 (92%)
329 (6%)
114 (2%)
Average Design Length

Average Nett Length
Average Cut-off Length
= 58.67m
= 57.28m
= 1.38m (2.4%)
Spun Pile Length
Bore Log Record For BHT 11 (near P163)
~ -55.00
SPT = 50
Spun Pile Length
Design Pile Length vs Actual Pile Length

Pier
Design Pile
Length (m)
Design Toe
Level (m)
Actual Toe
Level (m)
Differences
P161
59
-57.62 to -58.42 -56.14 to -57.02
<2m
P162
58
-56.63 to -57.42 -55.13 to -55.95
<2m
P163
56
-54.66 to -55.42 -53.20 to -54.49
<2m
P164
55
-53.67 to -54.42 -52.17 to -52.97
<2m
P165
53
-51.70 to -52.42 -49.71 to -51.09
<2m
Spun Pile PDA Test
PDA Test Summary

Description
Initial Strike
for Pile
Integrity
BTA
<80%
Re-strike
Total PDA
Done
Total (nos.)
331
396
735
PDA Test Frequency
At least two PDA to be carried out at a pair of pilecap :

i) PDA initial
: to verify pile integrity
ii) PDA re-strike : to verify pile capacity
Objective Of Pile Load Test
To determine the pile ultimate bearing capacity

To determine the pile ultimate resistance at pile base
To determine pile shaft skin friction parameter at each soil layer

To determine correlation between Static Load Test, PDA & Statnamic
To provide the basis for the revision of pile final set criteria
To provide parameters for verification or modification basis for working pile

PDA analysis
To obtain Load vs Settlement relationship
PDA Test...
Statnamic Test...
Static Load Test...

Load Cell
BHT 11 (P 163) Setting Up
Anchor Pile,
M2-1
Anchor Pile,
M2-2
Pile
Spun Pile
Pile
Length
Design Toe
Level
Actual Toe
Level
M2-1
1000mm
59m
-57.0
-56.98
M2-2
1000mm
59m
-56.0
-56.00
Reference Pile, M2-3

J2-2
M2-4
1000mm
59m
-56.0
-55.97
1000mm
59m
-56.0
-55.95
J2-1
1000mm
50m
-46.5
-46.43
J2-2
1000mm
50m
-46.5
-46.41
S2
1000mm
61m
-57.0
-56.88
4m
Reference Pile,
J2-1
Test Pile, S2
4m
Anchor Pile,
M2-3
4m
4m
Anchor Pile,
M2-4
* Working load = 3720kN
BHT 11 (P 163) Testing Process
Anchor Pile, M2-1

PDA (EOD)
Test Pile, S2
PDA (EOD)
Min. 7 days after pile installation
Statnamic
PDA (Restrike)
w/o instrumentation
Min. 28 days after pile installation
MLT
Min. 15 days after MLT
Statnamic
Comparison of Static 2nd Cycle Static and Statnamic Load

Test Results
Comparison of Static 2nd Cycle Nett Static and Statnamic

Load Test Results
Comparison of Static and Statnamic Load Test Displacement

Table 1 : Comparison of Static & Statnamic Load Test Displacement
Table 2 : Comparison of 2nd Cycle Nett Static & Statnamic Load Test Displacement
From Table 1, settlement recorded from Statnamic test for M2-1 at 2.0 WL is 5.14mm less than
Static test for S2
From Table 2, settlement recorded from Statnamic test for M2-1 at 2.0 WL is 2.38mm less than
Static test for S2
Summary Comparison Between Statnamic & Static Load Test
Comparison Between PDA & Static Load Test

Test
Pile
S2
Pile
Penetrated
Length
Length
(m)
(m)
64
54.68
Set
(mm)
Ultimate
Capacity of
MLT(kN)
Initial
PDA
(kN)
Restrike
PDA
(kN)
Restrike /
Initial
MLT / PDA
Initial
5.9
> 11,160
5150
10,800
2.10
>2.17
- Summary Comparison Between PDA & Static Load Test
It can be observed the analytical results of PDA test are accurate verified by BHT11s MLT
test result and can be concluded that the PDA test procedures are in order.
M-Factor of Spun Pile Using PDA

Major objective of PDA restrike test is to verify the pile capacity to satisfy the required
design capacity (2.5 times of working load)
In order to verify the capacity of piles which no restrike test but only end of drive test
(EOD) was performed, recommended mobilization factor is proposed based on :
i) pile embedment
ii) pile toe founding layer
iii) total number of blow
Mobilization factor of bearing capacity of a given pile can be obtained by dividing restrike
test capacity (Q2) by EOD test capacity (Q1)

M-Factor vs Pile Embedment
Relationship Diagram Between Pile Embedment & Mobilization
Factor
3
2.5
Mobilization
Factor
1.5
1
0.5
0
40
45
50
LP (m)
55
60

M-Factor vs Blow Count
Relationship Diagram Between Blow Count & Mobilization Factor
3
2.5
Mobilization
Factor
2
1.5
1
0.5
0
0
1000
2000
3000
Blow Count
4000
5000

Mobilization vs Set
Relationship Diagram Between SET & Mobilization Factor
3
2.5
Mobilization
Factor
2
1.5
1
0.5
0
0
SET (mm)
10
12
14

Mobilization vs Period
Relationship Diagram Between Period & Mobilization Factor
3
2.5
Mobilization
Factor
2
1.5
1
0.5
0
0
10
Period (Day)
15
Recommended M-Factor of Spun Pile Using PDA

Conservative Considering
According to the statistical result of comparison between M-factor and pile embedment,
final set and period, it is found that the effect of EOD set to M-factor is most dominant and
relatively obvious among the three factors considered.
98% of the restriked piles have penetration of 0.0mm. It is understood that most piles did
not achieve its maximum capacity during restrike test due to limited energy.
From the data collected from tested working piles, the average M-factor is 1.77. On the
other hand, the M-factor for BHT 11 test pile is 2.17.
Therefore, M-factor of 1.77 to 2.00 is a conservative engineering selection.
Recommended M-Factor
Based on the abovementioned analysis and statistics, it is recommended to use M-factor
of 1.7 for spun pile.

Pile Head Damage Cases vs Month
Cases
14
13
12
11
10
9
8
7
6
5
4
3
2
1
0 MayJuneJulyAugSepOct NovDec JanFebMarAprMayJuneJulyAugSepOct NovDecJanFebMarAprMayJuneJulyAugSep
09 09 09 09 09 09 09 09 10 10 10 10 10 10 10 10 10 10 10 10 11 11 11 11 11 11 11 11 11
Month
Pile Head
Damage Cases
Total cases = 55

% Pile Head Damage vs Monthly Progress
8%
7%
6%
5%
4%
3%
2%
1%
150
125
177
279
244
160
156
148
175
68
256
252
195
209
208
270
247
327
226
185
09 09
169
09
145
09
73
94
09
112
225
90
0%
220
% Pile Head Damage
May June July Aug Sep Oct Nov Dec Jan Feb Mar Apr MayJune July Aug Sep Oct Nov Dec Jan Feb Mar Apr May June July Aug Sep
09
09
09
10 10 10
10 10 10
10
10
10
10 10 10
Monthly Progress (nos.)
11 11
11
11 11
11
11 11
11

% Pile Head Damage vs Cumulative Piles Driven
1.59%
1.37%
1.14%
0.91%
0.68%
0.46%
0.23%
5187
5185
5035
4910
4733
4454
4210
4050
3894
3746
3571
3503
3247
2995
2800
2591
2383
2113
1866
1539
1313
1128
959
814
741
629
535
310
0.00%
220
% Pile Head Damage
May June July Aug Sep Oct Nov Dec Jan Feb Mar Apr MayJuneJuly Aug Sep Oct Nov Dec Jan Feb Mar Apr May June July Aug Sep
09
09
09 09 09 09 09 09
10 10 10
10 10 10 10
10 10 10 10 10
Cumulative Piles Driven (nos.)
11 11 11 11 11
11
11 11 11
List of Preventive Actions
No
Actions Taken
Remarks
QC on standard operating procedure

with introduction of additional
checklist (Spun pile production)
Mould
QC on standard operating procedure

(Piling Operation)
To
Factory visit, inspection and QAQC

procedure auditing at ICP factory
inspection
Concrete feeding process
Spinning process
Steam curing
Staking yard
More frequent checking on raw material
Concrete cubes & cores strength
Calibration certificates
replace hammer cushion once worn out
Provide sufficient cushion materials
Ensure hammer hits pile evenly and axially
Reduce pile driving stresses by controlling hammer drop
height during hard driving
Other Stringent QAQC Measures
Production data for each produced pile is recorded in In-process checklist.
2 hours waiting time was set aside for pile which has undergone spinning
process. On top of that, 8 hours of steam curing time is above the usual practice
of 5 hours.
Audit to supplier raw material suppliers (sand, aggregate) was conducted on a
regular basis to ensure the conformity of material supplied.
The allowable gap between end plates is only 2mm, which is much more
stringent than 5mm tolerance stated in MS1314: Part4:2004.
Monthly inspection from CHEC & MMSB to ensure all piles produced to the
highest standard as stipulated in the Technical Requirements for Spun Pile.

Welding facilities at ICP factory enable
us to overcome constraints of on-site
welding and reduce the possibility of
pile damage, which usually associate
with on-site welding. MIG wire was
used to ensure top quality welding work
was performed.
The welding quality of jointed pile was

further inspected with the use of
Magnetic Particle Test.
Top Beam Of Jacking Frame

Jack
Test Pile
Dial Gauges
Support
Support
Pile Bending Test (MS1314 Part 2:2004)
Pile Bending Test
List of Investigation Actions
No.
Actions Taken
Remarks
Thorough investigation involving ICPs

R&D department
Additional tests been carried out
Petrographic
Additional PDA tests been carried out
P160 (10
examination
X-ray diffraction (XRD)
nos)
P121-P123 (18 nos)
Comments On Additional Test Results
Raw material testing found comply to requirement
Petrographic examination & XRD found satisfactory except

some air and water voids
Additional PDA test results shown no pile integrity problem
Repair Method For Pile Head Damage
Carry out pile head strengthening work (with carbon fiber & ICP method)
PDA Test
Coring Test
PDA & coring test result found satisfactory
Pile considered acceptable
Validation Process
Piling work done in accordance with :
- Approved construction drawing
- Set criteria
- HPDI revised pile length confirmation
- Shop drawing (if any changes)
Pile Driving Record
Pile Certification Report

-PDA test report
- PDAR if required
- SOR / NCR closure if any
Pile Cutting
Set Criteria
Piling Record
H>2m
PDA Result
> 80%
> 2.5 x WL
Pile Driving Acceptance Record (PDAR)
PDAR is required when the different between design toe level and actual toe level
> 2m.
The pile is considered acceptable if :
- Pile capacity shown in PDA test > 2.5WL
- Pile integrity, BTA value in PDA test > 80%
BTA value classification:
i) 100 %
: Uniform. No apparent anomaly was detected
ii) 80-99%
: Minor anomaly. Relatively minor impedance reduction detected
iii) 60-79%
: Moderate anomaly. Relatively moderate impedance reduction detected
iv) <60%
: Major anomaly. Relatively major impedance reduction detected
Pile Driving Acceptance Record (PDAR)
Pile Certification Report
Cost Comparison For Different Types Of Pile Foundation
Pile Type
PHC
Driven
Spun Pile
Driven
Steel Pile
Bored Pile
(m)
1.0
Average
Length
(m)
53m
Number /
Pier
10
Economic
Rate
1.00
1.6
83m
2.87
1.5
105m
3.62
Diameter
Main Span
Pilecap Construction
Main Span Structure Location
P24
P25
P26
P27
Main Navigation Span
Span Length
p26
p25
p27
p24
117.5 m
240 m
117.5 m
150 m
Navigation
Navigation
ChannelChannel
Pylon Detail
30m
5m
General Description
Main Span arrangement : 117.5m 240m 117.5m
Cable at 6m (typical) spacing

Deck constructed by cast-insitu balanced cantilever method
Deck post-tensioned longitudinally and transversely
The structure design service life is 120 years.
P25 & P26 Pilecap Layout
17.5m
48.1m
6m
P25 & P26 Steel Fender Layout
P24 & P27 Steel Fender Layout
Steel Fender Cross Section
STEEL FENDER
P025 & P026
steel fender
P024 & P027
Construction Flow Chart
Clearing of formwork
platform
Installation of supporting
brackets and bearing beams
Demarcation of
platform
Platform clearing and 1st

stage rebar fixing
Installation of hydraulic
jacks
Hydraulic jacks in
operation
Discharge seawater, load

transfer
Installation of
operation platform
1st stage 3m thk. pilecap

concreting
Construction joint
Remove corbels below

platform
2nd stage rebar fixing
Installation of steel fender
Lower down formwork to

design level
Mass concrete casting
Fabrication of rebar
onshore
Platform leveling and

verticality check
2nd stage 3m thk. pilecap

concreting
Fabrication of rebar
onshore
Mechanism Of Lowering Down Steel Fender
Mechanism Of Lowering Down Steel Fender
Hydraulic Jack Arrangement
Steel
St eelCasing
case
Steel
St eelCasing
case
Steel Fender Installation
Lowering Mechanism Installation
Steel Fender At Design Level
Lean Concrete Casting
Transferring Of Support System

The transferring of supporting system will be carried out after water is
pumped out from mass concrete and before proceeding for installation
of 1st layer pilecap reinforcement.
+3.48m
-3.32m
-5.12m
Corbels as loading transferring points of hanging rods
Concreting Of Pilecap
+3.48m
+2.68m
2nd
Layer
the second layer concrete
of the pilecap(2.0m)
(2.0m)
the
ndsecond layer concrete
2 Layer
(3.0m)
+0.68m
steel fender
1sttheLayer
first layer concrete of
the pilecap(2.0m)
(2.0m)
steel fender
-1.32m
st Layer
1the
second layer concrete
(3.0m)
mass Concrete
concrete(1.2m)
Mass
(1.2m)
Mass
Concrete
mass concrete(1.8m)
(1.8m)
P025 & P026
P024 & P027
-2.52m
Temperature Control
JKR Specification
NO.
Items
Requirement
Placing Temperature
36
Maximum Internal Temperature
70
Maximum Temperature Gradient
27.7
Rise rate in Temperature
10/30min
Temperature Control Measures
Low
heat cement (Portland Pulverised-Fuel Ash Cement) to be
used
Additive like GGBS and silica fume are added to the design mix
to minimize the cement content
Water cooling pipe with cycling of ice water and thermocoupler
to be embedded in the concrete
Cooling Pipe System
Water boat
Thermocoupler
Cooling pipe
Temperature Monitoring For P24 & P27

1
10
11
Ambient Tempt.
Peak Temperature
80
Temperature/
70
60
50
40
30
20
10
0
0
20
40
60
80
100
Time/h
120
140
160
180
Thank You

TP10

Caricato da

Informazioni sul documento

Descrizione originale:

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

TP10

Caricato da

Copyright:

Formati disponibili

Penang Second Bridge

Marine Bridge Substructure

Ir. Cheng Kim Bong

Penang Second Bridge Alignment

Main Span Pilecap Construction

Penang Second Bridge

Penang Second Bridge Alignment

P0-P11 : Spun Pile

P28-P43 : Steel Pile P145-P282 : Spun Pile

Steel Pile (1.6m)

Spun Pile (1.0m)

Bored Pile (2.3m-2.0m)

66+1 (P26-20 rejected)

Bored Pile (1.5m)

Pile Testing Locations

Pile Testing On Spun Pile, Steel Pile & Bored Pile

1.2m Steel Pile

1.6m Steel Pile

MLT & PDA

1.0m Spun Pile

MLT & PDA

1.0m Spun Pile

MLT & PDA

1.0m Spun Pile

1.0m Spun Pile

MLT & PDA

1.2m Spun Pile

MLT & PDA

1.2m Steel Pile

MLT & PDA

1.0m Spun Pile

1.0m Spun Pile

1.0m Spun Pile

MLT & (Statnamic

1.5m Bored Pile

MLT & (Statnamic

1.6m Steel Pile

1.0m Spun Pile

2.0m Bored Pile

Spun Pile Detail

ICP Spun Pile Sectional Details

Spun Pile Detail

Pile Shoe Details

Spun Pile Detail

Spun Pile Detail

Spun Pile Detail

4 Lifting Points of Spun Pile

L= Pile Length L1 = 0.05L L2 = 0.28L L3 = 0.31L L4 = 0.23L L5 = 0.13L

Spun Pile Length

Design Pile Length vs Actual Pile Length

Average Design Length

Spun Pile Length

Bore Log Record For BHT 11 (near P163)

Spun Pile Length

Design Pile Length vs Actual Pile Length

-57.62 to -58.42 -56.14 to -57.02

-56.63 to -57.42 -55.13 to -55.95

-54.66 to -55.42 -53.20 to -54.49

-53.67 to -54.42 -52.17 to -52.97

-51.70 to -52.42 -49.71 to -51.09

Spun Pile PDA Test

PDA Test Summary

PDA Test Frequency