WING KONG PILING SDN BHD

METHOD STATEMENT FOR JACK-IN

PILING INSTALLATION - TPZB 260
Method Statement for Jack-In Pile Installation
1. SCOPE

1.1 This procedure refers to the installation of Jack-In piles only

2. EQUIPMENT

Jack-In Machine

2.1 System Used : Gripped System

2.2 Maximum Pile Size : 200mm ~ 400mm Square, 250mm ~ 500mm diameter
2.3 Maximum Jacking Force : 260ton

Other Equipment
2.1 Air Compressor/ Diamond Cutter
2.2 Welding Set
2.3 Generator Set

3. SETTING OUT OF LOCATIONS

3.1 The pile position is set out on site using steel peg.
3.2 2 reference steel peg would be installed equidistance from the pile centre at about 500mm away.
3.3 The pile would then be pitched and positioned into the exact pile point position such that the reference peg are
equidistance from the pile face.

4. HANDLING, PITCHING, INSTALLATION AND EXTENSION

4.1 All handling and lifting will be at the designed lifting points and support points.

During pitching and installation the verticality of the pile will be continuously monitored and plumbed to ensure
the pile is centrally in line with the pile axis to receive the ram to prevent pile whip, twist or rotation.
Each pile shall be clearly marked with red ink at 500mm intervals along its length to enable the jacked In
Pressure/force to be.recorded at every 500mm depth of pile penetration.
The pile will be extended by butt-welding the steels plate on the pile heads. On completion of welding the slag will
be chipped off and wife brushed to receive bitumen or anti rust paint.

4.2 Installation of Pile and Welding

The vertical support structure of the jack-in machine is plumbed to ensure vertically by means of a spirit level or
plumb line. This is achieved by adjusting the four stabilizers. Pile shall be lifted and inserted into the equipment by
crane. The pile shall be position into the grip of the equipment and gripped the pile body. Once the pile vertical and
in position, jacking commences.
During the pile installation, the hydraulic pressure of main jacks is measured by the pressure gauge, and the
corresponding pile penetrations are recorded by the site staff at regular intervals. The pile may be extended by means
of welding. Except for pile jointing, each pile is jacked in continuously until the required resistance or penetration
is reached.
Every extended pile by means of welding, the pile top steel plate will be clean from mud or any dirt before jointing both
side of pile. Once the pile is joined and the pile verticality will be measure again before we weld. If there is a slight gap
between the plates we will insert thin plates to fill up the gap. Upon finish welding we will use oxide paint to paint the
welded area before continue installation
The required resistance is normally twice the pile working load, or higher of the jack supervising engineer so desired.
The corresponding pressure in the main jacks and the penetration are recorded.
The portion of the installed piles which is above ground may be cut to enable movement of rig.

4.3 Termination Criteria

The jack-in force is determined by the engineer. Once the required pressure corresponds to the required jack-in force is
indicated in the pressure gauge, the pressure is held for 30 seconds. The set criteria is that the same required pressure is
achieved consecutively for 2 times, each time held for 30 seconds and each settlement should not exceed 2 mm

5. SAFETY

5.1 Statutory safety requirements (General Duties of Employees, Section 24, Occupational Safety and Health Act, 1994)
Site specific safety requirements, as set out in the contract; and the main contractor's Environment, Safety. Health
and Security Plan.

5.2 HSE Officer

HSE Officer will coordinating all safety-related activities at the work site, and ensuring that all safety requirement
are complied.

5.3 Pile Installation

Pile installation involves jacking and lifting. The potential hazards and the respective precautions are as below:

Hazard Precautions
Sinking 1. Ensuring ground is reasonably level.
2. Ensure equipment is level
3. Use matting if ground is soft
4. Do no attempt to track across water ponded area.

Pile falling during pitching 1. Use approved and tested wire ropes.
2. Double loop of wire rope around the pile to avoid slipping (pile surface is smooth)
3. Do no drag the pile more than 12m from the jack-in cylinder
4. Stay away from pile during dragging and pitching.

Others 1. Operator should always view at the worker working at the grip clamp and only
grip the pile where operator is free from clamp
2. Ensure no worker is under the object when being lifted.
3. Regular checking of lifting cables.

6. CUTTING OF PILES

The work involve cutting of piles with mechanical driven diamond cutter at high speed. The risks and precaution are as
follows:

Hazard Precautions

Stuck by flying material 1. Stay at least 4m during cutting.

Dust 1. Operator must wear dust mask
Cut by cutter 1. Only experienced worker is a allowed to work
Falling of piles 1. If piles above cut off level are more than 4m high, it
should be supported by crane or clamped by the equipment.
 主要技术参数 Main technical data for TPZB 260 - TOPPILE

项 目 Item 参 数 Parameter

最大压桩力（23Mpa） 117tf
中位主压桩缸单独工作 Max. Pile pressing force(23Mpa)
Main cylinder 最大压桩速度（油压＜12Mpa） 7.86m/min
Max. Pile pressing speed(Pressure<12
pressure pile Mpa)
working alone 最小压桩速度（油压=23Mpa） 2.5m/min
Min. Pile pressing speed(Pressure=23Mpa)
中位主副压桩缸同时工 最大压桩力（23Mpa） 260tf
作 Max. Pile pressing force(23Mpa)

Main&Sub cylinder 最大压桩速度（油压＜12Mpa） 1.7m/min

Max. Pile pressing speed(Pressure<12
pressure pile Mpa)
working 最小压桩速度（油压=23Mpa） 1.1m/min
together Min. Pile pressing speed(Pressure=23Mpa)
压桩行程（一次）Pressing-in stroke 1.6m
纵向行程（一次） ≤2.2m
Longitudinal stroke
行走能力 横向行程（一次） ≤0.6m
Capacity of motion Transverse stroke
转角（一次） ≤8.3◦
Every rotative angle
前进 Forward ≤8.1 m/min
行走速度 后退 Backward ≤16.9 m/min
Stepping speed 左移 Left ≤8.1 m/min
右移 Right ≤11.8 m/min
升降行程 Vertical motion stroke 1.5m
接地比压Ground 长船 long ship slide-way 11.25tf/m2
Pressure(at 260t) 短船 short ship slide-way 13.37tf/ m2
可配钳口 可配圆桩钳口 Y25、Y35、Y45 / Y30、Y40
Optional pile Optional circle pile clamping 、Y50
clamping jaw jaw
 可配方桩钳口 F25、F35 / F20、F30、
F40
续表
压桩额定压力（260tf时） 23Mpa
Pile pressing rated pressure(at
260t)
起重额定压力 18Mpa
Lifting rated pressure
液压系统 压桩流量（全流量时） 280L/min
Hydraulic system Pile pressing flow rate
起重流量（全流量时） 120L/min
Lifting flow rate
107（1台/1pcs）
液压泵型号
80（1台/1pcs）
Hydraulic pump model
80（1台/1pcs）
Y200L-4-V1（1台/1pcs）
电机型号
Y180L-4-V1（1台/1pcs）
Motor model
Y180L-4-B35（1台/1pcs）
压桩功率/pile pressing power 67KW

起重功率/lifting power 30KW

电气系统
Electric system 电压/voltage 380V

电流/Current 80 A

频率/Frequency 50HZ

电源电缆/Power cable YCW3×35+2×16

运输尺寸 主机（mm）
ions for Main body（L*W*H）(mm) 10720×2700×3500
transportation（
all of oversize or 长船（mm）
overweight parts Long Ship（L*W*H）(mm) 10500×1100×770
of machine）
 短船（mm）
Short Ship（L*W*H）(mm) 3600×2700×1230

起升角度与允许起重量的关系
Lifting angle and allowable lifting weight

表2 table 2
 长 臂 短 臂
Long Jib Short Jib
(度) 起重量(t) 回转半径(m) 起重量(t) 回转半径(m)
(°) Lifting Slewing Lifting Slewing radius(m)
weight(t) Radius(m) Weight
0 2.2 15 3.2 11.7
15 3.2 14.5 4.8 11.3
30 4.5 13 6.2 10
45 5.8 10 7.8 8
60 8.2 7.5 11 5.8
75 15 3.8 15 3

注意:起重时必须严格按表中的规定进行操作！
Attention: It must operate lifting according to table 2 strictly
3 基本构造Basic Structure
3.1 机器的外形shape of machine如图1所示：
The shape of machine is as figure 1.

1 - 边桩 压 桩台 2 - 主 操 作台 3 - 横 移回 转 机构 c r o s s m o t i o n a n d r o t a t i o n
m e c h a n i s m 4 - 纵移 机 构 l o n g i t u d i n a l m o t i o n m e c h a n i s m 5 - 配重 梁 6 - 压桩 台
p i l i n g p l a t f o r m 7 - 动 力组 件 M o t o r 8 - 夹桩 箱p i l i n g c l a m p i n g b o x 9 - 升降 机
构v e r t i c a l m o t i o n 1 0 - 机身 1 1 - 起 重机c r a n e
 图1 TPZB260型液压静力压桩机
Figure 1 TPZB260 hydraulic static pile driver

1-机身 main body 2-横移回转机构 cross motion mechanism 3-纵移机构

logitudinal motion mechanism 4-升降机构 vertical motion mechanism
5-压桩台 piling platform
图2 升降行走机构
Figure2 Vertical motion and moving mechanism
图5 Figure5
 图7 TPZB260运输外形尺寸图
TPZB260 LARGEST PARTS TRANSPORTATION DIMENSION

LONG SHIP SLIDEWAY COLLOCATION FOR ASSEMBLY

附表1 主要可拆部件重量、尺寸表Appendix table1
 总重量(
序号 名称 长（m) 宽（m) 高（m) 总体积(m3) 总数量
T)
Item Description Length Width Height Measurement Qty
Weight
主机
1 9.60 2.80 2.70 72.58 1 24
Main Machine
吊臂
2 9.34 0.49 0.84 3.84 1 3.83
Crane
压桩横梁
3 Pile pressing 1.30 0.40 3.20 3.33 2 4.75
crossbeam
夹桩箱
4 1.60 1.30 1.20 2.50 1 5.69
Clip pile box
长船（含油缸+辅助
5 配重梁+踏板） 10.50 1.10 0.70 16.17 2 18.9
Long ship
短船
6 3.60 2.70 1.20 23.33 2 17.1
Short ship
悬臂总成
7 1.70 0.40 2.10 5.71 4 6.3
Leg assembly
配重梁
8 4.90 0.30 0.60 1.76 2 3.49
Counterweight beam
辅助配重梁
9 2.00 0.30 0.60 0.72 2 0.88
Auxiliary beam
辅助悬臂
10 1.20 0.20 0.80 0.38 2 0.34
driver-sub beam
吊机机架
11 3.00 2.00 1.20 7.20 1 5.93
crane frame
吊机驾驶室
12 1.50 0.83 1.50 1.87 1 0.21
Crane Cabin
配件箱
13 1.48 0.75 0.60 1.33 2 0.60
Tool box
配件箱
14 1.48 0.75 0.60 0.67 1 2.00
Tool box
加油小车箱
15 0.75 0.75 1.15 1.94 3 0.20
Oil dolly
总计 143.35 51 94.22
注：Note：以上各件重量为理论计算值，加上外购件重量亦为理论计算值等原因，以上各件实际重
量与理论值会有一定的差别。
Weight of all parts above is theoretically calculated data. The weight of out sourcing
parts is also theoretic data. There might be a little difference between practical
data and theoretic value.

Appendix table 2 Oil pressure and pile pressing force

 压 桩 力 Force to press pile(tf)
主压桩缸单独压桩
油压Oil Main cylinder 主、副压桩缸同时压桩
Pressure(MPa) Main&sub
1 5 11.6
2 10 23.2
3 15 34
4 20 45
5 25 57
6 31 68
7 36 80
8 41 91
9 46 102
10 51 114
11 56 125
12 61 136
13 66 148
14 71 159
15 76 171
16 81 182
17 86 193
18 92 205
19 97 216
20 102 227
21 107 239
22 112 250
23 117 260