Bored Piling

Pre-Drilling - Site Investigation

 Pre-boring will be carried out at each location to ascertain the target founding level.
 Rotary rig drilling operations incorporate the use of a steel core that is used when a
core sample is required.  Another type of boreing is called “Wash Bore” or
“Percussive Bore” which simply means that a bore is flushed out and is used when no
soil sample is required.  Typical rates are...   

Type of Strata Plant Used Rate (m/hr)

Top soft deposits of site fill Percussive / Rotary 10.00
Grade V/IV rock deposits Wash Boring 3.15
Triple Tube Sampling 0.75
Grade III/II rock deposits Rotary 0.50
Triple Tube Sampling 0.50

With a standard rig, working a 12 hour shift, a typical output rate of 66 hrs/hole/rig is
possible. 

 As-Built Information. On Central Reclamation, Contract UA11/91, borehole drilling

completed with the following results... 

1. Average depth of 61.15 m, total depth of 428 m

2. Average rock socket depth of 4.65 m
3. The durations ranged from 4 to 8 days
4. Average of 5.85 days, total duration of 41 days.

The Target Founding level

 This is defined as the required socket into the bedrock, which is defined as moderately
decomposed rock grade III or better with a core recovery greater than 85% (allowable
bearing capacity of 5 mPa).  The continuity of the founding rock is demonstrated by
continuing the pre-bored hole a maximum of 5 metres or 3 times the pile diameter,
whichever is the greater.
 The cores are logged, stored and photographed and submitted together with proposed
founding levels for approval.

Setting Out

 Before starting excavation at the pile position the following steps are taken:

 
  Survey and record the existing ground level at the pile position
 Setout the pile location from the reference points and in order to monitor the position
of the steel casing, control pins are usually established at two orthogonal positions,
offset from the centre of the pile.

Pile Tolerances

 In the case of out of position casings, adjustment can be made to keep the vertical
alignment and plan position within the limits of no more than 75 mm off-centre on
plan position and not deviating by more than 1:75 from the vertical axis.

Pile Excavation / Casings

 The shaft of the pile is excavated within a temporary steel casing with an outside
diameter of say approximately 200 - 300 mm greater than the pile diameter.  The
casing is used mainly in areas of unstable ground and are driven using hydraulic
casing oscillator attached to a crawler crane or a casing vibrator.
 Shaft excavation is carried out using a single or double hammer grab supported by
crawler crane.  The steel casing toe is kept in front of the excavation level until it is
0.5 metres above the pile cut-of level.  The pile shaft is often flooded with bentonite
or water and excavation proceeds to the top of the CDG.
 Excavation then proceeds by reverse circulation drilling (RCD) using large diameter
drilling heads with special rock cutters and flushing by air lift.  Bentonite or water
levels are always maintained above the ground water level to ensure stability of the
shaft.

Calculation Of Bored Pile Construction / Excavation Time

 Piling times can be reduced by the use of service cranes for reinforcement and
concreting activities.
 An additional extended shift would often be required for certain piles, as would RCD
down-time. 

 Forecast construction times can be derived by using output rates (hours per item)...

 Operation Element Details Hours

Add or Remove Reverse Circluation Drill Plant (RCD) incl drill bit 2 hrs
(incl assembly of drill
Add or Remove RCD drill bit 5 hrs
string)
(incl drill string &
RCD bell-out bit 5 hrs
stabilisers)
Installation Airlift tremmie tube 5 hrs
(time for joining each
Reinforcement cages 2 hrs
cage)
(after finishing
Cleaning Time Initial airlift cleaning 8 hrs
excavation)
Final airlift cleaning (after fixing steel cage) 2 hrs
Concreting Incl extract casing ( < 70  m deep) 12 hrs
( > 70 and < 95  m deep) 14 hrs
 ( > 95 and < 135 m
48 hrs
deep)
Only required prior to removal of
Curing Time 72 hrs
telescopic casings
Cycle Time Move piling setup to next location 2 hrs
Shaft Rate
Strata Plant Used
Excavation (m/hr)
General Fill (upper ground levels) Grab 3.50 m/hr
Sand, Minor Rubble Grab 2.10 m/hr
Marine / Alluvium Deposits Grab 2.50 m/hr
CDG < 150 RCD/Grab 1.50 m/hr
CDG > 150 < 200 RCD 1.00 m/hr
CDG > 200, Compacted Gravel RCD 0.50 m/hr
CDT RCD / Grab 0.50 m/hr
Corestones RCD / Chisel 0.50 m/hr
Rock Socket - Grade IV/V RCD 0.25 m/hr
0.125
Rock Socket - Grade II/III RCD
m/hr
Rock Socket - (Tendering Rate) RCD 0.10 m/hr

 Forecast excavation or cycle times can then be derived by analysing ground

conditions.  Site investigation will provide the depths / types of strata which can then
be matched to production output rates (see above). 
 Note - A pile’s diameter has negligible effect on production time and as such is
ignored.

Example - For a pile founding on rock at 60 m deep...

 (a) Calculate Allowance For Plant Time / Other Elements (hrs)....

 

Element Hours
Set up RCD 5.0
See
Excavate Time
Below
Remove RCD (including drill bit, string and
5.0
stabilisers)
Setup / Remove Airlift Tremmie Tube 5.0
Initial Post-Excavation Airlifting 5.0
Place reinforcement (5 No cages @ 12m = 5 x 2 hrs) 10.0
Setup / Remove Airlift Tremmie Tube 5.0
Final Post-Reinforcement Airlifting 2.0
Concrete and remove casing 12.0
Move to next location 2.0
Calculate Total Construction / Plant Time 52.0 hrs
(b) Calculate Allowance For Excavation Time (hrs)...
 

Depth of Strata Production Rate Plant Time

Type of Rock
(m) (m/hr) Used (Hrs)
0 - 20 Sand/minor rubble 2.00 Grab 10.0
20 - 35 CDG less than 150 1.50 RCD/Grab 10.0
35 - 47 CDG more than 150 1.00 RCD 12.0
47 - 57 CDG > 200/corestones 0.50 RCD 20.0
57 - 60 Rock socket 0.20 RCD 15.0

 (c) Calculate Total Pile Excavation Time = 67.0 hrs

 (d) Overall Pile Time       

Construction / Plant Time (“b” above) 52.0 hrs

Excavation Time (“d” above) 67.0 hrs
OVERALL CYCLE (“b” +
119 hrs
TIME “d”)
9.9
(With 12 hr shifts) (“b” + “d”)
days

 Bored Pile Construction As-Builts

  General Rule of Thumb Pile Times (days)... 

Depth (m) <4 <13

<20 <70 <90
=> 0 5
4.0 10. 25.
Days Per Pile 8.0 45.0
* 0 0

Note - due to the required plant assembly and operation times, 4 days is the minimum
possible pile construction time for any situation.

Methods For Overcoming Obstructions

 If the obstruction is shallow (ie 0 to 2.5 m below ground level) a backhoe-breaker will
be used to form a suitable hole.
 Where the obstructions are located at greater depths an oversized temporary casing is
driven by the oscillator to the top of the obstruction.             

 If the obstruction is above water level a hand operated air hammer is used, a typical
rate of = 0.8 m/hr
 If below water level a down the hole hammer or heavy chisel supported by crawler
crane will be used, a typical rate of = 0.5 m/hr
  If a concrete “plug” is required to provide a well formed shaft wall when an
obstruction or excessive overbreak or fault is encountered... 

Element Hours
Remove RCD 5 hrs
Install Tremie Concrete Tube 5 hrs
Place Concrete Plug 2 hrs
Cure Concrete 36 hrs
Replace RCD and drill string 5 hrs
TOTAL TIME LOSS 53 hrs (2.2 days or 4.4 shifts)

Cleaning of Pile Base

 The hole of the pile shaft is cleaned using an airlift until the water becomes clean or
negligible particles in suspension is discharged.

Reinforcement Cages

 Cages are constructed in suitable sections, usually in the order of 12 m long, complete
with sonic tubes and coring tubes.
 Fabrication, 12 m long cage with 6 no fixers... 

Fabricate 1 cage 2.5 hrs

Total cages required 5 no
Overall Fabrication Time 12.5 hours

Steel Stanchion Fabrication and Installation

 Stanchions are usually fabricated off-site and delivered in sections.  Prior to

installation the sections are welded together to form the complete stanchion. 
Stanchion sizes are usually in the region of 525 mm x 525 mm. 
 With an average length of say 28 m, the welding time would be around 5 days and are
tested by an ultrasonic weld test and an MPI test.
 After the installation of the reinforcing cage in to the shaft the stanchion will be lifted
until it hangs vertical.  It is then lowered into the excavation and clamped into
position.

Concreting

 Pile concreting is carried out under water by "tremie" techniques maintaining the
water or bentonite head inside the casing at or above existing ground water level.  The
tremie tube (250mm) is withdrawn as concreting proceeds ensuring a minimum
concrete head of 2 metres above the top of the tremie tube.

Sequence Of Piling
  The sequence of construction of piles is chosen in such a manner that no damage can
be caused to nearby piles still under construction or recently concreted (i.e. less than 3
days).
 On a 12 metre grid, a normal layout would mean say having two non-worked on piles
between each open excavation in the longitudinal direction (ie a 36 metre spacing)
thus allowing room for the crane etc and a lesser spacing of every other pile being
worked on (ie a 24 metre spacing).

 Pile Testing

 The workability of concrete is tested on site by measuring the slump and temperature
of concreting at the time of discharge into the pile shaft.  Laboratory tests are carried
out in order to check the strength of the placed concrete.  A number of test cubes are
made and tested at 7 and 28 days.

 Coring Test - Certain piles selected by the Engineer will be cored their full depth. 
The depth of cores into the base material (rock) will usually be at least 600 mm. 
Cores are placed in correct order and relative position in core boxes which clearly
mark the depths of cores.  The cores are usually photographed and submitted to the
Engineer.  The testing of the coring will provide additional information about the
quality of the concrete as well as the condition of the interface between concrete and
rock.
 Sonic Logging Test - In order to test the quality of the concrete as well as the
integrity of the pile in its overall length and pile toe condition sonic core testing is
used.  Sonic tubes are installed with the reinforcement cage in order to allow the
lowering of the signal transmitter and signal receiver probe down the bottom of the
pile.  These tubes are sealed at the bottom.
 Vibration Tests - This test determines the pile length and shape and the overall pile
concrete quality.  This is a specialist test.