Lesson Learned Form

Lesson Learned Title: Dropped down of Pile Reinforcements

Division/Section/Unit C&PPID/MYDPIS/MYDPIU LL Number LL-MYDPIS-017/2019

Originator’s Name Dennis R. Alejandro Date Submitted November 25, 2019
e-Mail dennis.alejandro@aramco.com Contact No. 013 352 4063

Background (What/Where/When/How?)
Context:
During the trimming/cutting of concrete bored pile heads at King Salman International Complex for Maritime
Industries and Services Tuxedo Area for Anchor piles and Relieving Piles, it was observed that several piles
were dropped down from the cut-off level. The piles having diameter of 1.80m & 1.20m with length of 38m &
19m respectively, were casted few months ago by contractor (SARCO-HUTA) with the approved piling
procedure and equipment according to the approved execution plan. The affected piles are about 20 numbers
with dropped ranging from 1.2 to 3.5 meters below the reference cut-off level. Violation logbook entries were
issued upon discovery of the dropped piles and demands further issue of technical query for the proposed
corrective action. These results to delay of the succeeding works for the capping beams and relieving platform
slabs since the short piles needs to extend to the cut-off level for the connection of piles reinforcing bars to
the capping beam.
Cost/Schedule/Safety/Quality impact:
The above construction issues resulted to additional work for the contractor and greatly impact the schedule
for the succeeding activities. Additional cost for pile extension/splicing up to the cut off level that involves
equipment, steel and splicing, concrete and delay on the construction schedule.
Reference to applicable SAES, SAEP, SAMSS, GI or other Saudi Aramco process:
Project Specification for concrete in the Maritime Environment-PB4784-0000-MA-SP-0024 rev. 09, ICE
Specification for Pilling and embedded retaining walls 2nd edition 2007 B1.17, B3.4.1, B3.5.2.4, B3.5.5,
B3.5.9

Investigation/Root Causes (Why did this happen? If positive experience, what were the benefits?)
The following are identified factors that caused the above irregularities:
 The failure of contractor to assign competent personnel for monitoring drilling process and not
calibrated measuring device during excavation which lead to over drilled and steel cage dropped down.
 Poor monitoring during drilling of bore holes and de-sanding operation (cleaning of bore hole) which
leads to deeper bore hole than the required.
 Over drilled which may lead for the reinforcing steel cage to settle down to the bottom immediately after
concrete pouring of bored pile while concrete is still flowable.
 Drilling equipment depth monitoring is sometimes disturbed and will not give accurate readings.
 Early extraction of temporary steel casing which may lead for the reinforcing cage to settle and or drop
down due to presence of surrounding disturbance (vibrating equipment).
 Wrong survey information for top elevation of temporary steel casing which is a factor in locating
theoretical levels of reinforcements.

Recommendation (How would you handle this next time to prevent problem or repeat success?)
Preventive Actions
 Only Competent personnel shall be assigned for drilling and de-sanding operation to closely monitor
drilled depth to avoid over excavation.

Saudi Aramco: Company General Use

  Drilling equipment depth monitoring shall be calibrated more frequently, and if possible to counter check
randomly with alternative means of checking the depth.
 Survey elevations shall be provided accurate.
 Avoid equipment’s with vibrating output to operate within the working area while on-going concreting.
 Positional tolerance of reinforcement shall be properly maintained.
 Reinforcing steel cage shall be extended to bottom of bore hole to accommodate excavation overcuts.
 Avoid early extraction of temporary steel casing.
 Review of Lesson Learned related to Bored Pile works before commencement of the activities to avoid
repeat of mistakes and to anticipate possible similar conditions.

Attachments

B.I. No. 25-00053-0003

King Salman International Complex for Maritime Industries and Services -
Project Title
Maritime Yard Development Program
Location Ras Al Khair
Contractor Consortium of SEPCO and Sinohydro
Project Phase Installation
(Below To be used by the LL Evaluation Team Only)

Evaluated by: (at least two Archelle Garcesa, Thamer Albaqami

Committee Members):
Team Leader: Abdulrahman G. Asmari
Approved for PMOD Yes/No
Approved for ID LL data base Yes/No

Saudi Aramco: Company General Use