Static load test method statement cm - ms- bw - 003

Doc. Title Method Statement for Static and PDA Load Test of pile for Building TOA-TOYO JOINT VENTURE

Doc. No CM – MS – BW - 003 Rev. No. 0 Date July, 2010

Construction of Port Facilities and Buildings for Cai Mep International Container Terminal

CAI MEP INTERNATIONAL CONTAINER TERMINAL

METHOD STATEMENT FOR STATIC AND PDA LOAD TESTOF PILE FOR BUILDING




TABLE OF CONTENTS

I INTRODUCTION 3

II. STATIC LOAD TEST 3

1. SPECIFICATIONS OF TEST PILE 3

2. TEST PURPOSE 4

3. TEST METHOD 4

4. TEST EQUIP MENT 4

5. SETTLEMENT 6

6. PREPARATION 6

7. TEST PROCEDURE 7

8. TEST RESULT 12

9. CONCLUSION AND RECOMMENDATION 13

III. PDA TEST 13

1. TEST PURPOSE 13

2. TEST PRINCIPLE 13

3. TEST EQUIP MENT 13

4. TEST PROCEDURE 14

5. TEST RECORD 15

6. TEST RESULT 15

IV. APPENDIX




I. INTRODUCTION

This method statement for the static and dynamic load test for the three kind’s and seven numbers of driven preliminary piles shall be carried out to check the integrity of the initial design of these piles to be used as a building foundation for the project. Location and selection of piles to be tested will be designated by the Engineer and the number of these test piles conform to the number and location stipulated in the Specification of the project.

Result obtained from these tests and the method of driving will be submitted to the Engineer to re establish the final design of the pile and pile depth. The work will be done by a third party who will be accredited and approved by the Engineer.

The Standard Test method to use for these preliminary driven test piles will be ASTM 1143-81 (1994).

II. STATIC LOAD TEST

1.0 SPECIFICATIONS OF TEST PILE

The driven preliminary piles as test piles are tested after seven days, the test result must conform to or greater than the design friction and bearing capacity specified by the Engineer prior to the commencement of mass piling works. Materials used in the fabrication of these preliminary piles as test piles will be the same as for the fabrication used for working piles. And the construction method in driving these preliminary piles as test piles will be adopted throughout the mass piling works for building structures.

The location of maximum test load shall be decided by the Engineer. Test piles specifications and locations are listed in the table.

Table 1: Test Pile Specifications and Locations

TEST LOCATION Pile Type- DiameterMaximum test load (Qmax=200%Qu) Design Load(Qu)

Operation Building PHC pile-Ø500mm 184 tons 92.0 tons

PMB Branch office PHC pile-Ø600mm 266 tons 133.0 tons

Amenity Block PHC pile- Ø600mm 266 tons 133.0 tons

CFS Building RC pile (400x400)mm 78 tons 39 .0 tons

Maintenance Shop RC pile (400x400)mm 54 tons 27.0 tons

Container Gate RC pile (400x400)mm 54 tons 27.0 tons

Sub Station RC pile (400x400)mm 54 tons 27.0 tons




2.0 TEST PURPOSE

The static load test will be specified either on the preliminary pile or working pile in accordance with the program of quality control. The purpose of the static load test is to:

− Obtain the capacity and settlement rate and residual settlement of pile for every load increments and decrements.

− Check the actual load bearing capacity compared to the theoretically calculated design.

Loading test shall comply with ASTM 1143-81 (1994): Standard Test method for Piles Under axial Compression Load.

3.0 TEST METHOD

Based on the design requirements, the test will be done by the application of an axial static load to a single pile by compression method. By this process, a hydraulic jack is placed on the vertically driven pile, acting directly opposite in reaction to the series of statically placed Kent ledges load. The loading and unloading process of these weights will be in increments for increasing the load and decrements for decreasing the load. And these actions will be done at every interval of time specified in the loading cycle of the test, refer to the table on loading cycle. During the process, settlement will be recorded at every loading and unloading made. These data’s will be check on the four (4) numbers settlement gauges installed around the four corners of the plain plate placed on top of the test pile where the hydraulic jack rest. Note that the pile will resist the total reaction of the weights of Kent ledges transmitted by the hydraulic jack during the process of jacking off these weights.

4.0 TEST EQUIPMENT

The test equipment consists of apparatus for applying load, reaction system and settlement measuring instruments.

4.1 Apparatus for applying load

The apparatus for applying load consist of hydraulic jack operated under a hydraulic pump with pressure gauge. The list of apparatus for applying load and their specifications are as follows:

a) Hydraulic jack

− Type of jack : KN500T – 200

− Manufacturer : China




- Capacity force : 500 ton

- Diameter of cylinder : 400 mm.

- Maximum stroke : 200 mm.

- Outside diameter : 561 mm.

- Height : 567 mm.

- Weight : 940 kg.

- Quantity : 01 pc.

b) Hydraulic pump

- Type of pump : ENERPAC

- Manufacturer : USA

- Engine : 1.5 HP, 220V, 50 Hz

- Maximum Pressure : 10,000 psi.

- Oil flow : 1-11liter/minute

- Quantity : 1 pc.

- Measuring Capacity : 0-600 Kg/cm²

- Error : 1.5%

4.2 Reaction System

The reaction system contains test beams loading frame and kentledge. The loading frame is constructed by a system of cross beams. The kentledge of concrete blocks is placed safely on the loading frame; the test beam is placed directly or approximately under resultant weight of the loading frame to form a reaction system of the hydraulic jack or apparatus for applying load.

Lists of reaction system and their specification are as follows:

4.2.1 Test beam

- Material : High strength steel

- Dimension : (900x300) mm x 12m




- Weight : 4ton/pc.

- Quantity : 1pc.

4.2.2 Cross beams

- Material : High strength steel

- Dimension : (700 x 700) mm x 12m

- Weight : 2.5 ton

- Quantity : 4 pcs.

4.2.3 Kentledge (including two supporters)

- Material : Concrete

- Dimensions : (1x1x2) m

- Total weight : 350 tons

5.0 Settlement

The settlement measuring instruments consist of four (4) dial gauges and two reference beams. The dial gauges will be placed firmly on the stable reference beams to avoid the influence of soil movement or deformation of equipment in measuring data of settlement. Listed below the gauges specifications

- Manufacture : Japan

- Maximum travel : 50 mm

- Accuracy : 0.01 mm

- Quantity : 04 pcs.

Before testing, the inspection and calibration certificates of the dial gauges shall be submitted to the Engineer for approval. These certificates are attached hereinafter for purposes of counter checking measures.

6.0 PREPARATION

The preparation of this test shall include pile installation and pile head treatment, in order to ensure that the installation of steel plate will be flat and level as specified in the method of standard used.




7.0 TEST PROCEDURE

7.1 Loading Procedure for the three types of piles

Based on the loading procedures, the load shall be applied in increments load. Each load increment and decrement shall be held for specified interval of time. Readings of gross settlement, load, and time are taken and recorded immediately before and after the application of each load increment and decrement.

Following the application of each load increment and decrement, the load shall be maintained at the specified value for not less than the time shown on the lower portion of the table or until the rate of settlement is less than 0.25mm/60min in 02 cycles.




Table 1: Loading & Unloading cycle Procedure for 600mmØ PHC Pile

Cycle Designed Load (%)

Load (Ton)

Minimum Holding Time

0 0

5 6.65 10 minutes

Cycle 1

25

50

75

100

75

50

25

0

33.25

66.5

99.75

133

99.75

66.5

33.25

0

≥ 1 hour till the settlement rate ≤ 0.25 mm/hour

- ditto-

- ditto-

till the settlement rate ≤ 0.25 mm/hour and ≤ 6/hours

≥ 10 minutes

≥ 10 minutes

≥ 10 minutes


Cycle 2

25

50

75

100

125

150

175

200

175

150

125

100

0

33.25

66.5

99.75

133

166.25

199.5

232.75

266

232.75

199.5

166.25

133

0


- ditto-

- ditto-





till the settlement rate ≤ 0.25 mm/hour and ≤24hours

≥ 10 minutes

- ditto-

- ditto-

- ditto-


Note: The rate of settlement should be less than 0.25 mm per 60 minutes at every

stage.




Table 2: Loading & Unloading Procedure for 500mmØ PHC Pile

Cycle Design Load (%)

Load (Ton)


0 0

5 4.6 10 minutes

Cycle 1

25

50

75

100

75

50

25

0

23

46

69

92

69

46

23

0


- ditto-

- ditto-


≥ 10 minutes

≥ 10 minutes

≥ 10 minutes


Cycle 2

25

50

75

100

125

150

175

200

175

150

125

100

0

23

46

69

92

115

138

161

184

161

138

115

92

0


- ditto-

- ditto-






≥ 10 minutes

- ditto-

- ditto-

- ditto-



stage.




Table 3: Loading & Unloading Procedure for (400x400) mm square pile


Load (Ton)


0 0

5 1.95 10 minutes

Cycle 1

25

50

75

100

75

50

25

0

9.75

19.5

29.25

39

29.25

19.5

9.75

0


- ditto-

- ditto-


≥ 10 minutes

≥ 10 minutes

≥ 10 minutes


Cycle 2

25

50

75

100

125

150

175

200

175

150

125

100

0

9.75

19.5

29.25

39

48.75

58.5

68.25

78

68.25

58.5

48.75

39

0


- ditto-

- ditto-






≥ 10 minutes

- ditto-

- ditto-

- ditto-



stage.




Table 4: Loading & Unloading Procedure for (400x400) mm square pile


Load (Ton)


0 0

5 1.35 10 minutes

Cycle 1

25

50

75

100

75

50

25

0

6.75

13.5

20.25

27

20.25

13.5

6.75

0


- ditto-

- ditto-


≥ 10 minutes

≥ 10 minutes

≥ 10 minutes


Cycle 2

25

50

75

100

125

150

175

200

175

150

125

100

0

6.75

13.5

20.25

27

33.75

40.5

47.25

54

47.25

40.5

33.75

27

0


- ditto-

- ditto-






≥ 10 minutes

- ditto-

- ditto-

- ditto-



stage.




7.2 Measurement Procedure

During loading and unloading, the readings of time, load and settlement of pile head were taken and recorded for every increment and decrement at 0, 10, 20, 30, 45, 60, 90, 120 minutes. After these two hours, the settlement rate shall be hourly taken in next 10 hours and each two hours for the last 12 hours.

Unloading reading time will be 0, 10, 20, 30 and each 30 minutes for the hour following.

7.3 Abandonment of Load Test

Test shall be discontinued if any of the following occurs:

− Faulty jack or gauge.− Pile head crack or broken.− Initial readings are incorrect.

7.4 Failure

When the preliminary tests have been done as prescribed above, the tested piles shall be deemed to have failed or reached the ultimate load capacity if any one of the following criteria is observed

− Pile material is broken;− A settlement equal to 10% of the test pile diameter is recorded, or− The rate of settlement continues undiminished without further increment of

load.

8.0 TEST RESULT

The result of load test is recorded and submitted in two forms, these are in tabular and graphical form.

8.1 Tabular Form

The data in this form includes load readings, time and settlement, recorded during the test and is presented in "The Pile Load Test Report".

8.2 Graphical Form

From the test data, the following curves are established for tested pile:




− Load - Settlement Curve − Settlement - Time Curve − Load - Settlement - Time Curve

9.0 CONCLUSIONS AND RECOMMENDATIONS

Conclusion and recommendations will be raised as a result of observation in the execution and evaluation of the test result.

III. Pile Dynamic Testing

1. Test Purpose

The purpose of this test is to determine the load-bearing capacity of piles tested by PDA method. The result of the test includes:

1. Calculation of load bearing capacity by CASE method and CAPWAP software application.

2. Prediction of load-Settlement chart.

3. Determination of defect if any.

The test shall be carried out at least 7 days after driving the preliminary for test piles.

2.Test Principle

This method is based on the principle of transferring stress wave in elastic environment. The stress wave will move down to the pile toe that is caused by driving a hammer from the pile top. Its strength and velocity depends on hammer energy and physical characteristics through the made-pile materials. The transferring process is from the pile vertical movement caused by hammer energy to the resisting soil around the pile and also the resisting soil opposite to the pile toe. By this process, distribution of the soil resistance can be measured and analyze at different levels, and defects can be discovered as well.

3.Test Equipment

The equipment used is Pile Driving Analyzer, Model PAK, from Pile Dynamics, Ins., USA, including:

− 02 Strain sensors and 02 Accelerators.

− 01 Monitor with functions:




+ Receive and store all general information about the tested piles and working modes.

+ Receive and store the measured signals, and transferring from accelerated signals to velocity signals by integrating.

+ Transfer data collected to computer for laboratory analysis.

4. Test procedure

The procedure includes two steps as follows:

a- Measuring stress waves on site

b- Analyzing the measured data in laboratory.

4.1. Measuring Stress Waves on Site.

The test will be executed after the piles and its surrounding soil had already settled, or follows the number of settlement days specified by the standard method for testing of this type. The process of this test will be done as follows:

− Fixing the strain sensors and accelerators in pairs to the pile body to ensure the distance from them to the pile top smaller than 2D (D is the width of the pile section). The pairs will be installed at the same level and at the opposite sides through the center of the pile section (figure 1). Actually, the pairs on site are from 0.8 to 1.0-m level satisfying the above condition.

− Connecting the strain sensors and accelerators with PDA equipment. Inputting information as characteristics of the piles, the driving hammers,

Strain sensor 1

Accelerator 1

Strainsensor 2

D

≥(1.5 - 2.5)D

AcceleratorStrain sensor

Ground water level




The piles are driven by series of 1, 3, 5 and 10 hammering. During this process, the equipment automatically records the acceleration and velocity waves of each hammering and temporarily evaluates the load bearing capacities of the piles.

During the test, the following information will be noted:

− Number of tested piles;

− Equipment and method to settle the piles;

− Characteristics of the site soil;

− The ‘rest’ time;

− All related information to the load bearing capacity.

4.2. Analyzing the Measured Data

The received signals on site measurement are transferred to a computer to be further analyzed by CAPWAP software. Up to requirements, the bearing capacity would be calculated by one of two following methods:

− CASE method: the results can be quickly determined soon after ending the test.

− CAPWAP method: The tested pile and the soil would be modeled for analyzing. For each model, the measured wave velocity, Vm, is used to calculate the strain wave, Pc. By comparing Pc to the measured wave, Pm, we can evaluate whether the used model matches the measured data or not. This model would be gradually adjusted until Pc and Pm is the same. Pile loading diagram and calculation of the load bearing capacity are based on a model, which satisfies the above condition.

5. TEST RECORDS

Test Records:

− General information of the tested piles.

− Stress wave charts;

− Calculated results of the load bearing capacity by CASE method;

− Load - settlement chart;

Accelerator 2




− Defect evaluation;

− Other related information.

6. TEST RESULTS

− Determining the load bearing capacity of the tested piles by analyzing the measured stress waves.

− Defect evaluation.

6.1 Testing Company:

− Testing company shall be proposed to the Engineer by separate submission for accreditation and approval.

− Certificates of manpower, equipments and apparatus to be used for the test shall be submitted by separate submittal.

III. APPENDIX

− Organizational system

− Quality Control form

− Risk assessment plan

− Test pile layout plan

− Test schedule

− Work flow chart

− Inspection and test plan




Test set up sample plan




WORK FLOW AND PROCEDURE

Pile head treatment

Set up load frame & Girder Beam support

Set up 2 Girder Beam support

Set up steel plate on pile head

Set up Hydraulic jack eccentric to test pile resting on level steel

plate

Set up 2 Girder Beam support for the load beams

Set up the Load carrying beam system

Set up the ken ledge load on load Beams

Get the Approval of the Engineer at site

before commencing the test

YES=Proceed the TEST

NO= Clarify Objection

Check the efficiency of jack, gauges and the loads, beams and Girders for their proper position

Set up 2 reference beam for the 4 dial settlement gauges

Install the 4 dial settlement gauges and load gauge for the hydraulic

jack




MANPOWER ORGANIZATION

TOA -TOYO JV

Chief Engineer

Item No Title Numbers Remarks

1 Project Manager 1

2 Chief engineer 2

3 QC engineer 1

4 Safety officer 1

5 Site/Survey engineer 2

6 Eqpt. Operator/mechanic 2 Minimum for crane

7 Labor utilities 6 Minimum for testTotal→ 15

Safety Engineer Survey/Site Engineer

Qc Engineer

Static load test method statement cm - ms- bw - 003

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