Student Manual

Lesson 7 Begin Pile Driving

Lesson 7

BEGIN PILE DRIVING

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Learning Outcomes
Monitor and verify proper marking of the piles per contract documents and standards Verify & document contractor compliance with applicable tolerances Monitor, verify and document pile driving operations Identify applicable 455 specifications
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Inspectors Role

Verify Contractor Compliance with Project Plans and Specifications Monitor and Maintain Record of Driving Determine When to Stop Driving

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As discussed earlier, the Inspector has numerous responsibilities throughout the pile driving operations. During this phase of pile driving, the Inspector needs to verify compliance with the project Plans and Specifications for pile plan location, axial alignment and record the driving event. During the driving of the pile, there are specific duties, such as hammer and pile cushion inspection, together with the recording of the operation, blows, stroke height/pressure, etc.

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Inspectors Checklist

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A full size checklist is at the end of this lesson and in the Appendices.

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455-5.15 Allowable Driving Tolerances

455-5.15.1 General: Meet the tolerances described in this Subarticle to the piles that are free standing without lateral restraint (after the template is removed). After the piles are driven, do not move the piles laterally to force them to be within the specified tolerances. The Contractor may move battered piles laterally to overcome the dead load deflections caused by the piles weight. When this is necessary, submit calculations signed and sealed by a Specialty Engineer to the Engineer that verify the amount of dead load deflection prior to moving any piles.
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455-5.15 Allowable Driving Tolerances

455-5.15.2 Position: Ensure that the final position of the pile head at cut-off elevation is no more than 3 inches laterally in the X or Y coordinate from the plan position indicated in the plans. 455-5.15.3 Axial Alignment: Ensure that the axial alignment of the driven piles does not deviate by more than 1/4 in/ft from the vertical or batter line indicated in the plans.

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455-5.15 Allowable Driving Tolerances

455-5.15.4 Elevation: Ensure that the final elevation of the pile head is no more than 1 1/2 inches above, or more than 4 inches below, the elevation shown in the plans. Do not embed the pile less than 6 inches below the elevation shown in the plans unless a minimum cap or footing embedment is shown. For fender piles, cut off piles at the elevation shown on the plans to a tolerance of +0.0/-2.0 using sawing or other means as approved by the Engineer to provide a smooth level cut.

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455-5.15.2 Plan
Maximum Allowable Tolerance 3 In Any One Direction

As Built Pile Location Plan Pile Location

Maximum Allowable Tolerance 3 In Any One Direction

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455-5.15.3 Axial Alignment

1.0

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Checking Axial Alignment

Pile 4 ft. Builders Square positioned level on reference Reference 4

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455-5.15.4 Elevation
No more than 1 above Cutoff Elevation Cutoff Elevation No more than 4 below Cutoff Elevation

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455-5.1 Site Preparation

455-5.1.1 Predrilling of Pile Holes: Predrilled pile holes are either starter holes to the depth described in this section or holes drilled through embankment/fill material down to the natural ground surface. When using low displacement steel piling such as structural shapes, drive them through the compacted fill without the necessity of drilling holes through the fill except when the requirements for predrilling are shown in the plans. When using concrete or other high displacement piles, drill pile holes through fill, new or existing, to at least the elevation of the natural ground surface. Use the range of drill diameters listed below for square concrete piles..
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455-5.1.1 Predrilling of Pile Holes: 12 inch square piles 15 to 17 inches 14 inch square piles 18 to 20 inches 18 inch square piles 22 to 26 inches 20 inch square piles 24 to 29 inches 24 inch square piles 30 to 34 inches 30 inch square piles 36 to 43 inches The Contractor is not paid for Predrilled Holes. These are up to 10 ft or 20 % of the pile length (whichever is greater) starter holes. However, it is important that the Inspector recognize that whatever depth of predrilled hole was used in the Test Pile program is the depth used in production piles. Therefore, if 6 foot predrilled holes were used in the Test pile program and the Contractor wants to do 20 foot predrilled holes during production, this is not permitted. The Inspector should inform the Contractor it is not permitted, contact the PA and document the depth of hole predrilled.

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Predrilling through Fill

Natural Ground is defined as the ground surface prior to any roadway construction
Predrilled Hole

Existing Embankment Natural Ground Surface

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455-5.1.1 Predrilling of Pile Holes: Predrilled pile holes are either starter holes to the depth described in this section or holes drilled through embankment/fill material down to the natural ground surface... .When using concrete or other high displacement piles, drill pile holes through fill, new or existing, to at least the elevation of the natural ground surface. In the setting of permanent and test piling, the Contractor may initially predrill holes to a depth up to 10 feet or 20% of the pile length whichever is greater, except that, where installing piles in compacted fill, predrill the holes to the elevation of the natural ground surface

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455-5.1 Site Preparation

455-5.1.1 Predrilling of Pile Holes: (Continued) For other pile sizes, use the diameter of the drills shown in the plans or approved by the Engineer. Accurately drill the pile holes with the hole centered over the plan location of the piling. Maintain the location and vertical alignment within the tolerances allowed for the piling.

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455-5.1 Site Preparation

455-5.1.1 Predrilling of Pile Holes: (Continued) . For predrilled holes required through rock or other hard (i.e. debris, obstructions, etc.) materials that may damage the pile during installation, predrill hole diameters approximately 2 inches larger than the largest dimension across the pile cross-section. Fill the annular space around the piles as described in 455-5.9.1 with clean A-3 sand or sand meeting the requirements of 902-3.3.

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455-5.1 Site Preparation

455-5.1.1 Predrilling of Pile Holes: (Continued) . In the setting of permanent and test piling, the Contractor may initially predrill holes to a depth up to 10 feet or 20% of the pile length whichever is greater, except that, where installing piles in compacted fill, predrill the holes to the elevation of the natural ground surface. With prior written authorization from the Engineer, the Contractor may predrill holes to greater depths to minimize the effects of vibrations on existing structures adjacent to the work and/or for other reasons the Contractor proposes..
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Remember, the bottom of a Pre-drilled hole is NOT the bottom of an Excavation

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455-5.1 Site Preparation

455-5.1.1 Predrilling of Pile Holes: (Continued) . Perform such work the Engineer allows but does not require at no expense to the Department. When the Engineer requires such work, the Department will pay for such work as Preformed Pile Holes as described in 455-5.9.

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455-5.9 Preformed Pile Holes

455-5.9.1 Description: Preformed Pile Holes serve as a penetration aid when all other pile installation methods fail to produce the desired penetration and when authorized by the Engineer to minimize the effects of vibrations on adjacent structures. Preformed Pile Holes are necessary when the presence of rock or strong strata of soils will not permit the installation of piles to the desired penetration by driving or a combination of jetting and driving, when determined necessary by the Engineer, or when authorized by the Engineer to minimize the effects of vibrations on adjacent existing structures.
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The Contractor is paid for Preformed Holes if they are shown in the Project plans. Remember, Preforming depths are typically shown in the Pile Data Table and are given as an Elevation. Preformed Hole Depth, for recording purposes, is the depth or length of Preformed Hole drilled by the Contractor. Therefore, the Inspector needs to verify that the preformed Hole was drilled to the elevation specified and then record that length for pay purposes.

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455-5.9 Preformed Pile Holes

455-5.9.1 Description: (Continued) . The Engineer may require preformed holes for any type of pile. Drive all piles installed in Preformed Pile Holes to determine that the bearing requirements have been met. For preformed holes which are required through material that caves during driving to the extent that the preformed hole does not serve its intended purpose, case the hole from the surface through caving material. After installing the pile to the bottom of the casing, remove the casings unless shown otherwise in the plans. Determine bearing of the pile after removing the casing unless shown otherwise in the plans.
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Remember, the bottom of a Preformed hole is NOT the bottom of an Excavation.

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455-5.9.1 Description: (Continued) .Fill all voids between the pile and soil remaining after driving through preformed holes with clean A-3 sand or sand meeting the requirements of 902-3.3, after the pile has achieved the required minimum tip elevation, unless grouting of preformed pile holes is shown in the plans. If pile driving is interrupted during sand placement, drive the pile at least 20 additional blows after filling all of the voids between the pile and soil with sand at no additional compensation.
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455-5.9 Preformed Pile Holes

455-5.9.2 Provisions for Use of Preformed Pile Holes: The Department generally anticipates the necessity for Preformed Pile Holes and includes directions in the Contract Documents. The Department will pay for Preformed Piles Holes when the Contractor establishes that the required results cannot be obtained when driving the load bearing piles with specified driving equipment, or if jetting is allowed, while jetting the piles and then driving or while jetting the piles during driving.

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455-5.9.3 Conditions Under Which Payment Will Be Made: a) Inability to drive piles to the required penetration with driving and jetting equipment. (b) To penetrate a hard layer or layers of rock or strong stratum that the Engineer considers not sufficiently thick to support the structure. (c) To obtain greater penetration into dense (strong) material and into dense material containing holes, cavities or unstable soft layers. (d) To obtain penetration into a stratum in which it is desired to found the structure. (e) To minimize the effects of vibrations or heave on adjacent existing structures.

(f) To obtain a penetration up to 20 feet except where the Contract Documents show a required pile penetration in excess of 20 feet. (g) To minimize the effects of ground heave on adjacent piles.

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455-5.9 Preformed Pile Holes

455-5.9.4 Construction Methods: Construct Preformed Pile Holes by drilling, or driving and withdrawing a suitable punch or chisel at the locations of the piles. Construct a hole that is equal to or slightly greater than the largest pile dimension for the entire length of the hole and of sufficient depth to obtain the required penetration. Carefully form the preformed hole by using a drill or punch guided by a template or other suitable device, and do not exceed the minimum dimensions necessary to achieve the required penetration of the pile.
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455-5.9 Preformed Pile Holes

455-5.9.4 Construction Methods: (Continued) . When the plans call for grouting the Preformed Pile Holes, provide the minimum dimension of the pile hole that is 2 inches larger than the largest pile dimension. Construct the holes at the plan position of the pile and the tolerances in location, and ensure the hole is straight and that the batter is the same as specified for the pile. Loose material may remain in the preformed pile hole if the conditions in 455-5.9.3 are satisfied.

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455-5.9 Preformed Pile Holes

455-5.9.5 Grouting of Pile Holes: Grout Preformed Pile Holes for bearing piles, when the plans require grouting after driving. Clean the Preformed Pile Holes, and fill them with cement grout as shown in the plans. Use grout that has a minimum compressive strength of 3,000 psi at 28 days or as specified. Pump the grout through three or more grout pipes initially placed at the bottom of the preformed hole. The Contractor may raise the grout pipes when necessary to prevent clogging and to complete the grouting operations.
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Learning Outcome
Which, Predrilling or Preforming, is the Contractor Paid for accomplishing?

The tolerance for plan position is ______. A. B. C. D. 3 inches 4 inches 5 inches 6 inches
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Learning Outcome
Which holes, Predrill or Preform, are to have hole diameters approximately 2 inches larger than the largest dimension across the pile cross-section.

The tolerance for axial alignment for driven piles is ______. A. 2 inches/ft.
B. 1 inch/ft. C. inch/ft. D. inch/ft.
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Verify Marking of the Piles

English mark in 1 ft. intervals

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Generally, projects designed in English units will specify blows per foot, therefore the pile should be marked in 1 foot intervals.

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Verify Marking of the Piles

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455-6 Timber Piles

455-6.5 Cutting Off: Saw off the tops of all timber piles at the elevation indicated in the plans. Saw off piles which support timber caps to the exact plane of the superimposed structure so that they exactly fit it. Withdraw and replace broken, split, or misplaced piles . 455-6.6 Build-ups: The Engineer will not permit splices or build-ups for timber piles. Extract piles driven below plan elevation and drive a longer pile.

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455-7 Prestressed Concrete Piling

455-7 Prestressed Concrete Piling: 455-7.1 General: Provide prestressed concrete piles that are manufactured, cured, and driven in accordance with the requirements of the Contract Documents. Provide piles full length without splices when transported by barge or the pile length is less than or equal to 120 feet. When piles are transported by truck and the pile length exceeds 120 feet but is less than the maximum length for a three point pick-up according to Index 20600, and splicing is desired, provide minimal splices. Include the cost of the splices in the cost of the pile.
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455-7 Prestressed Concrete Piling

455-7.7 Extensions and Build-ups Used to Increase Production Lengths: 455-7.7.1 General:Where splices and build-ups for concrete piles are necessary, construct such splices and build-ups in accordance with Standard Index 20601. The Contractor may construct build-ups less than 2 feet in length in accordance with 455-11.8. When splicing a prestressed precast section onto the original pile and, after driving, the length of spliced section below cut-off elevation is 4 feet or less, remove the pile concrete to the cut-off elevation and leave the dowels in place to be incorporated into the cap as directed by the Engineer. The Contractor may cut the length of dowels which becomes exposed to a length of 48 inches from the plane of pile-splice

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455-7 Prestressed Concrete Piling

455-7.7.2 Extensions to be Driven or Those 21 feet or Longer: Construct extensions to be driven or extensions 21 feet or longer in length in accordance with the details shown in the plans and in a manner including the requirements, sequences, and procedures outlined below:

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(a) Cast a splice section in accordance with Section 450 with the dowel steel in the correct position and alignment. (b) Drill dowel holes using an approved steel template that will position and align the drill bit during drilling. Drill holes a minimum of 2 inches deeper than the length of the dowel to be inserted. (c) Clean the drilled dowel holes by inserting a high pressure air hose to the bottom of the hole and blowing the hole clean from the bottom upward. Eliminate any oil, dust, water, and other deleterious materials from the holes and the concrete surfaces to be joined. (d) Place forms around joints between the pile sections. (e) Mix the adhesive components in accordance with the manufacturers directions. Do not mix sand or any other filler material with the epoxy components unless it is prepackaged by the manufacturer for this specific purpose. Use adhesives meeting the requirements of Section 926 for Type B Epoxy Compounds. (f) After ensuring that all concrete surfaces are dry, fill the dowel holes with the adhesive material. (g) Insert the dowels of the spliced section into the adhesive filled holes of the bottom section and position the spliced section so that the axes of the two sections are in concentric alignment and the ends of the abutting sections are spaced 1/2 inch apart. The Contractor may use small steel spacers of the required thickness provided they have 3 inches or more of cover after completing the splice. Fill the space between the abutting sections completely with the adhesive. (h) Secure the spliced sections in alignment until the adhesive is cured in accordance with the manufacturers directions for the time appropriate with the prevailing ambient temperatures. Do not utilize the crane to secure the pile extension during the adhesive cure time. Utilize alignment braces to maintain the proper pile alignment during the epoxy cure time. (i) After curing is completed, remove alignment braces and forms and clean and dress the spliced area to match the pile dimensions.

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455-7 Prestressed Concrete Piling

455-7.7.3 Precast Reinforced Build-ups: Construct Precast Reinforced Buildups in accordance with the requirements of this Subarticle, Section 346, and Section 400. Provide the same material for the form surfaces for precast build-ups as was used to form the prestressed piles. Use concrete of the same mix as used in the prestressed pile and dimension the cross-section the same as piling being built up. Install build-ups as specified in 455-7.7.2(b) through 455-7.7.2(i).

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455-7 Prestressed Concrete Piling

455-7.8 Pre-Planned Splices: Splices shall be made by the doweled splice method contained in the Standard Indexes or may be made using proprietary splices which are listed on the Departments QPL. Splice test piles in the same manner as the production piles. Include in the pile installation plan, the chosen method of splicing and the approximate locations of the splice.

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455-7 Prestressed Concrete Piling

455-7.8 Pre-Planned Splices (continued) Generally, place the splice at approximately the midpoint between the estimated pile tip and the ground surface, considering scour if applicable. Stagger the splice location between adjacent piles by a minimum of 10 feet. Obtain the Engineers approval prior to constructing any pile sections. Construct piles which are to be spliced using the doweled splice with preformed dowel holes in the bottom section and embedded dowels in the upper section. .
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Constructing Splice- Concrete Piling

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Constructing Splice- Concrete Piling

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(a) Cast a splice section in accordance with Section 450 with the dowel steel in the correct position and alignment. (b) Drill dowel holes using an approved steel template that will position and align the drill bit during drilling. Drill holes a minimum of 2 inches deeper than the length of the dowel to be inserted. (c) Clean the drilled dowel holes by inserting a high pressure air hose to the bottom of the hole and blowing the hole clean from the bottom upward. Eliminate any oil, dust, water, and other deleterious materials from the holes and the concrete surfaces to be joined. (d) Place forms around joints between the pile sections. (e) Mix the adhesive components in accordance with the manufacturers directions. Do not mix sand or any other filler material with the epoxy components unless it is prepackaged by the manufacturer for this specific purpose. Use adhesives meeting the requirements of Section 926 for Type B Epoxy Compounds. (f) After ensuring that all concrete surfaces are dry, fill the dowel holes with the adhesive material. (g) Insert the dowels of the spliced section into the adhesive filled holes of the bottom section and position the spliced section so that the axes of the two sections are in concentric alignment and the ends of the abutting sections are spaced 1/2 inch apart. The Contractor may use small steel spacers of the required thickness provided they have 3 inches or more of cover after completing the splice. Fill the space between the abutting sections completely with the adhesive. (h) Secure the spliced sections in alignment until the adhesive is cured in accordance with the manufacturers directions for the time appropriate with the prevailing ambient temperatures. Do not utilize the crane to secure the pile extension during the adhesive cure time. Utilize alignment braces to maintain the proper pile alignment during the epoxy cure time. (i) After curing is completed, remove alignment braces and forms and clean and dress the spliced area to match the pile dimensions.

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455-8 Steel Piling

455-8.3 Pile Splices: Order and use the full authorized pile length where practicable. Do not splice to obtain authorized lengths less than 40 feet except when shown in the plans. Locate all splices in the authorized pile length in portions of the pile expected to be at least 15 feet below the final ground surface after driving. When it is not practicable to provide authorized pile lengths longer than 40 feet in a single length, use no more than one field splice per additional 40 feet of authorized pile length. Shop splices may be used to join single lengths of pile which are at least 20 feet in length. One shorter segment of pile may be used to achieve the authorized pile length when needed
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455-8 Steel Piling

455-8.9 Filling Pipe Piles: When required by the plans, fill pipe piles with the specified materials. Use clean concrete sands and concrete meeting the requirements of Section 346. Place concrete in pipes containing water using methods in accordance with 455-15.9 with modified tremie and pump line sizes. Concrete may be placed directly into pipes which are dry.

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Constructing Splice- Steel Pile

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455-5.8 Penetration
455-5.8 Penetration Requirements: Measure the penetration of piles from the elevation of natural ground, scour elevation shown in the plans, or the bottom of excavation, whichever is lower. When the Contract Documents show a minimum pile tip elevation or a minimum depth of penetration, drive the tip of the pile to this minimum elevation or this minimum penetration depth. In all such cases, the Engineer will accept the bearing of a pile only if the Contractor achieves the required bearing when the tip of the pile is at or below the specified minimum tip elevation or depth of penetration and below the bottom of the preformed or predrilled pile hole.
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Penetration is measured as the difference between the lowest of these three elevations and the tip of the pile. NOTE- The bottom of predrilled or preformed holes does not count as the bottom of an excavation.

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455-5.8 Penetration
455-5.8 Penetration Requirements: (Continued) . When the plans do not show a minimum depth of penetration, scour elevation, or minimum tip elevation, ensure that the required penetration is at least 10 feet into firm bearing material or at least 20 feet into soft material unless otherwise permitted by the Engineer. If a scour elevation is shown in the plans, achieve these penetrations below the scour elevation. The Engineer may accept a penetration between 15 and 20 feet when there is an accumulation of five consecutive feet or more of firm bearing material.

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455-5.8 Penetration
455-5.8 Penetration Requirements: (Continued) . Firm bearing material is any material offering a driving resistance greater than or equal to 30 tons/ft2 of gross pile area as determined by the Wave Equation (455-5.11.2). Soft material is any material offering less than these resistances. The gross pile area is the actual pile tip crosssectional area for solid concrete piles, the product of the width and depth for H piles, and the area within the outside perimeter for pipe piles and voided concrete piles.
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455-5.8 Penetration
455-5.8 Penetration Requirements: (Continued) . Firm bearing material is any material offering a driving resistance greater than or equal to 30 tons/ft2 of gross pile area as determined by the Dynamic Load Testing (455-5.11.4). Soft material is any material offering less than these resistances. The gross pile area is the actual pile tip crosssectional area for solid concrete piles, the product of the width and depth for H piles, and the area within the outside perimeter for pipe piles and voided concrete piles.
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455-5.8 Penetration

455-5.8 Penetration Requirements: (Continued) . Do not drive piles beyond practical refusal (20 blows per inch). To meet the requirements in this Subarticle, provide penetration aids, such as jetting or preformed pile holes, when piles cannot be driven to the required penetration without reaching practical refusal.

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455-5.10 Bearing Requirements

455-5.10.1 General: . The Engineer may accept a driven pile when the pile has achieved minimum penetration, the blow count is generally increasing and the minimum required bearing capacity obtained for 24 inches of consecutive driving. At his discretion, the Engineer may also accept a driven pile when the minimum penetration is achieved and driving has reached practical refusal in firm material.

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Prior to starting the Project, the Inspector should ask the PA how they want a decrease in blow counts, with an increased stroke height, handled. Typically, because an increased stroke height equates to more energy being imparted to the pile, less blows are required, as you will see in Driving Criteria Letters for Blow Count vs Stroke Height criteria.

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Data Recording
The Pile Driving Record, which includes: Hammer blows for each interval Stroke Height or bounce chamber pressure for each interval Making appropriate notes concerning driving operations

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Check Hammer Settings

Check Driving Criteria Letter for driving requirements.

Recommended stroke height of 5 to 6 ft (approx. fuel pressure of 150 psi)

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The Driving criteria Letter may provide a start of driving stroke height, fuel setting or pressure. This is quite common when dealing with concrete piles, especially if easy or soft driving initially is anticipated. Soft or little resistance at the tip and a big stroke height can result in excess tension in a concrete pile and damage the tip. Remember to document all fuel settings and changes.

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Fuel Settings- OED

4-setting fuel pump for Open-end Diesel hammer (lanyards)

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Shown above is a fixed four step fuel pump on a Delmag hammer. Generally open end diesel hammers are equipped with 4 fuel settings that enable the operator to control the stroke height. Fuel setting #1 is the lowest, and thereby produces the least combustion, hence the lowest stroke height. Typically, the higher the fuel setting the higher the stroke. A lanyard is connected to the pump and adjustments made by someone on the ground pulling the lanyard.

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Fuel Settings- OED

Adjustable pressure pump for changing fuel setting

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Shown above is an adjustable pressure pump for fuel setting on an ICE hammer. Closed end diesel, air/steam and hydraulic hammers are pressure operated and allow for a more precise setting of the hammer energy delivered than the open end diesel or drop hammer. Controls such as these are used to adjust the pressure being delivered to the hammer.

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Stroke Height Setting

Slide Bar2 Stroke Height Settings for Air Hammer

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The various types of hammers have various ways to control the stroke. With drop hammers the stroke height is controlled by the operator lifting the weight. Open end diesel stroke height is a function of the fuel setting and resistance to driving, so in a sense is not really set. On air/steam the slide bar (shown above) provides for the setting of a constant stroke height. Generally there are two settings allowing for a full stroke and a short stroke, which is usually no less than 2 ft.

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Check Auxiliary Equipment

Display

Total Blow Count Incremental Blow Count Display Selector Knob

Incremental Blow Count Reset

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Check Auxiliary Equipment

Bounce Chamber Pressure Gauge- Closed-end Diesel

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For closed end diesel hammers, the pressure is displayed on the Bounce Chamber pressure gauge. With these systems, the Inspector depresses the panel button, typically with their foot, for approx. 10 seconds, during each increment, and records the average pressure being displayed during that time. Dont forget to measure the hose.
BOUNCE CHAMBER PRESSURE - p.s.i.g.

LINK-BELT SPEEDER
25 23 21 19 17 15 13 11 16,000 18,000
t t. 0f o5 Ho se

MODEL 520 DIESEL PILE HAMMER BOUNCE CHAMBER PRESSURE vs. EQUIVALENT WH ENERGY SEA LEVEL TO 2000 ELEVATION

Up

Up

8 to

t. 0f

Ho

se

Up

t 10 f to 1

. Ho

se

EQUIVALENT WH ENERGY - FT. - LBS

20,000

22,000

24,000

26,000

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Common Problems- OED

Common Problems
Water in fuel Fuel lines clogged Fuel pump malfunctioning Fuel injectors malfunctioning Oil low Oil pump malfunctioning Water in combustion chamber Piston rings worn Tripping device broken Over heating

Indicators
Hollow sound, white smoke No smoke or little gray smoke Inconsistent ram strokes, little gray smoke or black smoke Inconsistent ram strokes, little gray smoke or black smoke Blows per minute rate is lower than specified Blows per minute rate is lower than specified Hollow sound, white smoke Low strokes Pawl does not engage piston Pawl engages but doesn't lift piston Paint and oil on cooling fins start to burn/sound changes

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Common Problems- Closed-end Diesel

Common Problems
Water in fuel Fuel lines clogged Fuel pump malfunctioning Fuel injectors malfunctioning Oil low Oil pump malfunctioning Water in combustion chamber Piston rings worn Tripping device broken Over heating Oil build up in bounce chamber

Indicators
Hollow sound, white smoke No smoke or little gray smoke Inconsistent ram strokes, little gray smoke or black smoke Inconsistent ram strokes, little gray smoke or black smoke Blows per minute rate is lower than specified Blows per minute rate is lower than specified Hollow sound, white smoke Low strokes Pawl does not engage piston Pawl engages but doesn't lift piston Paint and oil on cooling fins start to burn/sound changes Not visible from exterior
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Common Problems- Air/Steam

Common Problems Indicators
Air trip mechanism or hammer erratic operation rates or air valve sticking open or closed malfunctioning Cushion stack height incorrect (affects timing of trip mechanism air erratic operation rates valve) Compressor not supplying correct blows per minute rate is varying either faster or slower pressure & volume of air to hammer than the manufacturer specified Air supply lines either kinked or tangled in leads, boom, or other Moisture in air ices up hammer Lack of lubricant in air supply lines Packing around air chest worn allowing air blow by Nylon slide bar worn visually evident ice crystals exiting exhaust ports of hammer erratic operation rates ram raises slowly- blows/minute rate slower than specified by manufacturer- air leaking around piston shaft & air chest visually evident

Ram columns insufficiently greased visually evident

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Common Problems- Hydraulic

Common Problems Hoses getting caught in leads Fittings leaking Electrical connections Sensors visually evident

Indicators

hydraulic fluid leaking erratic performance erratic performance

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455-5.3 Cushions & Pile Helmet

455-5.3.1 Capblock: . Maintain capblocks in good condition, and change them when charred, melted, or otherwise significantly deteriorated. The Engineer will inspect the capblock before driving begins and weekly or at appropriate intervals determined by the Engineer based on field trial. Replace or repair any hammer cushion which loses more than 25% of its original thickness, in accordance with the manufacturers instructions, before permitting further driving.
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Check Hammer Cushions

The Driving Criteria Letter may specify a different inspection schedule.

The above pile driving criteria are based on a hammer driving system consisting of an ICE Model 60-S, single-acting, diesel hammer with a hammer cushion comprised of 0.5 inches of aluminum and 2 inches of blue nylon. Hammer cushions should be inspected on weekly, or appropriate intervals and maintained in accordance with 455-5.3.1. Preforming for the production piles should be conducted in the same manner as the test pile program. If there is a change in the driving system for the piles or the preforming depth and/or techniques, notify the Engineer so new driving criteria can be determined.

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The Inspector should check the Driving Criteria Letter as it may specify a different inspection schedule than the standard specifications. Note that the bottom highlighted area states no changes without the Engineers approval. For example: If the Contractor replaced a micarta cushion with the same type and thickness, thats OK. However, if they replaced the micarta with say hamortex and aluminum plates, this would be a change needing the Engineers approval.

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Check Hammer Cushions

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Good ____ or Bad____

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455-5.3 Cushions & Pile Helmet

455-5.3.2 Pile Cushion: . Maintain pile cushions in good condition and change when charred, splintered, excessively compressed, or otherwise deteriorated to the point it will not protect the pile against overstressing in tension and/or compression. Protect cushions from the weather, and keep them dry. Do not soak the cushions in any liquid. Replace the pile cushion if, during the driving of any pile, the cushion is either compressed more than one-half the original thickness or begins to burn.
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455-5.3 Cushions & Pile Helmet

455-5.3.2 Pile Cushion: (Continued) . Provide a new cushion for each pile unless approved otherwise by the Engineer after satisfactory field trial. Reuse pile cushions in good condition to perform all set-checks and redrives. Use the same cushion to perform the set-check or redrive as was used during the initial driving, unless this cushion is unacceptable due to deterioration, in which case use a similar cushion.

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Check Pile Cushion

The Driving Criteria Letter may specify a different inspection schedule.

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Check Pile Cushion

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The 455 specifications require a new pile cushion be used for each pile. A Note should be made in the Pile Driving Record when changing pile cushions as generally the blow count will increase as the new cushion compresses giving a false sense of increased bearing capacity. If the pile is getting close to taking up (achieving bearing) and the pile cushion has to be changed, the Engineer may want the have a certain number of hammer blows put on the new cushion prior to getting back on the pile and commencing driving

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Replace Charred or Burning Cushion

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Burning Cushion

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Pile Damage During Driving

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Remember, steel piles are more susceptible to damage from compressive stresses than from tension.

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Steel Piles
Typical causes of damage Transporting Steel Strength Lifting Driving (Compression) Welding Splices
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Possible indicators during driving

Types of damage

Pile moving out of position Bending during driving Buckling Abrupt blow count change Accordion Splitting

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Pile Damage During Driving

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Concrete Piles
Typical causes of damage Possible indicators during driving Types of damage Spalling- slabing Microcracks Transverse cracks Longitudinal cracks

Casting/stressing Cushions burning or compressed Concrete Strength Concrete Curing Puffs of concrete dust coming out of side of pile Transporting Pile walking out of position Lifting Driving (major cause) Post driving Construction

Hammer pile alignment bad Combination cracks Abrupt blow count change Tip damage
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455-5.10.5 Pile Heave

455-5.10.5 Pile Heave: Pile heave is the upward movement of a pile from its originally driven elevation. Drive the piles in an approved sequence to minimize the effects of heave and lateral displacement of the ground. Monitor piles previously driven in a pile group for possible heave during the driving of the remaining piles. When required by the Engineer, take elevation measurements to determine the magnitude of the movement of piles and the ground surface resulting from the driving process.
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455-5.10.5 Pile Heave

455-5.10.5 Pile Heave: (Continued) . Redrive all piles that have heaved 1/4 inch or more unless the Engineer determines that the heave is not detrimental to pile capacity. The Department will pay for all work in conjunction with redriving piles due to pile heave under the Pile Redrive Item.

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Learning Outcome
Unless otherwise approved by the Engineer, used pile cushions may be utilized to drive up to how many additional piles? A. None
B. 1 C. 2 D. No limit

Pile Heave refers to ___________. A. The unloading of piles from the transport vehicle.
B. The downward movement of a previously driven pile. C. The upward movement of a previously driven pile. D. The act of loading the pile into fixed leads.
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Learning Outcome
Hammer cushions should be inspected before driving begins and at approx. _____ intervals during driving. A. daily
B. hourly C. weekly D. monthly

True or False: Pile cushions are to be replaced when they are Compressed more than 25% of their original thickness? A. True
B. False
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Learning Outcomes
Monitor and verify proper marking of the piles per contract documents and standards Verify & document contractor compliance with applicable tolerances Monitor, verify and document pile driving operations Identify applicable 455 specifications
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Questions?

ANY QUESTIONS ?

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PILE INSPECTORS CHECKLIST

The following is a general checklist to follow when driving a Pile. The answer to each of these, if applicable , should yes unless plans, specifications, or specific approval has been given otherwise. CONSULT WITH THE RESPONSIBLE PROJECT ADMINISTRATOR FOR YOUR SPECIFIC PROJECT RESPONSIBILITIES.

EARLY REQUIREMENTS
1. 2. 3. 4. Do you have a copy of the Plans including latest revisions & located relevant items? (ex: Pile Date Table) Do you have and reviewed the accepted Pile Installation Plan? Are Dynamic Load Tests required and if so, is the PDA Engineer coordinated with? Have you downloaded and installed the current version of the FDOT Pile Technician Program on your field computer? 5. Have you setup Structure Files and Bent/Pier Models in the program? 6. Have you made the Initial Pile Data entries and Standard Notes entries in the program? 7. Have you scheduled or attended a Pre-Driving meeting with the PA/Geotechnical Engineer?

Yes No 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 9 10 11 12 13 A1 A2 A3 B1 B2 B3 C1 C2 D1 D2 D3 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 8 9 10 11 12 13 A1 A2 A3 B1 B2 B3 C1 C2 D1 D2 D3 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

NA

TEST PILE PROGRAM

8. Has the Contractor met the requirements of 455-1.1, Protection of Existing Structures? 9. Has the site preparation been completed for footings/excavations/abutments in accordance with 455-1.2 & 455-1.2.1? 10. Have the requirements of 455-1.4, Vibrations of Freshly Placed Concrete been met? 11. If a Cofferdam is required, does the Contractor have a qualified diver and safety diver for inspections in accordance with 455-1.3, Cofferdams? 12. If underwater diving is required, are the divers equipped with voice communications, per 455-1.3, Cofferdams? 13. Does the Contractor have the hammer equipment indicated in the Pile Installation Plan on-site? a. CLOSED END DIESEL HAMMER - Does the hammer have at least three fuel settings for the rebound stroke? (455-5.2.2) - Does the Contractor have a Bounce Chamber Pressure Gauge? (455-5.2.2) - Has the Bounce Chamber been calibrated within the last 30 days and a Chart provided? (455-5.2.2) b. OPEN END DIESEL HAMMER - Does the hammer have at least three fuel settings for the rebound stroke? (455-5.2.2) - Has the Contractor provided the hammer manufacturers chart equating stroke and blows per minute? (455-5.2.2) - Has the Contractor provided an approved device automatically determine and display ram stroke? (455-5.2.2) c. AIR/STEAM HAMMER - Does the air plant have gauges that are easy to read? (455-5.2.1) - Does the hammer have a slide bar capable of a minimum of two stroke height settings? (455-5.2.1) d. HYDRAULIC HAMMER - Does the hammer have at least three settings for reduced stroke height? (455-5.2.3) - Has pressure measuring equipment been calibrated? (455-5.2.3) - Have you been provided a means to determine hammer energy? (455-5.3.1) 14. Is the cap-block (hammer cushion) in good condition? (455-5.3.1) 15. Does the cap-block (hammer cushion) match the Contractors submittal (type, size, thickness, etc.)? (455-5.3.1) 16. Is the pile cushion new? (455-5.3.2) 17. Does the pile cushion match the Contractors submittal (type, size, thickness)? (455 -5.3.2) 18. Does the pile helmet meet the requirements of 455-5.3.3? 19. If required, does the template meet the requirements of 455-5.6? 20. Has the Contractor furnished elevations per 455-5.6? 21. Is a jet pump at the site, ready for use and of the proper size? (455-5.7) 22. If Predrilling or Preforming to be done, does the drill meet the requirements of 455-5.1.1 and 455-5.9? 23. Do the leads match the Contractors submittal and meet the requirements of 455 -5.4? 24. Has the proper type, size, and length of pile and applicable pile documentation been provided? 25. Have you inspected the pile for defects and if observed document and modify the PA? 26. Has the Contractor marked the pile in the applicable increments? 27. Is the test pile located per the plans and meet the requirements of 455-5.15.2? 28. Does the pile meet the axial alignment of 455.5.15.3? 29. Have you indicated this is a Test Pile in the Pile Technician Program and/or Pile Driving Record? 30. If applicable, have you indicated the pile has EDCs installed in the Pile Technician Program and/or Pile Driving Record? 31. Have you recorded the driving event in the Pile Technician Program and/or Pile Driving Record?

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PRODUCTION PILE DRIVING
32. 33. 34. 35. 36. 37. 38. 39. 40. Do you have the Driving Criteria Letter? If concrete piles, do you have the authorized Production Pile Lengths Letter? Do you have the Accepted Pile Installation Plan? Has the Contractor met the requirements for Protection of Existing Structures? (455-1.1) Has the site preparation been completed for footings/excavations/abutments in accordance with 455-1.2 & 455-1.2.1? Have the requirements of 455-1.4, Vibrations of Freshly Placed Concrete been met? If a cofferdam is required, have the requirements of 455-1.3, Cofferdams, been met? Have you inspected the piles of damage, and if observed, document same and notified the PA? (455-6,7,8,9) Does the Contractors equipment match the accepted Pile Installation Plan or revised Plan from the Test Pile Program? a. cranes b. barges c. hammer system, including: -model, type, serial number -capblock cushion type, thickness -capblock dimensions, inserts, striker plates -variable energy settings -hydraulic control indicator, fuel pump setting indicator -Saximeter -Pile cushion type, thickness -follower d. Leads e. Auger motor and flighting f. Auger leads g. Punches h. Jets and pump i. Templates -Does the template match the Contractors submittal? -Has a reference been provide to enable determining pile penetration? -Can the pile be driven to the cutoff elevation without requiring movement of the template? Has the Contractor provided an elevation on the template for your use? If Predrilling or Preforming, has the Contractor met the plan requirements and you documented the same? If grouting of Preformed Pile Holes is required, has this been completed per 455-5.9.5? Has the Contractor marked the piles in the correct increments? Have you recorded the blows, stroke height/pressure, and applicable notes in the record or program? Did splicing of piles meet the requirements of 455-7.7 for concrete and 455-8.3 for steel? If specified, has the pile met any Minimum Tip Elevation requirements? If no Minimum Tip is specified, has the pile met the Penetration requirements of 455-5.8, Penetration? Has the pile met the driving criteria specified in the Driving Criteria Letter? Has the pile reached Practical Refusal? (455-5.10.3) Do you have a Setcheck Criteria? If Setchecks or Redrives are performed, were they documented? Have any of the piles heaved? (455-5.10.5) If so, were they redriven? Yes 32 33 34 35 36 37 38 39 40 No 32 33 34 35 36 37 38 39 40 NA

41. 42.

41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58

41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58

43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54.

POST INSTALLATION
55. Has the Contractor met the tolerances required? (455-5.15, Allowable Tolerances) 56. Has the Contractor initiated a plan to protect driven piles from fill placement operations? (455-10) 57. Have you been provided the final post-driving elevations and entered them in the Pile Technician Program and/or Pile Driving Record? 58. Have you verified that the two piles meet the tolerances of section 455-5.15?

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