ESC SHEET PILE CATALOGUE - INSTALLATION PROCEDURES

Page 1 of 23

4.1.

General

The following document provides an introduction to the methods of installing the ESC sheet pile series. It is intended as a guide to an experienced sheet piling contractor who may be using the ESC system for the first time, or who is looking for specific details regarding ESC pile installation. It should not be used as a reference for anybody unfamiliar with sheet piling operations as much of the information below assumes a level of knowledge about piling in general that would only be available to an experienced contractor. This manual is specific to the installation of ESC piles and is not a general piling guide. The information presented here has been obtained through a combination of theoretical research and practical experience in driving ESC piles. Every piling operation is unique however, and the information in this manual may only be used as a guide to assist the installation contractor. Ultimately, the final decisions about the installation methods will come down to a combination of the site conditions, the information provided within this text, and the installation contractors knowledge and experience.

Port Dickson, Malaysia

Kuala Lumpur, Malaysia

Rawang To Ipoh Double Track, Malaysia

4.2.

Soil and Site Conditions

Prior to any decisions being made regarding the equipment or technique for the pile installation, detailed information is required about the soil conditions and the site conditions where the sheet pile is to be installed.

4.2.1

Site Conditions

The site conditions must be considered mainly to ascertain the problems of obtaining access to the driving area, and the consequences that the driving operations will have on other areas of the site, or on neighbouring facilities such as buildings, roads, services etc. Some of the factors that need to be considered are listed below; - Local laws and bylaws. - Construction standards and contract requirements - Safety, particularly when hoisting the pile in close proximity to the public. - Effects of ground vibrations on existing facilities - Noise pollution - Working area and platform stability - Existing services within the working area that may be affected This list is by no means complete, and every site will have aspects that will affect the selection of piles and piling equipment, each of which must be identified and addressed.
__________________________________________________________________________________________ ESC Group Rev.2 : 30/12/04

ESC SHEET PILE CATALOGUE - INSTALLATION PROCEDURES

Page 2 of 23

4.2.2

Soil Conditions

Soil conditions may be separated into three broad categories for the purposes of piling; - Granular soil - Cohesive soil - Rock Granular Soil: Consisting mainly of sands and sandy silts, granular soils resist pile penetration mainly as a point resistance at the toe of the pile, friction along the length of the pile contributing little to the overall resistance. The density of the soils being penetrated therefore governs the required driving force. Cohesive Soil: Consisting of clays and clayey silts, cohesive soils resist pile penetration primarily from adhesion between the soil and the body of the pile, with virtually no point resistance at the toe of the pile. The required driving force is therefore a function of the undrained shear strength of the soil and the surface area of the embedded pile. Rock: Rock may be in boulder form floating in soils or as a continuous layer underlying soil layers. The presence of any rock should be identified and its nature carefully categorised to determine if it is universally present or a local phenomenon likely to only affect a few piles. Sheet piles cannot be driven continuously through rock using conventional means, however it is sometimes possible to key a pile a short way (<1.0m) into highly weathered or soft rock varieties such as sandstone. Beyond this special installation techniques are required, which will remove the rock from in front of the pile. Considerations of all of the above factors are vital to the selection of the correct sheet pile and the necessary installation equipment. In several cases, the maximum structural properties of a sheet pile are selected not by the requirements of its final function, but by the stresses of the installation process. This is particularly true for granular soils, and if trying to toe into rock, though it is not such a factor for cohesive soils. Frequently however, a site consists of a combination of granular and cohesive soils within separate layers, so driving stresses on the sheet pile must always be considered.

__________________________________________________________________________________________ ESC Group Rev.2 : 30/12/04

ESC SHEET PILE CATALOGUE - INSTALLATION PROCEDURES

Page 3 of 23

4.3 Installation Techniques 4.3.1 Pile Installation

ESC wide piles should be driven using the staggered method, where every second pile is driven and then the intermediate pile slotted into the resulting gap. ESC wide piles are supplied as Type 1 and Type 2 piles, with the intention that the Type 1 piles are driven first and the Type 2 piles slotted in as infill piles. Figure 1 illustrates the staggered driving method. The unit width on the drawings will be different for each pile series. All wide piles should have a tolerance of + 20mm that the pile can flex during set up spacing. The staggered driving method is used as it offers the following advantages; i) Improved pile alignment. As each second pile is driven as an individual pile, the inherent problem of cumulative lean that always occurs during sheet pile driving is eliminated. If there is a slight misalignment between two adjacent Type 1 piles, the Type 2 pile has sufficient flexibility to accommodate variations in the resulting gap without the danger of detracking. Improved penetration in hard ground. As the Type 1 pile is considerably stronger than the Type 2, it can be used to penetrate hard soils under high driving forces, breaking the soil up as it enters. As there is no track friction, driving force is optimised. The Type 2 pile will then penetrate through the disturbed ground with significantly less resistance. The result is the ability to install sheet piles into harder ground conditions than would normally be possible. Quicker installation. Careful alignment control is required when installing the Type 1 pile, however as the Type 2 pile can only follow the tracks of its adjacent Type 1 piles, the time spent on alignment is minimal. The overall effect is an increase in piling speed.

ii)

iii)

Alor Setar, Malaysia __________________________________________________________________________________________ ESC Group Rev.2 : 30/12/04

ESC SHEET PILE CATALOGUE - INSTALLATION PROCEDURES

Page 4 of 23

Type 1

Type 1

Type 1

Type 1

Type 1

STAGE 1: INSTALLATION OF TYPE 1 PILES

Type 2

Type 2

Type 2

Type 2

STAGE 2: INSTALLATION OF TYPE 2 PILES AND COMPLETION OFPANEL

FIGURE 1: STAGGERED DRIVING TECHNIQUE FOR ESC PILES

__________________________________________________________________________________________ ESC Group Rev.2 : 30/12/04

ESC SHEET PILE CATALOGUE - INSTALLATION PROCEDURES

Page 5 of 23

The ESC U Pile has a different method of installation. The drivability of each U Pile section is a function of its cross-section properties, length, steel grade used, load applied and duration of its application and the method employed for installation. The cross-section properties of a pile are based upon the thickness of steel, depth and width of section and its designed shape. The greater the surface area of the piling profile, the greater the driving force required. However, tests in the field show that the same sheet piling installation equipment can be used for ESCs wide profile and conventional hot rolled sheet piles. The introduction of the U Pile has also been brought about by the demand in certain sectors for the ability for low noise and vibration installation techniques. The ESC U Pile of 400, 500 and 600mm is able to fit into standard press in or silent piling machines manufactured around the world. Whilst it is recognised that, in common with most civil engineering projects, a measure of flexibility is desirable to meet site conditions, every precaution must be taken to maintain the necessary standards of safety whilst giving the required alignment and verticality of the installed piles. The first sheet pile must be installed with great care and attention to ensure it is vertical in both planes of the wall. It is essential that the following piles are interlocked sufficiently to the preceding pile before being released and the hammer applied. This can be achieved by a preliminary dug-out trench in the wall line which automatically reduces the driving length. 4.3.2 Pitch And Drive

This method, where each sheet pile is driven to full depth before pitching the next one, is the simplest way of driving but can be practiced only for loose soils and short piles. The free leading interlock is constantly in danger of deviation. For dense sands and stiff cohesive soils or in the case of possible obstructions, panel driving is recommended.

4.3.3

Panel Driving

Sheet piles should be installed using the panel-driving technique in order to ensure that good verticality and alignment is achieved and to minimize the risk of driving difficulties or de-clutching problems. This technique also enables greater control to be maintained on the nominal wall length. Because a whole panel of piles has been pitched there is no need to drive all piles fully to maintain piling operations; if obstructions are encountered, individual piles can be left high without fear of disruption to the overall efficiency.
__________________________________________________________________________________________ ESC Group Rev.2 : 30/12/04

ESC SHEET PILE CATALOGUE - INSTALLATION PROCEDURES

Page 6 of 23

PANEL DRIVING
__________________________________________________________________________________________ ESC Group Rev.2 : 30/12/04

ESC SHEET PILE CATALOGUE - INSTALLATION PROCEDURES

Page 7 of 23

4.3.4

Staggered Driving

In difficult soil conditions panel installation combined with staggered driving is recommended. The piles are installed between guide frames and then driven in short steps as follows: piles 1, 3 and 5 first; then piles 2 and 4. If the soil is very dense sand, gravel or rock, piles 1, 3 and 5 can be reinforced at the toe. In this case, these piles are always driven first and piles 2 and 4 in the second stage.

STAGGERED DRIVING

__________________________________________________________________________________________ ESC Group Rev.2 : 30/12/04

ESC SHEET PILE CATALOGUE - INSTALLATION PROCEDURES

Page 8 of 23

4.3.5

Equipment

Vibratory hammers are the recommended equipment for the installation of ESC piles. Experience has shown that the ESC piles will penetrate all soil types when installed using the correct selection of hammer. Refer to the section Selection of Driving Equipment for details on the correct selection of hammers.

HYDRAULIC VIBROHAMMER

ELECTRIC VIBROHAMMER

4.3.6 Piling Guides

Piling guides are recommended in the installation of ESC piles, regardless of the installation technique or the equipment used to drive the piles. If a leader is used, with the vibro mounted on a slide on the mast, then only a bottom guide will be required to ensure correct positioning of the piles. If a free hanging vibro is used with a crane, then an upper and lower guide will be required.

Piling Guide, Port Dickson, Malaysia __________________________________________________________________________________________ ESC Group Rev.2 : 30/12/04

ESC SHEET PILE CATALOGUE - INSTALLATION PROCEDURES

Page 9 of 23

The selection and design of the piling guide will be mainly determined by the driving technique and the size of the pile, but will also be affected by a number of secondary considerations, including access, site conditions,and budget. It is the responsibility of the piling engineer to use his knowledge of the site, as well as his piling experience to select a suitable piling guide design.

Melaka River, Malaysia

4.4 Selection of Driving Equipment 4.4.1 Vibratory Hammer

ESC recommend that all piling operations are performed using a vibratory hammer. Vibratory hammers have long been proved the most efficient and common method of pile installation, and for this reason the selection guidelines contained here focus only on this type of equipment. Selection of the correct hammer is essential to obtain maximum driving efficiency and obtain the correct penetrations for the pile. The details below are only to be used as a guideline as every brand of vibratory hammer performs differently. It is recommended that prior to the final selection of any equipment, the equipment manufacturer should be contacted and precise specifications for the equipment obtained. Hammers are defined by three major parameters; Frequency - The frequency of the vibrations of the hammer, and subsequently the pile, are critical in determining the extent the friction between the pile and the soil will be broken, allowing the pile to penetrate. Johor Bahru, Malaysia

__________________________________________________________________________________________ ESC Group Rev.2 : 30/12/04

ESC SHEET PILE CATALOGUE - INSTALLATION PROCEDURES

Page 10 of 23

Generally, high frequencies enable the soil to liquefy better and the pile will penetrate more easily. Frequency is also critical if vibrating near existing structures. High frequency vibrations will not travel far in soil compared to low frequency vibrations, and will therefore have less chance of damaging neighbouring structures. For these reasons, ESC always specify high frequency hammers in their own contracting work if possible. Centrifugal Force - Centrifugal force is the magnitude of the blow that the hammer delivers to the pile and is critical for overcoming side resistance and tip resistance. Figure 2 below relates pile length to centrifugal force as a guideline to hammer selection. The Centrifugal Force diagram takes into account the structural condition of the soil. Higher structural density requires a greater centrifugal force. Table 1 should be used in conjunction with the selection diagram. Type of Soil Granular Loose Medium Dense Very Dense

Curve A B C D

Cohesive Soft Firm Hard Very Hard

Table 1: Soil Conditions for Centrifugal Force Selection Amplitude - Amplitude is the magnitude of movement the pile experiences during vibration. A large amplitude or stroke will result in a greater impact force at the toe of the pile. In cohesive soils, a large amplitude is sometimes necessary to break the elastic bond between the soil and the pile surface. Higher amplitudes are usually achieved at the expense of frequency in some machines however, so care should be exercised when selecting high amplitude machines. Figure 3 below provides a selection chart for amplitude vs. pile length. The figures given for amplitude in this chart are the vibration amplitude, not the full pile oscillation which is double the amplitude (up and down vibration). Caution should be used when reading an equipment specification, to determine if the values given are amplitude or oscillation values.
C E N T R IF U G A L F O R C E / D R IV IN G D E P T H
3500 D 3000 C

Figure 2
Centrifugal Force (kN) 2500 2000 1500 1000 500 0 0 5 10 15 20 25 30 35 D r i v in g D e p t h ( m )

B A

Figure 2: Required Centrifugal Force

__________________________________________________________________________________________ ESC Group Rev.2 : 30/12/04

ESC SHEET PILE CATALOGUE - INSTALLATION PROCEDURES

Page 11 of 23

AMPLITUDE / DRIVING DEPTH

10 9 8 Amplitude (mm) 7 6 5 4 3 2 1 0 0 5 10 15 20 25 30 35 Driving Depth (m)
granular cohesive

Figure 3: Required Amplitude

4.4.2

Diesel Hammers

A diesel hammer consists principally of a cylinder, a piston (ram) and an impact block at the bottom of the cylinder. In single acting hammers the top end of the cylinder is open, but with double acting types it is closed. This double acting effect can also be achieved by using a vacuum chamber. To start the single acting hammer, the piston is lifted to a pre-set height and automatically released. The falling piston compresses the air in the compression chamber and activates the fuel pump to spray fuel on top of the impact block. The impact block atomizes the diesel fuel, which ignites in the highly compressed air. This explosive energy throws the piston upward thus driving the pile downwards and re-starting the hammer cycle. Diesel hammers perform especially well in cohesive or very dense soil layers. Under a normal site conditions it is usual to select a ratio of ram weight to weight of pile plus cap of 1:2 to 1.5:1. Driving caps of flat anvil blocks are necessary to protect the pile heads during driving. A penetration of 25 mm per 10 blows should be considered as the limit for the use of diesel hammer in accordance with the hammer manufacturers recommendations. Under circumstances a penetration of 1 mm per blow could be allowed for a short period of time. Longer periods of time at this blow rate would cause damage to the hammer and equipment.

__________________________________________________________________________________________ ESC Group Rev.2 : 30/12/04

ESC SHEET PILE CATALOGUE - INSTALLATION PROCEDURES

Page 12 of 23

DIESEL PILE HAMMER

Diesel pile hammers operate as follows: 1. Raising Of Piston For starting the diesel pile hammer, the ram weight (piston) is raised by means of a tripping device and automatically released at a given height. 2. Injection Of Diesel Fuel And Compression While dropping, the piston will actuate the pump lever, so that a given quantity of diesel fuel is sprayed on top of impact block. After passing the exhaust ports, the piston will start compressing the air in the cylinder chamber. 3. Impact And Explosion The impact of the piston on the impact block will atomize the diesel fuel in the combustion chamber. The atomized fuel will ignite in the highly compressed air. The resulting explosive energy will force up the piston. 4. Exhaust While moving upwards, the piston will expose the exhaust ports. Exhaust gases will escape and the pressure in the cylinder will equalize. 5. Scavenging The piston keeps jumping upwards and will draw fresh air through the exhaust ports for scavenging the cylinder, while also releasing the pump lever. The pump lever returns to its starting position, so that the pump will again be charged with fuel.

__________________________________________________________________________________________ ESC Group Rev.2 : 30/12/04

ESC SHEET PILE CATALOGUE - INSTALLATION PROCEDURES

Page 13 of 23

4.4.3

Drop Hammers

General: This hammer is easily adapted to drive any of the pile sections for all ground conditions eg. above and below the water table, and also adopts the same ram weight ratio and driving sets as described for Diesel hammers. Ram weights up to 11 tonnes are available with a variable drop height of up to 1.2 metres. At maximum ram weight and stroke height a blow rate of 40 blows/minute can be obtained when used in automatic sequence. It is always preferable to use a heavy ram, with short stroke to minimize pile head damage and noise emission levels. The hammer controls are precise and used correctly this hammer can achieve 75-80% of rated output energy. Data recording units simultaneously store the relevant driving information. There are three main types of drop hammer: Cable Operated Drop Hammers These consist of a machine lifted weight which is then allowed to free fall to drive the pile. The falling height can be regulated by the cable winch. Steam Drop Hammers For these special drop hammers the cylinder represents the falling weight which is lifted by steam pressure. A valve system interrupts the pressure and causes the cylinder to fall. The height can be adjusted to the given conditions. Hydraulic Drop Hammers This type of hammer consists of a segmental ram guided by two external supports; the ram is lifted by hydraulic pressure to a pre-set height and allowed to free-fall on to the anvil or driving cap.

HYDRAULIC DROP HAMMERS AT ESC CONSTRUCTION SITES

__________________________________________________________________________________________ ESC Group Rev.2 : 30/12/04

ESC SHEET PILE CATALOGUE - INSTALLATION PROCEDURES

Page 14 of 23

4.4.4

Double-Acting Hydraulic Hammers (Hydrohammer)

This type of hammer consists of an enclosed ram that is lifted by hydraulic pressure. On thee downward stroke, additional energy is delivered to the ram, producing an acceleration of 2 g. The maximum stroke of 1 metre thus corresponds to a free fall drop of 2 metre. These hammers range from a maximum energy/blow of 35 kNm to 3000 kNm with a blow rate of 50/60 blows per minute. The electronic control system ensure optimum control of the piling process and the design enables a range of safety, monitoring and indicating devices to incorporated. The net energy supplied to the pile, which is measured during every blow, and shown on the control panel can be continuously regulated from maximum to less then 5%. The hydro-hammer can operate at any angles, above and below water level and is suitable both for driving and extracting piles. Under normal site conditions it is usual to select a ram weight that is in the ratio 1 : 1 to 1 : 2 with the weight of the pile plus driving cap. A heavy hammer with short drop is always preferable to minimise pile head damage and noise level emissions. Up to the present time only hydro-hammers from 36 kNm to 90 kNm energy per blow have been known to be used for sheet piling; hammers larger in capacity than these are considered to be too heavy.

4.4.5

Double-Acting Air/Steam Hammers (Rapid Blow)

With double-acting hammers compressed air or steam drives the striking ram (piston) when rising and falling. The air or steam arrives under pressure in a valve box containing a slide valve which sends it alternately to each side of the piston, while the opposite side is connected to the exhaust ports. When falling, the striking mass hits a flat anvil fixed to the cylinder resting on top of the sheet pile being driven. Then the pressure lifts the piston and allows it to be forced down again on the anvil. In comparison with drop hammers of the same overall weight the ram of the double-acting hammers is much less than that of the drop hammer. It is only 10-20% of the overall hammer weight but is effectively increased by the pressure (5-8 bars) on the upper end of the piston. The hammers are designed to operate at maximum efficiency when used with standard sizes of compressors normally available. For such hammers, 90% of the available energy blow is derived from the action of the air steam upon the piston. The ram weight of the hammers, which are generally used with steel sheet piles, ranges between 100 and 1300 kg and the drop height, which generally increased with hammer weight, varies from 110 to 500 mm. The total striking energy of the biggest double-acting hammer is around 30 kNm per blow, much less than the biggest single-acting or drop hammers. However, the striking rate of the doubleacting hammer is higher, being about 100 blows a minute for the biggest machines and 400 blows per minute for the smallest. This striking rate usually leads to continuous movement of the pile which increases its penetration capacity in soils. It is not advisable to insert a driving cap between the hammer anvil and the sheet pile being driven since this leads to an enormous loss of efficiency. The double-acting hammers can also be equipped to operate under water and for the extraction of piles.

__________________________________________________________________________________________ ESC Group Rev.2 : 30/12/04

ESC SHEET PILE CATALOGUE - INSTALLATION PROCEDURES

Page 15 of 23

For continuous driving it is normal to limit the driving rate to 150 mm/min, but for short periods of time a driving rate of up to 50 mm per minute may be permitted. A ration not less than 1 : 5 between the ram weight and the weight of the pile is normally chosen.

4.4.6

Sheet Pile Presses

The elimination of the noise of sheet driving, which had for years been accepted as a nuisance to be tolerated, was the original purpose of the development of sheet pile presses as an alternative to the classical methods. Originally developed to drive piles silently, the machines are also widely recognised for their vibrationfree operation. The machines, which are especially suited for the use in cohesive soils, are hydraulically operated and take most of their reaction force from the friction of the previously driven piles. In the standard system, the engine consists of a cross-head containing hydraulic rams and the hydraulic power pack mounted on the cross-head. Sheet piles are installed in a panel and the machine is set on the panel by means of a crane (Type 1). The rams (hydraulic cylinders) are connected to the piles and by pressurising two rams, whilst the others are locked, enables the piles to be pushed into the ground, two at a time, to the full extent of the rams. When all the rams have been extended, they are all retracted simultaneously causing the cross-head and power pack to be lowered and the cycle is then repeated to completion.

__________________________________________________________________________________________ ESC Group Rev.2 : 30/12/04

ESC SHEET PILE CATALOGUE - INSTALLATION PROCEDURES

Page 16 of 23

Note: Piles are extracted using the reverse operation of the above sequence

TYPE 1: MACHINE OPERATION

__________________________________________________________________________________________ ESC Group Rev.2 : 30/12/04

ESC SHEET PILE CATALOGUE - INSTALLATION PROCEDURES

Page 17 of 23

These presses can develop forces of up to 300 tonnes. Another type of machine with similar features uses a moveable frame to hold the installed panel and to move from panel to panel, giving complete independence from a crane. In this system, pre-drilling loosens the soil during the press operation (Type 2) A chain pull connected to a fixed point or to piles that have already been driven can provide supplementary press force.

TYPE 2: SHEET PILE PRESS (Taken From TESPA Reprint 2001)

__________________________________________________________________________________________ ESC Group Rev.2 : 30/12/04

ESC SHEET PILE CATALOGUE - INSTALLATION PROCEDURES

Page 18 of 23

Other kinds of presses jack one pile after another to the complete depth while walking on the previously set piles. These machines work completely independently from crane, and also use the reaction force of the piles already set to operate. These machines can accommodate limited circular construction if required (Type 3).

TYPE 3 (Picture courtesy of Giken Seisakusho Asia Pte. Ltd.) 4.4.7 Shackles

Besides the standard shackles widely used, a variety of ground release and ratchet-release shackles are available. These enable the crane connection to the pile top to be released, when required, from ground level or walkway waling level. This is fast, efficient and safe. The shackle uses a lifting hole in the head pile through which a shear pin passes. Friction grip methods of lifting should never be used as they can accidently release in a number of different circumstances. Method of operation for shackles when used in conjunction with pile threader (see Threaders, section 4.4.8)

(Brochure courtesy of Dawson Engineering Pte. Ltd)

__________________________________________________________________________________________ ESC Group Rev.2 : 30/12/04

ESC SHEET PILE CATALOGUE - INSTALLATION PROCEDURES

Page 19 of 23

4.4.8 Threaders As a consequence of panel driving, there is a need to interlock piles and release their crane connection, at high level, with efficiency and safety. The sheet pile threader is designed to interlock any steel sheet pile accommodating the different profiles, handling and interlock types without the need for a man to be employed at the pile top. Work on pitching piles can also continue in windy conditions which would stop manual interlocking, making the work more efficient as well as safe.

(Brochure courtesy of Dawson Engineering Pte. Ltd)

4.4.9 Reinforcing Shoes Having taken all precautions to guide the piles accurately during installation, pile design efficiency may still make the pile vulnerable to damage from artificial or natural obstruction such as cobbles, boulders, concrete and old timber piles. Reinforced shoes can be provided to give strength to the leading edge of the sheet pile and to help maintain its shape when passing through difficult ground.

4.4.10 Steel Handling Shoes. These are simple cast-steel shoes designed to slide between each pile in a stack to enable easy separation and handling.

__________________________________________________________________________________________ ESC Group Rev.2 : 30/12/04

ESC SHEET PILE CATALOGUE - INSTALLATION PROCEDURES

Page 20 of 23

(Brochure courtesy of Dawson Engineering Pte. Ltd)

4.4.11 Driving Caps General Driving caps with a dolly may be required when using hammers in order to transmit the blow directly to the pile and to protect the hammers and the pile heads. Guiding grooves for the pile are formed on the lower surface of the driving cap. A suitable connection between the leader and the driving cap can be obtained by a spacer insert to give the required clearance. The insert must have a sliding connection on the cap and on the leader.
__________________________________________________________________________________________ ESC Group Rev.2 : 30/12/04

ESC SHEET PILE CATALOGUE - INSTALLATION PROCEDURES

Page 21 of 23

4.4.12 Dolly The dolly is fitted into a recess on the upper surface of the driving cap. The dolly cushions the blow from the hammer and thus prevents damage to the hammer and the cap. Dollies are normally built of plastic or wooden components, with a combination of steel cables and steel plates which give a reasonable life expectancy and also quickly dissipate the heat generated. When hard driving is experienced the dolly has to be replaced more frequently than under normal requirements.

SPECIAL DRIVING CAP & DOLLY FOR ESC WIDE PROFILE SHEET PILES

4.5 Driving Asistance

In some circumstances, the force of the vibratory hammer alone may be insufficient to achieve the desired penetration. This may be due to obstructions or hard ground conditions. In this situation, the piling engineer has a range of options available to further the penetration of the pile. 4.5.1 Jetting The objective of jetting is to locate a pressure source at the toe of the pile, which during the vibration process will loosen and remove the material under the pile. Using jetting, dense to very dense soils can be penetrated by the sheet pile.

__________________________________________________________________________________________ ESC Group Rev.2 : 30/12/04

ESC SHEET PILE CATALOGUE - INSTALLATION PROCEDURES

Page 22 of 23

Three techniques of jetting are commonly available; - Air pressure - Low water pressure - High water pressure All systems use a similar technique of using pipes to transfer the pressure source to the toe of the pile. Two to four pipes are welded to the back of the pile and connected to the pressure source via flexible hoses. The pressure source is usually located at ground level. Table 5 shows a summary of the parameters for each of the jetting systems. Jetting Technique Air Pressure Low Water Pressure High Water Pressure Pipe Dia. (mm) 25 20 40 30 Nozzle Dia. (mm) 5 10 5 10 1.2 3.0 Supply Pressure (bar) 5 - 10 10 20 250 - 500 Supply Volume 4.5 6 m3/min 200 500 l/min 20 60 l/min Recommended Soils Cohesive Dense granular V. Dense granular

Table 2: Jetting Parameters

When using the jetting technique, care must be taken that the large volumes of water do not create any side effect problems. If there is a risk of settlement, high pressure jetting is preferred to low pressure due to the reduced amount of water being used. Using low pressure jetting, the soil characteristics are only slightly modified, although special care must be taken if the piles have to carry vertical load. Using high pressure jetting, soil mechanical characteristics are not affected. 4.5.2 Predrilling The ESC wide profile sheet pile range utilises a large clutching system, which offers advantages in certain areas but has the effect of increasing driving resistance. Toe resistance of the sheet pile can be reduced by the provision of predrilled holes in the ground, which coincide with the positions of the clutches on the Type 1 pile. The predrilled holes are ideally 150 350mm diameter and are drilled deep enough to accommodate the entire embedded pile. In certain circumstances, this technique is not feasible, such as; There may be a layer of loose or soft material overlying the hard material that needs to be drilled. Predrilled holes would be unable to stay open in the soft material and would collapse. The piles may be installed in a body of water, with the hard material that requires drilling below the sea / lake / river bed. In this case, it is recommended to use a custom ESC pipe sheet pile, which utilise a pipe clutch system. Using this series, the Type 1 pile can be driven until it encounters the top of the hard material. A down hole hammer, together with compressed air, are inserted into the pipe clutch and the hard material drilled away from beneath the pile. The Type 1 pile is then extended and driven to completion. The Type 2 pile will also be able to be driven to depth as the tracks will be cleared of all resistance.

__________________________________________________________________________________________ ESC Group Rev.2 : 30/12/04

ESC SHEET PILE CATALOGUE - INSTALLATION PROCEDURES

Page 23 of 23

Using this method, very hard soils, including soils with hard rock layers, may be penetrated with a degree of confidence. The method is particularly effective for installing sheet piles into marine conditions where there may be little or no soil covering the bed rock and it is necessary for the piles to penetrate sufficiently to obtain a toe support.

PRE-DRILLING MACHINE 4.5.3 Blasting

This process is reserved for soil conditions that are impossible to penetrate using any of the methods covered above. Two techniques are used; Normal Blasting Explosives are lowered into drilled holes and covered with soil before detonation. This creates a V-Shaped trench along the proposed line of the wall. Driving conditions in the loosened area are still very difficult and toe reinforcement of the piles is recommended. Low powered explosives are used to reduce the solid rock to a very fine granular material without displacing it, rather than blasting a cavity in the rock. The width of granulated rock zone is only slightly wider than the sheet pile wall and to the exact depth of the required pile penetration. The rock immediately adjacent to this zone remains totally intact. The sheet piles should be driven into this granulated zone as soon as possible after blasting to obtain maximum benefit from the process. The act of driving the sheet piles into this zone compact the soil ensuring adequate support for the embedded piles.

Shock Blasting -

4.6 Summary of Installation Procedures If any specialised installation techniques are to be employed to supplement driving into hard soil conditions, ESC should be notified at the time of ordering the piles. This will allow ESC time to make recommendations and suggest any modifications to the pile that may be required. For particularly hard driving, the top and toe of the sheet piles should always be reinforced, and ESC will provide this service if given notification.

__________________________________________________________________________________________ ESC Group Rev.2 : 30/12/04