CONSTRUCTION AND COMPLETION

OF THE PROPOSED INNER RING ROAD

KUCHING DIVISION – PACKAGE B

METHOD STATEMENT

FOR

BORED PILING WORKS

(REV. 2)

PROJECT : CONSTRUCTION AND COMPLETION OF THE PROPOSED INNER

RING ROAD KUCHING DIVISION – PACKAGE B

PREPARED BY : BORNEO GEOTECHNICAL

ENGINEERING SDN. BHD

CONTRACTOR : HOCK SENG LEE BERHAD

CONSULTANT : KTA (SARAWAK) SDN. BHD.

 CONSTRUCTION AND COMPLETION
OF THE PROPOSED INNER RING ROAD
KUCHING DIVISION – PACKAGE B

TABLE OF CONTENTS

1.0 INTRODUCTION......................................................................................................................................3

2.0 REFERENCES..........................................................................................................................................5

3.0 MATERIALS.............................................................................................................................................5

4.0 MANCHINERY & EQUIPMENT............................................................................................................6

5.0 MANPOWER.............................................................................................................................................7

6.0 CONSTRUCTION PROCEDURE............................................................................................................7

6.1 PROCEDURE FLOWCHART & DIAGRAM ..................................................................7

6.2 SETTING OUT .................................................................................................................8
6.3 REBAR CAGE FABRICATION .....................................................................................10
6.4 DRILLING OPERATION ...............................................................................................12
6.5 LOWERING OF REBAR CAGE & CASING
CONNECTION .....................................13
6.6 CONCRETING OPERATION ………………………………….………….……...…15
6.7 TESTING & DATA RECORDING ……………………………..………….……...…
16

7.0 SAFETY AND HEALTH.........................................................................................................................17

7.1 JOB AND HEALTH ANALYSIS ....................................................................................17

7.2 EMERGENCY
ARRANGEMENT ................................................................................17
7.3 SAFETY
REQUIREMENT…… .....................................................................................17

8.0 ENVIRONEMNTAL CONTROL............................................................................................................18

8.1 ENVIRONMENTAL ASPECTS &

IMPACTS................................................................18
8.2 CONTROL MEASURES TO BE
IMPLEMENTED .....................................................19

9.0 TRAFFIC MANAGEMENT PLAN........................................................................................................19

10.0 INSPECTION & TESTING ................................................................................................................19

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KUCHING DIVISION – PACKAGE B

11.0 APPENDIX............................................................................................................................................19

-BORED PILE INSTALLATION RECORD FORM

ABBREVIATION AND DEFINITION

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KUCHING DIVISION – PACKAGE B

Abbreviation Definition Abbreviation Definition

AHD Ahead m Meter
BH Borehole m.s.l Mean Sea Level
BK Back MO Mid Ordinate
BQ Bill of Quantity MS Method Statement
BRG Bearing N Nothing
BS British Standard NC Normal Crown
BVC Beginning of Vertical Curves No Number
CBR California Bearing Ratio NTS Not to Scale
CC Center of Circular Center OBP Old Belian Peg
CH Chainage OEP Outer Edge of Pavement
CIV Civil PG Proposed Grade
CMP Corrugated Metal Pipe PIL Proposed Invert Level
CS Curve to Spiral PVD Pre-fabricated Vertical Drain
CT Curve to Tangent R Radius
D Depth RC Reverse Crown
DL Drain Lining RCB Reinforced Concrete Box
DRA Drainage RCP Reinforced Concrete Pipe
DWG Drawing RE Resident Engineer
E Easting RL Reduced Level
EGL Existing Ground Level RM Reference Mark
EL Elevation ROW Right of Work
EQ Equation RQD Rock Quality Designation
ES External Distance RSD Road Side Drain
EVC End of Vertical Curve RT Right
F.R.L Finished Road Level S Invert Gradient of Drain
FS Full Super Elevation S.O. Superintendent Offi cer
FW Full Widening SC Spiral of Curve
GEO Geotechnical SE Super Elevation
GR Guard Rail SP Design Speed
H/W Headwall & Wing Wall SPEC Specification
HC Half Crown SPT Standard Penetration Test
HSL Hock Seng Lee Berhad SS Standard Survey
HW Headwall ST Spiral to Tangent
HWL High Water level T Tangent Length
IEP Inner Edge of Pavement TBA To Be Advice
IL Invert level TBM Temporary Bench Mark
IP Intersection Point TC Tangent to Curve
JKR Jabatan Kerja Raya TS Tangent to Spiral
km Kilometer Ts Transition Length
km/h Kilometer per Hour VCL Vertical Curve Length
LC Length of Circular Curve VIP Vertical Intersection Point
LO Length of Run Off W Widening
LR Length of Run Out
LS Length of Spiral Curve
LT Left

1.0 INTRODUCTION

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KUCHING DIVISION – PACKAGE B

This method statement illustrated the installation of the 600mm bored piling
work for upgrading the existing Sg Siol bridge to a dual-carriageway bridge
which is located along Petra Jaya, Kuching for the project “CONSTRUCTION
AND COMPLETION OF THE PROPOSED INNER RING ROAD KUCHING DIVISION
– PACKAGE B”. The locality and site phone as shown in Figure 1.1 and 1.2.

Figure 1.1 Locality of Sg. Siol Bridge

Figure 1.2 Site photo of existing bridge

The new bridge consists of 2 abutments, each with 12 bored pile points and 2
piers, each with 16 bored pile points. For each abutment, 6 of pile facing the

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KUCHING DIVISION – PACKAGE B

river pier is to be installed raked at a ratio of 1:5 while the other 6 are vertical
pile. For the 2 piers, all the pile is vertical. Total bored pile points to be
installed are 44 vertical and 12 raked.

Figure 1.3 Bridge plan view

Figure 1.4 Bored pile point layout

Before commencement of bored piling work, SI was conducted at each of the

abutment and pier, namely BH 1, 2, 3, 4. Based on the result, 2 nos of test pile
located at abutment A, AP3 and abutment B, BP3 was constructed and tested
with MLT to validate the result of SI report, able to achieve working load of
2200kN and to confirm the expected length of remaining bored piles.
Due to the presence of cavity in SI report for BH4, permanent casing is
prepared for the bored pile points at abutment B to socket over the cavity

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KUCHING DIVISION – PACKAGE B

zone. The remaining points will be stabilized using temporary casing. The
work sequence and detailed working schedule shall conform with the site
condition and after further discussion with main contractor.

2.0 REFERENCES

2.1 PROJECT DOCUMENTS

NO DOCUMENT REF NO.

JKR standard specification for Road
1 JKR/SPJ/1988
Works including Bridge Structures

2.2 CONSTRUCTION DRAWINGS

NO DOCUMENT REF NO.

1 Plan view, side view 7543/BR/S/010
2 Sectional view 7543/BR/S/011
3 Pile layout view, schedule 7543/BR/S/012
4 Pile details 7543/BR/S/013
5 Bridge general notes 7543/BR/S/100

Note: Construction drawing may be revised by consultant time to time.

Site work (i.e. the bored pile length) shall conform to the site condition.

3.0 MATERIALS

NO MATERIAL PURPOSE
1 Rebar T32 Main bar
2 Rebar T25 Main bar
3 Rebar T20 Main bar
4 Rebar T12 Spiral link

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KUCHING DIVISION – PACKAGE B

5 Sonic logging tube Sonic logging test

6 Steel casing (8mm thk) Borehole support
7 Concrete G40T2 Bore pile structure
8 Cement powder Grout infill sonic logging tube

4.0 MACHINERY & EQUIPMENT

The equipment and accessories must be capable of safely, speedily and

efficiently install piles to the design requirements at the project site.

NO MACHINERY & EQUIPMENT PURPOSE

1 Bore pile rig Borehole drilling
2 Crawler crane Lifting of casing and rebar cage
3 Excavator Platform clearing
4 Tremie pipe & hopper Concrete casting
5 Vibro hammer & power pack Steel casing driving
6 Welding set Welding of joint
7 Worker container Storage
8 Water pump Water supply
9 Cement mixer and pump Grout SLT tube
10 Steel plate Access & machine sitting

5.0 MANPOWER

An experienced bored pile supervisor will be stationed on site to monitor the

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KUCHING DIVISION – PACKAGE B

boring and concreting process.

NO MANPOWER PAX PURPOSE

1 Project Manager 1 Overall supervision
2 Engineer 1 Records
3 Bored pile supervisor 1 Supervision of work
4 Bored pile operator 1 Operate machine
5 Crawler crane operator 1 Operate machine
6 Excavator operator 1 Operate machine
7 Welder 1 Welding works
8 General worker 4 Supporting works

6.0 CONSTRUCTION PROCEDURE

6.1 PROCEDURE FLOWCHART & DIAGRAM

Figure 6.1 Bored pile procedure diagram

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KUCHING DIVISION – PACKAGE B

Figure 6.2 Bored pile procedure flowchart

6.2 SETTING OUT

i. The setting out of piles shall be carried out by a licensed surveyor and the
information shall be submitted for assessment as per stated in the contract
drawing. For abutment A and B, the river bank will be backfilled as access
and staging of machine. For pier 1 and 2, sheet pile cofferdam is proposed
to be installed and backfilled for piling work and pile cap construction
work to be carried out. The platform will be top up of 1.5 meter from
expected cut off level of piling and resurveyed by licensed surveyor to
confirm the final levels. Before mobilization of machinery in, main
Contractor’s licensed surveyor will peg up the exact piling points,
planning of test pile points & the overall piling work sequence.

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KUCHING DIVISION – PACKAGE B

ii. The survey control points, typically the TBMs are determined by the main
Contractor's surveyor. A numbers of control points will be established
using closed traversing method.

iii. These control points are rechecked periodically by the main Contractor's
surveyor to ensure continued accuracy. The location of these points shall
be sited at a place unlikely to be disturbed and are clearly marked.

iv. All piles position is pre-surveyed by the main Contractor’s surveyor in

reference to the grid lines or the site boundary line. These positions will
be pegged to indicate the precise pile position and the records will be
passed on to the consultant.

v. Since the pegged position is the center of pile, before boring work
commences, the center peg will be offset to 2 axis for reference and cross
checking.

vi. The verticality of the drilling rod will be checked before the drilling
process starts and confirmed by the consultant. For raked pile the drilling
rod should be adjusted to the desired raked ratio as per design. For
example, 1: 5 ratio checks with 100mm: 500mm template to confirm the
inclined angle.

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KUCHING DIVISION – PACKAGE B

Figure 6.3 Surveying point Figure 6.4 Checking verticality

6.3 REBAR CAGES FABRICATION

i. The rebar reinforcement cage for the pile shall be fabricated according to
the requirement and specification stated in BS5135 standards. Before any
reinforcement steel is brought to site, the mill certificates and reports of
tensile test will be submitted for acceptance by the S.O. The steel
reinforcement will be stored in clean and dry conditions where it is free
from loose rust, mill scale, oil, grease, paint, dirt or anything which may
reduce its bond with concrete.

ii. Main bars of correct lengths are lapped, and spiral reinforcement are fitted
into position. Three sets of rebar cage, with different main bar size will be
prepared with required jointing length (min 50x bar diameter) and the
lapping of main bars will be staggered to alternate bars. Plastic, concrete
or steel spacers will be used (subject to specification) to ensure that the
cage maintain at the correct position and to achieve concrete cover of
75mm.

iii. Links on the top and bottom of the cage will be welded accordingly to
provide a rigid reinforcement cage. Hooks will be welded to the top of the
steel cage to enable lifting of the cage into the borehole during installation

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KUCHING DIVISION – PACKAGE B

without permanent distortion. The welding works will be notified to S.O.

prior to carrying out the work and will adhere to BS5135 standard and be
conducted by welder qualified to do 6G welding. The qualification of
welder will be submitted for assessment by S.O. before commencement of
work.

iv. Concrete spacers or metal pads (BS-EN-1536 (1)) will be used to provide
75mm of cover where the spacers will be threaded onto the links and the
spacing of the spacer block shall be of 3m interval along the reinforcement
cage. A minimum of 4 layers of 4 nos. of concrete spacers or metal pads
per layer will also be provided for each 12m length of the concrete cage.
In addition, centralizer will be installed with 1500mm spacing at the main
reinforcement bar.

v. Tubes for integrity test using sonic logging method shall be installed in all
bored pile reinforcement cages equally spaced and secured with welding.

Figure 6.5 Spiral link preparation Figure 6.6 Completed rebar cage

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KUCHING DIVISION – PACKAGE B

6.4 DRILLING OPERATION

i. After checking and ensuring that the pegged position of the borehole is
accurate, the borehole will be drilled using appropriate drilling tools. The
borehole will be stabilized with the cased method which the permanent
casing was allowed in the contract otherwise stabilizing fluids bentonite /
water shall be used to stabilize the bored hole.

ii. After fixing the casing into its position, the borehole will be drilled to its
required depth by using bucket and auger as stated in the drawing provided.
For drilling into soils and weathered rock above the solid rock formation, a
suitable tool will be used, depending on the type of soil condition. Upon
encounter with rock surface where the soil drilling tools is unable to
penetrate through, the reduced level of the rock will be determined by SPT
test, and drilling shall be continued using rock drilling tools to drill through
the rock until the final socket length of 5500mm in sandstone.

iii. When cavity or weaker material is encountered, the founding level shall be
lower than the provision level or that established by the test pile. SPT shall
be carried out at every 2.0m interval to establish the strength of the
socketing material and the founding levels. SPT shall be carried out in two
stages, which seating drive and test drive

iv. When the designed depth has been achieved and approved by the S.O., the
base of the borehole will be cleaned by flushing out soil particles with
recirculation water or air. Then, the depth of the borehole will be measured
again by using a tape and the reading obtained will be recorded.

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KUCHING DIVISION – PACKAGE B

v. A detailed record of ground conditions and type of materials excavated as

well as material sample excavated per depth during the bore pile installation
process will be recorded and submitted to S.O.

Figure 6.7 Drilling process

6.5 LOWERING OF REBAR CAGE & CASING CONNECTION

i. After the depth of borehole approved by S.O. and cleaned, rebar cage will
be installed and joint to required length. Otherwise if the steel casing
length is not enough to socketing, casing will be extended to required
length by butt weld and driven to level.

ii. Rebar cage will be placed into the borehole by using a lifting chain after
sufficient laps have been provided to ensure there is no slippage of cages
while lowering the cage into the borehole. Welding shall be carried out
according to BS5135 and BS638 and as specified in detailed drawings for

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KUCHING DIVISION – PACKAGE B

parts of reinforcement to be welded. Welded joints shall also not be made

at bends in reinforcement.

Figure 6.8 Joining of casing

Figure 6.9 Joining of rebar cage Figure 6.10 Rebar cage in

borehole

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KUCHING DIVISION – PACKAGE B

6.6 CONCRETING OPERATION

i. Concrete mix will be discharged into the borehole by using a tremie pipe
of 190 mm diameter which will be lowered to the bottom of the bored hole
prior to filling it with concrete.

ii. The tremie pipe will be joined and lowered into the borehole where each
joint will be secured with thread method to ensure that it is water tight.
The concrete will be placed via a hopper which is attached to the top of
the tremie pipe. Before placing concrete, the borehole is cleaned by
air/water flushing method till clear water is obtained.

iii. The concrete shall be discharged continuously and the tremie pipe shall be
withdrawn upward as the concrete level in the borehole rises and the
bottom of the tremie pipe is ensured to be embedded at least 2m below the
concrete level in the borehole. Concrete level of the borehole will be
measured and recorded accordingly after each concrete truck discharged.
Concrete will be cast above the cut off level for minimum 1.3m.

iv. If temporary casing was used, it will be extracted slowly after the
concreting process completed.

v. The slump of concrete will be verified before pouring of concrete into

borehole and test cube will be prepared with overflowed fresh, clean
concrete from borehole.

vi. Concrete and cement grout test cubes for bored piles shall be taken from
the concrete overflowing from the top of the bored shaft. Test cubes shall

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KUCHING DIVISION – PACKAGE B

only be taken after the discharge from the shaft comprises clean concrete
that is free from soil contaminant.

Figure 6.11 Lower of tremie pipe Figure 6.12 Overflow of fresh concrete

6.7 TESTING & DATA RECORDING

i. Maintained load test (MLT), Pile integrity test (PIT), Sonic Logging Test
(SLT) and Pile Driving Analysis (PDA) will be elaborated in separated
method statement. MLT will be carried out for the test pile after the
concrete achieved required design strength, before commencing of other
piling works. All the test pile points will be confirmed and agreed with
S.O. before testing. After the sonic logging test was carried out, all the
sonic logging tube will be infilled with cement grout suit to pile concrete
strength. After testing was completed, pile head will be hacked to cut off,
elaborated in separated method statement.

ii. All the piling point as built will be surveyed and recorded by main
Contractor’s licensed surveyor after piling work was completed and
passed testing. The data will then be submitted to consultant for record.

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KUCHING DIVISION – PACKAGE B

iii. The 28 pilot boreholes will be arranged by main Contractor prior to bored
piling work.
7.0 SAFETY AND HEALTH

7.1 JOB AND HEALTH ANALYSIS

 Safety and health aspects shall be exercised before and when

implementation of he works and shall be in accordance to Safety and
Health Management Plan and other relevant documents.

 All control measures required in Job Safety and Health Analysis will be
disseminated to site personals including consultant, engineer, supervisor
and worker through Safety Induction Briefing, Tool Box Briefing, Notice
Board, Safety & Health Meeting and Campaign.

7.2 EMERGENCY ARRANGEMENTS

 Safety officer shall be informed of the works to be performed and

HIRADC of the works to be carried out is established and approved.

 Relevant personnel on site shall be briefed of the emergency contact

details, response and referred to procedures in accordance to Emergency
Response Plan. Safety and health aspects shall be exercised before and
during works and in accordance to Safety and Health Management Plan
and other relevant documents.

7.3 SAFETY REQUIREMENT

 Safety helmets & safety boots must be worn at all time on the
project/operation area and the helmet shall be properly adjusted.

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KUCHING DIVISION – PACKAGE B

 Mechanical or service personnel may have to remove helmet for operating

machine, but this should be discouraged.

 Helmets shall not be drill, cut or otherwise altered but it can be labelled
with stick on nametags.

 Comfort is an absolute necessity in the safety footwear and replacement is

necessary if defective.

 Glove shall be worn when necessary and type of glove shall suite the
operation and hazard.

 Reflective vest shall be wear by the person that directing vehicles

movement, working at night & dark area.

 Tasks that require breathing protection, dust mask shall be worn.

 Inspection of mobile heavy machineries, validity of road tax, validity of

insurance coverage, validity of driver licenses, fire extinguisher, spark
arrestor, hot work permit and DOSH certificate of fitness will be carried
out before issuing the authorized sticker.

 All machinery and equipment are to be check at the beginning of work to

ensure that it is well functioning.

8.0 ENVIRONMENTAL CONTROL

8.1 ENVIRONMENTAL ASPECTS & IMPACTS

 Complying with all the requirements, statutory requirements and best

industry practices to preserve and take due care of the local existing
environment.

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KUCHING DIVISION – PACKAGE B

8.2 CONTROL MEASURES TO BE IMPLEMENTED

 The potential environmental impacts shall be identified for all the related
activities and control measures shall be developed concurrently based on
the identified impacts. This control measures shall be implemented to
reduce or minimize the environmental impacts to the environment and the
local public.

9.0 TRAFFIC MANAGEMENT PLAN

- NOT APPLICABLE

10.0 INSPECTION & TESTING

 Implementation of QAQC works shall be in accordance to the approved

Contractor’s Project Quality Plan and relevant quality system procedures.
 The quality of works shall comply with the requirements of Testing &
Commissioning Manual and other relevant documents.
 The inspection and test plan (PQP) shall be approved by CRE.

11.0 APPENDIX

- BORED PILE INSTLLATION RECORD FORM

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