Caisson Piles Design & Construction

CAISSON PILES
DESIGN & CONSTRUCTION

2.34 Acres Mixed Development,
Damansara Perdana
By : BRYAN LEE
Date: 20TH NOV 2008
G&P Professionals Sdn Bhd (www.gnpgroup.com.my)
How are these
foundation being
constructed?
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Foundation Construction Challenging
Difficult in accessibility
Limited / Non-Flat
Working Space
High impose loads

Site & SI Layout Plan
Service Apartment
Block A2: 8 Floors
Service Apartment
Block A1: 13 Floors
Podium: Service Apartment

Commercial: 2 Floors Block B: 10 Floors
Car Park: 6 Floors
SI Borelog Profiles
8 Boreholes
7 Additional
Boreholes
Foundation Layout
Shallow Bedrock:
Deep Bedrock: Footing
Caisson + Micropiles
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Why using Caisson Piles?
Most of the deep foundation are on

slope (flat piling platforms are needed)
Site congested (big piling rigs; site is only

2.34 Acres)
Expensive of piling rigs mobilisation

(quantity of deep foundation not much)

Introduction of Caisson Pile
150 Apron
Technology from Hong Kong 250
Lift 1= 1.25m
Manual earth digging

75
75
Lift 2= 1.425m
Retained temporary with

Dowel
Bars
Pile
Diameter
cast in-situ concrete linings

Lift 3= 1.425m
Concrete
Continue excavate to
Linings
Lift 4= 1.425m
required founding level Lift 5= 1.425m
Steel reinforcing & concreting Lift 6= 1.425m
Dia. 1m 4m, max. 45m long

400 7000 ton capacity Bedrock

Construction Sequence 1a
150 Apron
250
Placing of Steel Mould
Lift 1= 1.25m
75
75
Lift 1
Lift 2= 1.425m
Dowel
Bars
Pile
Diameter
Lift 3= 1.425m
Concrete
Linings
Lift 4= 1.425m
Lift 5= 1.425m
Lift 6= 1.425m
Bedrock

Construction Sequence 1b
150 Apron
250
Placing of BRC A6
Lift 1= 1.25m
75
75
Lift 1
Lift 2= 1.425m
Dowel
Bars
Pile
Diameter
Lift 3= 1.425m
Concrete
Linings
Lift 4= 1.425m
Lift 5= 1.425m
Lift 6= 1.425m
Bedrock

Construction Sequence 1c
150 Apron
250
Linings Concreting
Lift 1= 1.25m
75
75
Lift 1
Lift 2= 1.425m
Dowel
Bars
Pile
Diameter
Lift 3= 1.425m
Concrete
Linings
Lift 4= 1.425m
Lift 5= 1.425m
Lift 6= 1.425m
Bedrock

150 Apron
250
Install Hoist Frame
Lift 1= 1.25m
75
75
Lift 1
Lift 2= 1.425m
Dowel
Bars
Pile
Diameter
Lift 3= 1.425m
Concrete
Linings
Lift 4= 1.425m
Lift 5= 1.425m
Lift 6= 1.425m
Bedrock

150 Apron
250
Ventilation & Lifting Bucket
Lift 1= 1.25m
75
75
Lift 1
Lift 2= 1.425m
Dowel
Bars
Pile
Diameter
Lift 3= 1.425m
Concrete
Linings
Lift 4= 1.425m
Lift 5= 1.425m
Lift 6= 1.425m
Bedrock

Construction Sequence 2a
150 Apron
250
2nd Lift Excavation
Lift 1= 1.25m
75
75
Lift 2= 1.425m Lift 2

Dowel
Bars
Pile
Diameter
Lift 3= 1.425m
Concrete
Linings
Lift 4= 1.425m
Lift 5= 1.425m
Lift 6= 1.425m
Bedrock

Construction Sequence 2b
150 Apron
250
Dismantle of Steel Mould
Lift 1= 1.25m
75
75

Dowel
Bars
Pile
Diameter
Lift 3= 1.425m
Concrete
Linings
Lift 4= 1.425m
Lift 5= 1.425m
Lift 6= 1.425m
Bedrock

150 Apron
250
Placing of Steel Mould
Lift 1= 1.25m
75
75

Dowel
Bars
Pile
Diameter
Lift 3= 1.425m
Concrete
Linings
Lift 4= 1.425m
Lift 5= 1.425m
Lift 6= 1.425m
Bedrock

Construction Sequence 2d
150 Apron
250
Placing of Steel BRC A6
Lift 1= 1.25m
75
75

Dowel
Bars
Pile
Diameter
Lift 3= 1.425m
Concrete
Linings
Lift 4= 1.425m
Lift 5= 1.425m
Lift 6= 1.425m
Bedrock

Construction Sequence 2d
150 Apron
250
Lining Concreting
Lift 1= 1.25m
75
75

Dowel
Bars
Pile
Diameter
Lift 3= 1.425m
Concrete
Linings
Lift 4= 1.425m
Lift 5= 1.425m
Lift 6= 1.425m
Bedrock

Construction Sequence 3
150 Apron
50
Continue of Sequence 2
Lift 1= 1.25m
75
75
Lift 2= 1.425m
Dowel
Bars
Pile
Diameter
Lift 3= 1.425m
Concrete
Linings
Lift 4= 1.425m
Lift 5= 1.425m
Lift 6= 1.425m
Bedrock

150 Apron
50
Rock Excavation
Lift 1= 1.25m
75
75
Lift 2= 1.425m
Dowel
Bars
Pile
Diameter
Lift 3= 1.425m
Concrete
Linings
Lift 4= 1.425m
Lift 5= 1.425m
Lift 6= 1.425m
Bedrock

150 Apron
50
Rock Inspection
Lift 1= 1.25m
75
75
Lift 2= 1.425m
Dowel
Bars
Pile
Diameter
Lift 3= 1.425m
Concrete
Linings
Lift 4= 1.425m
Lift 5= 1.425m
Lift 6= 1.425m
Bedrock

150 Apron
50 Rock Inspection Log

Lift 1= 1.25m
75
75
Lift 2= 1.425m
Dowel
Bars
Pile
Diameter
Lift 3= 1.425m
Concrete
Linings
Lift 4= 1.425m
Lift 5= 1.425m
Lift 6= 1.425m
Bedrock

150 Apron
50
Steel Reinforcement
Lift 1= 1.25m
75
75
Lift 2= 1.425m
Dowel
Bars
Pile
Diameter
Lift 3= 1.425m
Concrete
Linings
Lift 4= 1.425m
Lift 5= 1.425m
Lift 6= 1.425m
Bedrock

150 Apron
50
Concreting
Lift 1= 1.25m
75
75
Lift 2= 1.425m
Dowel
Bars
Pile
Diameter
Lift 3= 1.425m
Concrete
Linings
Lift 4= 1.425m
Lift 5= 1.425m
Lift 6= 1.425m
Bedrock

Construction Monitoring 1

Construction Monitoring 2
Sample of Caisson Monitoring:

refer to G\ 05G404\ Excel\ Caisson Pile Monitoring
Design of Caisson 1
All. Struc. Capacity, Qall
= 1/4 fcu Ac
= 1/4(35)(p*15002/4)
= 15,563kN say 15,000kN (Ft)
Econ = Ko+0.2fcu
= 20+0.2(35)
= 27GPa
Erock / qu = 200 (conservatively)
Erock = 200*20MPa
= 4000MPa= 4GPa
Econ/Erock = 27/4 = 6.75
Design of Caisson 2
All. Rock End Bearing Capacity, qa
= Ksp*qu (Canadian Foundation Engineering Manual)
= 0.1*20MPa
= 2000kPa qu=20MPa
Force, Fb = 2000*(p*1.52/4)
= 3534kN

Design of Caisson 3
Ft = 15,000kN
Fb = 3534kN Fb/Ft = 24%
From graph,
dr/ro = 2.3
ro = 1.5/2 = 0.75
Min rock socket required, dr = 1.73m
Ep/Er=6.75
dr/ro=2.3

Design of Caisson 4
Check:
Load taken by shaft friction
= (100-24%)*15,000kN = 11,400kN
Allow. Skin Resistance for Granite

= 5%qu = 0.05*20MPa = 1MPa
Fskin available = p*1.5*1.73*1000kPa

= 8152kN < 11,400kN
(rock socket length inadequate!)
Ep/Er=6.75
dr/ro=2.3

Design of Caisson 5
Try Rock Socket Length of 2.75m:
dr/ro = 2.75/0.75 = 3.67
From graph,
Fb/Ft = 16%
Load taken by shaft friction
= (100-16%)*15,000kN = 12,600kN
Fskin available = p*1.5*2.75*1000kPa

= 12,959kN < 12,600kN
(rock socket length adequate!)
So, adopt rock socket length of 2.75m for
f1500 caisson with working capacity of
15,000kN
Fb/Ft = 16 Ep/Er=6.75

Testing of Caisson 1
Instrumented Pile Testing


Testing of Caisson 3a
1 2
Arrangement for pile testing:
3 4
5 6

Testing of Caisson 3b
1 2
Arrangement for pile testing:
3 4

d1WL=3.11mm d2WL=6.84mm

Results Conclusion:
1) Total Pile displacement = 6.84mm
a) Pile Shortening = 4.71mm
b) Base Settlement = 2.13mm
2) Soil Mobilised Unit Shaft friction = 268kPa

(Ignore during design)
3) Rock Mobilised Unit Shaft Friction:

a) 1st m = 1037kPa
b) Subsequent 1.5m = 1738kPa
(Design fs = 1000kPa)
4) Rock Mobilised End Bearing = 3666kPa

(Design fb = 2000kPa)

Caisson Plate Bearing Test

Caisson Plate Bearing Test
d =1.6mm

Site Photos Caisson 1






Definition of Rock Excavation








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How are caisson piles constructed?

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What challenges are involved in foundation construction?

CAISSON PILES

DESIGN & CONSTRUCTION

High impose loads

G&P Professionals Sdn Bhd Quality Services - Our Commitment

Podium: Service Apartment

G&P Professionals Sdn Bhd

Most of the deep foundation are on

Site congested (big piling rigs; site is only

Expensive of piling rigs mobilisation

G&P Professionals Sdn Bhd Quality Services - Our Commitment

Technology from Hong Kong 250

Manual earth digging

Retained temporary with

cast in-situ concrete linings

required founding level Lift 5= 1.425m

Steel reinforcing & concreting Lift 6= 1.425m

Dia. 1m 4m, max. 45m long

G&P Professionals Sdn Bhd Quality Services - Our Commitment

G&P Professionals Sdn Bhd Quality Services - Our Commitment

G&P Professionals Sdn Bhd Quality Services - Our Commitment

G&P Professionals Sdn Bhd Quality Services - Our Commitment

G&P Professionals Sdn Bhd Quality Services - Our Commitment

G&P Professionals Sdn Bhd Quality Services - Our Commitment

Lift 2= 1.425m Lift 2

G&P Professionals Sdn Bhd Quality Services - Our Commitment

Lift 2= 1.425m Lift 2

G&P Professionals Sdn Bhd Quality Services - Our Commitment

Lift 2= 1.425m Lift 2

G&P Professionals Sdn Bhd Quality Services - Our Commitment

Lift 2= 1.425m Lift 2

G&P Professionals Sdn Bhd Quality Services - Our Commitment

Lift 2= 1.425m Lift 2

G&P Professionals Sdn Bhd Quality Services - Our Commitment

G&P Professionals Sdn Bhd Quality Services - Our Commitment

G&P Professionals Sdn Bhd Quality Services - Our Commitment

G&P Professionals Sdn Bhd Quality Services - Our Commitment

50 Rock Inspection Log

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G&P Professionals Sdn Bhd Quality Services - Our Commitment

G&P Professionals Sdn Bhd Quality Services - Our Commitment

G&P Professionals Sdn Bhd Quality Services - Our Commitment

Sample of Caisson Monitoring:

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G&P Professionals Sdn Bhd Quality Services - Our Commitment

Allow. Skin Resistance for Granite

Fskin available = p*1.5*1.73*1000kPa

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Fskin available = p*1.5*2.75*1000kPa

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G&P Professionals Sdn Bhd Quality Services - Our Commitment

G&P Professionals Sdn Bhd Quality Services - Our Commitment

Arrangement for pile testing:

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Arrangement for pile testing:

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Fskin available = p1.51.73*1000kPa

Fskin available = p1.52.75*1000kPa