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

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 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
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 SI Borelog Profiles

8 Boreholes
7 Additional
Boreholes
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 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)

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 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

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 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

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 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

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 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

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 Construction Sequence 1c
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

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 Construction Sequence 1c
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

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 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

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 Construction Sequence 2b
150 Apron

250
Dismantle of Steel Mould
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

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 Construction Sequence 2c
150 Apron

250
Placing of Steel Mould
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

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 Construction Sequence 2d
150 Apron

250
Placing of Steel BRC A6
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

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 Construction Sequence 2d
150 Apron

250
Lining Concreting
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

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 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

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 Construction Sequence 4
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

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 Construction Sequence 5
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

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 Construction Sequence 5
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

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 Construction Sequence 6
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

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 Construction Sequence 6
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

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 Construction Monitoring 1

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 Construction Monitoring 2

Sample of Caisson Monitoring:

refer to G\ 05G404\ Excel\ Caisson Pile Monitoring
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 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
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 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

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 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

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 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

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 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

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 Testing of Caisson 1
Instrumented Pile Testing

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 Testing of Caisson 2
Instrumented Pile Testing

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 Testing of Caisson 3a
1 2

Arrangement for pile testing:

3 4

5 6

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 Testing of Caisson 3b
1 2

Arrangement for pile testing:

3 4

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 Testing of Caisson 4
Instrumented Pile Testing

d1WL=3.11mm d2WL=6.84mm

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 Testing of Caisson 5
Instrumented Pile Testing

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)

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 Testing of Caisson 6
Caisson Plate Bearing Test

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 Testing of Caisson 7
Caisson Plate Bearing Test

d =1.6mm

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 Site Photos Caisson 1

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 Site Photos Caisson 2

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 Site Photos Caisson 3

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 Site Photos Caisson 4

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 Site Photos Caisson 5

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 Site Photos Caisson 6

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 Definition of Rock Excavation

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 Site Photos Caisson 7

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 Site Photos Caisson 8

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 Site Photos Caisson 9

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 Site Photos Caisson 10

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 Site Photos Caisson 11

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 Site Photos Caisson 12

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