2-3 Schöepf

Design and Construction
of Rock Socketed Piles

in Land Conditions
Manfred Schpf
BAUER Maschinen GmbH Schrobenhausen
Workshop
Deep Foundation Technologies for Infrastructure Development
in India
November 14, 2013, IIT Bombay Campus, MUMBAI
BAUER Maschinen GmbH, D-86529 Schrobenhausen
Agenda
Design aspects
Reference to international standards
Plant and Equipment

Effective use of drilling tools
Project references
Productivity
Logistics aspects
Health and safety features
Automation
Bangalore
Metro
Text
Typical bore log
Depth-Time diagram Pier P 354
other drilling rig
Questions
How to avoid unefficient work
drilling depth too deep because of rig power (Example 1)
using chisel for rock socketing (Example 2)
using combined system to save expensive drill rig (Example 2)
Definition of termination criteria for rock socket with rotary drilling rig
2
1
Design German practice
Every structure has to be classified in Geotechnical Categories GC

GC 1 GC 3
for GC 2 GC 3 a geotechnical expert has to decide if base

pressure alone or base pressure + shaft resistance can be
assumed
based on soil report

decision cannot be made by piling contractor
pile design can be made on the basis of empiric values

DIN 1054: 2010-12 Baugrund Sicherheitsnachweise im Erd- und Grundbau
EAPfhle (2012) Empfehlungen Arbeitskreis Pfhle" der DGGT e.V.
Design Experience values in German Code

unconfined compressive
strength quk
(MN/m)
base resistance
(MN/m)
ultimate shaft resistance

(MN/m)
0,50
5,00
20,00
1,50
5,00
10,00
0,08
0,50
0,50
Table B.5 Pile base resistance qb,k and shaft resistance qs,k in rock
(DIN 1054-2005)
Design Experience values in German Code

unconfined compressive
strength quk
(MN/m)
base resistance
(MN/m)
ultimate shaft resistance

(MN/m)
0,50
5,00
20,00
1,50 2,50
5,00 10,00
10,00 20,00
0,07 0,25
0,50 1,00
0,50 2,00
Range of experience values

for Pile base resistance qb,k and shaft resistance qs,k in rock
(EA Pfhle 2012)
Design German Practice

simplified example (for soil)
empiric values
DIN tables
1m
3
10
Fill
Sand
q (CPT) = 7,5 MN/m
highly weath. rock

UCS = 0,5 MN/m
friction
qsk = 0
Rsk = 0
friction
qsk = 0,05 MN/m
Rsk = 1,57 MN
friction
qsk = 0,07 MN/m
Rsk = 0,67 MN
base
qbk = 1,5 MN/m
Rbk = 1,17 MN
Rtot, ult. = 3,4 MN
Design German Practice

simplified example (for soil)
0,4
srg = 0,5xQrg+0,5
= 1,6 cm
1,2
2,8
3,4
4,2 [MN]
Qall= 1,7MN
1
2
2,0
Qall= 1,3MN
3
4
5
6
7
8
sg = 0,1x
= 10 cm
9
10
[cm]
F.S.= 2
10
Design Hongkong Practice

The Code of Practice for Foundation
(Building Department BD)
for all private structures
Housing Department or Architectural Service
Department (ASD)
for all public structures.
Additional: Civil Engineering Development
Departments (CEDD).
They all follow in principle the codes of BD.
ASD more stringent requirements such as:
Minimal socket length 0,6 m
Pile resistance only in base
11

(Clause 2.2)
Allowable bearing capacity for non-driven piles shall be determined by:

Rational Design Method:
interpretation of the results of the site investigation
assessment of test results []
analysis based on the laws of physics and recognized engineering
principles. Normally a factor of safety of 3 is applied.
Presumed values
allowable capacity may be taken as presumed values derived from
empirical correlations
Table 2.1 for allowable vertical bearing pressure
Table 2.2 for allowable friction between rock and concrete
12

Presumed allowable vertical bearing pressure
Category Rock (granites & volcanics)
Presumed bearing
pressure (kPa)
1 (a)
Fresh strong to very strong rock GRADE I

100% total core recovery, no weathered joints
minimum uniaxial compressive strength 75 MPa
10,000
1 (b)
Fresh to slightly decomposed strong rock GRADE II

> 95% total core recovery
7,500
1 (c)
Slightly to moderately decomposed moderately

strong rock GRADE III
5,000
1 (d)
Moderately decomposed, moderately strong to

moderately weak rock GRADE IV,
3,000
BD 2004 Table 2.1

13

Presumed allowable friction for piles
Category Rock (granites & volcanics)
Presumed friction
(kPa)
1 (c)
Slightly to moderately decomposed moderately
or better strong rock GRADE III
1 (d)
Moderately decomposed, moderately strong to
moderately weak rock GRADE IV,
700
300
under compression or transient tension
BD 2004 Table 2.2

14
Design Minimum socket length

Comparison of international codes
Country
Condition
min. socket length (m)
Germany
(EA Piles)
quk 5 MN/m
quk 0,5 MN/m
0,5 m
2,5 m
Hongkong
(BD 2004, 2.2.2)
Grade I (UCS >75 Mpa)

Grade II (UCS >50 Mpa)
Grade III (UCS >25 Mpa)
0,5 m
0,5 m
0,3 m
0,6 m
(ADS 2012)
USA
(IBC 2009)
min. 1
UK
Australia
no values stated
India
(IRC 78-2000)
UCS >12,5 Mpa

UCS 2,5 12,5 MPa
0,6 m
1,5 m
15
Design Termination Criteria

Germany
no criteria in code, if rock is harder than stated in SI: check condition with
geotechnical consultant with possibility of
modifying pile design (bigger diameter, 2 piles instead of one)
increasing bearing values with resulting shorter socket length
USA
no general criteria, earlier termination can be reached by a specific alternative
proposal or based on pile test results
Australia
no general criteria, rule of thumb (not backed up in codes: terminate if progress
< 100 300 mm/h
Comment: dangerous as general rule (rock condition, diameter, type of drilling
system, ability of operator!!!)
UK and Hongkong
no general criteria
16

India
Pile termination criteria as a quality control tool in rocks
IRC: 78-2000 (established initially for driven piles)
For bored piles:
Basis of consideration Pile Penetration Ratio (PPR)
PPR = (2*n*T*t) / (A*P)
and
HP (of rig) = (2*n*T) / 4.5
Ganpule (2005)
Dr. S. Basarkar
Comments of an equipment manufacturer and

foundation engineer
17

India
Results of formulae are only reliable if the input data are created in a
reproducible manner with standardized procedures and components.
Engine power:
only valid for one specific rig

rated power = theoretic value
actual efficiency: 30% - 60%
actual HP may vary from rig to rig
efficiency 10% during operation
Efficiency hydraulic system
18

India
Results of formulae are only reliable if the input data are created in a
reproducible manner with standardized procedures and components.
Influence of tool:
type of tool, status of wear

not standardized or normalized
Operator:
human factor, qualification

rough or smooth operating style
T
n
19
Termination criterion Visual inspection
gravel, pebbles, cobbles
rock cuttings
only indicative requires geotechnical experts approval
20
10
Drill rig BG
Main components
Kelly bar
3 4 parts (telescopic)
carries drilling tool
transfer M and V
Mast
torsion resistant
Extensions
Mast head
Connection base carrier
Rotary drive (KDK)

slides vertically
on mast
M = 120 500 kNm
Winches
Main winch
Auxil. winch
Crowd winch
(reeved)
Drilling tools
type and dimensions
variable
depends on
soil and pile design
170 600 kN
40 170 kN
200 600 kN
Base carrier
on crawlers
Engine
Hydraulic station
Controls
electronic
hydraulic
21
Development Drilling depth
1.
Kelly bar
Depth = 3 4 x A - overlap
22
11
Bauer Kelly System
Interlocking Kelly Bar
Friction Type Kelly Bar
standard 3- 4 part kelly bar

practical depths: 80 m
with 4 part kelly bar
not lockable
standard 5 fold kelly bar
(reduced torque)
max depths: 100 -110 m
Mechanical interlock
Friction surface
23
Rock Drilling Tools

for
BG Rigs
24
12
Kelly Drilling
Drilling with auger in dry soil

(typical sand, gravel, clay, weathered rock)
25
Kelly Drilling
Penetrating rock layers or cemented layers with core barrel
26
13
Kelly Drilling
Drilling with bucket below groundwater level

(typical sand, gravel, clay, weathered rock)
27
Kelly Drilling
What tools for socketing into rock?

28
14
Kelly Drilling Selection of tools
29
Rock Augers
moderately strong to
strong not laminated
rock
(10 100 MPa)
uncased bores or for
bigger diameters
Single cut auger with pilot bit
Tapered auger
very dense sand and gravel,

weak rock up to 20 MPa
very good for pile walls
Double cut auger

without pilot bit
moderately weak to
moderately strong
rock (5 50 Mpa)
very suitable in fractured
rock
30
15
Drill buckets
31
Tools Suitability of teeth types
BG operation
Excavator operation
3- dimensional movement
2- dimensional movement
32
16
Tools Flat teeth

Why special BG Flat Teeth?
Bauer Flat Tooth
Standard Flat Tooth
variable cutting angle

adaption to soil condition possible
tooth holder turnable
fixed cutting angle

no adaption to soil condition
tooth holder allows a fix position only
33
Tools Flat teeth
steep angle for hard soil conditions
flat angle for soft soil conditions
34
17
Tools Positioning of flat teeth

center of each tooth is located on
an exact reference circle on the tool
bearbeiten
midth of cutting shape creates

an 90 angle with tangential line
reference circle
elongation of cutting edge
to run through the center
35
correctly positioned teeth result in:

complete cutting edge is working
homogeneous wear and tear
outside teeth transfer soil into bucket
optimal filling of bucket
outside teeth create annulus
reduction of friction
36
18

unfavourable setting of teeth (example FZ 80)
elongination of cutting edge does not

guide through center of tool
inhomogeneous wear and tear
37
Tools Round shank chisel (bullet teeth)

exact three dimensional positioning
of the round shank chisel is essential for a proper function of this tool !!
8 - 30
cutting angle
inclination to ensure
rotation
38
19
Tools Round shank chisel positioning
side inclination of chisel to

ensure rotation
homogeneous wear
at chisel
increased lifetime of
chisel
39
39
Rock Drilling with Kelly

New bullet tooth
Used bullet tooth
Used in abrasive soil

Bullet tooth did not
turn
Tungsten carbide not
worn
Holder is probably
destroyed
40
20
Core barrel
41
Core barrel
round shank chisel with up to

four different positions,
in order to create an uniform
annulus
4
3
2
1
42
21
Roller bit core barrel
Suction pipe
43

pressurized air
flush head
pressurized air
compressor
lockable
kelly bar
roller bit
core barrel
44
22
Roller
bitder
core
barrel
Ziele
Bodenverbesserung
Destroying of core
rock auger
OR
cross-cutter
Cross-Cutter
46
23
BG 36 # 1366 - Dura/ South Africa

Drilling Rig:
BG 36
Drilling depth:
25 - 45 m
Drilling Diameter:
1.350 mm
Drilling system:
Kelly, uncased
Rock strenght:
250 - 350 mpa
Performance:
25 cm/ h
47

BG 40 # 988 - ZAP/ Singapore
48
Drilling Rig:
BG 40
Drilling depth:
45 m
Drilling Diameter:
1350 mm
Drilling system:
Kelly, uncased
Rock strength:
250 mpa
48
24
Roller bit tools with air flushing

Casing
drive
adapter
Kelly bar
Flushing
head
Advantage
Disadvantage
easy adaption
rock strength up to
250 MPa
little air consumption
780 1800 mm
quick discharge
(FFC)
solid rock required

water needed
high crowd force
required
not suitable for
boulders
Full face
cutter
Full Face Cutter FFC

49
Full Face Cutter

Project reference Finland
Bored piles for bridge foundation
Diameter:
1500 mm
Pile length:
6 -25 m
inclined piles 6
dipping level of
bedrock
strength:
> 150 Mpa

increasing with depth
socket length: 1-3 m
50
25
Full Face Cutter

Project reference Finland
0,5
1,5
1,0
drilling progress
[cm/min]
0,5
1,0
1,5
socket
length [m]
1,2 m socket length => 2 hours

average advancement 0,6 m/h
vertical pressure required approx. 60 t
vertical pressure available approx. 30 t
51
Rock Drilling
How to cope with boulder and Granite?
0m
Fill
3m
Boulders
100 MPa
Typical project
Diameter
1500 mm
Boulders from 3 to 23 m
Rock socketing in Granite
Options
10 m
Sand and
boulders
Conventional tools?
No
Roller bit tools?
No
Solution
Multi single down the hole hammer

23 m
Granite
250 MPa
52
26
MHD Cutting edge technique for rock
53
Rock Drilling
How to cope with boulder and Granite?
Typical project
0m
Fill
3m
Diameter
1500 mm
Boulders from 3 to 23 m
Boulders
Rock socketing in Granite
100 MPa
10 m
Sand and
boulders
23 m
Granite
250 MPa
Watch the boulders

laying in soft spots
54
27
+/- 360
Chippings get
flushed upwards
View into Calyx Basket
Advantage: No Air swivel required!

55

Key advantages
1. Can be attached to Kelly bar (no drill pipes required)

2. No impact into the rotary drive or Kelly bar
3. Boulders any size can be drilled
4. Rock up to 300 MPa and above
5. Dry boreholes are most suitable
6. Uniform hammer and bits for every diameter
Economical bit costs
56
28
Multi Hammer Drill Case study

secant pile wall
Quantity
Depth
Rock socket
135 no / dia 1180 mm

25 m
Fully cased to 18 m
7 m in Sandstone
150 - 170 MPa
Performance MHD 7 m rock drilling

2 h 20 min (3 m/h)
including emptying calyx basket
Wear and tear
maintenance after 120 m rock
exchanged bits and chucks
Comparison
secondary piles
(with concrete overcut)
with rock auger on BG 40.
1,20 m in 2 hours (0,6 m/h)
57
Multi Hammer Drill Case study

PROJECT:
Hot Rolling Processing

Facility, Pittsburgh, PA
DIMENSIONS:
128 Holes / dia 1067 mm

19m Overburden
7m Rock Socket
(UCS > 150 MPa
EQUIPMENT:
Calweld Rotary Attachment and Flushing Air
Kelly
Performance in rock: 2,9 m/h
BAUER BG 36 and BG 40
installing 19m of 1080 mm Segmental Casing
58
29

Limitations
MHD
Only this one
is working
These 2 do
not exhaust
the air
casing
DRILLING DIPPING ROCK SURFACE?
Yes, it is possible
MHD does not require high crowd force
Start with little crowd force until bottom is

flattened
Good indicator is the air pressure
Dipping rock
59

Limitations
DRILLING UNDER WATER?
Yes, it is possible
The hydrostatic pressure must be considered when chosing
air compressors
High pressure air compressor required for water depth > 12m
60
30

Limitations
DRILLING UNDER BENTONITE
No, the standard MHD cannot be used

under bentonite slurry, if there is no
casing!
use segmental casings or even a casing

liner (no bentonite in the borehole)
61
Project Reference BG 38
KL MRT Piling Project, Malaysia 2013
62
31
Project Reference Rock

KR-R 900
for pilot hole drilling
63
Project Reference Rock

Ordinary sandstone
Sandstone with
quartzite
3 piles during site visit,

all hit the sandstone with
quartzite
from 4m down to 12~14m!
Estimated rock strength
exceeds 150 MPa.
64
32
Project Reference Work sequence

Pile no.:
Pile diameter:
Pile depth:
BK 36/3
2,800 mm
18.8 m
G.L 0.0m to G.L. -8.0m:

rock auger
Net drill time:
34.6 hrs
G.L. -8.0m to G.L. -18.8m
2800
4 nos. pilot holes
KR-R 900
break remaining rock

on the left and right
KR-R/KR-X 1500
then enlarge step by step KR-R/KR-X1800,

KR-R/KR-X 2800
65
Project Reference
Stonecutter Bridge Hongkong
East Tsing Yi Viaduct

1.1km long + ramps
6 lane highway
263 nos. of bored piles
dia. 1500mm and 2000mm
depth up to 80m
and rock socket 5m to 8m
Courtesy:
Bauer Construction Malaysia
Dr.K.S.Rama Krishna L&T-ECC Division
66
33
Project Reference General soil profile

Reclaimed sand, loose to medium

dense (with obstruction in form of
seawalls)
Marine clays soft

Alluvium
Decomposed granite with boulders
Granite bedrock GI-GIII
UCS 100-200 Mpa
67
Project Reference Rock cores

Solid rock core
recovered on
Stonecutter Approach
Viaducts
68
34
Project Reference Performance

263 nos. of Bored Piles with extensive rock drilling were

completed in 9 months
4 nos. of Bauer BG 40 rigs were used

Production equivalent to 2.5 days per pile and rig
Rig output was doubled compared to conventionally production
of RCD-Drilling Rigs
69
Project Reference Quality control

Hong Kong has one of the most stringent pile testing regimes
100% predrilling prior to pile drilling
100% Sonic Logging
100% verticality check, 10% verticality check by Koden or as

per Specifications
100% Interface
Full core of pile 5% to 10% depending on Specifications
Material testing such as cube crushing and Rebar Tensile Test
as per Specifications
70
35
Project Reference Interface cores

71
Logistics Preparation of working platform

flat and stable platform required
if soft surface conditions use steel plates or similar
rig is top-heavy => careful movements
=> beware of badly covered open holes or soft backfill
=> avoid inclined hoist
housekeeping for safety reasons and for economy reasons
72
36
Logistics Working platform
BAD INSUFFICIENT
BACKFILL
73
Logistics Housekeeping at pile location
where is the borehole??
clean with good slurry management
=> unsafe and inefficient operation
=> safe and economic operation

74
37
Logistics Planning of work sequence

finished
pile
next
pile
traffic road
work area
work direction
drill spoil
traffic road
finished
pile
next
pile
traffic road
work area
work direction
drill spoil
traffic road
75
Logistics Selection of rig type
confined space
small diameter
limited number of piles
=> smaller rig
sufficient work space

large, deep piles
big number of piles
=> larger rigs
76
38
Logistics - BG kinematic system (V-System)

Criteria of
mast connection system:
developed by Bauer
2 big backstay cylinders
stiff and sturdy load transfer
for optimum flow of forces
(torque!)
typically used for rigs with high

torque
77
Logistics - BG kinematic system (V-System)
H
L
78
39
Logistics- Transport (V-System)
79
Logistics - BG kinematic system (H-System)
Backstay Cylinder
Kinematics Triangle
Support Boom
Boom
Boom Cylinder
3 Connecting Points
with base frame
80
40

Transport position
81
82
41
Modern cabin
increases safety, economy and comfort
83
B-Tronic screen
Mast
inclination and
positioning
Winches
and Crowd
info
Kelly
visualization:
Locking
position
Visualization of the
borehole and the Kelly bar
84
42
B-Tronic a fully integrated system

USB-Stick
PC
equipment
B-Report
Browser
files
B-tronicscreen
machine
control
DTR
Internet
Bauer
customer centre
BauerWeb-BGM
Bauer
data host
85
B-Report Analysis of pile production time
86
43
Safety Handling Assistant

1. Step:
NO
OK
Indication of safe and

critical work ranges
=> Operator has to react
2. Step:
!
Electronic control reacts

=> Operator controls
87
Safety Fall protection (Working at height)

Catwalk on
uppercarriage
Catwalk around
the base carrier
88
44
Safety Camera controls
Cameras:
1. Back View
2. Right hand side
Automatic view when
when slewing or travelling
89
Environment - Emissions reduction
90
45

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Design and Construction

of Rock Socketed Piles

Plant and Equipment

BAUER Maschinen GmbH, D-86529 Schrobenhausen

Depth-Time diagram Pier P 354

other drilling rig

BAUER Maschinen GmbH, D-86529 Schrobenhausen

BAUER Maschinen GmbH, D-86529 Schrobenhausen

Design German practice

Every structure has to be classified in Geotechnical Categories GC

for GC 2 GC 3 a geotechnical expert has to decide if base

based on soil report

pile design can be made on the basis of empiric values

BAUER Maschinen GmbH, D-86529 Schrobenhausen

Design Experience values in German Code

ultimate shaft resistance

BAUER Maschinen GmbH, D-86529 Schrobenhausen

Design Experience values in German Code

ultimate shaft resistance

Range of experience values

BAUER Maschinen GmbH, D-86529 Schrobenhausen

Design German Practice

highly weath. rock

Rtot, ult. = 3,4 MN

BAUER Maschinen GmbH, D-86529 Schrobenhausen

Design German Practice

BAUER Maschinen GmbH, D-86529 Schrobenhausen

Design Hongkong Practice

Design Hongkong Practice

Allowable bearing capacity for non-driven piles shall be determined by:

BAUER Maschinen GmbH, D-86529 Schrobenhausen

Design Hongkong Practice

Fresh strong to very strong rock GRADE I

Fresh to slightly decomposed strong rock GRADE II

Slightly to moderately decomposed moderately

Moderately decomposed, moderately strong to

BD 2004 Table 2.1

Design Hongkong Practice

under compression or transient tension

BD 2004 Table 2.2

Design Minimum socket length

min. socket length (m)

Grade I (UCS >75 Mpa)

UCS >12,5 Mpa

BAUER Maschinen GmbH, D-86529 Schrobenhausen

Design Termination Criteria

Design Termination Criteria

Comments of an equipment manufacturer and

BAUER Maschinen GmbH, D-86529 Schrobenhausen

Design Termination Criteria

only valid for one specific rig

Efficiency hydraulic system

BAUER Maschinen GmbH, D-86529 Schrobenhausen

Design Termination Criteria

type of tool, status of wear

human factor, qualification

Termination criterion Visual inspection

gravel, pebbles, cobbles

only indicative requires geotechnical experts approval

BAUER Maschinen GmbH, D-86529 Schrobenhausen

Rotary drive (KDK)

BAUER Maschinen GmbH, D-86529 Schrobenhausen

Development Drilling depth

BAUER Maschinen GmbH, D-86529 Schrobenhausen