USACE / NAVFAC / AFCESA / NASA UFGS-35 59 13.13 (April 2006)
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Preparing Activity: NAVFAC Replacing without change
UFGS-02395 (May 2003)
UNIFIED FACILITIES GUIDE SPECIFICATIONS
References are in agreement with UMRL dated January 2009
SECTION 35 59 13.13
PRESTRESSED CONCRETE FENDER PILING
04/06
NOTE: This guide specification covers the requirements for prestressed concrete
fender piling.
Edit this guide specification for project specific requirements by adding, deleting,
or revising text. For bracketed items, choose applicable items(s) or insert
appropriate information.
Remove information and requirements not required in respective project, whether
or not brackets are present.
Comments and suggestions on this guide specification are welcome and should
be directed to the technical proponent of the specification. A listing of technical
proponents, including their organization designation and telephone number, is
on the Internet.
Recommended changes to a UFGS should be submitted as a Criteria Change Request
(CCR).
NOTE: The extent and location of the work to be accomplished should be indicated
on the project drawings or included in the project specification.
NOTE: Refer to NFESC TM 53-89-03, "Prestressed Concrete Fender Piling User
Data Package" for details of these fender piles. The following information
shall be shown on the drawings:
1. Locations and design loads of piles.
2. Size, shape, and length of piles.
3. Locations, sizes, and number of longitudinal ducts for prestressing steel.
Unit stresses for prestressing strands or wire.
4. Details of reinforcement and tendons.
5. Soil data, where required.
6. Embedment depth.
PART 1 GENERAL
1.1 REFERENCES
NOTE: This paragraph is used to list the publications cited in the text of
the guide specification. The publications are referred to in the text by basic
designation only and listed in this paragraph by organization, designation,
date, and title.
Use the Reference Wizard's Check Reference feature when you add a RID outside
of the Section's Reference Article to automatically place the reference in the
Reference Article. Also use the Reference Wizard's Check Reference feature
to update the issue dates.
References not used in the text will automatically be deleted from this section
of the project specification when you choose to reconcile references in the
publish print process.
The publications listed below form a part of this specification to the extent referenced. The publications are
referred to within the text by the basic designation only.
[ACI INTERNATIONAL (ACI)ACI 211.1(1991; R 2002) Standard Practice for Selecting Proportions for Normal, Heavyweight, and Mass ConcreteACI 212.3R(2004) Chemical Admixtures for ConcreteACI 214R(2002) Recommended Practice for Evaluation of Strength Test Results of ConcreteACI 318M(2008) Metric Building Code Requirements for Structural Concrete and CommentaryACI SP-66(2004) ACI Detailing Manual][AMERICAN ASSOCIATION OF STATE HIGHWAY AND TRANSPORTATION OFFICIALS (AASHTO)AASHTO M 182(2005) Standard Specification for Burlap Cloth Made from Jute or Kenaf and Cotton Mats][AMERICAN WELDING SOCIETY (AWS)AWS D1.4/D1.4M(2005; Errata 2005) Structural Welding Code - Reinforcing Steel][ASTM INTERNATIONAL (ASTM)ASTM A 153/A 153M(2005) Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel HardwareASTM A 307(2007b) Standard Specification for Carbon Steel Bolts and Studs, 60 000 PSI Tensile StrengthASTM A 416/A 416M(2006) Standard Specification for Steel Strand, Uncoated Seven-Wire for Prestressed ConcreteASTM A 501(2007) Standard Specification for Hot-Formed Welded and Seamless Carbon Steel Structural TubingASTM A 53/A 53M(2007) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and SeamlessASTM A 563(2007a) Standard Specification for Carbon and Alloy Steel NutsASTM A 563M(2007) Standard Specification for Carbon and Alloy Steel Nuts (Metric)ASTM A 615/A 615M(2008b) Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete ReinforcementASTM A 706/A 706M(2008a) Standard Specification for Low-Alloy Steel Deformed and Plain Bars for Concrete ReinforcementASTM A 82/A 82M(2007) Standard Specification for Steel Wire, Plain, for Concrete ReinforcementASTM A 966/A 966M(2008) Standard Test Method for Magnetic Particle Examination of Steel Forgings Using Alternating CurrentASTM C 1240(2005) Standard Specification for Silica Fume Used in Cementitious MixturesASTM C 136(2006) Standard Test Method for Sieve Analysis of Fine and Coarse AggregatesASTM C 143/C 143M(2008) Standard Test Method for Slump of Hydraulic-Cement ConcreteASTM C 150(2007) Standard Specification for Portland CementASTM C 171(2007) Standard Specification for Sheet Materials for Curing ConcreteASTM C 172(2008) Standard Practice for Sampling Freshly Mixed ConcreteASTM C 309(2007) Standard Specification for Liquid Membrane-Forming Compounds for Curing ConcreteASTM C 31/C 31M(2008a) Standard Practice for Making and Curing Concrete Test Specimens in the FieldASTM C 311(2007) Sampling and Testing Fly Ash or Natural Pozzolans for Use as a Mineral Admixture in Portland-Cement ConcreteASTM C 33(2007) Standard Specification for Concrete AggregatesASTM C 39/C 39M(2005e1e2) Standard Test Method for Compressive Strength of Cylindrical Concrete SpecimensASTM C 494/C 494M(2008a) Standard Specification for Chemical Admixtures for ConcreteASTM C 595(2008) Standard Specification for Blended Hydraulic CementsASTM C 618(2008a) Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in ConcreteASTM C 989(2006) Standard Specification for Ground Granulated Blast-Furnace Slag for Use in Concrete and MortarsASTM D 1894(2008) Static and Kinetic Coefficients of Friction of Plastic Film and SheetingASTM D 2240(2005) Standard Test Method for Rubber Property - Durometer HardnessASTM D 256(2006e1) Determining the Izod Pendulum Impact Resistance of PlasticsASTM D 4020(2005) Ultra-High-Molecular-Weight Polyethylene Molding and Extrusion MaterialsASTM D 570(1998; R 2005) Standard Test Method for Water Absorption of PlasticsASTM D 638(2008) Standard Test Method for Tensile Properties of PlasticsASTM D 792(2008) Density and Specific Gravity (Relative Density) of Plastics by DisplacementASTM F 844(2007a) Washers, Steel, Plain (Flat), Unhardened for General Use][PRECAST/PRESTRESSED CONCRETE INSTITUTE (PCI)PCI MNL-116(1999) Manual for Quality Control for Plants and Production of Structural Precast Concrete Products]1.2 SUBMITTALS
NOTE: Review submittal description (SD) definitions in Section 01 33 00 SUBMITTAL
PROCEDURES and edit the following list to reflect only the submittals required
for the project. Submittals should be kept to the minimum required for adequate
quality control.
A “G” following a submittal item indicates that the submittal requires Government
approval. Some submittals are already marked with a “G”. Only delete an existing
“G” if the submittal item is not complex and can be reviewed through the Contractor’s
Quality Control system. Only add a “G” if the submittal is sufficiently important
or complex in context of the project.
For submittals requiring Government approval on Army projects, a code of up
to three characters within the submittal tags may be used following the "G"
designation to indicate the approving authority. Codes for Army projects using
the Resident Management System (RMS) are: "AE" for Architect-Engineer; "DO"
for District Office (Engineering Division or other organization in the District
Office); "AO" for Area Office; "RO" for Resident Office; and "PO" for Project
Office. Codes following the "G" typically are not used for Navy, Air Force,
and NASA projects.
Choose the first bracketed item for Navy, Air Force and NASA projects, or choose
the second bracketed item for Army projects.
Government approval is required for submittals with a "G" designation; submittals not having a "G" designation
are [for Contractor Quality Control approval.][for information only. When used, a designation following the
"G" designation identifies the office that will review the submittal for the Government.] The following shall
be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Piles
Driving helmets, capblocks, and pile cushions
SD-05 Design Data
Concrete mix design
Submit a concrete mix design before concrete is placed, for each type of concrete used for
the piles.
SD-06 Test Reports
Aggregates
Fly ash
Silica fume
Concrete
Submit concrete cylinder compressive strength test results.
SD-07 Certificates
Precasting manufacturer's quality control procedures
Suitability of pile driving equipment
[Curing of piles]
[Silica fume manufacturer's representative]
Prestressing steel
Portland cement
Concrete mix design
Reinforcing steel
[Rubbing surface]
Bolts, nuts, and washers
1.3 REQUIREMENTS
1.3.1 Piling Lengths and Quantity
Provide prestressed pretensioned concrete piles. Base bids upon the number, size, and length of piles as indicated.
Adjustments in the contract price will not be made for cutting off piles or for broken, damaged, or rejected
piles.
1.3.2 Piles
Prepare in accordance with ACI SP-66. Indicate placement of reinforcement including tendons. Indicate location
of special embedded or attached lifting devices, employment of pick-up points, support points other than pick-up
points, and any other methods of pick-up. [Provide certification of a professional engineer registered in any
jurisdiction, that layout and details of reinforcement and tendons conform with that shown on the structural
design drawings.]
1.3.3 Driving Helmets, Capblocks, and Pile Cushions
Show details of driving helmets, capblocks, and pile cushions. Submit 2 weeks prior to [test] pile installation.
1.4 QUALITY ASSURANCE
1.4.1 Quality Control Procedures
Submit [_____] copies of precasting manufacturer's quality control procedures established in accordance with
PCI MNL-116.
[1.4.1.1 Curing of Piles
Submit proposed materials and methods.
]1.4.2 Silica Fume Manufacturer's Representative
Provide statement that the manufacturer's representative will be present at plant to ensure proper mix, including
high range water reducer (HRWR), and batching methods.
1.4.3 Aggregates
Prior to pile fabrication, submit certified test reports for the following tests specified in ASTM C 33:
a. Grading
b. Amount of material finer than 75 micrometers No. 200 sieve
c. Organic impurities
d. Soundness
e. Clay lumps and friable particles
f. Coal and lignite
g. Weight of slag
h. Abrasion of coarse aggregate
i. Fineness modulus
j. Reactive aggregates
k. Freezing and thawing
1.4.4 Fly Ash
Furnish fly ash test results performed within 6 months of submittal date. Sampling and testing shall be in accordance
with ASTM C 311.
1.4.5 Silica Fume
Furnish silica fume test results performed within 6 months of submittal date. Sampling and testing shall be
in accordance with ASTM C 311.
1.4.6 Portland Cement
Certification identifying cement; brand name, type, mill location, quantity to be used, size of lot represented
by quality control sample, lot number, and destination of shipment.
1.4.7 Concrete Mix Design
Certify, using a Government-approved independent commercial testing laboratory, that proportioning of mix is
in accordance with ACI 211.1 or ACI 318M for specified strength and is based on aggregate data which has been
determined by laboratory tests during last 12 months.
PART 2 PRODUCTS
2.1 MATERIALS
2.1.1 Cement
NOTE: Insert type of cement required. Except where moderate or high sulfate
resistance is required, permit option for Type I, II, III, IP, or IS. For moderate
sulfate resistance, specify Type II, III, IP(MS), or IS(MS) with a maximum tricalcium
aluminate content of 8 percent. For high sulfate resistance, specify Type III
or V, with a maximum tricalcium aluminate content of 5 percent.
ASTM C 150, [Type I, II, or III] [_____], or ASTM C 595, Type [IP(MS) or IS(MS)] [_____] blended cement except
as modified herein. The blended cement shall consist of a mixture of ASTM C 150 cement and one of the following
materials: ASTM C 618 pozzolan or fly ash, or ASTM C 989 ground iron blast furnace slag. The pozzolan/fly ash
content shall not exceed 25 percent by weight of the total cementitious material. The ground iron blast-furnace
slag shall not exceed 50 percent by weight of total cementitious material. [Cement shall have a maximum tricalcium
aluminate content of [5] [8] percent.]
2.1.2 Water
Use potable water.
2.1.3 Aggregates
NOTE: For piles in areas where reactive aggregates are found, provide for additional
tests and certification to ensure that reactive aggregates will not be used.
While not wholly conclusive, petrographic examination (ASTM C 295), chemical
test (ASTM C 28/c 28M9), provide valuable indicators. The mortar bar method
(ASTM C 227), while more reliable, requires at least 6 months and preferably
one year to yield results. In areas where reactive aggregates cannot be avoided,
specify use of low alkali cement. Service records of concrete made with these
materials along with tests should be used in evaluating these materials.
NOTE: Include modification to ASTM C 33 when reactive aggregates could be encountered.
More modifications may be required. Additional tests and certifications may
be required in the submittal paragraphs.
ASTM C 33[, except as modified herein. Provide aggregate free from any substance which may be deleteriously
reactive with alkalies in cement in an amount sufficient to cause excessive expansion of concrete]. Do not mix,
store in same stockpile, or use fine aggregates from different sources of supply in same concrete mix or same
structure without approval. Maximum coarse aggregate size shall be 19 mm 3/4 inch.
2.1.4 Admixtures
NOTE: For guidance in use of either water-reducing admixtures, set retarding
admixtures, or combination of admixtures, refer to ACI 543R, "Recommendations
for Design, Manufacture, and Installation of Concrete Piles."
If required, ASTM C 494/C 494M, [Type A] [Type B] and ASTM C 618, Type [N] [F] [C]. Do not use admixtures containing
chlorides.
2.1.5 Mineral Admixtures
2.1.5.1 Fly Ash and Pozzolan
NOTE: Fly ash, pozzolan, and slag cement may produce uneven discoloration of
the concrete during the early stages of construction, depending upon the type
of curing provided. Fly ash or pozzolan meeting the specified test results,
which are more stringent than ASTM C 618, should provide acceptable end results.
Type C fly ash can be used as a replacement for up to 40 percent of the cement.
Types F and C fly ash increase durability of concrete. Type F fly ash and slag
are replacements for some sand and aggregates also adding to durability.
ASTM C 618, Type N, F, or C, except that the maximum allowable loss on ignition shall be 6 percent for Types
N and F. Add with cement. Fly ash content shall not exceed 25 percent by weight of the total cementitious material.
2.1.5.2 Silica Fume
NOTE: Use silica fume concrete for marine structures where low permeability
and enhanced durability are necessary. The silica fume and HRWR additive should
be from the same manufacturer. Since this is fairly new technology, the Contractor
and batch plant may need help from the manufacturer. Select weight percentage
based on performance required.
NOTE: Use for high durability and low permeability. The initial cost of the
concrete will increase, and supervision at the batch plant, finishing, and curing
is necessary. A HRWR must be used with silica fume, the slump can be increased
50 to 125 mm 2 to 5 inches without reducing strength. Finishing may be more
difficult. Proper curing is essential because there is a tendency for plastic
shrinkage cracking.
ASTM C 1240, provide silica fume that is a by-product of silicon or ferrosilicon production. Provide [5] [7]
[10] percent by weight of the total cementitious material.
2.1.6 Prestressing Steel
Use seven-wire stress-relieved or low-relaxation strand conforming to ASTM A 416/A 416M with a guaranteed minimum
ultimate tensile strength of 1861 MPa 270 ksi. Use prestressing steel free of grease, oil, wax, paint, soil,
dirt, and loose rust. Do not use prestressing strands or wire having kinks, bends, or other defects.
2.1.7 Reinforcing Steel
NOTE: If project has been designed for epoxy rebar, add ASTM A 934/A 934M,
"Epoxy-Coated Prefabricated Steel Reinforcing Bars" in this paragraph and in
the paragraph entitled "References."
[ASTM A 615/A 615M] [ASTM A 966/A 966M] [ASTM A 966/A 966M], Grade 60 or ASTM A 706/A 706M. Weld reinforcing
steel in accordance with AWS D1.4/D1.4M.
2.1.8 Ties and Spirals
NOTE: If project has been designed for epoxy rebar, add ASTM A 934/A 934M,
"Epoxy-Coated Prefabricated Steel Reinforcing Bars" in this paragraph and in
the paragraph entitled "References."
Steel, ASTM A 82/A 82M for spirals and ASTM A 615/A 615M for ties.
2.1.9 Pipe Sleeves
Use ASTM A 53/A 53M, Grade B, or ASTM A 501 galvanized pipe. Sleeves shall be galvanized in accordance with
ASTM A 153/A 153M with chromate wash. Do not place galvanized pipe in contact with any prestressing or reinforcing
steel.
2.1.10 Bolts, Nuts, and Washers
2.1.10.1 Bolts
ASTM A 307, Grade A.
2.1.10.2 Nuts
ASTM A 563MASTM A 563, Grade A, hex style.
2.1.10.3 Washers
ASTM F 844.
2.1.11 Ultrahigh Molecular Weight Polyethylene (UHMWPE) Rubbing Surface
2.1.11.1 General
a. Materials including additives shall be traceable by original lot number.
b. Materials used shall be FDA approved or otherwise harmless to marine life.
c. Fabricated form shall be virgin resin.
2.1.11.2 Resin
a. ASTM D 4020. Virgin resin shall be homopolymer of ethylene and have an intrinsic viscosity
(IV) between 22.0 and 28.0 dl/g.
b. No reprocessed resin shall be used.
c. Resin shall be oil and moisture free (0.2 percent weight maximum).
2.1.11.3 Composition and Fabricated Form
a. Resin shall comprise a minimum 95.0 percent by weight concentration in the formulation.
b. The finished form shall maintain ultraviolet stability for a minimum of 25 years and be
free of saltwater or petroleum product leachable materials.
c. No unfused areas or light patches greater than 300 micrometers No. 50 sieve shall be in
the final fabricated form.
d. The fabricated form shall have the following properties:
Density (ASTM D 792) 57.5-58.7 lb/cu.ft
Tensile Strength (ASTM D 638)
Ultimate, minimum 31.7 MPa
Ultimate Elongation, minimum 250 percent
Impact Strength (ASTM D 256)
Test Method A, Izod Non-break for all five
determinations in sample
Hardness (ASTM D 2240), minimum Shore D 65
Coefficient of Friction (ASTM D 1894)
Kinetic, maximum 0.13
Static, maximum 0.20
Water Absorption (ASTM D 570) Nil
Abrasion Index (relative to steel = 100),
maximum 10
Density (ASTM D 792) 0.92-0.94 g/cc
Tensile Strength (ASTM D 638)
Ultimate, minimum 4600 psi
Ultimate Elongation, minimum 250 percent
Impact Strength (ASTM D 256)
Test Method A, Izod Non-break for all five
determinations in sample
Hardness (ASTM D 2240), minimum Shore D 65
Coefficient of Friction (ASTM D 1894)
Kinetic, maximum 0.13
Static, maximum 0.20
Water Absorption (ASTM D 570) Nil
Abrasion Index (relative to steel = 100),
maximum 10
e. Color shall be black.
2.2 CONCRETE
2.2.1 Contractor-Furnished Concrete Mix Design
NOTE: Insert the specified compressive strength, f'c. Consider reducing average
overstrength factor to produce a more economical concrete mix design, since
these piles are not critical structural elements. ACI 318M may be modified
for a specified compressive strength, f'c, over 35 MPa 5000 psi to permit a
required average compressive strength, f'cr, of f'c plus 4.8 MPa 700 psi. Concrete
may be proportioned in accordance with ACI 214R for the probability of 1 test
in 10 falling below the specified compressive strength, f'c, if the mix design
reflects actual concrete plant standard deviations and the resulting production
concrete conforms to specified requirements. Do not use lightweight or fiber-reinforced
concrete.
Concrete shall have a minimum specified compressive strength, f'c, of [_____] psi at 28 days. The minimum cement
content shall be 354 kg/cu. meter 600 pounds per cubic yard of concrete. The design shall be prepared in accordance
with ACI 211.1 or ACI 318M. The mix design shall be based on current materials previously evaluated by the concrete
producer whose established methods of statistical quality control is in conformance with ACI 318M. In the absence
of such data, the Contractor shall sample and test the aggregates for the design of concrete.
2.2.2 Concrete Mix Design Proportioning
a. Water and cement ratio shall be equal to or less than 0.40. If fly ash is used, the water
and cement ratio shall be calculated as the weight of water divided by the weight of cement
plus 60 percent of the weight of fly ash. If silica fume is used, the water and cement ratio
shall be calculated as the weight of water divided by the weight of cement plus the weight of
silica fume.
b. Maximum aggregate size shall not exceed 19 mm 3/4 inch.
c. Air-entrainment shall be 5 to 8 percent. Determine air void structure in accordance with
ACI 212.3R. Spacing factor shall be less than 2.5 mm 0.01 inch, the specific surface area shall
be greater than 0.39 square meter per 0.000016 cubic meter 600 square inches per cubic inch
of air void volume, and the number of air voids per mm inch of traverse shall be significantly
greater than the numerical value of the percentage of air in the concrete.
2.2.3 Trial Mixtures
Trial mixtures having proportions and consistencies of the proposed mix design shall be made to document the
Contractor's ability to produce workable concrete which does not segregate or show excessive slump loss characteristics.
2.3 FABRICATION OF PRETENSIONED PILES
Piles shall be pretensioned concrete piles. Workmanship shall conform to standard commercial practice in prestressing
plants.
2.3.1 Formwork
Provide forms of metal, braced and stiffened against deformation, accurately constructed, watertight, and supported
on unyielding casting beds. Forms shall permit movement of pile without damage during release of the prestressing
force. Make piles to dimensional tolerances in accordance with PCI MNL-116 and as follows:
a. Length: 10 mm per 3 meters 3/8 inch per 10 feet.
b. Cross section: plus 13 mm to minus 6 mm plus 1/2 inch to minus 1/4 inch.
c. Deviation from straight lines: not more than 3 mm per 3 meters 1/8 inch per 10 feet of
length.
d. Pile head: plus or minus 6 mm per 0.30 meter 1/4 inch per foot of head dimension from true
right angle plane. Surface irregularities: plus or minus 3 mm 1/8 inch.
e. Location of reinforcing steel
(1) Main reinforcement: 3 to 6 mm 1/8 to 1/4 inch from position designated on drawings.
(2) Spacing of spiral: plus or minus 13 mm 1/2 inch from position designated on drawings.
f. Location of pipe sleeves from true position: plus or minus 10 mm 3/8 inch.
2.3.2 Pretensioning
Measure tension to which steel is to be pretensioned by jack pressure read on a calibrated gage and verify by
elongation of steel. Use gage calibrated within last 6 months by a laboratory approved by Contracting Officer.
Provide means for measuring elongation of steel to nearest 3 mm 1/8 inch. When difference between results of
measurement and gage reading is more than 5 percent, determine cause of discrepancy and correct. Give tensioning
steel a uniform prestress prior to being brought to design prestress. Induce same initial prestress in each
unit when several units of prestressing steel in a pile are stretched simultaneously.
2.3.3 Casting
2.3.3.1 Conveying
Clean conveying equipment thoroughly before each run. Convey concrete from mixer to forms as rapidly as practicable
by methods which will not cause segregation or loss of ingredients. Deposit concrete as nearly as practicable
to its final position. During placing, make any free vertical drop of the concrete less than one meter 3 feet
. Remove concrete which has segregated in conveying or placing.
2.3.3.2 Placing and Casting
NOTE: Select chamfer required. Consult with local producers. Where project
requires a large quantity of piling, a specific value may be specified, otherwise,
use a minimum or a range of values.
Perform concrete casting within 3 days after pretensioning steel; however, do not deposit concrete in forms until
placement of reinforcement and anchorages have been inspected and approved by pile manufacturer's quality control
representative. Produce each pile of dense concrete straight with smooth surfaces with reinforcement retained
in its proper position during fabrication. Use vibrator with heads smaller than the minimum distance between
steel for pretensioning. Make surface of pile ends perpendicular to axis of pile. Chamfer, [a minimum of 19
mm 3/4 inch,] [[_____] mm inch,] [between 19 and 28 mm 3/4 and 1 1/8 inch,] ends of piles and corners of square
piles.
2.3.4 Curing of Piles
Cure piles using moist or accelerated curing.
2.3.4.1 Moist Curing
a. Impervious sheeting: ASTM C 171; waterproof paper, clear or white polyethylene sheeting,
or polyethylene-coated burlap.
b. Pervious sheeting: AASHTO M 182.
c. Liquid membrane-forming compound: ASTM C 309, white pigmented, Type 2, Class B.
2.3.4.2 Accelerated Curing
After placement of concrete, moist cure for a period of 4 hours. Accelerate curing until concrete has reached
specified release strength. Enclose casting bed for accelerated curing with a suitable enclosure. During
application of steam or heat, increase the air temperature at a rate not to exceed 15.6 degrees C 60 degrees
F per hour. Cure at a maximum temperature of 15.6 degrees C 160 degrees F until concrete has reached specified
release strength. Reduce temperature at a rate not to exceed 15.6 degrees C 60 degrees F per hour until a temperature
of -7 degrees C 20 degrees F above ambient air temperature is reached. After accelerated curing, moist cure
using either water or membrane curing until a total accelerated and moist curing time of 72 hours is achieved.
2.3.5 Detensioning
NOTE: Specify "release strength." Release strength of 30 MPa 4000 psi (design
strength of 35 MPa 5000 psi) or 0.8 of the 28 day design strength is desirable;
however, some regions use 0.7 of the design strength (25 MPa3500 psi for design
strength of 35 MPa 5000 psi). A minimum release strength of 0.6 of the design
strength is required. Check with local pile manufacturers.
Perform releasing of prestressed steel in pretensioned piles in such an order that eccentricity of prestress
will be minimized. Gradually release tension in strands from anchorage. Detension after approval by pile manufacturer's
quality control representative. Perform transfer of prestressing force when concrete has reached a minimum compressive
strength of [_____] MPa psi.
2.3.6 Marking
Mark pile to identify in-place impact face. Marking shall be clearly visible during driving.
2.4 PRODUCT QUALITY CONTROL
Where piling is manufactured in a plant with an established quality control program as attested to by a current
certification in the PCI Certification Program for Quality Control, perform product quality control procedures
in accordance with PCI MNL-116. Where piling is manufactured by specialists or in plants not currently enrolled
in the PCI Certification Program for Quality Control, set up a product quality control system in accordance with
PCI MNL-116 and perform concrete and aggregate quality control testing using an independent commercial testing
laboratory approved by the Contracting Officer in accordance with the following.
2.4.1 Aggregate Tests
Take samples of fine and coarse aggregate at the concrete batch plant and test. Perform mechanical analysis
(one test for each aggregate size) in accordance with ASTM C 136 including determination of the specific gravity.
Tabulate the results of the tests in accordance with ASTM C 33.
2.4.2 Strength Tests
Sample concrete in accordance with ASTM C 172 at the time the concrete is deposited for each production line.
Compression tests shall conform to methods of ASTM C 39/C 39M and ASTM C 31/C 31M. Perform slump tests in accordance
with ASTM C 143/C 143M. Mold at least six cylinders per day or for every 15 cubic meter 20 cubic yards of concrete
placed, whichever is greater. Test two cylinders of the set at 7 days of 14 days, or at a time for establishing
transfer of prestressing force (release strength) and removal of pile from forms. Perform strength tests 28
days after molding using the remaining cylinders of the set. Cure the cylinders in the same manner as the piles
and place at the point where the poorest curing conditions are offered. This is the coolest point in the bed
for steam curing. Cylinders to be tested at 28 days shall be moist cured.
2.4.3 Changes in Proportions
If, after evaluation of strength test results, the compressive strength is less than the specified compressive
strength, make adjustments in the proportions and water content and changes in the temperature, moisture, and
curing procedures as necessary to secure the specified strength. Submit changes to the Contracting Officer in
writing.
2.4.4 Compressive Strength Test Results
Evaluate compression test results at 28 days in accordance with ACI 214R using a coefficient of variation of
10 percent. Evaluate the strength of concrete by averaging the test results (two specimens) of each set (four
specimens) of standard cylinders tested at 28 days. Not more than 10 percent of the individual specimens tested
shall have an average compressive strength less than specified average compressive strength.
PART 3 EXECUTION
3.1 PILE DRIVING
3.1.1 Driving Piles
Piles shall not be driven until 100 percent of design strength has been attained and until at least 14 days after
detensioning. Drive piles to the indicated tip elevation and to the minimum embedment depth shown on the drawings.
Pile driving shall be conducted as one continuous operation. The pile shall be driven until the resistance
criterion is met. During the initial driving and until the pile tip has penetrated beyond layers of very soft
soil or below the bottom of prejetted or preformed holes, use a reduced rated driving energy of the hammer of
not more than 20,235 Joules 15,000 foot-pounds per blow or as otherwise directed by the Contracting Officer,
to prevent high tension-wave driving stresses which could damage the pile. Resistance criterion shall be 20
blows for 0.3 m one foot or less. The Contracting Officer may modify the criteria based upon the actual hammer
being used and its rated energy and its compatibility as verified by a pile test program. If a pile fails to
reach the indicated butt elevation or minimum embedment, the Contractor shall notify the Contracting Officer
and perform corrective measures as directed. Provide hearing protection when noise levels exceed 140 dB.
3.1.2 Pile Driving Leads and Templates
Piles shall be driven with the hammer positioned in a fixed or swinging lead. "Free hammer" will not be permitted.
Swinging lead shall be used only in conjunction with a template system to spot the piles.
3.1.3 Installation of Piles
Take care to avoid damage to piles during handling, when placing the pile in leads, and during pile-driving operations.
Inspect piles when delivered, when in leads immediately before driving, and after installation. No visible cracks
will be permitted. Notify the Contracting Officer of any visible cracks and perform corrective measures as directed.
Laterally support piles during driving, but allow rotation in leads. Take special care to maintain the pile
orientation during driving. Square the top of the pile to the longitudinal axis of the pile. Maintain axial
alignment of pile hammer with that of pile.
3.1.4 Tolerances in Driving
Drive piles with a variation of not more than one percent from vertical for plumb piles. Maintain and check
axial alignment of pile and leads at start of pile driving and when the pile top is approximately 1.5 m 5 feet
above the indicated elevation. Make intermediate checks of pile alignment if there is evidence of pile drifting.
If subsurface conditions cause pile drifting beyond the allowable axial alignment tolerance, notify the Contracting
Officer and perform corrective measures as directed. Place butts within 50 mm 2 inches of the location indicated.
Manipulation of pile within specified tolerances is permitted, but do not manipulate piles more than one percent
of their exposed length above the mudline. Check piles for heave. Redrive, to the indicated elevation, piles
found to be heaved.
3.1.5 Jetting and Predrilling Holes
If predrilled holes are used, the diameter of the hole shall not exceed the diagonal dimension of the pile and
the hole shall be kept open until the pile is inserted and advanced to the bottom of the hole. Piles shall be
installed in holes immediately after predrilling to minimize the potential for sloughing and collapse of the
hole. Jetting of the pile to obtain penetration is permitted. Discontinue jetting or predrilled hole at a depth
of 1.5 m 5 feet from the indicated tip elevation, and achieve the remaining penetration by driving. Before starting
the driving of the final 1.5 m 5 feet, firmly seat the piles in place by the application of a number of reduced-energy
hammer blows. The Contractor shall arrange to provide an ample supply of water at adequate pressure for effective
jetting. The use and details of jetting or predrilled holes shall be approved by the Contracting Officer.
3.1.6 Splices
Splicing of piles is not permitted.
3.1.7 Buildup
Buildups are not permitted.
3.1.8 Pile Cutoffs
Cut off piles with a smooth level cut using pneumatic tools, sawing, or other suitable methods approved by the
Contracting Officer. The use of explosives for cutting is not permitted.
3.1.9 Patching
a. Embedded Lifting Loops. Provide a 25 mm one inch minimum conical depression around embedded
lifting loops. Cut off lifting loops at bottom of depression and patch depression with epoxy
mortar.
b. Pile Butt. Apply 25 mm one inch thick layer of epoxy mortar cover over exposed prestressing
strand on pile butt after driving.
3.2 EQUIPMENT
3.2.1 Pile Hammers
Furnish a hammer having a capacity at least equal to the hammer manufacturer's recommendation for the total weight
of pile and character of subsurface material to be encountered. Obtain the required driving energy of the hammer,
except for diesel hammers, by use of a heavy ram and a short stroke with low-impact velocity. The pile hammer
shall be capable of operating at a reduced energy level (1/2 to 2/3 of rated energy level) during seating of
the piles in preformed holes and when driving through soft or loose materials. The driving energy of the hammer,
at final driving, shall be not less than 40.650 Joules 30,000 foot-pounds. At final driving, operate the pile
hammer in accordance with the manufacturer's recommendation. At final driving, operate diesel-powered hammers
at the rate recommended by the manufacturer for hard driving. Maintain sufficient pressure at the steam hammer
so that (1) for double-acting hammer, the number of blows per minute during and at the completion of driving
of a pile is equal approximately to that at which the hammer is rated; (2) for single-acting hammer, there is
a full upward stroke of the ram; and (3) for differential-type hammer, there is a slight rise of the hammer base
during each downward stroke.
3.2.2 Driving Helmets, Capblocks, and Pile Cushions
3.2.2.1 Driving Helmets or Caps and Pile Cushions
NOTE: Insert minimum and maximum thicknesses for pile cushion. An absolute
minimum would be 75 mm 3 inches and the actual required thickness would depend
upon pile length, hammer energy, design load, required final penetration resistance,
and character of subsurface material to be encountered. Generally thicker
blocks are required for longer piles, larger hammers, and harder driving. A
wave equation analysis is useful in determining required thicknesses for pile
cushion. Minimum thickness is to protect head of pile. Pile cushion should
also have a maximum thickness to ensure effective driving. Select when pile
cushion is to be replaced. It is generally recommended that a new pile cushion
be used at the start of driving of each pile.
Use a steel driving helmet or cap, including a pile cushion between top of pile and driving helmet or cap, to
prevent impact damage to pile. The driving helmet or cap-and-pile cushion combination shall be capable of protecting
the head of the pile, minimize energy absorption and dissipation, and transmit hammer energy uniformly over the
top of the pile. The driving helmet or cap shall fit sufficiently loose around the top of the pile so that
the pile may be free to rotate without binding within the driving helmet. The Contractor shall demonstrate to
the satisfaction of the Contracting Officer that the equipment to be used on the project performs the above function.
The pile cushion shall be of laminated construction using softwood boards with the grain parallel to the end
of the pile. The thickness of the pile cushion shall be 300 mm 12 inches minimum. The cushion shall not be
changed near the end of driving. Replace the pile cushion when it has become compressed beyond two-thirds of
its original thickness, charred, or burned, or has become spongy or deteriorated in any manner. Use new cushions
for initial driving of each pile. During redriving or restriking of piles, a used cushion assembly shall be
used. The Contractor shall submit to the Contracting Officer at least 2 weeks before the start of pile driving
operations detailed drawings of the driving helmet and pile cushion to be used.
3.2.2.2 Hammer Cushion or Capblock
NOTE: Select either wood or aluminum/micarta capblock. Delete inappropriate
sentences. An aluminum/micarta capblock is recommended because of its consistent
elastic properties and long life. If final pile penetration resistance is
based on a wave equation analysis, the type capblock used should be the same
as that used in the analysis.
Use a hammer cushion or capblock between driving helmet or cap and hammer ram consisting of [a solid hardwood
block with grain parallel to the pile axis and enclosed in a close-fitting steel housing] [aluminum and micarta
(or equal) discs stacked alternately in a steel housing]. Use steel plates at top and bottom of capblock. [Replace
wood capblock when it becomes highly compressed, charred or burned, or becomes spongy or deteriorated in any
manner.] [Replace aluminum or micarta discs that have become damaged, split, or deteriorated in any manner.]
[Do not replace wood capblock during final driving of any pile.] Do not use small wood blocks, wood chips, rope,
or other materials that permit excessive loss of hammer energy.
3.3 FIELD QUALITY CONTROL
3.3.1 Pile Records
For each pile, keep a record of the number of blows required for each 0.30 m foot of penetration and the number
of blows for the last 150 mm 6 inch penetration or fraction thereof. Include in the record the beginning and
ending times of each operation during driving of pile, type and size of the hammer used, rate of operation, stroke
or equivalent stroke for diesel hammer, type of driving helmet, and type and dimension of the hammer cushion
(capblock) and pile cushion used. Record re-tap data and any unusual occurrence during driving of the pile.
Include in the record performance characteristics of jet pump, unassisted penetration of pile, jet-assisted penetration
of pile, and tip elevation before driving and at end of driving. Notify Contracting Officer 10 days prior to
driving of piles. Submit complete and accurate records of installed piles to Contracting Officer within 15 calendar
days after completion of the pile driving. Make pile-driving records available to the Contracting Officer at
the job site within 24 hours of each day's pile driving. A preprinted form for recording pile driving data is
included at the end of this section.
PILE DRIVING LOG
CONTRACT NO.________________________ CONTRACT NAME_______________________
CONTRACTOR_____________________________ TYPE OF PILE_____________________
PILE LOCATION_____________ PILE SIZE: BUTT/TIP: ________ LENGTH_________
GROUND ELEVATION_________________________ CUT OFF ELEVATION______________
PILE TIP ELEVATION_________________ VERTICAL (_____) BATTER 1 ON (_____)
SPLICES ELEVATION____________________ COMPANY____________________________
HAMMER: MAKE & MODEL_________________ WT. RAM______________________
STROKE______________________ RAM RATED ENERGY__________________________
DESCRIPTION & DIMENSIONS OF DRIVING CAP_________________________________
CUSHION MATERIALS & THICKNESS___________________________________________
INSPECTOR_________________________________________________________________
"DEPTH" COLUMN OF PILE DRIVING RECORD REFERENCED TO:
_____________________ CUT-OFF ELEVATION
_____________________ FINISH FLOOR ELEVATION
TIME: START DRIVING_______ FINISH DRIVING________ DRIVING TIME_________
INTERRUPTIONS (TIME, TIP ELEV. & REASON)________________________________
JET PRESSURE & ELEVATIONS_________________________________________________
__________________________________________________________________________
DRIVING RESISTANCE
__________________________________________________
DEPTH NO. OF DEPTH NO. OF DEPTH NO. OF
M BLOWS M BLOWS M BLOWS
__________________________________________________
0 _____ 5.4 _____ 10.8 _____
0.3 _____ 5.7 _____ 11.1 _____
0.6 _____ 6.0 _____ 11.4 _____
0.9 _____ 6.3 _____ 11.7 _____
1.2 _____ 6.6 _____ 12.0 _____
1.5 _____ 6.9 _____ 12.3 _____
1.8 _____ 7.2 _____ 12.6 _____
2.1 _____ 7.5 _____ 12.9 _____
2.4 _____ 7.8 _____ 13.2 _____
2.7 _____ 8.1 _____ 13.5 _____
3.0 _____ 8.4 _____ 13.8 _____
3.3 _____ 8.7 _____ 14.1 _____
3.6 _____ 9.0 _____ 14.4 _____
3.9 _____ 9.3 _____ 14.7 _____
4.2 _____ 9.6 _____ 15.0 _____
4.5 _____ 9.9 _____ 15.3 _____
4.8 _____ 10.2 _____ 15.6 _____
5.1 _____ 10.5 _____ 15.9 _____
SHEET 1 OF 2
16.2 _____ 23.1 _____ 29.7 _____
16.5 _____ 23.4 _____ 30.0 _____
16.8 _____ 23.7 _____ 30.3 _____
17.1 _____ 24.0 _____ 30.6 _____
17.4 _____ 24.3 _____ 30.9 _____
17.7 _____ 24.6 _____ 31.2 _____
18.0 _____ 24.9 _____ 31.5 _____
18.3 _____ 25.2 _____ 31.8 _____
18.6 _____ 25.5 _____ 32.1 _____
18.9 _____ 25.8 _____ 32.4 _____
19.2 _____ 26.1 _____ 32.7 _____
19.5 _____ 26.4 _____ 33.0 _____
19.8 _____ 26.7 _____ 33.3 _____
20.1 _____ 27.0 _____ 33.6 _____
20.4 _____ 27.3 _____ 33.9 _____
20.7 _____ 27.6 _____ 34.2 _____
21.0 _____ 27.9 _____ 34.5 _____
21.3 _____ 28.2 _____ 34.8 _____
21.6 _____ 28.5 _____ 35.1 _____
21.9 _____ 28.8 _____ 35.4 _____
22.2 _____ 29.1 _____ 35.7 _____
22.5 _____ 29.4 _____ 36.0 _____
22.8 _____
__________________________________________________________________________
Driving resistance in blows per 25 mm for last 0.30 m of penetration:
DEPTH________ DEPTH________
25mm___ 50mm___100mm___125mm___150mm___175mm___200mm___225mm___ 250mm___
275mm___300mm___
ELEV._______ ELEV.________
REMARKS___________________________________________________________________
__________________________________________________________________________
CUT OFF ELEVATION: FROM DRAWING ________________
TIP ELEVATION = GROUND ELEVATION - DRIVEN DEPTH = ________________
DRIVEN LENGTH = CUT OFF ELEVATION - TIP ELEVATION = ________________
CUT OFF LENGTH = PILE LENGTH - DRIVEN LENGTH = ________________
SHEET 2 OF 2
PILE DRIVING LOG
CONTRACT NO.________________________ CONTRACT NAME_______________________
CONTRACTOR_____________________________ TYPE OF PILE_____________________
PILE LOCATION_____________ PILE SIZE: BUTT/TIP: ________ LENGTH_________
GROUND ELEVATION_________________________ CUT OFF ELEVATION______________
PILE TIP ELEVATION_________________ VERTICAL (_____) BATTER 1 ON (_____)
SPLICES ELEVATION____________________ COMPANY____________________________
HAMMER: MAKE & MODEL_________________ WT. RAM______________________
STROKE______________________ RAM RATED ENERGY____________________________
DESCRIPTION & DIMENSIONS OF DRIVING CAP___________________________________
CUSHION MATERIALS & THICKNESS_____________________________________________
INSPECTOR_________________________________________________________________
"DEPTH" COLUMN OF PILE DRIVING RECORD REFERENCED TO:
_____________________ CUT-OFF ELEVATION
_____________________ FINISH FLOOR ELEVATION
TIME: START DRIVING_______ FINISH DRIVING________ DRIVING TIME_________
INTERRUPTIONS (TIME, TIP ELEV. & REASON)__________________________________
JET PRESSURE & ELEVATIONS_________________________________________________
__________________________________________________________________________
DRIVING RESISTANCE
__________________________________________________
DEPTH NO. OF DEPTH NO. OF DEPTH NO. OF
FT. BLOWS FT. BLOWS FT. BLOWS
__________________________________________________
0 _____ 18 _____ 36 _____
1 _____ 19 _____ 37 _____
2 _____ 20 _____ 38 _____
3 _____ 21 _____ 39 _____
4 _____ 22 _____ 40 _____
5 _____ 23 _____ 41 _____
6 _____ 24 _____ 42 _____
7 _____ 25 _____ 43 _____
8 _____ 26 _____ 44 _____
9 _____ 27 _____ 45 _____
10 _____ 28 _____ 46 _____
11 _____ 29 _____ 47 _____
12 _____ 30 _____ 48 _____
13 _____ 31 _____ 49 _____
14 _____ 32 _____ 50 _____
15 _____ 33 _____ 51 _____
16 _____ 34 _____ 52 _____
17 _____ 35 _____ 53 _____
SHEET 1 OF 2
54 _____ 77 _____ 99 _____
55 _____ 78 _____ 100 _____
56 _____ 79 _____ 101 _____
57 _____ 80 _____ 102 _____
58 _____ 81 _____ 103 _____
59 _____ 82 _____ 104 _____
60 _____ 83 _____ 105 _____
61 _____ 84 _____ 106 _____
62 _____ 85 _____ 107 _____
63 _____ 86 _____ 108 _____
64 _____ 87 _____ 109 _____
65 _____ 88 _____ 110 _____
66 _____ 89 _____ 111 _____
67 _____ 90 _____ 112 _____
68 _____ 91 _____ 113 _____
69 _____ 92 _____ 114 _____
70 _____ 93 _____ 115 _____
71 _____ 94 _____ 116 _____
72 _____ 95 _____ 117 _____
73 _____ 96 _____ 118 _____
74 _____ 97 _____ 119 _____
75 _____ 98 _____ 120 _____
76 _____
__________________________________________________________________________
DRIVING RESISTANCE IN BLOWS PER INCH FOR LAST FOOT OF PENETRATION:
DEPTH________ DEPTH________
1"___2"___3"___4"___5"___6"___7"___8"___9"___10"___11"___12"___
ELEV._______ ELEV.________
REMARKS___________________________________________________________________
__________________________________________________________________________
CUT OFF ELEVATION: FROM DRAWING ________________
TIP ELEVATION = GROUND ELEVATION - DRIVEN DEPTH = ________________
DRIVEN LENGTH = CUT OFF ELEVATION - TIP ELEVATION = ________________
CUT OFF LENGTH = PILE LENGTH - DRIVEN LENGTH = ________________
SHEET 2 OF 2