Ssab RD1000 Installation Manual Download Page 1 | Manualshive

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Ssab RD1000 Installation Manual Download Page 1

DESIGN AND INSTALLATION MANUAL

This manual deals with driven and jacked SSAB’s RR and RRs piles, shaft grouted driven
CSG-RR piles and drilled RD and RDs piles. It covers all SSAB’s steel pile sizes. The manual is
based on the piling instructions of the Finnish Piling Manual PO-2016 and the Eurocodes system.
The manual describes the basics of the design and dimensioning of SSAB’s steel piles and pile
foundations according to Finnish application of Eurocodes, gives recommendations on the
selection of pile type and size and provides advice on the handling and installation, quality control,
measurements and documentation of piling. The manual includes pre-calculated dimensioning
tables and design and implementation examples to facilitate the design and implementation of
piling. When SSAB steel piles are used outside Finland, national requirements (implementation
and national annexes of Eurocodes) shall be taken into account in design and execution of piles.
SSAB’s RR, RRs, RD and RDs piles have European Technical Assessment ETA 12/0526.

Applications:

•  1 and 2 family houses
•  single- and multi-storey commercial, office, industrial and storage buildings
•  multi-storey residential buildings
•  sports arenas
•  underpinning of foundations
•  bridges
•  pile slabs and other structures for transport infrastructure and

municipal engineering

•  noise barriers and fences
•  ports
•  wind turbines and other power plants

ETA 12/0526

RR

®

and RD

®

piles

www.ssab.com/infra

SSAB is a Nordic and US-based steel company. SSAB offers value added products and services developed in close cooperation with its customers to create

a stronger, lighter and more sustainable world. SSAB has employees in over 50 countries. SSAB has production facilities in Sweden, Finland and the US.

SSAB is listed on the NASDAQ OMX Nordic Exchange in Stockholm and has a secondary listing on the NASDAQ OMX in Helsinki. www.ssab.com.

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Summary of Contents for RD1000

Page 1: ...nal requirements implementation and national annexes of Eurocodes shall be taken into account in design and execution of piles SSAB s RR RRs RD and RDs piles have European Technical Assessment ETA 12 0526 Applications 1 and 2 family houses single and multi storey commercial office industrial and storage buildings multi storey residential buildings sports arenas underpinning of foundations bridges ...

Page 2: ...y stress wave analysis 17 5 5 4 Resistances determined by dynamic load tests 17 5 5 5 Resistances determined by pile driving formulas 17 5 5 6 Resistances determined on the basis of ground test results 17 5 5 7 Resistances determined by static load tests 19 5 6 Geotechnical dimensioning of tension piles 19 5 7 Structural resistance 19 5 7 1 Resistance of RR piles during installation 19 5 7 2 Struc...

Page 3: ... 42 7 5 9 Welding 42 7 5 10 Inspection of Welded splices 42 7 6 Pile cut off 43 7 7 Pile cleaning 43 7 8 Reinforcement and concreting of piles 43 7 9 Bearing plate installation 44 7 10 Installation of shaft grouted CSG RR piles 44 7 10 1 Installation equipment 44 7 10 2 Driving of pile into soil and its splicing 44 7 10 3 Grout injection 44 8 SUPERVISION AND QUALITY CONTROL OF PILING WORK MEASUREM...

Page 4: ...ign and implementation of support structures made of SSAB s steel piles such as the RD pile wall various Combi wall structures and driven or drilled steel pipe piles used in other retaining walls 2 SSAB S STEEL PILES 2 1 General SSAB has CE marking based on European Technical Assessment ETA 12 0526 which is the most comprehensive CE marking to be granted to pile structures made of structural steel...

Page 5: ...d pile sizes RR140 to RR220 by separate internal splices RRs piles are manufactured in eight different sizes All RRs pile sizes can be joined by external splice sleeves External splice Internal splice Rock shoe Bottom plate Bearing plate Figure 1 Structure and parts of RR piles pile sizes RR75 to RR220 The splices meet the requirements of PO 2016 for rigid splices and those of the national appendi...

Page 6: ...n through to an inclined bedrock surface or a bedrock surface under thin coarse grained or moraine soil layers Rock shoes make it possible for piles to penetrate compact or rocky soil layers better and remain straighter SSAB s pile shoes are dimensioned to withstand the stresses from pile installation and use provided that the instructions of Sec 7 3 are observed in installation Jacked RR micropil...

Page 7: ...steel grades used for RR large diameter piles are S355J2H S440J2H and S550J2H Against special order the piles may also be delivered in MH steel grades according to standard EN10219 or X grades according to API5L Standard dimensions and the availability of steel grades are presented in Table 6 The diameters primarily recommended for design are RR400 RR500 RR600 RR700 RR800 RR900 RR1000 and RR1200 I...

Page 8: ...o its the Rd L value Figure 3 Shoe types of large diameter RR piles Rock shoe with structural steel dowel Rock shoe with hardened steel dowel Rock shoe with hollow dowel Toe reinforcement 2 4 2 Pile shoes In soil conditions typical of the Nordic countries RR large diameter piles are usually equipped with RR rock shoes SSAB s standard rock shoes were granted the Finnish Transport Agency s use permi...

Page 9: ... are also available All steel grades of SSAB s steel pile products can be used as steel grades of RD400 to RD1200 piles The pile sizes and availability of steel grades Threaded pile section Threaded splice sleeve Bearing plate Welded splice beveled ends Casing shoe ring bit Figure 4 Structure of RD micropile of RD piles are presented in Table 8 Dimensions RD400 RD500 RD600 RD700 RD800 RD900 RD1000...

Page 10: ...ing and steel grade selection of RD piles RD piles are spliced using external threaded sleeves t 8mm and D 220mm Figure 6 by threaded and welded splice pieces RD270 10 RD270 12 5 max fy 460 MPa RD320 10 RD320 12 5 max fy 550 MPa or by welding Mechanized welding is used specially in underpinning projects When using a DTH hammer the threads of the pile pipe and the sleeve are left handed but right h...

Page 11: ...r larger than the pile pipe The purpose of the collar is to keep the grouting holes open during installation and to make a hole larger than the pile pipe in the ground A guide device directs the tip of the pile and protects the collar from possible obstructions The length of the guide device is usually 0 5 to 1 0 m Table 11 shows the diameters of pre dimensioned shoe collars The collar of a pre di...

Page 12: ...6 6 1508 1260 167 4 137 4 351 289 114 3 6 3 16 8 2138 0 36 10261 54 7 312 7 657 86 8 1711 1432 244 5 201 4 514 423 114 3 8 0 21 0 2672 0 36 10261 66 4 379 5 797 108 5 2245 1966 311 3 268 2 654 563 127 0 6 3 18 7 2389 0 40 12667 68 7 436 2 916 96 9 1914 1603 342 3 282 7 719 593 139 7 8 0 26 0 3310 0 44 15328 103 1 720 3 1513 134 4 2788 2445 595 1 515 2 1250 1082 139 7 10 0 32 0 4075 0 44 15328 123 ...

Page 13: ...7035 7295 4 259350 9 544637 1762 8 40741 38962 242498 9 231359 0 509248 485854 762 0 8 0 148 8 18950 2 39 456037 3535 0 134683 0 282834 769 4 16082 14175 113931 3 100205 7 239256 210432 762 0 10 0 185 5 23625 2 39 456037 4383 9 167028 4 350760 959 2 20757 18850 146276 7 132551 0 307181 278357 762 0 12 5 231 0 29433 2 39 456037 5426 0 206731 0 434135 1195 0 26565 24658 185979 3 172253 7 390557 3617...

Page 14: ...out 1 2 to 2 0 times than that of an RR pile of corresponding size Owing to the comprehensive pile size range foundation structures can always be optimised by using several typically two or three pile sizes at a site Installability of piles RD piles can be installed in all soil conditions In very exacting conditions such as those involving thick fill layers containing large boulders the smallest R...

Page 15: ...ile foundation At conventional sites where the piles are mainly subject to axial loading the design of a steel pile foundation includes 1 Selection of pile type suitable for the site soil conditions pile drivability installability and functioning of the pile foundation loads from the superstructure and actions due to ground displacement structures and conditions in the piling area and its surround...

Page 16: ...he Finnish Transport Agency are observed in infrastructure construction Geotechnical investigations must be complemented with sufficiently extensive investigations of nearby structures ducts pipes cables underground structures etc their location and condition foundation methods as well as sensitivity to displacement and vibration Geotechnical information and its assessment are presented in the gro...

Page 17: ... always recommended even with PTL2 Correlation coefficients and related model coefficients are presented in PO 2016 The dimensioning program for RR and RD piles calculates correlation coefficients automatically on the basis of input data Dimensioning based on dynamic load tests can in principle be performed in two different ways 1 The design value of geotechnical resistance Rd is selected on the b...

Page 18: ...lf of external shaft resistance in preliminary analyses However the capacity consisting of internal shaft resistance and point resistance of the area of the steel cross section of the pile must not exceed the capacity of a plugged pile of corresponding size due to point resistance 5 5 6 2 Geotechnical resistance of grouted CSG RR piles bearing on a soil layer The dimensioning geotechnical diameter...

Page 19: ...xample by drilling the RD pile first to the surface of bedrock and then continuing to drill with a smaller drill bit deeper into bedrock The drill hole is flushed clean filled with concrete grouting mortar or injection grout and then a steel pipe equipped with centralisers at least 30 mm smaller in outer diameter than the diameter of the hole in the bedrock is installed in the hole The bond stress...

Page 20: ...h a torch or an inclinometer the radius of curvature determined on the basis of the measurements can be used in design The dimensioning program for RR and RD piles can be used for easy calculation of the radius of curvature used in the dimensioning of a pile The calculated radius of curvature depends on the critical unbraced length which in turn depends on the stiffness of the pile the modulus of ...

Page 21: ...25 0 90 1 75 2 60 3 50 Note 1 Corrosion rate is usually highest in a splash or tidal zone at low tide level In most cases however the highest flexural stresses occur in areas permanently under water 2 Values for 5 and 25 years are based on measurements while others have been extrapolated Table 19 Average surface corrosion mm of unprotected steel piles in soil above and below ground water level Tar...

Page 22: ...ings being damaged Even then the use of a coating should be considered case by case and the durability of the coating ensured for example by test installations In the case of electric protection methods the electric current required by the system and the replaceability service life of galvanic anodes must be taken into account 5 8 Vertical displacements of pile foundation If necessary vertical dis...

Page 23: ... of soil is 50 ks 50 x cu k deff and that used to calculate the extreme value of lateral resistance is 9 pm 9 x cu k gR e The buckling analysis of piles has been performed by a structural model where the partial safety factor of soil resistance is applied to the characteristic values of the resistances of the springs representing the soil The springs themselves have been calculated on the basis of...

Page 24: ... S550J2H Lcr 400 3177 3883 4331 4636 4813 5016 2059 2745 3432 Lcr 600 3663 4211 4542 4842 5010 5195 Corrosion allowance 2 0 mm RR75 S460MH Lcr 400 191 234 284 307 321 338 195 259 324 Lcr 600 223 271 299 323 336 351 RR90 S460MH Lcr 400 251 308 350 376 391 408 230 307 384 Lcr 600 292 341 368 393 408 424 RRs100 6 3 S550J2H Lcr 400 317 388 472 511 535 561 318 423 529 Lcr 600 367 446 496 535 558 583 RR...

Page 25: ...15 1876 1114 1353 1533 1637 1693 1805 RD170 12 5 S460 Lcr 400 1057 1295 1604 1797 1887 2094 1016 1245 1542 1682 1762 1946 1037 1271 1575 1777 1863 2058 Lcr 600 1234 1501 1736 1887 1976 2169 1185 1441 1630 1765 1844 2014 1211 1473 1716 1863 1948 2128 RDs170 12 5 S550 Lcr 400 1057 1295 1604 2031 2158 2457 1016 1245 1542 1906 2021 2286 1037 1271 1575 1851 1936 2119 Lcr 600 1234 1501 1844 2133 2263 25...

Page 26: ...tre to centre distance increases linearly to 1150 mm at a pile length of 25 m Smaller centre to centre distances than those presented in Table 24 may be used with caution with RD piles if they can be installed straight or at the designed inclination and the piles bear securely on bedrock When designing downward spreading pile groups the upper ends of piles can be spaced closer than in the table In...

Page 27: ...ab or bearing plate structure e emax 0 10 m individual pile in a small pile group 4 to 8 piles e emax 0 15 m individual pile in a larger pile group e emax 0 2 m however for the centre of gravity of the entire group e emax 0 05 m in pile foundations used in building construction e emax 0 15 m in particularly exacting conditions such as areas of pre penetratable fills relief drilling etc e emax 0 20...

Page 28: ...in pore water pressure and lateral displacements and heave of soil usually remain very small Owing to their small cross sectional diameter the piles can be driven below ground water level in loose silty and sandy soils with low impact energy whereby the compaction of compacting soil layers due to piling remains minor Correspondingly penetration of dense soil layers that cause vibration can be achi...

Page 29: ...le by stress wave analyses and it is recommended that piling contractors file and if necessary analyse their stress wave measurement results The information is revised in connection with major changes to the driving equipment or when installing new pile types with the equipment in question When RR piles are installed with driving equipment suspended from a crane the pile must be supported adequate...

Page 30: ...R pile 5 RR400 RR500 7 RR500 RR700 9 RR700 RR800 7 3 1 3 Hydraulic rams Hydraulic rams are rapid percussion pile drivers extremely well suited for installing RR micropiles They are also suitable for the installation of larger piles if full geotechnical compressive resistance is not required of the piles The advantages of hydraulic rams in the installation of RR piles include high blow rate and imp...

Page 31: ...trol blows are also necessary when installing RR pile elements with mechanical splices with vibrators The splices may remain loose without being subjected to a sufficiently high compressive force during the installation In piling class PTL1 with clear and sufficiently well known soil conditions sufficient geotechnical resistance can be assumed if pile lengths and soil survey results support each o...

Page 32: ... an internal splice is used the splice is installed to the bottom pile section so that the relief groove in the splice piece coincides with the longitudinal weld of the pile The splice piece is pressed or driven carefully for some distance so that a gap remains between the pile and the splice piece The next pile section is installed correspondingly on the splice so that the relief groove coincides...

Page 33: ...e piles even thousands of blows may be required Similar principles are followed when driving RR400 to RR1200 piles with rock shoes and structural steel dowels into the surface of bedrock A pile extending to bedrock may bounce off the rock during driving causing the point to remain out of contact with the rock surface In such a case a few blows are delivered after the last series of final blows usi...

Page 34: ...y soil it may take considerably longer The target depth level and or final driving resistance of piles are determined on the basis of the results of dynamic load tests 7 3 11 Project specific driving instructions Project specific driving instructions must always be prepared in piling class PTL3 and they must include at least the end of driving criteria and maximum drop heights for drop and hydraul...

Page 35: ...drill rods are rotated in the opposite direction to drilling whereby the reamer wings close and whole drill bit can be removed from inside the RD pile With reamer wings the casing shoe is not necessary part of load bearing structure of the RD pile Especially when using wing bits but also when using ring bits the compatibility of the tolerances of the pilot bit the casing shoe and the pile pipe mus...

Page 36: ...emoved soil material exceeds that of the RD pile Drilling in fine grained soil layers may cause soil disturbance and an increase in pore water pressure That results in lower soil layer strengths Strength returns quite slowly and in the case of overconsolidated layers only partially Disturbance and an increase in pore water pressure can be prevented for instance by selecting a drilling method suite...

Page 37: ...allation of splices 7 4 4 4 Installation Drill bits It is recommended to ensure before drilling starts that the outside diameter of the used ring bit is compatible with the outside diameter of the splice sleeve Table 27 shows drill bits recommended for normal soil conditions In case the soil contains hard to penetrate obstacles like wood piles or concrete structures special purpose bits are to be ...

Page 38: ...ical damages to the threads During final tightening care must be taken not to squeeze the splice which prevents its tightening The lower and upper pile elements should be gripped when tightening not the sleeve especially when tightening is done by piling equipment The threaded sleeve splice is dimensioned so as to meet the set requirements at the minimum tightening torque values presented in Table...

Page 39: ...inimum yield strength 420 MPa 46 minimum yield strength 460 MPa 50 minimum yield strength 500 MPa 55 minimum yield strength 550 MPa of qualification Qualification tests must correspond to the requirements of the work Factors to be considered include welding procedure type of joint steel grade material thickness external pipe diameter and welding position as indicated in the standard Qualification ...

Page 40: ... B 42 H5 ESAB OK 48 08 EN ISO 2560 E 46 5 1Ni B 32 H5 ESAB OK 55 00 EN ISO 2560 E 46 5 B 32 H5 ESAB OK 74 78 EN ISO 18275 E 55 4 MnMo B 32 Tubular cored electrodes TRI MARK TM 770 EN ISO 17632 T 42 2 P M 2 H10 TRI MARK TM 881 K2 AWS E81T1 K2J E81T1 K2 MJ H8 ESAB OK Tubrod 15 14 EN ISO 17632 T 46 2 P M C 2 H10 ESAB Dual Shield 55 EN ISO 18276 A T55 4 Z P M H5 ESAB Filarc PZ 6138 EN ISO 17632 A T 50...

Page 41: ...ion Single V preparation is suitable for welding in all positions Single bevel preparation is preferable for welding upright piles Single V joint preparation is used to splice full length piles delivered from the works If piles need to be crosscut on site the groove may also be prepared as a single bevel preparation that is a square edge against a beveled edge Pile ends damaged during transport or...

Page 42: ...f a tubular cored electrode is 1 2 mm However tubular cored electrodes ranging from 0 9 mm to 1 6 mm are available depending on the intended application and requirements The supplier of the welding apparatus provides the necessary training for mechanized welding Piling can be continued when the weld is cooled below 500 C 7 5 10 Inspection of Welded splices Inspection of welds is conducted in accor...

Page 43: ... has ended Figure 16 Cutting a pile by peeling 7 7 Pile cleaning The cleanness of RR and RD piles with a closed lower end to be concreted is checked before concreting and any possible impurities are removed RD piles are generally flushed with compressed air in connection with the extraction of the pilot bit Any possible drilling mud in the piles is rinsed off with water A pile can normally be assu...

Page 44: ...s No clearance is allowed between the underside of the bearing plate and concrete If necessary perforated bearing plates are to be used to enable post injection of any possible void under the plate 7 10 Installation of shaft grouted CSG RR piles 7 10 1 Installation equipment A shaft grouted driven CSG RR pile can be installed with the same driving equipment as an ungrouted RR driven pile Use of sl...

Page 45: ...G WORK MEASUREMENTS 8 1 Supervision and monitoring of piling work Supervision and monitoring of the installation of steel piles is implemented according to Ch 2 Sec 6 1 of PO 2016 The quality control of steel pile installation is based on the implementation and quality plan of the site PO 2016 Ch 2 Sec 5 1 The piling manager is responsible for quality control and related measures The piling manage...

Page 46: ...oning a dimensioning value is calculated for pile strength based on it which is compared to the design value of the load taken by the pile 8 4 Testing of piles Implemented according to Ch 2 Sec 6 3 of PO 2016 The test methods applicable to steel piles are indicated in Sec 5 5 Tests are documented according to Ch 2 Sec 7 3 of PO 2016 9 DOCUMENTATION OF PILING WORK 9 1 General In building constructi...

Page 47: ...ore quake qt d 120 mm elastic compression of soil around pile before quake qs 2 5 mm Smith s damping factor at pile tip Jt 0 5 25 σt s m σt MPa soil failure stress under pile tip Drop and hydraulic hammers up to 2000 kg have been analyzed using the SELF PJ hammer model created for GRLWEAP using typical moving part dimensions based on hammer weight Drop and hydraulic hammers have been calculated wi...

Page 48: ...esistance is presented in the end of driving tables for each hammer pile size and pile length In case calculated end of driving settlement exceeds 100 mm 30 s the magnitude of end of driving settlement is limited to 100 mm 30 s in the table An end of driving settlement exceeding 100 mm 30 s can be used case specifically but then it must be taken into account that the actual number of hammer blows ...

Page 49: ...follows 1 764 560 kN 988 kN Based on the end of driving graph the end of driving settlement is about 16 mm 30 s 10 PTL1 100 20 95 30 77 10 PTL2 32 20 17 30 5 10 PTL2 2 1045 20 2 990 30 2 955 10 PTL3 2 1045 20 2 990 30 2 955 10 PTL3 2 1045 20 2 990 30 2 955 793 450 955 535 1058 860 1190 661 1322 749 Hammer efficiency 80 Pile length m Piling class 2 xxx mobilised geotechnical resistance xxx kN when ...

Page 50: ...u Teräslaji PTL1 PTL2 PTL3 RR75 S460MH 343 458 572 RR90 S460MH 406 541 677 RRs100 6 3 S550J2H 560 747 934 RR115 6 3 S460MH 531 708 885 RR115 8 S460MH 664 885 1106 RRs115 8 S550J2H 793 1058 1322 RRs125 6 3 S550J2H 710 946 1183 RR140 8 S460MH 822 1096 1370 RRs140 8 S550J2H 983 1311 1638 RR140 10 S460MH 1012 1350 1687 RRs140 10 S550J2H 1210 1614 2017 RR170 10 S460MH 1235 1647 2059 RRs170 10 S550J2H 1...

Page 51: ...700 18 7512 9311 11639 10017 12415 15519 12521 15519 19398 11610 RR700 20 8323 10316 11097 13754 13872 17193 11610 RR750 8 3633 4503 5628 4844 6003 7504 6055 7504 9380 12340 RR750 10 4529 5613 7017 6038 7484 9355 7548 9355 11694 12340 RR750 12 5 5642 6993 8742 7523 9324 11655 9404 11655 14569 12340 RR750 14 2 6395 7926 9908 8527 10568 13210 10658 13210 16513 12340 RR750 16 7188 8910 11137 9585 118...

Page 52: ... 5267 4250 5267 6584 9680 RR600 14 2 2888 3580 4475 3851 4773 5967 4814 5967 7458 9680 RR600 16 3245 4022 5027 4326 5362 6703 5408 6703 8378 9680 RR600 18 3638 4509 4851 6012 6063 7515 9680 RR650 8 1781 2207 2759 2374 2943 3679 2968 3679 4598 10060 RR650 10 2219 2750 3438 2959 3667 4584 3699 4584 5730 10060 RR650 12 5 2763 3425 4281 3684 4567 5708 4605 5708 7135 10060 RR650 14 2 3131 3880 4851 417...

Page 53: ...4 6376 7969 14890 RR900 12 5 3847 4768 5961 5130 6358 7947 6412 7947 9934 14890 RR900 14 2 4362 5407 6758 5816 7209 9011 7270 9011 11264 14890 RR900 16 4905 6080 7600 6540 8106 10133 8176 10133 12666 14890 RR900 18 5506 6825 8531 7342 9099 11374 9177 11374 14218 14890 RR900 20 6104 7566 8139 10088 10174 12610 14890 RR900 23 6996 8672 9329 11562 11661 14453 14890 RR1000 10 3435 4257 5321 4579 5676 ...

Page 54: ...s a secondary listing on the NASDAQ OMX in Helsinki www ssab com The accuracy of this instruction sheet has been inspected with utmost care However we do not assume responsibility for any mistakes or direct or indirect damages due to incorrect application of the information The right to make changes is reserved Copyright 2018 SSAB All rights reserved SSAB and SSAB brand names are registered tradem...

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