OBAYASHI VIETNAM CORPORATION

TOYOTA NANKAI HAI PHONG WEST PROJECT

CONSTRUCTION METHOD
AND QUALITY CONTROL PLANNING
FOR
PILE PRESSING WORK
(Pretension Spun Concrete Piles)

OBAYASHI VIETNAM CORPORATION

TOYOTA NANKAI HAIPHONG WEST PROJECT - SITE OFFICE

DEPUTY PROJECT
DESIGN DIRECTOR PROJECT MANAGER BUILDING A.MANAGER
MANAGER

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CONTENTS
1. GENERAL
1.1. Scope
1.2. Alteration

2. OUTLINE OF PROJECT
2.1. Project Outline
2.2. Work Outline
3. ORGANIZATION CHART
4. SCHEDULE

5. SPECIFICATION OF MATERIAL AND QUALITY OF MATERIAL

5.1. Specification of materials
5.2. Pile fabrication
5.3. Pile transportation

6. METHOD OF PILE WORK

6.1. Preparation at site
6.2. Site Survey work – Pile Location determination
6.3. Pile Stock at Site
6.4. Pile Pressing work

6.4.1. Selection of pressing equipment

6.4.2. Mobilization and installation of equipment
6.4.3. Pile pressing
6.4.4. Stop pressing work’s condition
6.4.5. Pressing, check and acceptance

7. QUALITY CONTROL MANAGEMENT

8. INSPECTION
8.1. Outline of Inspection
8.2. Method of Inspection

9. SAFETY CONTROL PLAN

10. APPENDIXES

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1. GENERAL
1.1 Scope
This Construction Method and Quality Control Planning shall be applied to piling work.
This document provides a proper procedure and management of the piling work.
1.2 Alteration
This Construction Method and Quality Control Planning may be subject to change or
alter due to its version and consideration. In that case, corrected or adjusted requirement
shall prevail after its official written approval.
2. OUTLINE OF PROJECT
2.1 Project Outline
- Name of the project: TOYOTA NANKAI HAI PHONG WEST PROJECT
- Location: KM 88, LUONG QUAN HAMLET, AN DUONG DISTRICT, HAI
PHONG CITY, VIET NAM.
- Owner: TOYOTA NANKAI HAI PHONG WEST CO., LTD.
- Designer: OBAYASHI VIETNAM CORPORATION
- Contractor: OBAYASHI VIETNAM CORPORATION
- Subcontractor: MINHDUC CONCRETE AND CONSTRUCTION CO.,LTD
- Main construction period: From April 01st 2017 to December 30th 2017
- Piling work period: From April 01st 2016 to April 30th 2016
- Building area: 3464.15 m2
- Floor area: 9317.75 m2
2.2 Piling work Outline
Estimated quantity of pile are 258 PHC piles D400 (Without tunnel), L=36 met / pile
and 119 PHC piles D400 , L= 46 met / pile . Total quantity of pile length is 14762 met .
3. ORGANIZATION CHART
Please see attached Appendix 1 for OVC and Sub-contractor organization chart and
workers’ certificate & licenses
4. SCHEDULE
Please see attached Appendix 2 for detail pile driving plan and schedule

5. SPECIFICATION OF MATERIAL AND QUALITY OF MATERIAL

5.1 Specification of materials:
The company who make Hollow pre-stressed concrete pile for TOYOTA Nankai Hai
Phong West Project is a company specialized in pile fabrication and pile pressing work
and quality management system conformed to ISO 9001-2008.
This company will submit the check list of materials to make concrete pile: stone sand,
water, cement, and steel bar. The production lines also certified for producing PC/PHC
Piles according to TCVN and JIS Standards as follows:
- TCVN 7888: 2008 Pretension Spun Concrete Piles
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- JIS G 3137: 1994: Small size-deformed steel bar for pre-stressed concrete
- JIS G 3532:2000 Specification for cold-drawn steel wire for concrete reinforcement.
See attached Appendix 3 for certification of materials
5.2 Pile fabrication
OVC’s supervisor & pile producer's supervisor check steel bars of piles; position,
quantity, variety and check the form; dimension, stability and concrete.
Procedures and details of PHC pile Production and Quality assurance and control are
described as follows:
a. Connect both End plates with rebar

b. Move rebar with End plate to form

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c. Pour concrete

d. Force stretching rebar

e. Forming pile by Centrifugal Machine

.
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f. Curing concrete by heated steam in tank

g. Remove formwork

h. Shift pile to stock yard area for curing.

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Requirements for testing and piling works shall conform to the latest revisions and
amendment of the following Standards:
- TCVN 7888: 2008 Pretension Spun Concrete Piles (PC, PHC pile)
- JIS A5335-1987: Pretension Spun Concrete Piles;
- TCXDVN 286: 2003 “Pile Pressing and Driving – Standard for construction, checking
and acceptance”
- TCVN 1961:1975: Manual Arc Welding
Testing work shall be conformed to ASTM D1143 – Standard Test Method for Piles
under Static Axial (2007) Compressive Load.
5.3 Pile transportation.
Pile shall be cured at least 5 days after casting and sample testing for compressive
strength shall be carried out at 5 days. If the strength of concrete sample reaches over
85% of designed strength (R28), those pile segments can be ready for delivery to the
site.
Piles are transported to site by approved semi trailers. Each delivery of piles is attached
with following documents to be checked before acceptance by OVC engineer:
- Delivery certificate
- Pile delivery slip
- Result of concrete compression test
- Result of dimension test by ruler
For safety and to avoid pile broken: When using the pile should be taken from top layer
to bottom layer. Pulling and pushing the pile from inside of stack to out is prohibited.

6. METHOD OF THE WORK

6.1 Preparation at site:
Before start for pilling work, we have to level for existing land . Existing land have
organic surface soil with wild grass at top. Therefore, we have to remove and disposal
that layer to out of land . Existing land have a stone layer thickness 500-600 (mm) on
the top so we have to excavate the stone layer at pile location before start pilling work .

6.2 Site survey work – Determination of Pile location

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We make benchmark net system, these benchmarks are used to determine the pile
location.
Before pressing work, all pile locations should be marked and checked as following
steps:
a. Step 1: Basing on bench marks, use theodolite and ruler tape to determine pile locations.
VINYL STRING
b. Step 2: To making location
of pile. We will used BAMBOO STAKE
bamboo stake with D =

200~150
10~15mm, L = 15 ~ 20 cm EXISTING LEVEL EXISTING LEVEL
then tie color vinyl wire at

100~150
top of bamboo stake. After
that, insert bamboo stake
into soil with full length and
appear only color vinyl wire b) c)
to easy detect.
c. Step 3: After all pile locations are checked again, bamboo stakes are hammered down
into the soil.
d. Step 4: To find the concealed stake: from the nearby driven piles, use measure to find
roughly location of the stake. Then use spade to raking soil until the stake exposed.
e. Step 5: Pull off bamboo stake; guide the pile tip to the remaining hole.
6.3 Pile stock at Site

The piles are stocked along the pressing direction.

At the site, a flat plan area is prepared for storage of pile and the piles’ stack layer
should not be more than 3 layers.
Pile segments shall be arranged to have the advantage of moving equipment and avoid
damage to pile segments during execution period.
6.4 Pile pressing work
6.4.1 Selection of pressing equipment
Based on the specification and size of pile
Based on the calculation of bearing capacity of a pile P Design = 75 ton. The necessary
pressure and stopped at P Pressure Max = 3.0 time of design bearing capacity, So
P Pressure Max = 225 tons (= 75 ton x 3.0)
Required Weight for load:
P Load ≥ 1.1 P Pressure Max (P Load ≥ 247.5 Tons)
Notes: When pile length of P1 pile pressed up to 36 m and pile length of P2 pile pressed
up to 46 m but pressure not obtain 225 tons yet. At that time we still continue pressing
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pile until the pressure is 225 tons and when pressing pile not enough 36 m with P1 pile
and 46 m with P2 yet but the pressure is obtain 225 tons. So, we can stop pressing pile.
The pressure is from the two hydraulic jacks. The diameter of the cylinder and the area
of the cylinder following machine specification sheet which was verified by authorized
firm (see attached appendix 4 for verified press machines).
Crane for lifting counterweight and RC pile: Base on the working ground to choose the
crane. The piles shall be arranged within the reach of the crane.
6.4.2 Mobilization and assemble of equipment
Automated press machine (Called Robot) is transported to site by transporter truck and
erected from individual parts including base, frame, drive cab, hydraulic oil presser by
special crane.
Press comprises of 4 parts: Base, frame, counterweight, hydraulic oil pump. Those parts
shall be transported, load and unload by special truck and crane.
Assembling machine shall be started from the foot upward. Install base, frame,
counterweight, hydraulic oil pump.
After assembled of Robot, theodolite shall be used to adjust the frame, jack and pile
casing to ensure they are in line and perpendicular to the standard surface. The
permissible inclination shall be ≤ 0.5%. Oil pump shall be the last to be installed.
Check the assembled machine and then conduct test run of the machine to ensure proper
operation (with load or without load)
See attached Appendix 4 for Press Machine & Crane Validation certificate.
6.4.3 Pile pressing
Important notes:
Every fabricated pile’s segment must be checked and approved with quality certificates
prior to be set into the designed position.
There are adjustment gauges in control cab so that the operator can adjust the balance of
the Robot follow horizontal, and the pressing direction of the equipment is vertical and
perpendicular to the balance of robot. Adjust to ensure the balance of robot is always
horizontal and the pile is always vertical during pressing of the whole pile. Declination
of pile must be less than 1:100mm and allowable tolerance for location of pile ≤
100mm. Pressing load is slowly increased to ensure that the penetration speed of pile is
less than 2cm/s
Pressing first segment (tip segment)
The first segment (with tip) shall be installed carefully. We use 1.2 meter length of
“Water balance ruler” for checking pile placed perpendicularly to the vertical axis. The
first segment must brace to the guide-bar on the frame.
When first segment pile obtains friction, start to adjust pressure gauge. At beginning
moment, oil pressure is still at low speed so it needs special attention to ensure pressing
speed of first segment of no more than 2cm/s.
Notes: When the pile inclination is sloped, have to stop pressing work immediately and
adjust the pile’s verticality.

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Leave 40÷50cm of first segment above the ground to create favorable condition for
welding.
Pressing middle segments
Prior to erection of middle segment, adjust the axis of middle segment coincidental to
the axis of jack and first segment and check surface of top for each pile segment to
ensure it is balance, the inclination of pile less than 1%.
Loading a force for top of pile from 10÷11.25 ton (10÷15% Pdesign ) to make contact
between upper pile segment and below pile segment then start to weld as required.
The pressing load slowly increased to ensure that the penetration speed of pile is less
than 2cm/s
Welding work:

Welding Hw =6~8mm

- Welding of joint of piles shall be by semi-automatic welding machine, welding gun with
contact tube of 10~15mm for current <250A and 15~25mm for current >250A.
- The welding joint shall be filling-up all around the gap between the two piles-end
flanges by at least 2 layers welding. The pile diameter is divided two parts; one welder is
in charge of one part. In order to ensure that the temperature shall not increase suddenly,
the two welders shall start welding in opposite position rather than in the same position,
they also need to follow the same direction during welding. Moreover, during welding
process, the speed of welding gun movement shall not exceed 240mm/minute, the
welder should also weld the pile connection in at least 2 layers to ensure that the welding
height conform to the specifications. (Hw= 6mm~8mm)
- All welding joint shall be carried out by skilled workers having welding certificate,
under careful supervision on thickness, quality as well as the verticality of two pile
segments before and after welding.
- Welding work shall only be started to meet following conditions:
+ The axis of pile segment shall be corrected at least two directions
+ The axis of second pile segment coincides with that of first pile segment
+ Surface of two pile head tightly contact together
- The pile head shall be cleaned before moving to welding position.

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- Check the welding equipment: working condition, electric current, cables, welding
cables, joints.
Check quality of welding joint: Visual checking and take photo of 100% joint of
installed piles and include in pile check sheet.
Pressing final segment (top)
Prior to erection of final segment, adjust the axis of middle segment coincidently to the
axis of jack and middle segment.
Loading a force for top of pile from 10÷11.25 ton (10÷15% Pdesign ) to make contact
between upper pile segment and below pile segment then start to weld as required.
About pile connection welding required please see above of middle segment procedure.
Increase the pressure so that the machine can create sufficient force for the pile top to
penetrate.
At first, middle segment penetrates with speed no more than 2cm/s and keep the
permissible pressure so that the pile shall obtain conditioned length.
The pressing speed for 60cm remain shall be 1cm/s
The pile shall be pressed so as to avoid collision and false bearing. OVC and sub-
contractor assigned technical inspect and keep record.
6.4.4 Stop pressing work’s condition
Pile pressing’s supposed to get normal condition and stop pressing when actual pressure
force reached at P Pressure Max = 3.0 time of design bearing capacity (P Pressure Max = 225 tons).
Pile pressing work is deemed to get trouble and stop pressing in case:
- The pressure on pile is sufficient but actual pile length is shorter than design pile length.
- Pile gets big crack.
- Pile or pile head broken
- Pile suddenly shifts from original location…
Then OVC design section should re-sign for troubled pile location (if any) to add piles
or extend pile cap…
Notes: Record the initial pressure when the piles penetrate to the depth the keep record
at each itinerary of machine’s piton length (Example with format of pressing record =
1.8 meter). If the hand of the gauge moves abnormally, site engineer must record the
depth and pressure on the construction journal. The construction journal shall be kept
until the design length is reached
6.4.5 Pressing journal, check and acceptance
+ Each press shall have a pressing journal.

+ During the whole pressing period, the inspection by OVC engineer and Sub-contractor
is required. Accept immediately at the finishing of a pile. If the pile satisfies the
specifications then representative of each party shall sign on the pressing journal.

+ The pressing journal shall have seal of the pressing unit.

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+ At the remark on the journal, it is necessary to note down the welding quality, reason
and time of delay, continue time and watch pressure value accurately.

+ Keep record of pile, pile range, number of pile

7. QUALITY CONTROL PLAN

From pile fabrication to pile pressing, welding connection… all the works are followed
strictly by OVC engineer in charge.
Checking Pile location after pressing
We use 1.2 meter length of “Water balance ruler” for checking pile placed
perpendicularly to the vertical axis.
Check location of piles during and after pressing pile. By this way the tolerance of pile
location at each side can be determined easily.
The tolerance of pile location is less than 100mm.
Otherwise, engineer must report to design section immediately when the pile have
problem (Location, crack when pressing…)
We also use leveler machine to measure level of pile top and record in piling form.
After pile pressing work finished, we will execution by PIT method for 10% per total
pile pressed of project. Please see PIT method statement in item 8. as below.
8. PIT METHOD
8.1 The object:
- This method use mechanical impedance to applying in homogeneous medium, which is
defined by transmittal properties of wave with velocity C.
- The Low Strain Method of dynamic pile testing may be applied to any concrete pile
either driven or cast in-situ. They require as a minimum the impact of a small hand held
hammer on the shaft top and the measurement of the shaft top motion.
8.2 Principle of method:

- The motion record, more specifically the pile top velocity, must be displayed and pro-
duced on hard copy as a function of time. Where high soil friction forces are present, in-
tegration with exponentially increasing magnitude should be applied to the velocity sig-
nal such that the pile toe reflection is enhanced. In general, several records should be av-
eraged; however, the test engineer is responsible for assuring that consistent records are
included in the average. The averaged, amplified velocity is the standard result of the
Sonic Pulse Echo Method. In addition to the velocity record as a function of time, the
amplified and averaged difference between velocity and force may also be depicted.
This graph would provide additional information as to be the quality near the pile top.
The velocity vs. frequency plot and its transform may add valuable pile length and dam-
age location information.
- We use the data to calculate the depth of foundation in the time of first and diffusing, or
calculate the depth of foundation in the time of diffusing successively (t p). It can express
following as:
D=Vpx tp/2

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Where: D is depth of foundation at diffusing position.

Vp is wave velocity in pile

The location transducerr

The location type hummer

Figure 2. Positions of test on the top the pile

Figure 3. Work diagram of transferring of stress wave

8.3 Equipment for testing:

- To evaluating density of concrete and elastic stiffness of piles system, we use special-
ized equipment.
- Specialized equipment Pile Integrity Tester TM (P.I.T.) with PTE software can record the
reflex velocity of wave from bottom pile or intermediate point.

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- Velocity s performed by spectral of graph. Error position is found by analysis wave.

Measure of error is defined by amplitude of first wave.
- This testing is quick and simply;
TM
- Specialized equipment Pile Integrity Tester (P.I.T.) is providing Pile Dynamics, Inc
(USA).
8.4 Test and report:
- Preparing and checking system.

- Preparing the top of pile to apply accelerometer.

- Assembling equipment.

- In put the data to definite properties pile.

- At the 03 positions. A small hand held hammer connecting to receiver creates impulse.
- Linking data to Computer.

- Analysing and making report.

8.5 Test standard for applying:

To evaluating quality of pile, we use test standards following as:

a) ASTM. D5882-96 test Standard method for low strain Integrity testing of piles.
b) ASTM D143, ASTM D4945-89, NF. P94-160-4, NF P194-160-2
c) New technology for to evaluate quality of piles - TS Nguyễn Hữu Đẩu NXBXD -
2000
d) Testing and inspect concrete pile quality Cung Nhat Minh, Diep Van Linh, Luu
Huu Loc - NXB XD
e) TCXDVN 359: 2005 low strain Integrity testing of piles
f) TCVN 9397:2012 test Standard method for low strain Integrity testing of pile
8.6 Quality control plan
During the whole testing method, the supervised by OVC manager and Sub-contractor’s
engineer is required

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Please see machine’ certificate & worker’s licenses

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9. INSPECTION
9.1 Outline of Inspection
During the whole pressing period, the inspection by OVC engineer and Sub-contractor is
required. Accept immediately at the finishing of a pile. If the pile satisfies the
specifications then representative of each party shall sign on the pressing record sheet
and check sheet
9.2 Method of Inspection
To control quality for pile pressing work at site, we have to follow documents as below:
a. Pile pressing record at site:

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b. Photo record at site:

c. Pile pressing report:

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d. Quality control sheet:

10. SAFETY CONTROL PLAN

All workers and engineer of subcontract have been trained working safety, site
regulation, health, security and environment system, fire fighting system…
Daily inspection about pilling equipment, truck, crane, electric cable, lifting cable,
lifting hook, workers PPE…
Before lifting and transport pile, have to check equipment and ensure all area good
condition.
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During pile erecting and pressing course, no unauthorized workers permitted to enter
area of pressing pile location and also make barricade around pile pressing area.
All workers must wear helmet, shoes and glove, safety belt, safety jacket.
Put 02 (two) extinguishers and a water basket near the welding place.
Clear area after one pile finished.
11. APPENDIXES
Appendix 1: OVC and Sub-contractor organization chart and workers’ certificate &
licenses
Appendix 2: Detail pile pressing direction & schedule
Appendix 3: Certification of materials
Appendix 4: Press machine and crane validation certification
Appendix 5: Sub-contractor profile
Please see appendix attached file as below:

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