METHOD STATEMENT

Pile Head Preparation

Concrete Trimming & Repair
PROJECT
Construction of Bid Pack 5A&5B-Roads, Site Utilities,
Substations, Surface Parkings, Landscaping and Oasis
Works Sabah Al-Salem University City- Kuwait
University

Contract No.: KU/KUCP/C0251/10-11

DATE: 13th AUG 2014

REV.: 1

Sinohydro Corporation Limited Copri Construction Enterprises

W.L.L

KUWAIT UNIVERSITY-BID PACK 5A&5B

CONTRACT NO KU/KUCP/CO251/10-11

Method Statement for the pile head preparation.

-Concrete Trimming & rectification works

Revision: 01
13/08/2014

Method Statement For

Pile Head Preparation

KU/KUCP/CO251/10-11
Revision: 01

REV.
1

DESCRIPTION
First issue

DATE
mm/dd/yy
08/13/2014

2
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Method Statement For

Pile Head Preparation

KU/KUCP/CO251/10-11
Revision: 01

1.

INTRODUCTION

Method Statement for the pile head preparation for the underpass piles
belonging to the foundations of Sabah Al Salem University City- BP 5A&5B, contract
no: KU/KUCP/CO251/10-11.
The document details the various steps involved in the pile head preparation;
including the trimming of additional concrete above the Cut Of Level (COL) and pile
concrete rectifications if any encountered.

2.

SCOPE OF WORK

General construction practices adopted worldwide for the construction of bored

cast in situ piles (Wet Method/ Slurry Displacement Method), includes a mandatory
provision to cast the concrete above the COL. This is to ensure that the top of the pile
is free from any contamination brought up from the pile bottom during the slurry
displacement process. Post construction and the initial setting of the cast concrete,
the top of the pile above COL is exposed and trimmed till the required COL, using
industry proven methodology.
This literature establishes the various methods adopted by the piling contractor
for the pile head preparation inclusive of the trimming of the concrete above the COL
and the repair works carried out on defective concrete (if encountered anywhere).

3.

TRIMMING OF THE CONCRETE ABOVE THE C.O.L

The following steps shall be adopted by the piling contractor for the trimming of the
concrete above the COL:1) After the construction and the initial curing of the cast pile concrete, excavation
works shall commence to expose the concrete above the COL. The concrete
used for the underpass piles in the above foresaid project is K450.

Method Statement For

Pile Head Preparation

KU/KUCP/CO251/10-11
Revision: 01

2) As a common industry practice and as suggested by the Federation of Piling

specialists (Pile Breaking Guidance-May 2008) pile concrete should be allowed
to cure for at least 5 days before excavation and trimming.
3) In this particular project, excavation and trimming shall commence after at least
7 days. Since the use of high strength concrete in the piles, it is highly advisable
to start the pile trimming immediately after the 7 days for ease of operations.
4) After exposing the concrete till the pile COL, the surveyor shall mark a level
10cm above the COL, on the pile. A cut of maximum 1cm depth, shall be made
along the perimeter of the pile using concrete cutting discs. This is done to
create an artificial plane of cleavage and to eliminate spreading of any cracks
below this plane of cleavage.
5) The concrete above the cut-off level shall be trimmed in three stages as shown
in the figure 1, which is self explanatory.
6) The segment A, shall be trimmed using either Hydraulic hammers mounted over
a mini excavator/Skid Loader or manually operated pneumatic hammers (7kg32kg capacity). The jack hammers shall be held at an angular position (15-30)
for ease of operation.
7) The segment B, shall be trimmed manually using pneumatic hammers or
electric hammers only.
8) The final 10cm of concrete- segment C, shall be chipped using electric operated
hammers, to have more control over the trimming process.
9) During all above operations, the debris from the pile head shall be removed
manually using hand held shovels.

Method Statement For

Pile Head Preparation

KU/KUCP/CO251/10-11
Revision: 01

Method Statement For

Pile Head Preparation

KU/KUCP/CO251/10-11
Revision: 01

4.

QA-QC PROCESURE DURING TRIMMING OF CONCRETE ABOVE C.O.L

1) All excavation and trimming operations shall commence only after submission of
project approved check list forms (WIR) to the Engineer.
2) All excavations and trimming works to commence after a period of minimum 7
days after the casting of the piles.
3) All operations to be undertaken under the supervision of qualified piling
contractor staff. Due care shall be given towards the HSE procedures and
regulations.
4) All employees involved in the operations shall be all the time equipped with
appropriate PPE including but not limited to Hard Hats, Hard shoes,
recommended Gloves, ear plugs, protective eye glasses & dust masks.
5) Periodic Inspections shall be done by the piling contractors Site Engineer to
ensure the project specific guidelines.
6) Post Trimming of the concrete till the required COL, inspection shall be arranged
for the approval of the Engineers representative.

5.

EQUIPMENTS USED FOR THE CONCRETE TRIMING WORKS

1) Mini-excavator / Skid loader mounted hydraulic jack hammers.

2) Pneumatic jack hammers (7Kg-32Kg)
3) Air compressor (minimum180cfm)
4) Electric hammers (HILTI/BOSCH )
5) Concrete cutter/grinder
6) Hand held shovels

Method Statement For

Pile Head Preparation

KU/KUCP/CO251/10-11
Revision: 01

Fig 2: Mini excavator mounded hydraulic jack hammer.

Fig 3: Skid loader mounted hydraulic jack hammer.

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Method Statement For

Pile Head Preparation

KU/KUCP/CO251/10-11
Revision: 01

Fig 4: Pneumatic Jack Hammers and Chisels

Fig 5: Electric Jack Hammer and application

Method Statement For

Pile Head Preparation

KU/KUCP/CO251/10-11
Revision: 01

6.

REMEDIAL WORKS ON PILE CONCRETE

The subsequent section of this literature addresses the rectification works intended to
be carried out on pile surface in case of any defected or faulty workmanship.
The damages or faulty workmanship if any can be of the following two categories,
which are addressed under these two sub sections:1. Defects discovered at the top of the pile (Contaminated concrete at or under
the COL, honeycombing or accidental trimming of pile below the required COL)
2. Defects discovered along the face of the pile (honeycombing, damage to the
pile due to excavation works etc).
Repair works shall follow the industry proven construction practice of using specialized
products approved in the project and in compliance with the project particular
specifications.
Based on the piling contractors previous local and international experience with similar
situations, specialized concrete repair products from BASF is mentioned in this
literature. However, similar products from other brands can also be used, provided it is
approved in the project:
6.1 Defects at the top of the pile (>15 cm repair works/shuttered works):
BASF CONCRESIVE 1414 (bonding agent) is a bonding agent which is
used in areas where repair for pile is greater than 15 cm. The bonding agent is
applied at the cleaned and finished concrete level and later concrete of same
grade is casted over it.
The product data sheet is attached at the end for the review and consideration
of the Engineer. Separate transmittals shall be submitted for the approval of the
product in the project.
The repair works is carried out following the below steps:.
a. The pile section requiring the repair is identified. The repair area is
cleaned from any loose material using water or pressurized air.
b. Appropriate shutter/form works are provided around the area which
needs the repairing.

Method Statement For

Pile Head Preparation

KU/KUCP/CO251/10-11
Revision: 01

c. This repairing product unit consists of a base and a reactor. The base is
added to reactor and mixed well with a paddle drill. This mixing is then
continued for about 3 minutes.
d. The mixed chemical is then applied over the surface with a short haired
paint brush, uniformly and allowed to settle as suggested in the product
data sheet.
e. After waiting the recommended time, same concrete (Same Mix Design,
strength and characteristic) as that of the pile concrete is casted over the
applied product coating.
f. Product Data sheet (attached at the end of the literature) describes the
manufacturers recommendation which is self explanatory.
6.2 Defects at the face of the pile (<15 cm repair works/non-shuttered works):
BASF EMACO S88 CT (filling agent)- is a cementitious filing agent used to
rectify any defect up to 15cm. Defect above 5 cm is filled in layers with the
repair product, the data sheet of which is attached along the literature.
This material is used to fill any honey-combs present or minor edge breaks.
The repair works shall be carried out using the below steps:
a. Area to be applied with the BASF EMANCO S88 CT is roughened,
cleaned and wetted.
b. Add 3.5 liters of water into a mixing bucket and start the paddle mixer
fitted to drill machine. Start the mixing and add the EMACO S88 CT
powder rapidly and continuously.
c. Mix for 3 minutes after all the powder has been added until mortar is
homogeneous and lump free.
d. Add water, if necessary, within the limits given, until the required
consistency is achieved. Mix for a further 1-2 minutes. The amount of
water required will be affected by ambient temperature and relative
humidity.
e. After mixing EMANCO S88 CT can be applied over the affected area by
spraying with a trowel.
f. Leveling and initial finishing should be carried using a wooden or plastic
float. Final finishing should be carried out using a steel float.

--------------------------------------------------------end of literature--------------------------------------

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Pile Head Preparation

KU/KUCP/CO251/10-11
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Appendix: For BASF repair products (For the review of the Engineer)

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Pile Head Preparation

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Pile Head Preparation

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Pile Head Preparation

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