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Industrial Concrete Products Sdn Bhd (ICP) is the largest manufacturer of pretensioned spun concrete piles in Southeast Asia, known as ICP PC piles. ICP piles are circular, range in diameter from 250mm to 1200mm, and can be manufactured up to 46m in length. They are used for foundations of structures like buildings, bridges, and marine projects. ICP piles have advantages like durability, ability to be driven through hard soil, and environmentally friendly installation.
Industrial Concrete Products Sdn Bhd (ICP) is the largest manufacturer of pretensioned spun concrete piles in Southeast Asia, known as ICP PC piles. ICP piles are circular, range in diameter from 250mm to 1200mm, and can be manufactured up to 46m in length. They are used for foundations of structures like buildings, bridges, and marine projects. ICP piles have advantages like durability, ability to be driven through hard soil, and environmentally friendly installation.
Industrial Concrete Products Sdn Bhd (ICP) is the largest manufacturer of pretensioned spun concrete piles in Southeast Asia, known as ICP PC piles. ICP piles are circular, range in diameter from 250mm to 1200mm, and can be manufactured up to 46m in length. They are used for foundations of structures like buildings, bridges, and marine projects. ICP piles have advantages like durability, ability to be driven through hard soil, and environmentally friendly installation.
Email: icppg@ijm.com August 2012 Wisma IJM Annexe, Jalan Yong Shook Lin, 46050 Petaling Jaya, Selangor Darul Ehsan, Malaysia. Tel: 603-7955 8888 Fax: 603-7958 1111 E-mail: icpsales@ijm.com Website: www.icpb.com Senai INDUSTRIAL CONCRETE PRODUCTS SDN BHD MS 1SO 9001 : 2008 REG. NO AR0122 SPECIAL FEATURES OF ICP PILES INDUSTRIAL CONCRETE PRODUCTS SDN BHD (ICP) is the first commercial manufacturer of HIGH PERFORMANCE PRETENSIONED SPUN CONCRETE PILES (ICP PC PILES) in Malaysia. Presently, ICP is the largest manufacturer in South East Asia. The company was incorporated in Malaysia on 6 April 1977 and commenced business in September 1977. In September 1993, ICP started manufacturing HIGH PERFORMANCE Pretensioned Spun High Strength Concrete Piles (ICP PHC PILES) which offer an economical foundation system with consistent and superior quality compared to the ordinary concrete piles. With the vast experience in the manufacturing of pretensioned spun concrete piles and utilising the latest concrete technology, ICP is the market leader in concrete piles. ICP Piles are circular in cross-section and are manufactured in sizes ranging from diameter 250mm to 1,200mm with standard lengths varying from 6m to 46m in single pieces. ICP Piles can be easily joined to any combination of length as per design requirement. ICP Piles are manufactured with steel end plates for splicing. ICP Piles have been used extensively as foundation piles for power stations, highrise buildings, civil engineering works, bridges, marine structures, harbours, schools and government projects, etc. ICP Piles are exported to Brunei, Singapore, Sri Lanka, the Middle East, Indonesia, Philippines, Vietnam, Myanmar, USA, Canada and Maldives. As a market leader in the concrete industry, ICP constantly improves the quality of its products and services. All ICP factories are MS ISO 9001 : 2008 certified. Chenor Bridge, Maran Pahang Aden Flour Mill Jetty at Aden, Yemen Areas of Application Bridges Building Foundations Civil Engineering Works Marine Structures Piled Embankments Product Attributes Spinning process results in more durable concrete with high resistance to corrosion. Grade 80 concrete enables the piles to be driven through hard strata. Can be manufactured up to dia. 1200mm and a maximum single length of 46 metres. Environmentally friendly installation by hydraulic jacking equipment which are free of noise, air pollution and vibration. Kementerian Perusahaan, Perdagangan dan Komoditi, Putrajaya
1km Container Terminal at Chittagong Port, Bangladesh E-gate, Penang Sg. Buloh Hospital, Selangor SPECIAL FEATURES OF ICP PILES INDUSTRIAL CONCRETE PRODUCTS SDN BHD (ICP) is the first commercial manufacturer of HIGH PERFORMANCE PRETENSIONED SPUN CONCRETE PILES (ICP PC PILES) in Malaysia. Presently, ICP is the largest manufacturer in South East Asia. The company was incorporated in Malaysia on 6 April 1977 and commenced business in September 1977. In September 1993, ICP started manufacturing HIGH PERFORMANCE Pretensioned Spun High Strength Concrete Piles (ICP PHC PILES) which offer an economical foundation system with consistent and superior quality compared to the ordinary concrete piles. With the vast experience in the manufacturing of pretensioned spun concrete piles and utilising the latest concrete technology, ICP is the market leader in concrete piles. ICP Piles are circular in cross-section and are manufactured in sizes ranging from diameter 250mm to 1,200mm with standard lengths varying from 6m to 46m in single pieces. ICP Piles can be easily joined to any combination of length as per design requirement. ICP Piles are manufactured with steel end plates for splicing. ICP Piles have been used extensively as foundation piles for power stations, highrise buildings, civil engineering works, bridges, marine structures, harbours, schools and government projects, etc. ICP Piles are exported to Brunei, Singapore, Sri Lanka, the Middle East, Indonesia, Philippines, Vietnam, Myanmar, USA, Canada and Maldives. As a market leader in the concrete industry, ICP constantly improves the quality of its products and services. All ICP factories are MS ISO 9001 : 2008 certified. Chenor Bridge, Maran Pahang Aden Flour Mill Jetty at Aden, Yemen Areas of Application Bridges Building Foundations Civil Engineering Works Marine Structures Piled Embankments Product Attributes Spinning process results in more durable concrete with high resistance to corrosion. Grade 80 concrete enables the piles to be driven through hard strata. Can be manufactured up to dia. 1200mm and a maximum single length of 46 metres. Environmentally friendly installation by hydraulic jacking equipment which are free of noise, air pollution and vibration. Kementerian Perusahaan, Perdagangan dan Komoditi, Putrajaya
1km Container Terminal at Chittagong Port, Bangladesh E-gate, Penang Sg. Buloh Hospital, Selangor PROPERTIES OF ICP PILES - STANDARD PRODUCTS (Subject to change without prior notice) FORMULA FOR AXIAL LOAD Based on BS 8004: 1986, the maximum allowable axial stress that may be applied to a pile acting as a short strut should be one quarter of (specified works cube strength at 28 days less the prestress after losses) N = fca x A = 1/4(fcu - fpe) x A Where, N = maximum allowable axial load A = cross section area of concrete fca = permissible compressive strength of concrete fcu = specified compressive strength of concrete fpe = effective prestress in concrete CLASS A (EFFECTIVE PRESTRESS 4.0 N/mm 2 ) CLASS B (EFFECTIVE PRESTRESS 5.0 N/mm 2 ) CLASS C (EFFECTIVE PRESTRESS 7.0 N/mm 2 ) EXTENSION PILE STARTER PILE SPIRAL WIRE AT 50 mm PITCH x 3D SPIRAL WIRE AT 100 mm PITCH SPIRAL WIRE PILE SHOE FILLET WELD MS PLATE PRESTRESSING BAR PRESTRESSING BAR SEE DETAIL A SPIRAL WIRE AT 50 mm PITCH x 3D D 1 5 MS JOINTING PLATE MS BAND SECTIONAL DETAILS OF ICP PILES JOINT WELDING DETAILS Dia Of Pile D Throat Thickness A W Root R Dia Of Pile Dia. Quantity L HT Bars BONDING ICP PILES INTO PILE CAP As the PC bars are bonded with concrete, ICP Piles may be cut off at any point. The piles need not be stripped down to expose the bars, and can be bonded to the pile cap as shown in the following sketch. If the piles are not subjected to tensile loads, the recommended h.t. bars are considered adequate. DETAIL A mm mm mm mm 250 8.5 4.0 1.5 300 8.5 4.0 1.5 350 8.5 4.0 1.5 400 10 4.5 1.5 450 10 4.5 1.5 500 12 5.0 1.5 600 12 5.0 1.5 700 12 5.0 1.5 800 14 6.0 2.0 900 14 6.0 2.0 1000 14 6.0 2.0 1200 14 6.0 2.0 HT BARS PILE CAP ICP PILE GRADE 30 CONCRETE PLUG 1.5 mm MS PLATE TACK-WELDED TO HT BARS D D mm No. mm mm 250 4 12 500 300 4 12 500 350 5 12 550 400 5 12 700 450 5 15 800 500 6 15 900 600 8 15 1000 700 8 18 1200 800 8 20 1400 900 10 25 1500 1000 12 25 1500 1200 20 25 2000 kNm 9.0mm 10.7mm12.6mm kNm kNm kNm kNm kNm PROPERTIES OF ICP PILES - STANDARD PRODUCTS (Subject to change without prior notice) FORMULA FOR AXIAL LOAD Based on BS 8004: 1986, the maximum allowable axial stress that may be applied to a pile acting as a short strut should be one quarter of (specified works cube strength at 28 days less the prestress after losses) N = fca x A = 1/4(fcu - fpe) x A Where, N = maximum allowable axial load A = cross section area of concrete fca = permissible compressive strength of concrete fcu = specified compressive strength of concrete fpe = effective prestress in concrete CLASS A (EFFECTIVE PRESTRESS 4.0 N/mm 2 ) CLASS B (EFFECTIVE PRESTRESS 5.0 N/mm 2 ) CLASS C (EFFECTIVE PRESTRESS 7.0 N/mm 2 ) EXTENSION PILE STARTER PILE SPIRAL WIRE AT 50 mm PITCH x 3D SPIRAL WIRE AT 100 mm PITCH SPIRAL WIRE PILE SHOE FILLET WELD MS PLATE PRESTRESSING BAR PRESTRESSING BAR SEE DETAIL A SPIRAL WIRE AT 50 mm PITCH x 3D D 1 5 MS JOINTING PLATE MS BAND SECTIONAL DETAILS OF ICP PILES JOINT WELDING DETAILS Dia Of Pile D Throat Thickness A W Root R Dia Of Pile Dia. Quantity L HT Bars BONDING ICP PILES INTO PILE CAP As the PC bars are bonded with concrete, ICP Piles may be cut off at any point. The piles need not be stripped down to expose the bars, and can be bonded to the pile cap as shown in the following sketch. If the piles are not subjected to tensile loads, the recommended h.t. bars are considered adequate. DETAIL A mm mm mm mm 250 8.5 4.0 1.5 300 8.5 4.0 1.5 350 8.5 4.0 1.5 400 10 4.5 1.5 450 10 4.5 1.5 500 12 5.0 1.5 600 12 5.0 1.5 700 12 5.0 1.5 800 14 6.0 2.0 900 14 6.0 2.0 1000 14 6.0 2.0 1200 14 6.0 2.0 HT BARS PILE CAP ICP PILE GRADE 30 CONCRETE PLUG 1.5 mm MS PLATE TACK-WELDED TO HT BARS D D mm No. mm mm 250 4 12 500 300 4 12 500 350 5 12 550 400 5 12 700 450 5 15 800 500 6 15 900 600 8 15 1000 700 8 18 1200 800 8 20 1400 900 10 25 1500 1000 12 25 1500 1200 20 25 2000 kNm 9.0mm 10.7mm12.6mm kNm kNm kNm kNm kNm Cage Making / Mould Setting PC bars in coil form are straightened and cut to correct lengths. The ends are warm- headed to form button heads. The bars are passed through the cage forming machine where spiral wires is automatically spot-welded at the correct spacings. End plates are fitted to the cage. The whole cage is then placed onto the bottom half mould. Pile Spinning The filled mould is then placed on the centrifugal spinning machine to be spun automatically in four stages. Spinning results in high compaction and squeezes out excess water. The resulting decrease in final water cement ratio increases the concrete strength in pile. 1 Stressing The PC bars are stressed against the mould through a central shaft and stressing plate. The stressing being carried out in a single operation ensures uniformity of stress in all the PC bars and hence straightness of the pile. 3 2 Concrete Feeding Concrete from the computerised batching plant is discharged into a feeding hopper. Concrete is then fed into the bottom half mould through a reversible screw feeder. The top half mould is then bolted to the bottom half. 4 5 6 MANUFACTURING PROCESS OF ICP PILES Standards ICP PHC Piles comply with MS 1314:Part 4:2004 and also generally comply with JIS A 5337:1987. ICP PHC Piles are modified to suit BS 8004:1986 - Foundations and BS 8110:1997 - Structural Use of Concrete. Materials Aggregates Coarse aggregates shall be 20mm granite. Fine aggregates shall be clean river sand or washed mining sand. Cement Ordinary Portland cement to MS 522:1989. Prestressing Steel High frequency induction heat treated bars manufactured to JIS G 3137:1994 or equivalent. Spiral Wire Hard drawn wire. Concrete Strength Minimum concrete cube strength: at transfer of prestress 28 days 30 N/mm 2 78.5 N/mm 2 Joint The joint is designed to have the same performance as the main body particularly in respect of bending strength. All ICP PHC Piles will be supplied with steel extension plates for splicing. Lifting Points Two lifting points will be marked on all piles exceeding 12m. No special lifting bolt or wire rope is cast into the piles. Lifting is by wrapping wire ropes round the piles at specified points. Pile Shoes All ICP PHC Piles will be supplied either open ended, with a flat shoe or with an X-pointed shoe. Curing After casting, the piles are steam cured. When the concrete reaches the specified transfer strength, the piles are demoulded, marked and checked for quality. The piles can normally be transported and driven when the cube strength reaches 50 N/mm 2 . Identification All ICP PHC Piles have the typical markings as follows: Logo as Trademark Companys Initial Malaysian Standard Pile Size and Class Date of Cast (yy/mm/dd) Serial No & Factory Code Pile Length and Type Other markings if used, S for Starter (flat shoe or X-pointed shoe) Standard Lengths ICP PHC Piles are available in lengths of 6m to 46m subject to certain limitations. Delivery Usually two to three weeks from date of confirmed order. ICP Standard Piles are normally available ex- stock for test driving. Technical Data Technical data of piles are given in the table on the next page. They refer to our standard products. Please note that the axial loads represent the structural capacities of the piles. Whether the driven piles can safely carry these loads depend on the soil conditions and the pile slenderness ratio. Appropriate reduction of axial loads should be applied for (a) marine structures, (b) piles subjected to bending, (c) high upstand, (d) piles driven through very poor top stratum, (e) raking piles, etc. Definitions ICP PHC Piles: High Performance Pretensioned Spun High Strength Concrete Piles MS : Malaysian Standard JIS : Japanese Standard BS : British Standard GENERAL SPECIFICATION FOR ICP PILES Delivery When the cube strength reaches the required strength the piles can be transported and installed. Curing Steam curing enables the piles to be demolded earlier. MS 1SO 9001:2008 REG. NO. AR0122 Cage Making / Mould Setting PC bars in coil form are straightened and cut to correct lengths. The ends are warm- headed to form button heads. The bars are passed through the cage forming machine where spiral wires is automatically spot-welded at the correct spacings. End plates are fitted to the cage. The whole cage is then placed onto the bottom half mould. Pile Spinning The filled mould is then placed on the centrifugal spinning machine to be spun automatically in four stages. Spinning results in high compaction and squeezes out excess water. The resulting decrease in final water cement ratio increases the concrete strength in pile. 1 Stressing The PC bars are stressed against the mould through a central shaft and stressing plate. The stressing being carried out in a single operation ensures uniformity of stress in all the PC bars and hence straightness of the pile. 3 2 Concrete Feeding Concrete from the computerised batching plant is discharged into a feeding hopper. Concrete is then fed into the bottom half mould through a reversible screw feeder. The top half mould is then bolted to the bottom half. 4 5 6 MANUFACTURING PROCESS OF ICP PILES Standards ICP PHC Piles comply with MS 1314:Part 4:2004 and also generally comply with JIS A 5337:1987. ICP PHC Piles are modified to suit BS 8004:1986 - Foundations and BS 8110:1997 - Structural Use of Concrete. Materials Aggregates Coarse aggregates shall be 20mm granite. Fine aggregates shall be clean river sand or washed mining sand. Cement Ordinary Portland cement to MS 522:1989. Prestressing Steel High frequency induction heat treated bars manufactured to JIS G 3137:1994 or equivalent. Spiral Wire Hard drawn wire. Concrete Strength Minimum concrete cube strength: at transfer of prestress 28 days 30 N/mm 2 78.5 N/mm 2 Joint The joint is designed to have the same performance as the main body particularly in respect of bending strength. All ICP PHC Piles will be supplied with steel extension plates for splicing. Lifting Points Two lifting points will be marked on all piles exceeding 12m. No special lifting bolt or wire rope is cast into the piles. Lifting is by wrapping wire ropes round the piles at specified points. Pile Shoes All ICP PHC Piles will be supplied either open ended, with a flat shoe or with an X-pointed shoe. Curing After casting, the piles are steam cured. When the concrete reaches the specified transfer strength, the piles are demoulded, marked and checked for quality. The piles can normally be transported and driven when the cube strength reaches 50 N/mm 2 . Identification All ICP PHC Piles have the typical markings as follows: Logo as Trademark Companys Initial Malaysian Standard Pile Size and Class Date of Cast (yy/mm/dd) Serial No & Factory Code Pile Length and Type Other markings if used, S for Starter (flat shoe or X-pointed shoe) Standard Lengths ICP PHC Piles are available in lengths of 6m to 46m subject to certain limitations. Delivery Usually two to three weeks from date of confirmed order. ICP Standard Piles are normally available ex- stock for test driving. Technical Data Technical data of piles are given in the table on the next page. They refer to our standard products. Please note that the axial loads represent the structural capacities of the piles. Whether the driven piles can safely carry these loads depend on the soil conditions and the pile slenderness ratio. Appropriate reduction of axial loads should be applied for (a) marine structures, (b) piles subjected to bending, (c) high upstand, (d) piles driven through very poor top stratum, (e) raking piles, etc. Definitions ICP PHC Piles: High Performance Pretensioned Spun High Strength Concrete Piles MS : Malaysian Standard JIS : Japanese Standard BS : British Standard GENERAL SPECIFICATION FOR ICP PILES Delivery When the cube strength reaches the required strength the piles can be transported and installed. Curing Steam curing enables the piles to be demolded earlier. MS 1SO 9001:2008 REG. NO. AR0122 Unit 1-13-01, Menara IJM Land, No.1 Lebuh Tunku Kudin 3, 11700 Gelugor, Penang. Tel: 604-296 1399 Fax: 604-296 1398 Email: icppg@ijm.com August 2012 Wisma IJM Annexe, Jalan Yong Shook Lin, 46050 Petaling Jaya, Selangor Darul Ehsan, Malaysia. Tel: 603-7955 8888 Fax: 603-7958 1111 E-mail: icpsales@ijm.com Website: www.icpb.com Senai INDUSTRIAL CONCRETE PRODUCTS SDN BHD MS 1SO 9001 : 2008 REG. NO AR0122