oe {AL 08 /wWe-OlCy SUH cie-B /PROrEE /ceMOANN A008 CONSTRUCTION METHOD FOR BORE PILE WORKS CONSORTIUM OF INDONESIAN CONTRACTOR SURAMADU APPROACH BRIDGE PROJECT ADHI - HUTAMA — WASKITA - WIJAYATABLE OF CONTENTS a 1. Introduction 1 - Al ‘Resourves, a 1.1.1 List of Personnel ___ 2 LL2 List of Rquipment if 18 Site Layout 2 1.3 Pile Date. 8 $2. Cemtramntian Praggramm rere cert rere Here reer een eere erste 2.1 Descrtption 3 2.2 Production Capacity 8 &. Deseription of Work 3.1 Drilling Platform, 3 8.2 Drilling Procedure 4 3.8 — Reitforcement 5 3.4 — Conereting Procedure B 3.4.1 Concrete Placement, 6 342 Batching Plant and Materials Storage, 8 3.5 Test Pile 9 3.6.1 Osterberg Cell Test C) 3 4, Mik Desig u - — & guslity Assurance Plan UW 8.1 Pile Boring Opstation u 5.2 — Rebitoroement i 5.3 Coherete ja 6. Safety Plan, 1s % Document Cotttrol 1s1. Introduction ‘This document describes the construction procedure of the piling operation for the Suramadu Approach Bridges in Madura Strait. There are a total of 288 piles of 1.8 m diameter and 70 piles of 2.2 m diameter. The piling operation will be located in the sea with the depth of water varying from -3.04m to -17.4m. The highest water level is +1.5m while lowest water level is -0.99m. Permanent steel casings have already been installed at the correct location for each pile. A drilling platform, supported off the steel casings, will be installed at each pile group prior to drilling, The scope of work covered in this document consists of three main tasks namely the drilling of the piles, the fabrication and placing of the rebar cage and the concreting operation. The drilling method will be means of an auger. A positive head of seawater will be maintained in the casing to prevent collapse of the wall during Grilling. The rebar cage will be assembled in the storage yard at Marina Shipyard and transported to the site to be installed. The concrete will be supplied from a barge mounted batching plant. It will be pumped to a hopper and placed in the bored hole using a tremie. The batching plant will be re-supplied from the material storage at Marina Shipyard. Removal of waste material will be done by barge to designated areas. ‘This document will cover in detail the construction program, safety and all quality assurance measures including laboratory testing related to the piling operation. Test piles will be required at pile groups P45 and P43 on the Surabaya side and at P48 and P88 on the Madura side. The test piles at these locations will be a priority in the construction program and the test piling procedure will be covered in detail in this document, Refer to the flow chart below for the sequence of the tasks in the piling procedure. Construction Prepamiion SeciGurme, Esbica Install Working Platform Beet Diiling Machine ‘Gheckihe Diameter and Figure 1-1 Flow Chart for Bore Pile Work1.1 Resources 1.1.1 List of Personnel List of personnel involved in the piling operation. Wo Name Position 1 | Budi Jaya Iniana | Manager 2 | Hartono Supervisor 8 | [Made Denen Supervisor 1LL@ List of Equipment Refer to Appendix 2 for complete list of equipment involved in the piling operation. 1.2 Site Layout During the piling operation there will be a drilling rig equipment barge, a batching plant barge and a rebar cage supply barge located at each'pile group. At necessary times there will also be a materials re-supply barge required to transfer materials to the batching plant. The drilling rig and crane barge will normally be situated at ‘one end of the platform to allow access for the required equipment at the temporary ramp. To facilitate efficient operations the equipment location and anchorage must: ‘be carefully determined. Refer to Appendix 3 for layout drawings of the various equipment barges at the construction site. 1.3 Pile Data Conerete Grade = 050 Reinforcement Yield Strength = 390 MPa Reinforcement Diameter = As per shop drawings (Appendix 4). ‘able 1-1 List of Pile Casing Pier sv | 38 | 39 | 40 | 4i | 42 | 45 [ 4a | 45 Depthm) | 30 | 26 | go | 30 | 30 | sa | 32 | 33_| 30 Pier 48 | 49 | 50 | 51 | 52 | 83 | 54 | 5B | 86 DepthGm) | 38 | 87 | 37 | 37 | 34 | 3a | 33 | 33 | 35 Table 1-2 List of Pile Lengt 42 Pier 7 | 38 [ so [ 40 | 41 45 [44 | 48 Depihdmy | 61 | 71 | 69 | 80 | a9 | 93 | 86 | 90 | 80 Pier 48 {49 | so | 81 | 82 | 83 | 54 [55 | 56 Depih(m) | se [ se | 64 | 94 | 92 [a3 | vv | vy | 752. Construction Program 2.1 Description ‘The drilling platform installation will start at the pile groups that have been designated for test piles. The designated piles are P45 no.18, P48 no.18, P40 no. 6, P43 no.6, P81 no. 1 and PSS no.13, Four drilling rigs, two for 1.6m and two for 2.2m diameter piles will be used to expedite the piling operation. Drilling will resume at P45, P48, P43 and P40 then relocate to PS] and PSS to comply with the construction procedure in the detail design. Therefore drilling rig will be installed following drilling sequence. As the piling operation is completed on the Surabaya side it will move to the Madura side to complete operations in @ similar sequence to the Surabaya side. Refer to Appendix 4 for a complete program of piling operations. 2.2 Production Capacity Refer to Appendix 4 for production capacity tables. 3. Description of Work 8.1 Drilling Platform ‘* After one group of driving casing work completed, quality of driving shall be checked by quality checking engineer. If they are qualified, material for drilling platform will be transported by barge to construction site. * In order to stabilize pile casing position, bracing shall be installed between casings. WF250x125 steel beam is placed horizontally and fully welded. + For the supporting of the platform, 300x500x84.8kg/m UC is enough to support load from above. Triangle truss also construct as support. Beam is fully welded to steel casing with 10 mm welding thickness. All the surface supporting H bracket shall be horizontal. The welding joint shall be firm, The site technical personnel shall check carefully. The bracket top surface of main beam shall be at the same elevation. © 400x400x168kg/m UC steel beam will be used es main beam. Main beam will be Jaid above support and spotted welded. As for the non installed main beam and installed beam part, it will be welded and elongated in site. © To distribute actual load to main beam, 5 400x400x168k¢/m UC steel beam will be installed above main beam and behaved as distribution beam. As though main beam, distributed beam will be welded and elongated in site. © After distributed beam is installed, plate with 25 mm thickness shall be installed. Plate will cover the platform and piling hole. In the time that drilling ‘work shail be commence in a hole, plate and distribution beam which cover over a hole will be lifted and move to other place in platform. + During the construction, the waste or remnant can not be thrown to the sea. If some steel materials fall to the pile casing, it shall be reported to the shift head. Most endeavours will be made to salve and the records will be made.3.2. Drilling Procedure «© A materials barge is used to carry boring plant and other equipment to site. To mobilize the boring rig and equipment a removable ramp shall be installed to connect the materials barge and drilling platform. The removable ramp is placed in the front of the barge so that the barge is positioned perpendicular to the bridge's centreline (see Appendix 3). © The boring rig shall be accurately positioned within the required horizontal tolerance of maximum 7.5 cm in any direction. The position of the auger shall be accurate and must be approved by the engineer prior to drilling. © After the boring rig position has been approved it should be well secured in position. The boring rig should be stable and level. The boring operation may now be commenced, © Hill permanent casing with sea water up to a level of approximately 1.5m above ‘HWL (actual condition is +1.9m). The objective of filling the casing with water is to keep positive head to prevent the uncovered bore pile wall from collapsing. After filling with water start the drilling machine. Drilling auger type BG-25 and’ BG-80 shall be used for the drilling work (see Appendix-10 for detailed of drilling machine). The water level in the casing must be maintained at all times during the drilling operation. * During the boring operation the verticality and the diameter of the pile must be checked. According to Contract Document Volume II Section 7.8.6 (b), variations from the vertical shall not exceed 20 mm per meter. ‘The diameter of unlined ore shall be 0 to + 5% of the nominal diameter at any position. © After drilling machine is ready om the platform with the coordination of the crane, the sideline mark of the drilling machine chassis shall be made on the platform according to the pile location centre and the dimension of the drilling machine chassis. Before and during drilling, cheok the verticality of kelly bar. On the basis of the mark, the drilling machine shall be lifted and positioned by crane, and levelled and fixed. Lateral displacement of the head of pile from its specified position shall not exceed 75 mm in any direction. © Fora hole depth of more than 80 m, only the auger type BG-25 can be used. * Drilling should continue 50cm past the pile design level to leave space for cleaning of the hole. The cleaning of the hole will be carried out using an auger with slug drill. The auger shall scrape the hole until all loose and unused material is lifted out. When this is complete the drilling machine can be lifted. © The depth of the bored pile shall be carefully checked and approved by the engineer. ‘+ After the depth of the hole is confirmed the drilling machine is lifted out and the ‘reinforcement cage can be placed into the hole, The rebar operation is described in Section 8.2 of this document. + After completion of placing the reinforcement cage, a tremie and hole cleaning pipe shall be installed for a second cleaning of the hole. ‘+ The concreting operation as described in Section 8.3 can now commence.‘+ The waste material from the boring operation will be disposed of using a barge for this purpose, 3.3 Reinforcement ‘* ‘The reinforcement cage shall be assembled in a designated area at Marina Shipyard and then transported to the construction site by barge. © ‘The rebar details including splicing and fixing are shown in the attached shop drawings. + Concrete cover for the rebar cage shall be maintained using spacer concrete blocks, + The axial reinforcement shall protrude 40 x bar diameter past the pile cut off evel into the pile cap to ensure good interface between pile and pile cap. « Three 60mm diameter sonic test pipes will be installed in each cage for 1.8m diameter piles. The 2.2m diameter piles will have four sonic testing pipes of 60mm diameter. « For the rebar shop drawings see Appendix 1 3.4 Concreting Procedure ‘The concreting procedure as discussed in this document will consist of two main operations which will be discussed separately. * First is the main concreting operation consisting of the placement of the concrete in the bored pile by means of tremic, ‘+ Second is the preparation of matetials including the stockpiling, supply to the ‘atehing plant and the batching process located on a barge at the construction site. ‘© All concrete testing will be discussed separately in Section 8.2 of Quality Assurance. © ‘Test piles will follow a similar provedure as the main concreting operation but will be discussed separately and in more detail in Section 5.3Hole cleaning n of ‘Treme installati plant Teal nie [itopperinstallation Material delivery Dewatering Cut offpile Figure 8-1 Flowchart of conoreting &4,1 Concrete Placement © Concrete shall be placed by the underwater tremie method. The tremie pipe will have an inner diameter of S00 mm, The length of tremie segment is varying from 1 m up to 4 m, The length of the upper most section, which will have a funnel, will be 1 m. The tremie pipe segments will be coupled and be sealed with gaskets to ensure a watertight seal. The discharge end of the tremic will be fitted with a seal at the start of the concreting operation so not to allow any water into the tremie pipe. ‘The tremie should have clear height indication markings. © Once the tremie is in position the initial batch of concrete will be placed by hopper to ensure that the discharge end of the tremle is gealed in at least 1m of conerete. The maximum first bateh should be 9.82 m! for pile with 1.6 m diameter and 12.17 m° for pile with 2.2 m diameter to ensure a preferred embedment depth of 2 metres. ‘+ The placement of the first batch of conerete is done using a hopper and funnel as shown in figure 3-2, The hopper is used throughout the conoreting operation for continuity in case of uneven or interrupted pump supply from the batching plant. © Madura Strait can have high rainfall periods so weather conditions should be monitored on the day of conoreting so that measures cah be taken to cover the hopper in case of rain. © When placing underwater concrete the tremie shall never be embedded less than Im in the conerete and preferably be controlled between 2 ~ 6 m. This shall be controlled by measuring the level of conorete and comparing to the height of the tremfe. When the conorete surface depth is measured, it must be done at three points for every location to be measured, and the deepest value is taken.If no defects or abnormal conditions are found during the measuring of the tremie depth the placement should continue rapidly and continuously. At no time shall the tremie be removed from the sealing layer of concrete unless the operation is suspended or the pile is complete, During the pouring process, the ascending height of concrete surface shall be carefully monitored by means of a measuring phimb. The tremie shall be properly lifted and shortened by removing upper segments to maintain the required embedded depth. This process shall be recorded and documented to maintain the preferred embedment: depth of 2-6 m. ‘When the level of concrete is near the top of pile, the required final volume of ‘concrete must be carefully calculated in order to strictly control the elevation of top of pile. The concrete must be poured to at least 1m but preferably 1.8 m above design elevation to ensure good quality concrete after pile cutting. ‘To keep the forces continue from pile cap to pile, pile head must be cut. Cutting of a complete concrete surface should be 0.16 m higher than the top of designed pile. Top of steel casing shall be -0.99 or the same level with bottom of pile cap to prevent reinforcing bar from corrosion because of sea water. Cut the pile manually using chisel, hammer, ete, After pile head have been cut, let uncover reinforcing bar in thelr shape then assemble tt properly so when pile cap is poured, they have strong tight between pile’ cap concrete and pile reinforcing bar. Final pile elevation should be 150mm above the bottom elevation of the pile cap. Dewatering can begin when underwater conorete is sufficiently hard and strong as determined by the Engineer. Batching Plant Hopper ton? Cigar) Pannel > Conerte Pump FI Batching Berge Dailng Platform ‘Temi 300 mm, Figure 5-2 Sketch of concreting for bored pile3.4.2 Batehing Plant and Materials Storage ‘© The material stockpiles are situated at Marina Shipyard. These stockpiles will be used for the re-supply of the bange batching plant. * Cement will be stored in airtight bins off the ground and be protected from moisture. © Coarse aggregate and sand will be stockpiled to a suitable low height to avoid segregation. No material moving equipment will be permitted on top of stockpiles to avoid contamination and breaking up of the aggregate. Stockpiling ‘will be kept to a minimum reasonable amount. Aggregates of different sizes will ‘be separated by partitions to avoid mixing. Aggregates will also be protected from rain. © Coarse aggregates will be kept moist as required in Contract Document Volume 1 Section 7.1.5(6) a. Moisture in the aggregates will be carefully monitored and controlled prior to transporting to batehing plant. + Water will be supplied from Suci, Gresik and will be tested for suitability as desoribed in Contract Documents Volume II Section 7.1.2 (2). © Materials for resupply of the batching plant will be loaded onto a barge and transported to the batching plant as required. + A total of two floating batching plants will be used for the supply of conerete to the piling operations. ‘The batching plants have all the necessary equipment required for the mixing and pumping of conerete to the piling operation. Prior to any concrete placement the batching plants will be thoroughly checked to ensure that equipment is in good working order and safe for all operators. All equipment will be certified approved. All scales will be calibrated by qualified personnel and certified. ‘© The maximum capacity of one batching plant is 40m*/h. The batching plant will be operated at an approximate capacity of 50m°/h. One batch capacity is 1.8m°. The weighing system of the batching piant is an auto-controlled electronic balance system. = The concrete will be supplied to the concrete hopper at the operating platform conerete pump. The delivery capacity of pump is 40m°/h. + The batching plant materials capacity is as follows Cement = 54m$ Sand = 144m* Aggregate 5-10mm = 264m* Aggregate 10-20mm = 264m° Water = 20m" «For the piling operation the batching barge would need to be re-supplied every day for cement, sand and twice a day for water.3.5 Test Pile ‘+ The test piles will be located at the pile groups P40, P43 & P45 on the Surabaya side and P48, P51 & P55 on the Madura side. © The test piles will be drilled and concreted as per the procedures as described in Sections 3.1~3.3 and will be used as working piles on satisfactory completion of the test. + The purpose of the pile test is to determine the end bearing capacity and the skin friction capacity. © An Osterberg cell test will be carried out to determine the combined ultimate bearing capacity of the pile. ‘© The test shall be conducted by a qualified geotechnical engineer who has done this test several times previously. © The load test shall be done according to AASHTO D-1143 (Quick Test Method) © This test will be described in detail in Appendix 6 of this document. 5.1 Osterberg Cell Test a Introduction ‘© ‘The purpose of the pile test is to determine the end bearing capacity and the skin friction capacity to give a combined ultimate capacity for the pile. ‘= The Osterberg Cell method will be adopted for this test pile procedure. * To determine the combined ultimate capacity of the pile the O-cell is installed at a predetermined height above the toe of the pile, Hydraulic pipes are routed from the load cell along the inner side of the reinforcement cage and connected to a hydraulic pump with gauge. Telitale rods and dial indicators will indicate the cell top plate displacement and similarly the top of pile displacement. This will indicate the skin shear capacity. Linear vibrating wire displacement ‘transducers (WWD!) will indicate the movement of the bottom plate of the load cell indicating the end bearing capacity of the pile, © The ultimate combined capacity will be obtained by jacking the coll as specified and reoording the various gauge readings on computer. b. Preparation of the Osterberg Cell Test ‘The test pile shall be drilled as desoribed in Section 3.1 of this document. A positive head of water must be maintained to avoid wall collapse. The hole must be thoroughly cleaned after drilling. © Tho load cell top and bottom plates are welded to the reinforcement cage. The ‘ign pressure hydraulic feed and return lines can be attached to the inside of the reinforcement cage. « The two LVWDT (linear vibrating wire displacement transducer) can be connected to the bottom plate of the load cell at opposite sides. Two telltale rods can now be attached to the top of the load cell top plate. The telltale rods areencased in # larger pipe, protruding through the top opening and sealed with an O-ring. The complete system must be tested and the acouracy of the hydraulic pump and gauge must be within 5% of the applied load. The load cell must be celibrated to within 2% of the applied load. Calibration certificates must be supplied. ‘At the designated test pile, the Osterberg cell, hydraulic supply lines and the other attachments will be prepared and installed. The faces of the load cell plates should be greased. Two grouting lines should also be installed to grout the space between the load cell top and bottom plates. After the bored pile hole has been checked and accepted, concrete will be poured to the correct level to suit the position of the load cell. Then a layer of high strength quick setting grout must be deposited for the load cell to seat. While the grout is still wet the reinforcement cage will be installed to the correct depth. Now the conoreting of the remainder of the pile may proceed to the required elevation. For the test pile it is recommended to cast the concrete to near the top of casing elevation for ease of access to the top of concrete pile. Bight concrete specimens (cubes) will be taken for testing compressive strength. ‘Three of these shall be tested prior to commencement of the Osterberg cell test. ‘The standard slump and trial mix tests must also be conducted. A steel reference beam can now be attached to the adjacent casings. This beam smust be of adequate strength to not bend under self weight plus the weight of all measuring equipment attached to it. One end of the beam must be free sliding. During the Osterberg cell test no drilling activity will be allowed within a minimum radius of 18 m from the test point. ‘Test Procedure ‘The test shall be conducted by a qualified geotechnical engineer who has done this test several times previously. ‘The load test shall be done according to AASHTO D-1143 (Quick Test Method) ‘The dial gauge, digital gauge or linear vibrating wire displacement transducer (LVWDT), which can be used for recording the end bearing and shear movement, shall have 100 mm minimum travel and the accuracy of 0.1 mm. ‘Two telltale rods with digital dial gauges will read the movement of the top of the load cell while two more will read the movement of the top of the pile. This will indicate the upward movement of the pile as well as the amount of compression in the pile, The two LVWDT’s will record the movement of the bottom of the cell and will be an indication of the bottom pressure of the pile. ‘The test loading procedure will be as follows; ‘The total load to be applied will be 200% of the pile design load. The load increments will be 10 to 15% of the proposed design load. At each increment of the load the gauges must be read at 1, 2, 4 end 8 minute intervals after the load has stabilized. Continue the increments until continuous jacking is required 10to maintain the test load or until the specified capacity of the load cell is reached (whichever oocurs first). At this time stop jacking. Hold the load for 5 minutes and then release the load in 4 equal stages with a 8 minute interval between each decrement. * The following readings must be taken and recorded; + Read and record time, load and displacement at each load increment and at the time intervals specified above. When the maximum load has been applied and the jacking has stopped take readings and again at 2 ¥ and 5 minute intervals. Take readings at 2% and 6 minute intervals at each decrement of the load and agin after the total load has been released, © All readings must be recorded on a data logger and transferred to the supplied data sheets for distribution to the correct personnel for analysis. «After the test has been completed the load cell can be grouted, all materials and equipment are to be removed and the pile can be used as a working pile in the pile group. © After written confirmation from the engineer thet the pile test results are satisfactory, the piling operation may prooeed. 4, Mix Design Refer to Appendix: for detailed mix design 8. Quality Assurance Plan A pile record sheet must be kept for each pile. The sample sheet is attached in Appendix 6. 5.1 Pile Boring Operation © ‘The pile casings are already in position and the pile locations are fixed. The drilling rig must be aligned to each individual casing prior to drilling. The Grilling rig position must be accurately checked prior to drilling due to the small tolerances between casing and drilling diameter. ‘* Once the position has been confirmed the verticality of the Kelly bar must be checked and recorded. * The drilling depth must be confirmed to ensure that the design depth has been achieved. This data must also be recorded. * ‘The casing must be continuously checked to ensure that a positive head of water is maintained to prevent wall collapse. 5.2 Reinforcement ‘Reinforcement steel should be procured from an approved supplier, Material certificates confirming the quality of each batch ordered must be supplied. * Prior to constructing the rebar cage care must be taken to ensure that the rebar diameters, lengths and shapes comply with the shop drawings. uw© Where welding is required it must strictly adhere to the procedures noted in the shop drawings. Welding rods must comply with the applicable standards and be certified. «Welds must be examined as per the requirements stated in the drawings. © Splices must be positioned in accordance with the shop drawings and the splice lengths must be carefully checked. + Check that all reinforcement is securely fastened with the correct binding wire. ¢ Ensure that adequate concrete spacer blocks are installed. « Ensure that the rebar cage is adequately braced to avoid deformation during handling. « Ensure that the overall length of the rebar cage is correct as per the shop drawings for the relevant pile depth. ‘If cage is to be installed in segments ensure that adjacent segments fit together easily to minimize installation difficulties on site, 5.3 Concrete The concrete for the piling operation 1s mixed in the ratios stated in the mix design already submitted for approval. © All materials must conform to the specifications as set out in the Contract Document Volume I. The material suppliers must be approved and where applicable certification of quality must be supplied, All approval documents must be attached in Appendix 7 of this document. © A trial mix will be prepared as per the mix design. Trial mixes must meet the requirements stated in Tables 7.1.3.1) and () of the Contract Document Volume I. «The weighing system of the batching plant should be calibrated by authoritative department. The tolerance of raw material weight should comply with the following: ‘Name Gement | Coarse Agéregate | Sand | Water Admincture | Tolerance (%) 1 a @ 1 1 | ‘+ Aggregates will be carefully controlled to ensure that tempetatures are within acceptable limits and that moisture levels are acceptable for the mix design. ‘+ The mixing time of each batch must be carefully monitored. For a 1.6m batoh the mixing time should be approximately 2 minutes. However this figure must ‘be finalized at site according to prevailing conditions. © Samples of concrete must be taken after mixing and tested for slump and compressive strength. At least one slump test must be carried out for each batch of concrete placed. One compressive test must be carried out for every 60m® consisting of four identical specimens. These must be tested after 3, 7, 14 and 28 days respectively. 12Slump tests must be conducted in the presence of the engineer. Test cubes must ‘be transported to the laboratory for testing according to approved methods. + No concrete placement may take place at ambient temperatures of more than 30 degrees Celsius. © During the concreting operation the actual volume of concrete used must be compared to the expected volume to ascertain if there is any overrun or underrun of concrete. « All test results must be obtained using the formula given in the Contract Document Volume II - 7.1.6. and be carefully recorded in piling record sheets. 6. Safety Plan Refer to Appendix-9 for safety plan of bore pile works. 7. Document Control * During construction all document control procedures shail be strictly adhered to. ‘+ All documents pertaining to the quality control and testing of concrete as well as raw materials shall be sorted and stored in easily accessible, properly indexed files. © This should include but not be limited to all certificates to proceed with work and all completion of work certificates as well as variation orders and survey data, 13C&C Appendix - 1 Rebar Shop Drawingfeet .qwnoy unpssinse sais ao totes: 1st ens arn em cet a feb Br are boand wha Brin 2m spac sang ie le. NE cash ne connect mono is pss one rope eed 5A posrng Mek petted rove ech Mb on ae logged ong pe to (ay ie erection ol erent cop. 4: Legh for i = ATEN ATTTO eS TTR IFFT 105, Lint rab el ABCTERTEPT? 5. 3so eng eich oe bandh in brs 6 Perales pL, eb see MATERA TARE ed 7. is revo is epee fr PST~PE4 on APSE, Olin be race see a, 1, PI, 52 wise peop hickesses ae 3m CORSORTILM OF CHINESE CONTRACTORS DETAILED DESIGN FOR |NOONESIAN SURAUDU BRIDGE sion | cage | AST i" out 1, bre cz REIRFORCEMBNT DETAILS OF PILE (1) Bs Jie 004ELEVATION, = a io, = ots |.Al drains ore ine esep i of ede in 5 Params ob see MATERULS TALE EEE Maar bint ith nin brn 2 spc cage Ho cols wis 7. ving apt er ples aS oP, {he caonectrs of msn er, psans con be prose edule, Dain the broke are fer he ies of P48. 3.6 patieing Wek repented arund ech Ne ba, coe slggee ang {he ple to eosy he exection of redecemencoge. Length ol bor WL ol ABHOH/APT TO ba ea of bar NS: Leer TBO 54 ae teat pies, wich re bana wt sincere ain cath pe BOAT 128180 sya | Ca” | FE SEBS | FIM Tray ae are Lai LEB [Fete [ouwem [oan cossrricy or case comrucrons | yy QE BEEN FORT a concpear amis oF PE @MATERIALS TABLE (1) py. ofa) ame [Pe Sat Se > ns) = ee Oe whee ep ees Sey “ep opepeTe| fea ea peepee 7 [ea [wa [| Sea [ee | — ng OY 2 faa [3s [a [ast [ins | —oney —[ wore CCN 3 [ea] ans ie enie | ass pangs poole EE EE >| co foo ff ae [2 Li Foe eae fu [ea | ffs Ti af [ea] terse" | [adc [we [so const) = [oi] wan [ Ponte [aroe [o30 cone) etue Safe [ena [i] aie ra Se | rs |v [rs at 1 fos) ome [ws P| ag 7 | we [se | — ag [as [so] “5 —[a [west [er | — sony [aa i z sais [ainsi | —omag [arm | fee] sw | aa Feu alae | 3 16 se [sina bona] ae se fg a_i [i ao fe | asf a | wee [1 owior [s fso coat see 3 1 | Se so] samme fr | wae | se + 7 ‘se [rss [| sot} ang aa 1 * 2 [ae | 65 [a nse Paar | —siong sa : + 3 [x9 [ose] sie [re pagina eal t j . fom foo [nef so [i ®t a i fm fs fe 2 foo] sar [1 [amir [ie fsa contend} saat : 1 [anise 250 fo concatend| aunar Sef [nna [a fine [ony = 7 oe 1 [ews [amo | aso | ares a9) rears = [=| eoas0 ~_exsigy ome fe] 9 [we Pas | ens Pa Tes + aa oy | sae 3] so [95 [w| Siie [a fate al Ta wa a a al rao | fo fs fof fi se [in ae || asf ET 3 [om] wes Ti [ene [aah oso conctend) sense =[0 1 [site [aan fse conc) ate [oo esse prensa [0a] vam [ rf waer fae (faa) mas fe Pate | es | aap a i [as oats [a [ee [sem | aay [rma 2 | ao] ae T+] vas | zoe | ving es 2] se | —a8—[ 9 [ase | maa 1 —smy—S 3 [5] efor] wn” saan foasignentmat sw 3 [| se [as av gael ae ul | jo oJ fff a avn fo foe) [of PL si am | Son | soma [1 [mr | aa eso cncetn| ase 5 [asec [1 [ose] ar fo conrad gene i i Sele mae [1 oar | sae fee [wna [Pane me Bap Pea | TOE] ae HA CORSRTIIN OF cuTese co¥TRACTONS | noyett Se egg REINFORCEMENT OaTAILS oF ruLa cy) [ar LW | dave | ieee | ent “awnMATERIALS TABLE (2) 0-1 am ee ee ste MATERIALS TABLE (3), <9 wo HO Tm Te [| Sownlt — to wm | 09 EEE eee err Pee 7] ea [as [ane [wane | soap [at a [ea | ws fo | ams [wm | etapa 2 [ee | wo fie sist ras fetgsoa ceed ve], Tru] _Poomtes fades] Sie0 om] TE a mayen [oso a ass 6) Tee [wear [er] eu rie co Peete Toft co Fe ew i 5 fom [wa [1 | 30728 [158 eso concrete] sea ES Be] eof rete f(s | wee a [oa |~s0 fel esa pete eee tfee | eae [> [ese | onan | amg | mw 3 [ee | “36a [ane sig Pen i [em] as [of snes | ss | rig evgaa | [es] em fas | js] [tees | wes [| ase sna potoigs peal ae 2 | sae | faco|s [ns so 2[22| 25] | es0 | 0036 fant ale [as [serfs are Seg | TT Poesia ana | wee 3 feof wows [i [os [as al scaar 5 [om [mamas [1 [sis [iar Joso contend] samen [oo ams fr fear [sa ef ae mice [1 [ae | one 1 [es] ous pan 1 fer sie9 [| 750 [ier | — a 2 [48 [ae seo] S| see A + [aes [a [oa 3 | 25 | “as ‘an | emai rea eee ea aa re ari [ns fy a} ean Js |e fuse es] vs Paste go “tae fi] aah | ew eel 6 tu) | Seneca Sef Sams | [eee [air Je30 cones’) ees Sf owt [ete nil { Soe Loses [1 Dosis | oar fen [noes [Pao pimar pai + [ee [ sea [ | roe [sense | aap | te a ai [ise cain Ey | | [fe [es [a [fees | og aise [30 corte me Te im Pam som) ps ass a fee eet © [oo | mas [1 [amare [sie lesoconctei| 381 MATERWS SUMMARY OF PLES FOR APPROACH BRIDGE foe [ses [1 [ws [oem Sree eee 1 [em [te [a [nese [m0] pag ae 2 fea [ves [of ses [zs | weg | av ews | tat Sea} 208 [wr] vaso | ses Pott ed m8 es] 8 Je) 0 Tee | ae | ess = saya Tow [mai [7 [sae [ee foo cosctet) asn04 sing | a Se eof tent | [iar | oa ong [tne se rg |e [ase [eee] aa Fen paaf cs _| | fer] we fs ess |e ora | som i fam | ess p22] 8 fi or | ao pg lat cso cmerteon®l eons i [os [ans fae [| eat S Tor [sess [1 [86 | eas Joo coneettndy sd L | Vase iaesss | Tanase Fr Mes ae a sane a "ATCO covrte nce labs is 30 vderatr cone St _[Feitegeet ed [ass [60 Gone Ke consortia oF cmese cxrtcrens | mcr sutaveu omoge || MENPORCBNToetarts oF prey PE] | [ERB | a [ame —C&C Appendix — 2 ResourcesList of Equipment for Bore Pile Work No] Tem ‘Quantit Remarks [Piling Barge Antara Koh P38 Dimension : 4om(L) x 18m(B) x 3.2¢H) |Gross Tonnage : 739 ton }Nett Tonnage : 221 ton License No. : SR.2559C Vertical Pilling Leader Approx. 52m. | | Year Made : 1988 [Equipment on board 1. DENYO DCA 180 SPK Il Diesel Generator 2. DENYO DCA 60 SPI Diesel Generator. [3.15 nos of Winches, Max. 12t0n, Min. 3t0n 4. MILLER Big Blue 600XCC Diescl Engine Welder 5. DENYO CDI 500 EI Diesel Diese! Welder. [Diesel Hammer Delmag D-100-13, 2 |Ram weight 10ton [Country of Origin : German | |Steel Anchor Boat ABUT [Dimension : S28(L) x 16.38(8) x 6f(H) |Gross Tonnage : 42.4 ton 3 [Picense No. : 81957. Year Made : 1993 [Equipment on board - 7, 35GPM, 3000PSI REXROTH Hydraulic Power Pack. [2. 6.5ton Anchor Winch, Hydraulic Motor i ICrane Barge ASL7 sed 1990 Fully Deck Steel Work Barge lOffical No. : 384634 License No. : SR 1172Z [Class : GERMANISCHER LLYOD. |Equipment on board : FMC 238-A 102t0n Pedestal Boom Crane . Single Line Pull Twin Drum Anchor Mooring Winch 22 dram '35GPM REXROTH Pump Diesel Hydraulic Power Pack NISSAN NES 9OSHE Silent Type Diesel Generator DENYO DCA 36 KVA 3 PH Silent Type Diesel Generator ‘MILLER Big Blue 6020 Diesel Engine Welder SEP EERE /- MILLER Big Blue 600XCC Diesel Engine Welder jw) -|-[-]-Jo]— [Material barge : Antasena IT [License No : PK.674/03/KPL-BTM-05 . |Cindonesia Flag) lo/w : Fixed Ramp and Winches 2 drums winch 5 [3 drums winch [Equipment on board 1. Bauer rotary drilling rig BG30 SENNEBOGEN BS90 o/w trimie pipe, kelly bar & accessories: [2 THit DCH800 S0ton lifting capacity hydraulic crawler crane clw 120f boom main & aux. hook. 3. MiLLer Model : Big Blue 600XCC Diesel Engine Welder [4 YANMAR Tower Light 2x400W laja lollC&C Appendix — 3 Site Layouti © E z 6 8 o 6 6 6 o jooo joao oe © @ ® © oO lo ® @ 410 © © ape es aye oe ooo ae Ho Shane © © DAarwom |}{O © Qaase oO Qnnal #19 DO Qarwome loog loog oe gf oo & lo o @ LHe © © LH© © o LZ © O © © HO _© © one a f em ® ® on Madura, ie aor serve He O00 8 io Oo 6 oo 6 oo Oo 0000 eo 8 @ eo oO 1© © oO O0000 lo e@ a ie yee G1 © Qarsree) #1 © Bornom |4C © Qannew OO OO Renan lo o A lo og oo oo00”g HO © | © © © 2 © 9 CoCO000 DO ODO) Mreenmasqintensnonieae gantapartenmnseoe (CONSORTIUM OF INDONESIAN CONTRACTORS SURANADU BRIDGE, NOONESIA PLELAYOUT + | emma aeot @ m ‘eg @ ? iain Sy” vy 00086 fe sa : CoOo0o0°0 ooG joo G eo 6 lao od lo oo jo e oO oo0o00°0 loo a lo oo lo © a wm 00° Boo ep off oo offf joo 00° i> © o lb © oO lb © oO oo0o0°0 © 9 ©.o ge jo © oO Qoo000 Gf Surabaya @) ee ®) on jee @ Masa, t i ©" sal part f © o 64] fos oo 4 (ome 5 6 eo © a ood lo oo lo oo e200 oo oy ey ooo oot Oo OR, semad® © FF pesasmd® © OF) snow © S/F) samsua® © OF emenf © © lb Oo O 9 O@ wm © 9 i> © oO » © O lo © @ ooo loo e lo og lo © Gh cossorTeor neces cOMBATORS supancy nose omen uvowreoeriewomasce =] | SE et seatCBC Appendix -— 4 Construction ProgramBe | BORED PILE SCHEDULE (DRAFT) 5, ane ora [Sa] = Rs Le aT |e See FT ae RT aT a SS ee arog eRe Cua e eee Hee oe el me Casing L=30 m at Stockyard OG Odays| Wed Jul 12,06 Wed sul 12,06] M2 TEE i t ce cantnneme tox| Eke] merce : cuaecms $2 Sate] mane nib 7 oa toon E ‘Odays| ‘Sal hun 17,06 pate cae oestts fe ‘aon vector reaet et Tae ne re oe calvaoes a oe tapas ay increas Tecate oa Tan] eaaniee| saree Seer iat ES) Raa Dativery to CICS Stockyard ‘Cdays| Mon bl Ti, 06] Sol t22, 06 ovata fam| enices| starry aoe $25| Mitine| teat Fate on Say) CRUE] Tonos tee na mm ee] cuniee| anes Facene stoop seen wena ei sa Roane Dey 0 Sass B_] ces Watog eae 7 m bina PAK Ba] _P4adn, wo z Faas ABT - Ed B ‘ics Wie cat Fin] DaiogPADoyAK sito 2.06 HT]__ PHA, sree 0h 2.05 =| Farina AAS CO Fant Fen 8 ANS.) ane Soahees et 1,08 re GCS Sad eng 06) 2223 a Oe Weng rca wig et Toomgz2 06) 3 7 eg Sy AK wean. S| Pete ites) S82 | __ Fikesinnans | semg27 Dairy 6 OC Sayed is Weg racket e ‘Ding PB by AK BH] Pe a=30m, 1800s) 3 Faieaion a ALIS Siiginess Detvey CIs Sechyard Dakar to Cs Sayre (Cs Won Saket Ding by AK P49 (atm, tence) aeaion nS Sratiness Doivey CIC Sted lcs Weng Brkt 7BORED PILE SCHEDULE (DRAFT) Detey'o CC Satyr iC Wake Braet hing PD by AK Bday} _Teelov'4, 1 toaays| Tho Nov0. 6] ‘ator 90,05 Fae 105 samie2 6] en Do, Tuo tor 2,03 Sato. jan "| Mebiaion ASL [05] Nebo ol rasa Seago) “ini Frame eC Tet Teno. 18 ‘vation a OC is Ora Rap) Frat fepen SF rue rest scence For mens Pio For Dring ace Supp Pst Irtatfon of UC ba econ) Irtton of UC AAD e003) nnd Plat ten Oilegea. 8 bar Faso eye) {ets te OC Tet borin & 0.18 Goreng 00,18 Int Man Fane OC Tet ‘OC Tet wo. 18 Exdaton OC test (rt Repo) Fat Rope Ye [PLE TEST SCHEDULE FOR PETS FEL] Pleorm Fe ting [tas 6 Gre) Zee | Meng 1608 ear] FAA 8, 05 ay] Mon Sen4, 0 in Sep 8 5 Bie] FaSepe | 2éay3|_ Non Ser 1,05 ap Non sep 1,5) Todaye| Fc Aug 10 ridge) Fang to TOT} ” Cea Gerace ot ASL “Sa 16, 06] Tl 8 08 [705] Orton Cece of Atte t ots, 06] Fitz, FOI] Phsorm For Ding “he-20,06| Aug, 10 Seal Spat i Tui, 05) Wet Aig | i staan Ue eee ston) Smpin6. 3 [Fa] hese of UC tO cn 1 itt Zin i gn. 18 Two han 25 TiS | Rear Facies FIG] "Ca baton or 00 est TF nae AGE pas wien are Ree ae ae a oe EE a a Se, aoe | Somes cot Supp Paton Tens] Fuaog 8-06] | Thu Ag 24,0 Z i E : staon ef UC ae ean) dna] Teng 7-06] FSep 1,08 staan UC AD felon 2} Gon] SatS292. 05) Thu S97, 05 fier i 7 al Plate 250 Séap| Thusep7, 06] Sat Sen9, 00 Ba f eEddd EEEERD | tinge oe] Tuesops2 6] FiSeptssee) PP TET i Ete i 7 L si ed ae Es ee Powe + may EY aes AY ones TaeBORED PILE SCHEDULE (DRAFT) tafe For ring Fase 2, 06 “Baka Saper Inlalaton of UC at an ILE TEST SCHEDULE FOR PERS Retr eaten & cal ro 13 Cong 0,12 etl sa Fane OC Fes cesta. 13 Evasion fr OC test rt op) Frat Rept Pane Fac Bing race Sopot Po elation of C4000 acon) _| = = ae eas ee PLE = a aT RT aa oa ines gee Seay Moan eee ee ae ea eee ea Fada abrcton aca) Taya! ASLO SET * > mie nnn? 5 y sale t fatale Coin ocr Yel mooie] ese ; fe Biles mei ei mowecnteirns ‘Z| sien) soos : coment 12) SSne| Sew cen sab] aneeiw|_ wos we olaee —| Jinan ects i ‘Evauation for OC test (Oraft Repo) ‘2oays| Thu Oct 19, 06 Fri Oct 20, 06) teh s ataon ee| twoue| men] : Beh racteneoceronnera | —Tsnp|tovana |" Ss opp eae ceppee lation For Oxilig ‘Mdeys| Sontag 27,06] Mon Sep 25, 05) - acer gS a veel Sagal "sieere : : Insaiaion of UC 400x400 (section 4) Hag FiSep 6,06] "Mon Sep 11, 05) it 4 +s i amecvconeneaea | tar) teapteul snoo EEE) CNEEE) : inal Pte 250 |, Sdn] son 7- 06] Te Sep 8,03 3 ! 7 : Dailing 90.6 ‘days Fe Sep22, 06 | Mon Sep 28.06 | 4 4 secre tax] sete] mops CUES Se CS ns | cause 2s], soeprie| nope : EPEEEeS | minnooetarnb %| seat] wees eeeeeae i i Sr Conger a] Teapae| teooa CE BE EEEEEES TBC saturate son] aneeae| ‘mesa eee: : Em] Sime ierte| Sore ESEEE SEs | Sacer oceosteant tn BEEP EEE i Ter fad Repot Sun ov 79, [pase stoma rote feent : ae m3 L BBC] sana Fame boc Tet 2 Fo cts TE] Fraaton er OC et rt Re) | FratRept ‘ar [pore Pte Tue we 4'7 [a] pest som Sama. 07 | _—_ ing 0) tweFes71, 17 [aa] Petar Fan? cu eg (4 Sar BE] P7307) wearovtar mi Dating re Sao, 07 BE] Retort (es TueFe 1,07 BE Gere G48) wed Fab 14.07 Lar | rien ae Sunda 97 {| 88] Siting 1700) Teen, 07 [a8] Return 0) Sasa FO} Geen (7 8 7 Sing RO ewceeere Tou 207 [aa ! patra i) Seon 2,07 [as far wsaaton (1808) Meosin 22.07 [a corres 8 00) Tuodand 07 Te] nse) ria] Won sses | on zs, 7 3 Balog (1 ee) Séaje| Mendis ot Fale. oer 7a om saBORED PILE SCHEDULE (DRAFT) a eats oe Fa DE — Ramet “ein Rl Cae BE ter a = : 5 Fatih abslties iin a ial or aneee anata Sates aia eet | Ra TT Saag) Worn, | SANE] a fel sh 536 Conceating {17 nos) Bdays| Thu Jen 18,07] Mon Mar 26,07 | a Ppp r ys Y TH] steerer dam] Wedann2G-t| TheAgr,7 rg (800) ear] Won OT] Snare. Or abr tls (620 Teon|_Sauan27 7 Genser Boe Wseae| Eon Fr 6im-sen) eon ba (ee Sia 1.07 TERT} a) aches, a wy 10 (ay Paoteream Sunder, ba) arte Scop) Wotan 7.07 T. i “0 sao 11.07 To Ae 25,07 a} Farebi6 Ur) Saiageastr a Teepe) Satreo 7.07] Sinage23. cr ta ses aaye| WedFeb 2t 07] Wed un 1,7 tay Zidops| WiotFeb 2,07) Sun Mor 25,07 | tse | Tanrz.01| — Sataa 3.07 [2 Weape| Faery] Ton 12.07 om Tecoye| Seid, 07| Won 13,07)” 2 Fad, 07 a wy 3 Poocramstm) ae Patoen — adne| iho May 7,07 en 607 Teal 97 Cag Teeqe| Woe stv stn sy “TRews| Fam. 07 Gereresig (8s) Sali 6,07 PEI arg fos) Peal else ela falafel alee aaah Se 3 aa Bes Reap) Tedd 7,07 Tears) Teds, 07 Teap|_FAaex, Salts. Fads, 07 sim0a7,12| especial ing? Ppersltoceceenteomenmmmmneetets i! bie eens iar uo Dec 47 fbb: fo guinea etemeagy 2! fe tep 8-07]! i gbbep bh Meee cee ne reas] Imseprsw/| Sac o7 i 5 rége| Stsepis 7] sentees7 : CPE? i Pda] Sa Sep 16.07 = ieee : Pe uu raraane Te =a oe = pow wane ee ee rr Snr = : ;1 Equioment list 1 Auger Machine 2 Crane Borge 3 Material Barge _ 4 Driling Plant 2 Cycle Time OF Driling 1 Setting Position of Barge 2 Setting Drilling Plant in Platform 3 Settling Drilling Machine 4 Diiling, depth 93m 5 Ist Hole Cleaning 6Placingrebor = 93m 7 Jointing 8 2nd Hole Cleaning Total cycle fime per | ple 120.00 70.00 30.00 2790.00 70.00 228,20 120.00 90.00 minuie minute minute minute minute minute minute 3613.20 minuie 60.22 hours1 Equioment list Diesel hammer Piling Barge Service Crane Tug Boat 2. Cycle Time Of Piing Production Capacity of Steel Casing Driving Setting Position of Barge = 30.00 , minute Unload casing steel to Piling Barge = 10.00 minute Toke a steel casing onto the top of dieselhammer = 10.00 minute Setting Position of piling = 45,00 minute Driving Casing Assume: 25 blow per 30 cm > capacity of diesel hammer while working at the SPT 20-30 3 Casing Production per day ( 8 hours working time) 0.83 blow/em 83.33 blow/m 125.00 sec/m 2500.00 sec for: 20 meters iength or 42.00 _minute for 20 meters length 137.00 - minute 228 hours Total cycle time per | pile wo 8 4 pile per dayPro ion Capacity of Concret 1 Equipment list 1 Batching Barge= 30 m3/h 2 Crawler Crane 1001 3 Tremie Pipe 4 Concrete Pump= 30 m3/h 2 Cycle Time Of Conereting 1 Setting Position of Barge 2 Seiting tremie pipe and hopper 3 Setting position for concreting 4 Concreting Volume: Bore Pile ¢ 1.8m = 299.98 m3 Total cycle time per | ple ¢18m Bore Pile @ 2.2m = 410.33 m3 Total cycle time per! pile 618m 120.00 minute 60.00 minute 60.00 minute 599.97 _minute 839.97 minute 14.00 hours 820.66 __minute. 1060.66 minute 17.68. hoursit Hw yw Hw ae H Volume of First Batch of Bore Pile J» mg v22 2 nen oH 4 4 —— 7D Pile L a D Hi He Ew yw ye. bl Vv (m) (m) Gm) (my (mm) (@) @/ms) | @/ms) (m)_|_@3) 37 61.00 0.80 1.86. 0.40 2.00 62.10 1.03 2.40 26.52 8.33 38 71.00 0.30 1.88 0.40 2.00 72.10 1.03, 2.40 30.79 8.63, 3 69.00 0.30. 1.85 0.40 2.00 70.10 1.08 2.40 29.94 8.57 40 80.00 0.50. 1.85 0.40 2.00 81.10 1.03 2.40 34.64 8.90 41 89.00 0.80 1,86 0.40 8.00 90.10 1,08 2.40 38.48 9.17 42 | 93,00 0.80. 1.85 0.40 8.00 94.10, 1.08 2.40 40.19 9.29 43 86.00 0.30 1.86 0.40 2.00 87.10. 1.08 8.40 87.20 9.08 44 90,00, 0.30 186 [0.40 2.00 91.10 1.03. 2.40 38.91 9.20 46 80.00, 0.30 B25 0.40 8.00 81.10 1,03 2.40 34.64 11.99 48 | 86,00 0.30 B26 0.40 8.00 87.10 1,03 2.40 37.20 12.17 49 86,00. 0,30 1,85 0.40 2.00 87.10 1.03 2.40 87.20 9.08 50 84.00 0.30 1.85 0.40 2.00 86.10 1.08 B40 36.54 9.02 BL 94.00 0.30 1,88 0.40 2.00 96.10 1.03 8.40 40.62 9.32 5a 92.00, 0.30 1.88 0.40 8,00 93.10 1,08 8.40 39.76 9.26 83, 83,00 0.30 1.88. 0.40 2.00 | 84.10 1.03 a 35.92 8.99 84 | 77.00 0.30 1.88. 0.40 8.00. 78.10 1.03 240 | 33.56 8.81 55 77.00 | 0.30 1.85. 0.40 8,00 | , 78.10 1,03 8.40 33.38 8.81 86 73.00 0,30 1.85 0.40 2.00 74.10 1.03. 2.40 31.65 8.69CAC Appendix — 5 Osterberg Cell testSuramadu Approach Bridge, Indonesia Load Cell Test of Piles TEST SCHEME College of Civil Engineering, Southeast University Jul. 24, 2006 , Nanjing , P.R.ChinaLoad cell test scheme of Suramadu Approach Bridge Piles Project in Indonesia Contents I Introduction... 2 Load Cell method.. 3 Test instruments... 4 Test procedures, loading/unloading grade and the corresponding standard ....... 5 Contents of the test report .......cs+0ee 6 Owner and Main Contractor Assistances.... 7 Tillie Schedule... 8 Members of the test group and their assignmients...... 9 Detail Drawing of test piles.. 10 Grouting ... : 11 Détail drawing of loail cell. aan! 12 Detail drawing of load cell conitection.. eee 23 Collegeof chil engineering at Southeast Universly —0086-25-83791829 0861380155830 Email: scugongm@isina.com Web: Hupiwaewddrph comLoad cell test scheme of Suramadu Approach Bridge Piles Project in Indonesia Load Cell Test Scheme of Suramadu Approach Bridge 1 Introduction 1.1 Site Description ‘The Suramadu Bridge is located across the Madura Strait connecting Surabaya City dan Madura Island. The bridge’s entrance at the Surabaya side is located in ‘Tambak Wedi, Kedung Cowek and the other end at the Madura side is in Labang, Bangkalan, It is 5,438,0 meters of total length, The main span is $18.0 meters in length, and approach span of each side is 1,344 meters in length. The length of approach span near the shoal is about 3,276 meters, and there is a connection about 18.5 kilometers long beside the approach viaduct. 1.2 Test Objective (1) Determine the total bearing capacity and test some parameters such as pile base resistance and side frictional resistance of each section of bored pile in the approach bridge, The load cell method is used for the test piles. (2) Obtain the load-deformation curve when loading and unloading (3) Verify related data in the geotechnical report by the tested base resistance and side frictional resistance of each section. Determine the ultimate bearing capacity of single pile , which provides important parameters for verifying’ and guiding the design of large diameter drilled bored pile. (4) Provide important parameters for selection of proper construction machinery and construction technology for drilled bored pile by test and monographic study on construction technologies such as mud gradation, gradation of underwater concrete, pore-forming, pile-forming and grouting. 1.3 Requirements for test piles According to related requirements and geological information of the test pile (the BH43, BH45, BH48, BH55, BH40 and BHS1 borehole), the specific requirements are shown as below: (1) Six test piles are selected, which also can be used as engineering piles; (2) The total bearing capacity will be determined, as well as the frictional resistances of the main soil layers and the end resistances, 3) The geological parameters can be obtained from the geological report (not extracted repeatedly). Main parameters are listed in Table 1 Calloge of coil engineering t Southeast University 0086-25-83791829 0086-13801598300 2 E-mails seu a.com Web: Hlupiwwwdézph.comLoad cell test scheme of Suramadu Approach Bridge Piles Project in Indonesia Table |__ Main Parameters of test piles “ Level - i Pile Estimated ‘Test Pile of Pile | Pile Reference | Level of li Pie |Re* | Diameter | Top | no. |“ | poretole | toadeen | “eding Value v No. «ma | Gm (m) Upper 360 | 2X 4emm0 6 43 SZA | P43 1s 0.990 86.0 He Lower 83.0 2x Upper 50.0 [2x amND ‘SZB | P45 22 0.990 | 18 80.0 45 — 7 Lower -77.0 2x snp Upper-33.5| 2x anim ‘Pas 22 0.990 | 18 86.0 48 aa Lower-#3.0| 23> dD Upper -47.0 2x nD n: 55 ‘SZD | P55 1s 0,990 | 13 o Hi Lower 740 2x Upper -51.0 2x temp : 990] 6 | 00 | HA0 S2E | PAO 18 ce Lower -77.0 2x7xD Upper -60.0 2x aan0D 8 [0990] 13] 940 ) HSL SZF | PSL ' Lower -910 | 2x 7D 2 Load cell method ‘The load cell test method was first put forward in 80's by J.Osterberg. Basing on : theoretical research, Southeast University began to proceed research on it in 1996, and it has been applied in more than 300 projects including over 1000 piles .The largest bearing capacity of pile tested is up to 130000KN, the largest diameter is 2.8 meters, 7 and the largest length has reached 130 meters. data ee cetbieceaoms neater oe -reference beam system ee ¢ il pipe a stelteltale rods oor telltale casings Joad elt ‘College af chil engineoring Email, seusoogwm@sina com 1 Sketch of load cell test method "0086-25-83791829 _O086-13801S98300 3 Webs. Hitpifwaw.dzph comLoad cell test scheme of Suramadu Approach Bridge Piles Project in Indonesia For the proposed testing Southeast University will provide load cells and instruments, provide on site assistance during installation, carry out testing, interpret the test results and deliver the report. Load cells are made in PRChina, which are strictly calibrated when leave factory .The principle of the load cell method is shown in the figure 1 3 Test instruments 3.1 Instruments The maximum pile end bearing capacity and the maximum frictional resistance of pile shaft are tested respectively by two load cells embedded in different depth. The frictional resistance of the main soil layers is tested by the embedded grating sensors. 3.1.1 Loading instruments ‘Two ring load cells are embedded in each test pile (as shown in Fig. 2). The loading rate curve is calibrated by Measure Authority. Parameters of load cells are listed in Table 2. The location of the load cells and the calculated bearing capecity of each segment of the pile are shown in Fig, 4 High pressure hydraulic oil pump: The maximum pressure is 6OMPa , pressure scale precision is 0.4MPa/ graduation, calibrated by Measure Authority Fig.3 Electronic Displacement Transducer Taliogs oS carening w Sotheant Univeniy “COR DSATOTADD — WOB6-1380159R300 4 E-mail, ssussngwm@sins com WebrHip/aenaeph oom