Driven piles of ductile cast iron

Transcription

1 Ductile iron pipe systems for Pile foundations Quick, easy and safe! Driven piles of ductile cast iron Axial compression forces up to 1400 kn Piles are full-displacement Piles of a desired length up to 50 metres

2 Driven piles of ductile cast iron Safe and highly versatile foundation components The building industry needs simple and safe pre-formed driven pile systems which are suitable for a wide range of applications. The driven cast iron pile is driven into the ground to a desired length and transmits forces from the structure situated above it into the ground. The ductile pile is an economical and technically acceptable alternative to conventional methods of laying deep foundations. Carrying working loads of up to 1400 kn, the ductile pile is suitable for foundation work of almost any kind. Being economical while giving high productivity on sites which are simple to set up, this system is not only suitable for large-scale projects but can also be used at low cost on small to medium-sized building projects. The load is transmitted either by end-bearing pressure in the case of ungrouted end-bearing piles or by skin friction in the case of pressure-grouted piles. The advantages Sites are simple to set up because the equipment used is relatively light and easy to manoeuvre. Corrosion resistance is high compared with structural steel. Pile lengths can be adjusted reliably to changing soil conditions. The shaft bearing capacity can be checked while piles are being driven. Individual pile pipes are quickly connected by frictional connections on the site itself and no special tools or welding are needed. Installation with almost no transmitted vibration. Piles can be installed on gap sites. Minimum spacing of pile centreline from existing buildings is 40 cm. Extremely economical. Capital costs are low and productivity is high at running metres a day. No spoil from boring, no off-cuts and no re-machining of the heads of piles. Austria Factory enlargement in the centre of Salzburg Pressure-grouted driven piles of ductile cast iron up to 59 m in length transmit loads of 800 kn

3 Highly versatile, with the environment in mind Buildings Foundations for buildings on gap sites: the manoeuvrable equipment and short completion times are a big advantage on inner-city sites. The use of pile caps of the same width as the walls means considerable savings on foundation concrete. Industrial buildings Foundations for prefabricated buildings: loads can be carried safely by piles grouped to support small pocket foundations. Highly suitable for lightweight structures with their sensitivity to settlement and especially to differential settlement. Wind loads and loads from the supporting structure are transmitted safely into the ground. Spain Lebrija solar energy park. 14 hectares, 3.2 MW Bridge-building Foundations for bridge abutments: sites are quick and easy to change over for pile driving. Moments are transmitted by pile bents and horizontal forces by raking piles. Pile-supported pipelines Foundations for pipelines: can be used in sewer and water pipeline laying to prevent unacceptable settlement in soils of low bearing capacity. Software-assisted sizing of pile-supported pipe systems. Austria Poysdorf-Wilfersdorf wind park. 14 Vestus V90 wind turbines, 28 MW Slope stabilisation Stabilisation against slippage of slopes, embankments, ground prepared for ski runs, and so on. To provide stability, piles can be installed in vertical to near-horizontal positions to accompany construction work or as an urgent remedial measure. Silo foundations Foundations for silos, tower cranes, power line pylons and radio masts: foundations are stressed in compression and tension. Structures of considerable height subject to cyclic wind loads are founded on pile bents with additional tensile reinforcement. Trench shoring To create a retaining wall in the area of an adjacent existing building. The piles are held in the soil of good bearing capacity at a point below the floor of the trench and at the head end they are connected to an anchored belt of reinforced concrete. Uplift control Foundations for sedimentation tanks, road underpasses and construction trenches at depths within the range of variation of the water table. The concrete floor is safeguarded against floating up by additional tensile reinforcement set into the concrete. Strengthening of foundations Strengthening and underpinning of existing structures: inside industrial and other buildings where the working height is limited, old foundations are strengthened or new foundations are laid retrospectively to carry additional loads or for underpinning. Austria Grimming-Therme low energy building. 500 geothermal heat probes, 22,000 m 2 Italy Noise barriers for the Brenner railway line, barriers along a 4.5 km stretch of the line Austria Flood protection for the Leutascher Ache river, environmental upgrading of a section of the river

4 An approved pile system 5.0 metre long pile pipes The ductile cast iron pile pipes, with a tapering spigot end and a tapering socket, are assembled into a continuous pile of a desired length. Efficiently transportable and site logistics are simplified Easy to handle Pile lengths can be up to 50 metres Frictional socket joint The driving process and the high impact energy produce a rigid joint stiff in bending between the pile pipes. The individual pipes can be connected quickly on the site itself No special tools or welding work needed Flexible adjustment to the foundation ground: assurance of correct lengthening of the pile shaft The lengthening of the pile is performed quickly, safely and securely by means of a frictional tapered socket joint A full range of products The pile system includes all the accessories to form the heads and toes of piles, and anvils to suit any hydraulic hammer. Pile-supported pipelines: Pile-pipe saddles for DN 200 to DN 500 pipelines Drive shoes and drive tips for grouted and ungrouted piles Coupling sleeves for connecting shortened piles when headroom is limited Typ Wall thickness mm Mass kg/m Moment of inertia cm 4 Resisting moment cm , , European technical approval and CE marking Pile accessories to suit the nature of the load transmission and the foundation ground and supported structure Grouting and non-grouting anvils available for many different types of hammer

5 Economical to use Driving equipment used is compact Even when the space available is confined, the low weight of the pile pipes to be driven means that they can be driven with a light and manoeuvrable hydraulic digger using a hydraulic double-acting hammer. Sites are quick and easy to set up and change over Low capital investment costs Space required is small and driving platform requirements are modest Piles are full-displacement Each pile pipe is inserted in the tapered socket of the pipe driven previously and the pipe string is driven into the foundation ground to the final depth by displacing the soil. The projecting end is cut off precisely to the planned height. No drilling spoil is produced hence no disposal costs No re-machining of the pile heads No waste: the length cut off is re-used as an initial pile pipe No driving for redundant lengths: driving takes place in the already completed prior excavation No change in the groundwater balance Checking of shaft bearing capacity during driving Grouting takes place simultaneously with the installation of the pile Ungrouted and grouted piles Depending on the nature of the soil, ductile piles can be driven either ungrouted (end-bearing piles filled with concrete) or grouted (friction piles, sheathed and filled with mortar). Simultaneous pressure grouting A widened driving shoe creates a cavity around the entire circumference of a pile pipe as it is driven. As the driving progresses, a pump continuously grouts this cavity with mortar. Short installation times High productivity of 200 to 400 m a day Pile lengths are optimised by the compacting of the soil and the interengagement with it No re-grouting required An incision for concrete to escape through is made in the first pipe The projecting end is cut to the planned height and re-used as a starting section for the next pile

6 Proven over more than 3 million metres Check on base bearing capacity The pile pipes are available in two diameters, 118 mm and 170 mm, and in wall thicknesses from 7.5 mm to 10.6 mm. They are generally filled or grouted with concrete of strength class C20/25 or C25/30. Sized to Austrian Technical Regulation ONR Corrosion rate does not have to be considered for mortar-sheathed grouted piles Safety factor of 1.5 for the cast iron material Safety on the site The soil is displaced sideways and therefore no need for drilling spoil to be flushed out with high-pressure water or air. The manual work is confined to minor physical exertions which are not dangerous. Less risk of accidents Check on shaft bearing capacity Ductile piles are driven to the final depth, which is established from penetration resistance. The penetration resistance which is measured is used as a criterion for stopping the driving and for the bearing capacity of the ground strata which are entered. Pile length can be matched to the soil conditions actually encountered Shaft bearing capacity can be checked during driving Skin friction values of up to 150 kn/m 2 Correlation exists between driving times and permitted skin friction values Driving with little vibration Measurements made on sensitive sites have repeatedly shown that the installation process is an environmentally gentle one. The vibration levels measured were always only a fraction of the permitted levels. Piles can be driven with centrelines down to 40 cm from existing structures Type Wall thickness mm Pile Bearing capacity in kn (C20/25) (C25/30) ,212 1, ,352 1,391 Table 1: Maximum permitted base bearing capacity (kn) for pressure grouted piles, and for non-pressure-grouted piles up to corrosiveness level AS1 under Austrian standard B (no corrosion rate). Type Wall thickness mm Pile Bearing capacity in kn (C20/25) (C25/30) ,133 1, ,272 1,311 Table 2: Maximum permitted base bearing capacity (kn) for non-pressure-grouted piles corrosiveness level AS2 under Austrian standard B (corrosion rate of 1.5 mm at diameter for 100 years). Driving times s/m Compactness of ground DPH (N10) SPT (N30) Skin friction values kn/m 2 Pressed Very loose 0-2 < Loose (40) Medium density Dense >30 Very dense >30 > Table 4: Correlation between driving time, number of impacts in driving tests and associated skin friction values for non-cohesive soils (safety factor of 2.0 included). Driving times s/m Stiffness of ground DPH (N10) SPT (N30) Skin friction values kn/m 2 Pressed Mushy 0 Pressed Soft Soft to stiff (20) Stiff (40) Semi-firm >30 Firm >15 > Table 5: Correlation between driving time, number of impacts in driving tests and associated skin friction values for cohesive soils (safety factor of 2.0 included). Type Wall thickness mm Pile Bearing capacity in kn (C20/25) (C25/30) ,001 1, ,141 1,180 Table 3: Maximum permitted base bearing capacity (kn) for non-pressure-grouted piles corrosiveness level AS3 under Austrian standard B (corrosion rate of 4.0 mm at diameter for 100 years).

7 Made of a modern material Corrosion resistance The high carbon and silicon contents and the annealing skin produced by the production process give ductile cast iron (spheroidal graphite cast iron) greater corrosion resistance as compared with structural steel. Material is 100% recycled The metal charge for the smelting of the basic iron consists entirely of raw materials from the recycling industry, laminated transformer and other cores, carefully sorted steel scrap and other recycled material. High impact resistance The addition of magnesium to the molten iron shortly before it is centrifugally cast and the post-annealing process which follows endow the cast iron with its ductility and strength. Can be driven with powerful hydraulic hammers No risk of over-stressing during the driving Pipes are produced from recycled iron and are themselves fully recyclable Pile production from molten iron by the centrifugal casting process Industrial pre-forming As an accompaniment to production, continuous checks are made on quality to the relevant standards. The quality assurance process covers the chemical composition, the mechanical properties and the dimensions. Quality monitored to EN standards, ISO 9001 certification Large stock: even short delivery times are possible EN-GJS spheroidal graphite cast iron Compression strength 900 MPa Tensile strength 420 MPa 0.2% offset yield stress 300 MPa Modulus of elasticity 170,000 MPa Density 7,050 kg/m 3 The formation of spheroidal graphite confers high corrosion resistance and impact resistance Accompanying monitoring of the quality of each individual pipe

8 Your contacts GERMANY Manfred Schmied M +49 (0) manfred.schmied@duktus.com AUSTRIA & SWITZERLAND Thomas Aumüller M +43 (0) thomas.aumueller@duktus.com INTERNATIONALLY Jérôme Coulon M +43 (0) jerome.coulon@duktus.com Duktus S.A. Innsbrucker Straße Hall in Tirol Austria T +43 (0) /10 e DBH