Driven piles of ductile cast iron
Ductile iron pipe systems for
Pile foundations
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 200-400 running metres a day. • No spoil from boring, no off-cuts and no re-machining of the heads of piles.
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 •
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
Driven piles of ductile cast iron
Ductile iron pipe systems for
Pile foundations
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 200-400 running metres a day. • No spoil from boring, no off-cuts and no re-machining of the heads of piles.
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 •
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
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.
Your contacts GERMANY
AUSTRIA & SWITZERLAND
INTERNATIONALLY
Manfred Schmied
Thomas Aumüller
Jérôme Coulon
M +49 (0) 171 30 58 547
M +43 (0) 664 44 30 723
M +43 (0) 664 85 64 195
[email protected]
[email protected]
[email protected]
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.
Austria – Grimming-Therme low energy building. 500 geothermal heat probes, 22,000 m2
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. Italy – Noise barriers for the Brenner railway line, barriers along a 4.5 km stretch of the line
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.
Duktus S.A. Innsbrucker Straße 51 6060 Hall in Tirol Austria T +43 (0) 5223 503-215 www.duktus.com Austria – Flood protection for the Leutascher Ache river, environmental upgrading of a section of the river
© • 006 • 02/10 • e 2 500 • DBH
An approved pile system
Economical to use
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.
Frictional socket joint The driving process and the high impact energy produce a rigid joint stiff in bending between the pile pipes.
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.
• Efficiently transportable and site logistics are simplified • Easy to handle • Pile lengths can be up to 50 metres
• 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
• 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
Checking of shaft bearing capacity during driving
Typ
Wall thickness mm
Mass kg/m
118
7.5
21.0
Moment of inertia cm 4
399
Resisting moment cm 3
68
118
9.0
24.4
461
78
118
10.6
28.0
521
88
170
9.0
37.2
1,480
174
170
10.6
42.6
1,693
199
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).
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
Grouting takes place simultaneously with the installation of the pile
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
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
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
An approved pile system
Economical to use
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.
Frictional socket joint The driving process and the high impact energy produce a rigid joint stiff in bending between the pile pipes.
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.
• Efficiently transportable and site logistics are simplified • Easy to handle • Pile lengths can be up to 50 metres
• 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
• 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
Checking of shaft bearing capacity during driving
Typ
Wall thickness mm
Mass kg/m
118
7.5
21.0
Moment of inertia cm 4
399
Resisting moment cm 3
68
118
9.0
24.4
461
78
118
10.6
28.0
521
88
170
9.0
37.2
1,480
174
170
10.6
42.6
1,693
199
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).
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
Grouting takes place simultaneously with the installation of the pile
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
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
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
Proven over more than 3 million metres
Made of a modern material
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.
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.
• Sized to Austrian Technical Regulation ONR 22567 • 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.
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/m2 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.
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
• Less risk of accidents • Piles can be driven with centrelines down to 40 cm from existing structures
Type
Wall thickness mm
Bearing capacity in kN Pile
Pile + concrete (C20/25)
Pile + concrete (C25/30)
Driving times s/m
Compactness of ground
DPH (N10)
SPT (N30)
Skin friction values kN/m2
118
7.5
521
660
678
Pressed
Very loose
0-2
30
Very dense
>30
>50
150
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 5013-1 (no corrosion rate).
Type
118
Wall thickness mm
7.5
Bearing capacity in kN Pile
Pile + concrete (C20/25)
465
604
Pile + concrete (C25/30)
622
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
Pressed
Stiffness of ground
Mushy
DPH (N10)
–
Pressed
Soft
0-1
SPT (N30)
–
Skin friction values kN/m2
0
0-2
0
118
9.0
561
692
709
5-10
Soft to stiff
2-5
3-8
(20)
118
10.6
660
782
799
10-15
Stiff
5-7
8-15
(40)
170
9.0
831
1,133
1,174
15-30
Semi-firm
8-15
16-30
70
170
10.6
982
1,272
1,311
>30
Firm
>15
>30
100
Table 2: Maximum permitted base bearing capacity (kN) for non-pressure-grouted piles – corrosiveness level AS2 under Austrian standard B 5013-1 (corrosion rate of 1.5 mm at diameter for 100 years).
Type
Pipes are produced from recycled iron and are themselves fully recyclable
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
Pile production from molten iron by the centrifugal casting process
EN-GJS-400-10 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
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).
Bearing capacity in kN
Wall thickness mm
Pile
Pile + concrete (C20/25)
Pile + concrete (C25/30)
118
7.5
375
514
118
9.0
471
602
532 619
118
10.6
570
692
709
170
9.0
699
1,001
1,042
170
10.6
851
1,141
1,180
Table 3: Maximum permitted base bearing capacity (kN) for non-pressure-grouted piles – corrosiveness level AS3 under Austrian standard B 5013-1 (corrosion rate of 4.0 mm at diameter for 100 years).
The formation of spheroidal graphite confers high corrosion resistance and impact resistance
Accompanying monitoring of the quality of each individual pipe
Proven over more than 3 million metres
Made of a modern material
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.
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.
• Sized to Austrian Technical Regulation ONR 22567 • 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.
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/m2 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.
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
• Less risk of accidents • Piles can be driven with centrelines down to 40 cm from existing structures
Type
Wall thickness mm
Bearing capacity in kN Pile
Pile + concrete (C20/25)
Pile + concrete (C25/30)
Driving times s/m
Compactness of ground
DPH (N10)
SPT (N30)
Skin friction values kN/m2
118
7.5
521
660
678
Pressed
Very loose
0-2
30
Very dense
>30
>50
150
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 5013-1 (no corrosion rate).
Type
118
Wall thickness mm
7.5
Bearing capacity in kN Pile
Pile + concrete (C20/25)
465
604
Pile + concrete (C25/30)
622
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
Pressed
Stiffness of ground
Mushy
DPH (N10)
–
Pressed
Soft
0-1
SPT (N30)
–
Skin friction values kN/m2
0
0-2
0
118
9.0
561
692
709
5-10
Soft to stiff
2-5
3-8
(20)
118
10.6
660
782
799
10-15
Stiff
5-7
8-15
(40)
170
9.0
831
1,133
1,174
15-30
Semi-firm
8-15
16-30
70
170
10.6
982
1,272
1,311
>30
Firm
>15
>30
100
Table 2: Maximum permitted base bearing capacity (kN) for non-pressure-grouted piles – corrosiveness level AS2 under Austrian standard B 5013-1 (corrosion rate of 1.5 mm at diameter for 100 years).
Type
Pipes are produced from recycled iron and are themselves fully recyclable
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
Pile production from molten iron by the centrifugal casting process
EN-GJS-400-10 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
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).
Bearing capacity in kN
Wall thickness mm
Pile
Pile + concrete (C20/25)
Pile + concrete (C25/30)
118
7.5
375
514
118
9.0
471
602
532 619
118
10.6
570
692
709
170
9.0
699
1,001
1,042
170
10.6
851
1,141
1,180
Table 3: Maximum permitted base bearing capacity (kN) for non-pressure-grouted piles – corrosiveness level AS3 under Austrian standard B 5013-1 (corrosion rate of 4.0 mm at diameter for 100 years).
The formation of spheroidal graphite confers high corrosion resistance and impact resistance
Accompanying monitoring of the quality of each individual pipe
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.
Your contacts GERMANY
AUSTRIA & SWITZERLAND
INTERNATIONALLY
Manfred Schmied
Thomas Aumüller
Jérôme Coulon
M +49 (0) 171 30 58 547
M +43 (0) 664 44 30 723
M +43 (0) 664 85 64 195
[email protected]
[email protected]
[email protected]
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.
Austria – Grimming-Therme low energy building. 500 geothermal heat probes, 22,000 m2
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. Italy – Noise barriers for the Brenner railway line, barriers along a 4.5 km stretch of the line
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.
Duktus S.A. Innsbrucker Straße 51 6060 Hall in Tirol Austria T +43 (0) 5223 503-215 www.duktus.com Austria – Flood protection for the Leutascher Ache river, environmental upgrading of a section of the river
© • 006 • 02/10 • e 2 500 • DBH
