Saes Q 004
Saes Q 004
Saes Q 004
1 Scope............................................................. 2
2 Conflicts and Deviations................................ 2
3 References..................................................... 3
4 Pile Marking and Installation Records............ 4
5 Pile Installation Planning................................ 5
6 Driven Pile Installation................................... 6
7 Drilling.......................................................... 13
8 Insert or Grouted Piles................................. 17
9 Grouting........................................................ 17
10 Conductors and Conductor/Piles................. 23
1 Scope
This standard presents the basis for installation of piles for use in offshore structures
and coastal zones. This specification does not apply to onshore pile installation.
This standard describes the equipment, materials, personnel and procedures that shall be
used to install offshore structure piles and conductors. The intent of this specification is
to provide minimum installation requirements for offshore pile foundations, including
anticipated problems and recommended remedial action that may be required in the
event that pile installation does not proceed as expected.
The project specification for each individual job shall include penetrations of piles and
conductors, lengths of concrete plugs or any other specific construction requirements to
supplement the general requirements of this SAES.
Commentary:
A project specification is issued for most projects and gives requirements applicable
for the site specific soil conditions, structure, pile types and loads.
In addition to the above information, the pile installation specification should also
include project site geotechnical data, pile design drawings, pile capacities with applied
safety factors, pile acceptance, driving criteria, and description of planned remedial
action.
2.1 Any conflicts between this standard and other applicable Saudi Aramco
Engineering Standards (SAESs), Materials System Specifications (SAMSSs),
Standard Drawings (SASDs), or industry standards, codes, and forms shall be
resolved in writing by the Company or Buyer Representative through the
Manager, Consulting Services Department of Saudi Aramco, Dhahran.
2.2 Direct all requests to deviate from this standard in writing to the Company or
Buyer Representative, who shall follow internal company procedure SAEP-302
and forward such requests to the Manager, Consulting Services Department of
Saudi Aramco, Dhahran.
Page 2 of 24
Document Responsibility: Offshore Structures SAES-Q-004
Issue Date: 30 November 2004 Installation of Piles and
Next Planned Update: 1 December 2009 Conductors for Offshore Structures
3 References
The selection of material and equipment, and the design, construction, maintenance, and
repair of equipment and facilities covered by this standard shall comply with the latest
edition of the references listed below, unless otherwise noted.
Page 3 of 24
Document Responsibility: Offshore Structures SAES-Q-004
Issue Date: 30 November 2004 Installation of Piles and
Next Planned Update: 1 December 2009 Conductors for Offshore Structures
Piles and added lengths of pile in excess of the water depth shall be marked with
12 mm wide stripes on 0.25 m centers. Stripes are to be painted with oil-based
paint to cover at least 50% of the pile perimeter. Every fourth stripe shall be
marked with the corresponding meter number, measured from the tip of the pile.
Pile driving records shall be kept on Saudi Aramco Form 3063-ENG, "Pile
Driving Record".
4.2.1 Driving
4.2.2 Drilling
The following records shall be kept for all drilling operations: date, time,
bit size, centralizers spacing, hole penetration, pile tip penetration (if
applicable), type, weight and viscosity of drilling fluid, and interruptions
during drilling. Any unusual phenomena or difficulties related to the
drilling program shall also be recorded. This includes drilled hole
collapse, drill bit plugging, equipment breakdown, and withdrawal from
drilled hole.
Page 4 of 24
Document Responsibility: Offshore Structures SAES-Q-004
Issue Date: 30 November 2004 Installation of Piles and
Next Planned Update: 1 December 2009 Conductors for Offshore Structures
4.2.4 Grouting
Contractor shall provide for all grouting operations: date, time, grout
mix, setting time, and unit weight of grout samples, grouting pressure,
ability to establish static head, volume change, compressive strength,
seafloor leakage, interruptions or other problems encountered during
grouting, time and number of each grout sample taken, and any unusual
conditions observed during the grouting operation.
4.2.5 Distribution
5.1 Procedures used to install piles to achieve the specified design capacity shall be
selected on the basis of the results from the geotechnical site investigation
performed at the site, pile drivability analyses, and pre-installation planning.
All piles shall be installed by driving into existing undisturbed soil, except
where sound rock strata greater than three (3) pile diameters thick is located
within 12 m of the seafloor, or where pile refusal occurs above terminal
penetration.
Jetting will NOT be permitted either on the inside or on the outside of any pile.
Pile installation procedures that are acceptable for use in Saudi Aramco
operating areas are listed in Table 1. Alternative installation procedures will be
subject to review and approval by Supervisor, Civil Engineering Unit, CSD.
Page 5 of 24
Document Responsibility: Offshore Structures SAES-Q-004
Issue Date: 30 November 2004 Installation of Piles and
Next Planned Update: 1 December 2009 Conductors for Offshore Structures
Contractor shall stab all piles or pile sections in all corner legs of the
platform and predrive by putting the hammer weight on each pile. The
sequence of stabbing should attempt to follow a diagonal pattern to
reduce sideways drift. The expected penetration under pile weight plus
hammer weight shall be analyzed prior to installation as part of the pre-
installation planning work effort.
Page 6 of 24
Document Responsibility: Offshore Structures SAES-Q-004
Issue Date: 30 November 2004 Installation of Piles and
Next Planned Update: 1 December 2009 Conductors for Offshore Structures
If the platform jacket is not level after setting and predriving, the
Contractor shall first drive the pile or initial section of the pile at the
lowest corner of the jacket. Then the jacket shall be leveled and the top
of the jacket leg shall be attached to the driven pile or pile section with a
temporary welded connection. The remaining piles shall then be driven
to design penetration. Finally, (if required) the first pile shall be spliced
and redriven. During driving, every effort should be made to maintain
the jacket top at the specified elevation.
Unless specified otherwise, the Contractor shall have available at the site
a minimum 9 m long section of piling in addition to the design length of
piling. This extra length shall be available for each pile to cover the
possibility of having to drive piles deeper than the design penetration.
The purpose of insurance piling is to allow pile driving to continue while
additional pile material is brought to the site.
Closure devices are used on the lower end of the jacket columns and pile
sleeves to provide buoyancy. They should be designed to avoid
Page 7 of 24
Document Responsibility: Offshore Structures SAES-Q-004
Issue Date: 30 November 2004 Installation of Piles and
Next Planned Update: 1 December 2009 Conductors for Offshore Structures
Closure devices shall NOT be removed by punching them off with the
piles. Diaphragm rupturing tools can be used to remove the closure
plates.
Guides should be designed to support the full weight of the add-on pile
section prior to welding the pile sections together.
Lifting eyes and weld-on lugs used for pile handling shall be designed to
accommodate stresses associated with initial pile pickup, stabbing and
impact loads as may occur during the handling of the pile.
Where lifting eyes and weld-on-lugs are used to support the initial pile
section from the top of the jacket, each eye or lug should be capable of
resisting the entire hanging weight.
In all cases, the padeyes should be designed to resist all possible out-of-
plane bending loads.
Where lifting eyes and/or weld-on-lugs are on lengths of pile that will
remain in service, they should be removed by torch cutting 6 mm from
the pile steel surface and subsequently be ground smooth to prevent
damage to internal jacket leg elements such as packers during pile
driving.
Contractor shall supply all equipment and experienced personnel for driving
piles in accordance with plans and specifications.
All pile driving equipment shall be in good operating condition when brought to
the work site and shall be approved by the Saudi Aramco Representative at the
site.
Contractor shall select suitable pile hammers to drive the piles to the
Page 8 of 24
Document Responsibility: Offshore Structures SAES-Q-004
Issue Date: 30 November 2004 Installation of Piles and
Next Planned Update: 1 December 2009 Conductors for Offshore Structures
Pile hammer guides shall provide a close fit to the pile wall and must
hold the hammer properly in line with the pile.
All pile installations shall be monitored with dynamic pile monitoring (DMS)
equipment, operated by trained personnel and analyzed by engineers, all
approved by Supervisor, Civil Engineering Unit, CSD.
6.3.1 The choice of the DMS system to be used will be made by the
Supervisor, Civil Engineering Unit, CSD, based on the results of the pile
drivability analyses, pile driving experience in the area, experience with
a specific pile hammer, confidence in the site investigation data and
assigned soil parameters, and expected installation problems
identified during the pre-installation planning effort.
Page 9 of 24
Document Responsibility: Offshore Structures SAES-Q-004
Issue Date: 30 November 2004 Installation of Piles and
Next Planned Update: 1 December 2009 Conductors for Offshore Structures
Page 10 of 24
Document Responsibility: Offshore Structures SAES-Q-004
Issue Date: 30 November 2004 Installation of Piles and
Next Planned Update: 1 December 2009 Conductors for Offshore Structures
Commentary:
Page 11 of 24
Document Responsibility: Offshore Structures SAES-Q-004
Issue Date: 30 November 2004 Installation of Piles and
Next Planned Update: 1 December 2009 Conductors for Offshore Structures
Design penetration shall be based on the static axial pile capacity and
lateral load requirements for each site, calculated in accordance with the
procedures presented in SAES-M-005.
In the event that the pile refuses at a penetration less than the design
penetration and the calculated static axial capacity is less than the design
requirements, remedial action shall be taken to provide the design pile
capacity requirements.
If there has been a delay in pile driving operation for one hour or longer,
the above refusal criteria shall not apply until the pile has been advanced
at least 25 cm or the hammer has been operated at the manufacturer's
rated speed for at least 15 minutes, following the resumption of pile
driving.
Page 12 of 24
Document Responsibility: Offshore Structures SAES-Q-004
Issue Date: 30 November 2004 Installation of Piles and
Next Planned Update: 1 December 2009 Conductors for Offshore Structures
Minimum final driving resistance for driven piles shall be specified for
each individual job.
Any splice made to a pile extending more than 5 m into clay layers at
penetrations of more than 15 m below the seafloor will probably
experience sufficient increases in driving resistance (set-up) to make the
continuation of driving difficult. Therefore, splice locations shall be
chosen to minimize the possibility of refusal due to the increase in
driving resistance.
When the soil plug is drilled out of the pile and the pile re-driven or a
predrilled hole is used to facilitate driving, a grout plug must be placed to
develop end bearing of the pile. The pile should first be cleaned out as
described in Paragraph 7.2.7 and the grout plug placed in accordance
with Paragraph 9.3.7. The length of the grout plug shall be specified for
each specific job.
7 Drilling
The Contractor shall supply all equipment, materials and experienced personnel
required to drill soil plug from inside piles, drill pilot holes, and drill holes or
pre-drill holes for insert or grouted piles. Before arriving at the site, all
Page 13 of 24
Document Responsibility: Offshore Structures SAES-Q-004
Issue Date: 30 November 2004 Installation of Piles and
Next Planned Update: 1 December 2009 Conductors for Offshore Structures
The drill rig shall be either a rotary type, power swivel or turbo drill. The
rated torque for these units shall not be less than 8100 N.m. (6000 ft. lbs).
The support equipment to accompany the drill rig shall include the
following:
(1) As a minimum, a supply of drill pipe that is at least 125 mm
diameter to drill to design penetration, including pup joints and
cross-over subs with a 100% reserve.
(2) An adequate supply of drill collars to provide bit manufacturer's
recommended weight to drill bit and bumper subs for use from
floating barge.
(3) Stabilizers of appropriate size and number to keep drill string
aligned in hole.
(4) Two roller type bits with jets of each size required.
(5) Positive displacement pump(s) capable of providing at least
1100 liters per minute to the bit together with suction and discharge
hoses.
(6) Small tools and spare parts for rig and pump repairs to maintain
equipment in good working order.
(7) Air lift equipment for removing cuttings.
7.1.4 Specifications
Page 14 of 24
Document Responsibility: Offshore Structures SAES-Q-004
Issue Date: 30 November 2004 Installation of Piles and
Next Planned Update: 1 December 2009 Conductors for Offshore Structures
All drilling equipment shall be mobilized at the job site in time to allow
testing at least one day prior to earliest need.
7.1.6 Personnel
7.2.1 Purpose
The soil plug can be removed from a pile using a bit with a diameter
slightly less than the inside diameter of the pile.
Drilling to remove a soil plug should stop one pile diameter or at least
1.5 m above the tip of the pile, whichever is greater.
A predrilled pilot hole to assist driving shall stop two pile diameters or
2 m above terminal penetration whichever is greater. The diameter of
the pre-drilled hole shall be less than 75% of the outside diameter of the
pile when mostly in clay and, less than 50% of the outside diameter of
the pile when mostly in sand.
Page 15 of 24
Document Responsibility: Offshore Structures SAES-Q-004
Issue Date: 30 November 2004 Installation of Piles and
Next Planned Update: 1 December 2009 Conductors for Offshore Structures
Where pilot holes are used the axial pile capacity shall be re-evaluated to
account for the reduction in insitu soil stress caused by the drilling. In
all cases the driven pile skin friction and end bearing unit values in
disturbed zone shall be reduced by at least 25%. In addition, the unit
skin friction values shall be reduced by 25% along the length of the
already driven pile for a distance of at least five (5) pile diameters above
the pile tip.
For anchor piles subject to lateral loads only, the diameter of the
predrilled hole may be increased to the outside diameter of the anchor
pile.
Predrilled holes for grouted insert piles or grouted piles should provide at
least a 76 mm clear space around the pile to be grouted to the full design
penetration.
Seawater with an air assist can be used as drilling fluid to remove drill
cuttings in stable clays, rock and sand layers of limited thickness.
Drilling mud shall be used to pre-drill holes in unstable clays and sand
deposits greater than 4.5 m thick. Specifications for drilling mud are
given below:
7.2.7 Stabilizers
Page 16 of 24
Document Responsibility: Offshore Structures SAES-Q-004
Issue Date: 30 November 2004 Installation of Piles and
Next Planned Update: 1 December 2009 Conductors for Offshore Structures
7.2.8.1 Internal Grout Plug - After drilling out the internal soil plug
and re-driving the pile to an acceptable penetration and prior to
installing the grout plug, all loose soil shall be removed from
the inside of the pile.
7.2.8.2 Pilot Hole - After drilling the pilot hole and re-driving the pile
to an acceptable penetration, all loose soil shall be removed
from inside the pile prior to placing the grout plug.
Insert or grouted piles shall be of the size and length indicated in the Pile
Installation Specification and drawings for a specific job.
8.2 Centralizers
Piles shall be placed in the predrilled holes and should advance into the hole
under self weight plus the weight of a pile hammer, if necessary. No blows shall
be applied to any pile to be grouted. The tip of pile shall be 30 cm above bottom
of predrilled hole.
9 Grouting
Contractor shall provide all equipment, materials and experienced personnel required to
grout structure piles in jacket sleeves, structure piles to insert piles and structure or
insert piles to foundation formations. All equipment shall be in good operating
Page 17 of 24
Document Responsibility: Offshore Structures SAES-Q-004
Issue Date: 30 November 2004 Installation of Piles and
Next Planned Update: 1 December 2009 Conductors for Offshore Structures
condition when it is brought to the job site and shall be approved by the Saudi Aramco
Construction Engineer at the site.
(1) One air operated grout surge tank unit with mixing
hopper.
Page 18 of 24
Document Responsibility: Offshore Structures SAES-Q-004
Issue Date: 30 November 2004 Installation of Piles and
Next Planned Update: 1 December 2009 Conductors for Offshore Structures
9.1.4 Personnel
9.2 Materials
The cement used for grouting shall be ASTM C150, type V (Sulfate
resistant Portland cement) with 30% Fly ash. Fly ash shall comply with
ASTM C618.
Page 19 of 24
Document Responsibility: Offshore Structures SAES-Q-004
Issue Date: 30 November 2004 Installation of Piles and
Next Planned Update: 1 December 2009 Conductors for Offshore Structures
The grout mix shall have high fluidity to ensure flow during grouting
process. Chemical admixtures complying with ASTM C494 can be used
to achieve the required fluidity of the grout mix. The maximum water to
cementitious ratio (water/ cement + Fly ash) shall not exceed 45%. The
mixing water shall be from oils, acid, organic matter of other deleterious
substances and shall have total dissolved solids (TDS) less than 500 ppm
as per AASHTO T26. The minimum compressive strength of the grout
mix shall be 17.2 MPa (2500 psi). Contractor shall conduct trial mixes
to meet the specified requirement prior to commencing the grout
application.
9.2.4 Quantities
When ordering materials, the contractor shall consider that grout seals
are normally imperfect, that grout loss can occur in the formation and at
the seafloor.
9.3.1 Purpose
Page 20 of 24
Document Responsibility: Offshore Structures SAES-Q-004
Issue Date: 30 November 2004 Installation of Piles and
Next Planned Update: 1 December 2009 Conductors for Offshore Structures
9.3.3 Sampling
The annulus between pile and jacket leg should be filled with grout
where it is required by SAES-M-005 after the pile has been installed to
grade and is completely shimmed and welded to the jacket. Sealer plates
should be omitted until after grouting. The grouting procedure shall be
as follows:
Page 21 of 24
Document Responsibility: Offshore Structures SAES-Q-004
Issue Date: 30 November 2004 Installation of Piles and
Next Planned Update: 1 December 2009 Conductors for Offshore Structures
(5) Allow four hours for plug to harden, then fill remainder of annulus
using upper grout line. Grouting should be continued until returns at
the jacket leg are 1860 kg/m³ grout.
(6) Fill any empty space that occurs from grout settling with hand-
mixed grout within 24 hours and install sealer plates.
Grouting insert piles to foundation formation and initial pile section shall
be done after the insert pile with centralizers is placed in the predrilled
hole. Two pressure heads and a 3 inch grout pipe shall be provided by
fabricator for contractor's use. The stepwise grouting procedure of insert
piles shall be as follows:
(1) Run grout pipe to 1 m above the tip of the pile. The length of grout
plug will be specified in pile installation specification for
individual projects or shown on the drawings.
(2) Connect pressure head and weld to cover top of insert pile.
(3) Hook-up lines to pressure head and pump seawater until all air in
insert is displaced through exhaust valve, then close exhaust valve.
(4) Pump 0.4 m³ to 0.6 m³ low density grout, 1280 kg/m³ to serve as a
scouring medium ahead of structural grout.
Page 22 of 24
Document Responsibility: Offshore Structures SAES-Q-004
Issue Date: 30 November 2004 Installation of Piles and
Next Planned Update: 1 December 2009 Conductors for Offshore Structures
(9) Relieve pressure through exhaust valve, remove pressure head and
grout pipe.
(2) Connect the grout lines and pump 0.4 m³ to 0.6 m³ of low density
grout, 1280 kg/m³, to serve as a scouring medium ahead of further
pumping of structural grout.
(3) Station the diver at the seabed, then pump grout at minimum
density of 1860 kg/m³ until good returns show at sea floor and pile
up around jacket leg.
(4) Grout the annulus between pile and jacket as outlined in Paragraph
9.3.4. Inflatable grout seals are required to allow lowering of insert
piles with projecting centralizer plates.
Placing a grout plug in a driven pile shall follow the stepwise procedure
given below:
(1) Run the grout line to the top of the soil plug.
(2) Connect the grout lines and pump a quantity of grout adequate to
fill all grout lines and to provide the required length of grout plug
in the pile plus 0.3 m³ and lift grout line.
(3) Wait four hours, then measure top elevation of the grout plug. If
not adequate, repeat Steps 1 and 2.
10.1 Conductors are used as part of the oil drilling and/or production operations and
are not used to provide axial or lateral foundation support to the structure.
Conductor/piles serve a dual use and are depended upon and designed to provide
axial or lateral foundation support in addition to serving oil production and
drilling functions. The use of conductor/piles is generally not recommended
except for minimum structures.
Page 23 of 24
Document Responsibility: Offshore Structures SAES-Q-004
Issue Date: 30 November 2004 Installation of Piles and
Next Planned Update: 1 December 2009 Conductors for Offshore Structures
10.2 Conductor/piles shall be installed using the techniques given in this standard for
piles. All requirements for grout should be met detailed procedures and
materials used for installing conductor/piles should be approved at least two
months prior to installation by Supervisor, Civil Engineering Unit, CSD.
Revision Summary
30 November, 2004 Major revision.
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