BAUER MALAYSIA SDN BHD

1-Day Seminar on Proven Solutions to Complex

Geotechnical and Engineering Challenges

CONSTRUCTION OF THE DEEPEST KELLY

SYSTEM FOUNDATION PILES IN
KUALA LUMPUR, MALAYSIA

Presented by: Vijayakumar Viramuthu

25th June 2022
Contents

1. The L&M Project + KLCC Development

2. Geology & Design

FY 2020

3. Scope of Works

4. Equipment

5. Construction challenges of Deep Piles

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1. The L&M Project + KLCC Development

FY 2020

Petronas Twin Tower

The KLCC masterplan

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2. Geology & Design

FY 2020

Competent rock mapping for the piling works in the Tower area

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2. Geology & Design

FY 2020

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2. Geology & Design

FY 2020

3D-model of the subsoil based on SI information (left), used to

specify the 2m-embedment into competent rock, indicated by
red columns (right)

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2. Soil investigation

FY 2020

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3. Scope of Works
Employer : Arah Moden Sdn Bhd (Company of KLCC Holding)

Consultant Engineer : Arup Malaysia & LERA Consulting Structural Engineers

Scope of Works : Main works - Bored Piles:

- 88 nos. Podium piles dia. 2.0 m and 137 nos. Tower Piles dia.
2.5 m, max. upto depth 150 m
- Plunge Columns (Kingposts): 154 nos. FY 2020

Enabling Works:
- Diaphragm Wall – 1.0m thickness up to 39m depth
- Structural monitoring
- Geotechnical instrumentation / monitoring
- Dilapidation survey
- Utilities Diversion – Temporary works

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3. Scope of Works

Tower

FY 2020

Podium
Storage

Site Layout and Structure Areas

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4. Equipment

TECHNICAL REQUIREMENT : ABLE TO DRILL 150m

Choice of telescopic Kelly : 4 sections or 5 sections

If 4 section = 150/4 + 2.5m = 40 m
If 5 section = 150/5 + 2.5m = 32.5 ( Manageable from transport)
FY 2020

Kelly section : Outer diameter is 559mm and last section diameter is 229mm. Have to
consider last section not to be too slender otherwise it will twist like a cock screw during
drilling. 5 section Kelly is not suitable for rock drilling

Weight of Kelly close to 39 tons with a mast of 36m to cater for a 32.5m Kelly will determine
the type of Base machine and counterweight required for stability to avoid overturning.

Weight of overall rig needs to be considered as proper concrete working platform is needed

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4. Equipment
MOBILISATION AND ASSEMBLY TAKES SPECIAL PLANNING AND EXECUTION

FY 2020

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4. Equipment – Bored Pile
The Biggest Rotary Kelly Drilling Rig

BG 48:
Mast Height 36 m
Main Winch 60 to
Kelly 5-fold Lockable
Drilling Depth 125 m
Max diameter 3.5 m FY 2020

Operating Weight 270 to

BG 72:
Mast Height 43 m
Main Winch 60 to
Kelly 5-fold Lockable
Drilling Depth 150 m
Max diameter 4.6 m
Operating Weight 280 to
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4. Equipment

Thank you

FY 2020

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4. Equipment – Diaphragm Wall

Thank you

FY 2020

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4. Diaphragm Wall – Cage Installation

Thank you

FY 2020

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4. Diaphragm Wall – Concreting process

Thank you

FY 2020

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5. Construction challenges of Deep Piles

DRILLING and CONSTRUCTION CONTROL

Drilling :
- Performance versus Verticality Balance
- Risks of deviation with
FY 2020
- increased depth
- increased diameter

Use of specialist long core barrels, augers and

buckets

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5. Construction challenges of Deep Piles - Drlling

FY 2020

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5. Construction challenges of Deep Piles

SPECIFICATIONS

Verticality Bored Piles:

- 75 mm at pile Cut-off level (“datum ring”) in about
27 m below Ground level (1:300)
- followed by Overall Verticality 1:100 FY 2020

Kingposts:
- 1:200

Material-Installation:
- Within 36 hours from Completion of Drilling

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5. Construction challenges of Deep Piles - Verticality for Piles L<100 m
Koden Tests for BAUER’s internal x-check
- well-known and proven, for D-walls, Barrettes and for Circular Shafts

FY 2020

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5. Construction challenges of Deep Piles - Verticality for Piles L<100 m

FY 2020

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5. Construction challenges of Deep Piles - Verticality for Piles L>100 m
Specified: Sonic Caliper Tests on every Pile
- Patented System by Fugro
- ultrasonic echo device similar to Koden, but 360-degree scanning
- determines contour and verticality of the pile

FY 2020

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5. Construction challenges of Deep Piles
Fluid Support :
- Polymer was preferred against bentonite as bentonite would require desanding process
which would take 5 to 6 hours. Time was is an essence as there is a requirement in the
specification to complete pile casting within 36hours from completion of drilling.

Reinforcement Steel Cage:

- 24m prefabricated sections were spliced over open bore hole to reduce time
FY 2020

Concrete:
- Quality ( Placing temperature was below 32oC and slump was above 220mm )
- Supply rate needed to be between 60 to 80 cum/hr. 12 cum volume trucks were used

Kingpost installation:
- Required verticality 1:200. Kingpost was one section up to length 33m and weighs to a
maximum of 84 tons. For lifting a 300 ton crane was used in some instance.

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5. Construction challenges of Deep Piles - Polymer

FY 2020

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5. Construction challenges of Deep Piles - Polymer

FY 2020

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5. Construction challenges of Deep Piles - Polymer

FY 2020

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5. Construction challenges of Deep Piles – Steel Cage

FY 2020

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5. Construction challenges of Deep Piles – Steel Cage

FY 2020

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5. Construction challenges of Deep Piles - Concreting

FY 2020

Concrete, a major Challenge

130 m Pile with COL at 27 m needs about 600 m³

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5. Construction challenges of Deep Piles - Concreting

FY 2020

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5. Construction challenges of Deep Piles - Concreting

FY 2020

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5. Construction challenges of Deep Piles - Concreting

FY 2020

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5. Construction challenges of Deep Piles - Concreting

FY 2020

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5. Construction challenges of Deep Piles – King Post

FY 2020

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5. Construction challenges of Deep Piles – King Post

FY 2020

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A safe job is a good job

FY 2020

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The Deepest Kelly System Foundation Piles in Kuala Lumpur

Thank you

FY 2020

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Contact person: Vijayakumar Viramuthu
Designation: Managing Director - Operations
Mobile number: +6012-201 4944
Email: [email protected]

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