icp brochure grade 80

Unit 1-13-01, Menara IJM Land, No.1 Lebuh Tunku Kudin 3, 11700 Gelugor, Penang.Tel: 604-296 1399 Fax: 604-296 1398

Email: [email protected]

August 2012

Wisma IJM Annexe, Jalan Yong Shook Lin, 46050 Petaling Jaya, Selangor Darul Ehsan, Malaysia.Tel: 603-7955 8888 Fax: 603-7958 1111 E-mail: [email protected] Website: www.icpb.com

INDUSTRIAL CONCRETE PRODUCTS SDN BHD

MS 1SO 9001 : 2008 REG. NO AR0122

SPECIAL FEATURES OF ICP PILESINDUSTRIAL CONCRETE PRODUCTS SDN BHD(ICP) is the first commercial manufacturer ofHIGH PERFORMANCE PRETENSIONED SPUNCONCRETE PILES (ICP PC PILES) in Malaysia.Presently, ICP is the largest manufacturer inSouth East Asia.

The company was incorporated in Malaysiaon 6 April 1977 and commenced business inSeptember 1977.

In September 1993, ICP started manufacturingHIGH PERFORMANCE Pretensioned Spun HighStrength Concrete Piles (ICP PHC PILES) whichoffer an economical foundation system withconsistent and superior quality compared tothe ordinary concrete piles. With the vastexperience in the manufacturing ofpretensioned spun concrete piles and utilisingthe latest concrete technology, ICP is themarket leader in concrete piles.

ICP Piles are circular in cross-section and aremanufactured in sizes ranging from diameter250mm to 1,200mm with standard lengthsvarying from 6m to 46m in single pieces. ICPPiles can be easily joined to any combinationof length as per design requirement. ICP Pilesare manufactured with steel end plates forsplicing.

ICP Piles have been used extensively asfoundation piles for power stations, highrisebuildings, civil engineering works, bridges,marine structures, harbours, schools andgovernment projects, etc.

ICP Piles are exported to Brunei, Singapore, Sri Lanka, the Middle East, Indonesia,Philippines, Vietnam, Myanmar, USA, Canadaand Maldives.

As a market leader in the concrete industry, ICP constantly improves the quality of itsproducts and services. All ICP factories are MSISO 9001 : 2008 certified.

Chenor Bridge,Maran Pahang

Aden Flour Mill Jetty at Aden,Yemen

Areas of Application

• Bridges• Building Foundations• Civil Engineering Works• Marine Structures• Piled Embankments

Product Attributes

• Spinning process results in more durable concrete with high resistance to corrosion.

• Grade 80 concrete enables the piles to be driven through hard strata.

• Can be manufactured up to dia. 1200mm and a maximum single length of 46 metres.

• Environmentally friendly installation by hydraulic jacking equipment which are free of noise, air pollution and vibration.

Kementerian Perusahaan, Perdagangandan Komoditi, Putrajaya

1km Container Terminal atChittagong Port, Bangladesh

E-gate, Penang

Sg. Buloh Hospital, Selangor

SPECIAL FEATURES OF ICP PILESINDUSTRIAL CONCRETE PRODUCTS SDN BHD(ICP) is the first commercial manufacturer ofHIGH PERFORMANCE PRETENSIONED SPUNCONCRETE PILES (ICP PC PILES) in Malaysia.Presently, ICP is the largest manufacturer inSouth East Asia.

The company was incorporated in Malaysiaon 6 April 1977 and commenced business inSeptember 1977.

In September 1993, ICP started manufacturingHIGH PERFORMANCE Pretensioned Spun HighStrength Concrete Piles (ICP PHC PILES) whichoffer an economical foundation system withconsistent and superior quality compared tothe ordinary concrete piles. With the vastexperience in the manufacturing ofpretensioned spun concrete piles and utilisingthe latest concrete technology, ICP is themarket leader in concrete piles.

ICP Piles are circular in cross-section and aremanufactured in sizes ranging from diameter250mm to 1,200mm with standard lengthsvarying from 6m to 46m in single pieces. ICPPiles can be easily joined to any combinationof length as per design requirement. ICP Pilesare manufactured with steel end plates forsplicing.

ICP Piles have been used extensively asfoundation piles for power stations, highrisebuildings, civil engineering works, bridges,marine structures, harbours, schools andgovernment projects, etc.

ICP Piles are exported to Brunei, Singapore, Sri Lanka, the Middle East, Indonesia,Philippines, Vietnam, Myanmar, USA, Canadaand Maldives.

As a market leader in the concrete industry, ICP constantly improves the quality of itsproducts and services. All ICP factories are MSISO 9001 : 2008 certified.

Chenor Bridge,Maran Pahang

Aden Flour Mill Jetty at Aden,Yemen

Areas of Application

• Bridges• Building Foundations• Civil Engineering Works• Marine Structures• Piled Embankments

Product Attributes

• Spinning process results in more durable concrete with high resistance to corrosion.

• Grade 80 concrete enables the piles to be driven through hard strata.

• Can be manufactured up to dia. 1200mm and a maximum single length of 46 metres.

• Environmentally friendly installation by hydraulic jacking equipment which are free of noise, air pollution and vibration.

Kementerian Perusahaan, Perdagangandan Komoditi, Putrajaya

1km Container Terminal atChittagong Port, Bangladesh

E-gate, Penang

Sg. Buloh Hospital, Selangor

PROPERTIES OF ICP PILES - STANDARD PRODUCTS

(Subject to change without prior notice)

FORMULA FOR AXIAL LOADBased on BS 8004: 1986, the maximum allowable axial stress that may be applied to a pile acting as a short strutshould be one quarter of (specified works cube strength at 28 days less the prestress after losses)

N = fca x A= 1/4(fcu - fpe) x A

Where, N = maximum allowable axial loadA = cross section area of concretefca = permissible compressive strength of concretefcu = specified compressive strength of concretefpe = effective prestress in concrete

CLASS A (EFFECTIVE PRESTRESS 4.0 N/mm2)

CLASS B (EFFECTIVE PRESTRESS 5.0 N/mm2)

CLASS C (EFFECTIVE PRESTRESS 7.0 N/mm2)

EXTENSION PILE

STARTER PILE

SPIRAL WIRE AT 50 mmPITCH x 3D

SPIRAL WIRE AT 100 mm PITCH

SPIRAL WIRE

PILE SHOE

FILLET WELD

MS PLATE

PRESTRESSING BAR

SEE DETAIL “A”

MS JOINTING PLATE

MS BAND

SECTIONAL DETAILS OF ICP PILES

JOINT WELDING DETAILSDia Of Pile

Throat Thickness

A WRoot

Dia Of Pile Dia.Quantity L

HT Bars

BONDING ICP PILES INTO PILE CAPAs the PC bars are bonded with concrete, ICP Piles may be cut off at any point. The piles need not bestripped down to expose the bars, and can be bonded to the pile cap as shown in the following sketch. If the piles are not subjected to tensile loads, the recommended h.t. bars are considered adequate.

DETAIL “A”

mm mm mm mm250 8.5 4.0 1.5300 8.5 4.0 1.5350 8.5 4.0 1.5400 10 4.5 1.5450 10 4.5 1.5500 12 5.0 1.5600 12 5.0 1.5700 12 5.0 1.5800 14 6.0 2.0900 14 6.0 2.01000 14 6.0 2.01200 14 6.0 2.0

HT BARS

PILE CAP

ICP PILE

GRADE 30CONCRETE PLUG

1.5 mm MS PLATETACK-WELDED TO

HT BARS

mm No. mm mm250 4 12 500300 4 12 500350 5 12 550400 5 12 700450 5 15 800500 6 15 900600 8 15 1000700 8 18 1200800 8 20 1400900 10 25 15001000 12 25 15001200 20 25 2000

kNm9.0mm 10.7mm12.6mm

kNm kNm

PROPERTIES OF ICP PILES - STANDARD PRODUCTS

(Subject to change without prior notice)

FORMULA FOR AXIAL LOADBased on BS 8004: 1986, the maximum allowable axial stress that may be applied to a pile acting as a short strutshould be one quarter of (specified works cube strength at 28 days less the prestress after losses)

N = fca x A= 1/4(fcu - fpe) x A

Where, N = maximum allowable axial loadA = cross section area of concretefca = permissible compressive strength of concretefcu = specified compressive strength of concretefpe = effective prestress in concrete

CLASS A (EFFECTIVE PRESTRESS 4.0 N/mm2)

CLASS B (EFFECTIVE PRESTRESS 5.0 N/mm2)

CLASS C (EFFECTIVE PRESTRESS 7.0 N/mm2)

EXTENSION PILE

STARTER PILE

SPIRAL WIRE AT 100 mm PITCH

SPIRAL WIRE

PILE SHOE

FILLET WELD

MS PLATE

PRESTRESSING BAR

SEE DETAIL “A”

MS JOINTING PLATE

MS BAND

SECTIONAL DETAILS OF ICP PILES

JOINT WELDING DETAILSDia Of Pile

Throat Thickness

A WRoot

Dia Of Pile Dia.Quantity L

HT Bars

BONDING ICP PILES INTO PILE CAPAs the PC bars are bonded with concrete, ICP Piles may be cut off at any point. The piles need not bestripped down to expose the bars, and can be bonded to the pile cap as shown in the following sketch. If the piles are not subjected to tensile loads, the recommended h.t. bars are considered adequate.

DETAIL “A”

mm mm mm mm250 8.5 4.0 1.5300 8.5 4.0 1.5350 8.5 4.0 1.5400 10 4.5 1.5450 10 4.5 1.5500 12 5.0 1.5600 12 5.0 1.5700 12 5.0 1.5800 14 6.0 2.0900 14 6.0 2.01000 14 6.0 2.01200 14 6.0 2.0

HT BARS

PILE CAP

ICP PILE

GRADE 30CONCRETE PLUG

1.5 mm MS PLATETACK-WELDED TO

HT BARS

mm No. mm mm250 4 12 500300 4 12 500350 5 12 550400 5 12 700450 5 15 800500 6 15 900600 8 15 1000700 8 18 1200800 8 20 1400900 10 25 15001000 12 25 15001200 20 25 2000

kNm9.0mm 10.7mm12.6mm

kNm kNm

Cage Making / MouldSetting

PC bars in coil form arestraightened and cut to correct

lengths. The ends are warm-headed to form button heads.The bars are passed through

the cage forming machine wherespiral wires is automaticallyspot-welded at the correct

spacings. End plates are fittedto the cage. The whole cage isthen placed onto the bottom

half mould.

Pile SpinningThe filled mould is then placed

on the centrifugal spinningmachine to be spun automaticallyin four stages. Spinning results

in high compaction andsqueezes out excess water. The

resulting decrease in finalwater cement ratio increasesthe concrete strength in pile.

StressingThe PC bars are stressed against

the mould through a centralshaft and stressing plate.

The stressing being carried outin a single operation ensures

uniformity of stress in all the PCbars and hence straightness of

the pile.

Concrete FeedingConcrete from the

computerised batching plant isdischarged into a feeding

hopper. Concrete is then fedinto the bottom half mouldthrough a reversible screw

feeder. The top half mould isthen bolted to the

bottom half.

MANUFACTURING PROCESS OF ICP PILES

StandardsICP PHC Piles comply with MS 1314:Part 4:2004 andalso generally comply with JIS A 5337:1987. ICP PHCPiles are modified to suit BS 8004:1986 - Foundationsand BS 8110:1997 - Structural Use of Concrete.

MaterialsAggregatesCoarse aggregates shall be 20mm granite. Fineaggregates shall be clean river sand or washedmining sand.CementOrdinary Portland cement to MS 522:1989.Prestressing SteelHigh frequency induction heat treated barsmanufactured to JIS G 3137:1994 or equivalent.Spiral WireHard drawn wire.

Concrete StrengthMinimum concrete cube strength:

at transfer of prestress 28 days30 N/mm2 78.5 N/mm2

JointThe joint is designed to have the same performanceas the main body particularly in respect of bendingstrength. All ICP PHC Piles will be supplied with steelextension plates for splicing.

Lifting PointsTwo lifting points will be marked on all pilesexceeding 12m. No special lifting bolt or wire rope iscast into the piles. Lifting is by wrapping wire ropesround the piles at specified points.

Pile ShoesAll ICP PHC Piles will be supplied either open ended,with a flat shoe or with an X-pointed shoe.

CuringAfter casting, the piles are steam cured. When theconcrete reaches the specified transfer strength, thepiles are demoulded, marked and checked for quality.The piles can normally be transported and drivenwhen the cube strength reaches 50 N/mm2.

IdentificationAll ICP PHC Piles have the typical markings as follows:

Logo as Trademark

Company’s InitialMalaysian StandardPile Size and ClassDate of Cast (yy/mm/dd)Serial No & Factory CodePile Length and Type

Other markings if used, S for Starter (flat shoe orX-pointed shoe)

Standard LengthsICP PHC Piles are available in lengths of 6m to 46msubject to certain limitations.

DeliveryUsually two to three weeks from date of confirmedorder. ICP Standard Piles are normally available ex-stock for test driving.

Technical DataTechnical data of piles are given in the table on the next page. They refer to our standard products.Please note that the axial loads represent thestructural capacities of the piles. Whether the drivenpiles can safely carry these loads depend on the soil conditions and the pile slenderness ratio.Appropriate reduction of axial loads should beapplied for (a) marine structures, (b) piles subjected to bending, (c) high upstand, (d) piles driven through very poor top stratum, (e) raking piles, etc.

DefinitionsICP PHC Piles: High Performance Pretensioned SpunHigh Strength Concrete PilesMS : Malaysian StandardJIS : Japanese StandardBS : British Standard

GENERAL SPECIFICATION FOR ICP PILES

DeliveryWhen the cube strength

reaches the required strength the piles can be

transported and installed.

CuringSteam curing enables the

piles to be demoldedearlier.

MS 1SO 9001:2008 REG. NO. AR0122

Cage Making / MouldSetting

PC bars in coil form arestraightened and cut to correct

lengths. The ends are warm-headed to form button heads.The bars are passed through

the cage forming machine wherespiral wires is automaticallyspot-welded at the correct

spacings. End plates are fittedto the cage. The whole cage isthen placed onto the bottom

half mould.

Pile SpinningThe filled mould is then placed

on the centrifugal spinningmachine to be spun automaticallyin four stages. Spinning results

in high compaction andsqueezes out excess water. The

resulting decrease in finalwater cement ratio increasesthe concrete strength in pile.

StressingThe PC bars are stressed against

the mould through a centralshaft and stressing plate.

The stressing being carried outin a single operation ensures

uniformity of stress in all the PCbars and hence straightness of

the pile.

Concrete FeedingConcrete from the

computerised batching plant isdischarged into a feeding

hopper. Concrete is then fedinto the bottom half mouldthrough a reversible screw

feeder. The top half mould isthen bolted to the

bottom half.

MANUFACTURING PROCESS OF ICP PILES

StandardsICP PHC Piles comply with MS 1314:Part 4:2004 andalso generally comply with JIS A 5337:1987. ICP PHCPiles are modified to suit BS 8004:1986 - Foundationsand BS 8110:1997 - Structural Use of Concrete.

MaterialsAggregatesCoarse aggregates shall be 20mm granite. Fineaggregates shall be clean river sand or washedmining sand.CementOrdinary Portland cement to MS 522:1989.Prestressing SteelHigh frequency induction heat treated barsmanufactured to JIS G 3137:1994 or equivalent.Spiral WireHard drawn wire.

Concrete StrengthMinimum concrete cube strength:

at transfer of prestress 28 days30 N/mm2 78.5 N/mm2

JointThe joint is designed to have the same performanceas the main body particularly in respect of bendingstrength. All ICP PHC Piles will be supplied with steelextension plates for splicing.

Lifting PointsTwo lifting points will be marked on all pilesexceeding 12m. No special lifting bolt or wire rope iscast into the piles. Lifting is by wrapping wire ropesround the piles at specified points.

Pile ShoesAll ICP PHC Piles will be supplied either open ended,with a flat shoe or with an X-pointed shoe.

CuringAfter casting, the piles are steam cured. When theconcrete reaches the specified transfer strength, thepiles are demoulded, marked and checked for quality.The piles can normally be transported and drivenwhen the cube strength reaches 50 N/mm2.

IdentificationAll ICP PHC Piles have the typical markings as follows:

Logo as Trademark

Company’s InitialMalaysian StandardPile Size and ClassDate of Cast (yy/mm/dd)Serial No & Factory CodePile Length and Type

Other markings if used, S for Starter (flat shoe orX-pointed shoe)

Standard LengthsICP PHC Piles are available in lengths of 6m to 46msubject to certain limitations.

DeliveryUsually two to three weeks from date of confirmedorder. ICP Standard Piles are normally available ex-stock for test driving.

Technical DataTechnical data of piles are given in the table on the next page. They refer to our standard products.Please note that the axial loads represent thestructural capacities of the piles. Whether the drivenpiles can safely carry these loads depend on the soil conditions and the pile slenderness ratio.Appropriate reduction of axial loads should beapplied for (a) marine structures, (b) piles subjected to bending, (c) high upstand, (d) piles driven through very poor top stratum, (e) raking piles, etc.

DefinitionsICP PHC Piles: High Performance Pretensioned SpunHigh Strength Concrete PilesMS : Malaysian StandardJIS : Japanese StandardBS : British Standard

GENERAL SPECIFICATION FOR ICP PILES

DeliveryWhen the cube strength

reaches the required strength the piles can be

transported and installed.

CuringSteam curing enables the

piles to be demoldedearlier.

MS 1SO 9001:2008 REG. NO. AR0122

Unit 1-13-01, Menara IJM Land, No.1 Lebuh Tunku Kudin 3, 11700 Gelugor, Penang.Tel: 604-296 1399 Fax: 604-296 1398

Email: [email protected]

August 2012

Wisma IJM Annexe, Jalan Yong Shook Lin, 46050 Petaling Jaya, Selangor Darul Ehsan, Malaysia.Tel: 603-7955 8888 Fax: 603-7958 1111 E-mail: [email protected] Website: www.icpb.com

INDUSTRIAL CONCRETE PRODUCTS SDN BHD

MS 1SO 9001 : 2008 REG. NO AR0122

icp brochure grade 80

Documents