Proceedings of the First International Conference on Press-in Engineering 2018, Kochi

Piling Technologies in Ukraine: Some Recent Developments
George MESHCHERIAKOV
Chief process engineer, EC Transzvuk, Odessa, Ukraine

Michael DOUBROVSKYProfessor and Head of Sea and River Ports Department, Odessa National Maritime University, Odessa, Ukraine.
Director, International Press-In Association.
Email: doubr@tm.odessa.ua

Olga DUBROVSKA
Senior Project Engineer, DeepOcean, Haugesund, Norway

ABSTRACTThe first part of the paper sets the actual scientific task to develop the integrated piling process aimed at the automatedconstruction of pile foundations and sheet pile walls for civil and industrial buildings/structures. The technology isbased on the application of the Modular Aggregative Piling System (EC Transzvuk), intended for pressing into theground precast pile elements by a flow-production method with the highest possible performance at the lowest cost oflabor. High productivity of piling works is provided by non-stop operation of the equipment, due to the integrity of thebasic non-interruptible automated process: pile installation – piling machine displacement. The second part of the paper
considers some recent innovations of piling technologies developed to simplify tubular piles press-in installation by
prevention of the soil plug formation. One of the proposed approaches uses separate (step-by-step) driving of pile tip(shoe) and pile shaft concentrating energy of pile driving machine on tip or on shaft. Another approach is based onalternate driving of tubular pile and internal core avoiding formation of soil plug at the pile tip.
Key words: Coordinate piling method, Automated piling system, Process modeling, Piled cluster, Mono-piled dolphin

labor expenses, from 20% to 50% of the total volume of

1. Introduction
1.1. Status of the problem
Industry 4.0's strategy

construction and installation works, still remains slow,
toimproveindustry

most hazardous and expensive. Auxiliary operations

efficiency through the integration of cyber physicalassociated with the positional motion of piling equipment

systems (CPS) into manufacturing and construction

take up to 90% of the machining.

processes, aims at overcoming the nonconformity

The piling works automation on the basis of the

between the pace of urbanization, population growth andflexible structure of technological operations under thetheconditions of industrial construction, corresponds to thepossibilitiesofconventional

construction

technologies. For this purpose, conceptual equipment andcurrent world trends.

automated construction processes are being developed allover the world, for instance, the large-scale 3D Printing

1.2. Background and objectives
The integrated automated technological processes

systems (Khoshnevis & Hwang, 2006). However, thedescribed below, are the result of the complex research

problem of the disproportion between the pace ofwork of the EC Transzvuk team. The results of full-scale

overgroundthephysical and technological modeling of pile installation

underground parts installation, still remains unsolved.

processes, as well as the experimental and field research

Underground construction which consumes considerableof the presented technology, were used. Huge data base

parts

of

buildings

erectionand- 361 -

Proceedings of the First International Conference on Press-in Engineering 2018, Kochi

has been accumulated during the industrial exploitation ofgravity type is intended for automated pressing into thethe Piling System (more than 100 large-scale projects

ground precast building elements: concrete piles withsince 2008). The research is aimed to developing:cross-section up to 450×450 mm, metal pipes and sheet

flow-speed production methods for pile foundations

piles not more than 500 mm width, with insertion force

and retaining structures; unmanned operation for pilingup to 2300 kN. The PM weight is 14.3 tons. It is the best

works under the radioactive contamination;

performance for piling equipment in relation: insertion

safe, labor protected and environmentally friendly

force of the machine to it weight. The operation of the PM

construction methods.

incorporates the principle of a pile self-centering by side

2. Construction machinery

wedge-operated clamping system and its cyclic pressing

2.1. Piling system
A Modular Aggregative Piling System (MAPS) is a

into the ground an automatic mode. The PM is anchoredmultifunctional construction equipment intended for

200 tones) is determined by the soil resistance forces.

installation of precast pile elements by a flow-production

When installing the piles below the ground level (up tomethod (Meshcheriakov & Vakulin, 2011). The MAPS as

12 m), a metal inventory pile is used. The inventor of the

exemplified in Fig. 1 is equipped with the original Piling

Piling Machine CO-450 is А.Vakulin, EC Transzvuk,

Machine and a Modular Coordinating Skidding System,

1998.

by a crane with metal loads (Fig. 1) a total mass (up to

designed according to the general principles of theInternational Standard (ISO 2848:1984) for building
engineering. The MAPS is applied for the construction of

2.3. Modular skidding system
The concept of the Modular Coordinating Skidding

pile foundations and sheet pile cutoff/retaining structures

System (MCSS) provides highly precise (± 10 mm),for civil buildings. Its main technical specifications are

two-axis controlled, coordinated (X - Y) positioning ofgiven in table 1.

the PM without remounting and reanchoring operations.
The hydraulic push-pull skidding system of theground type consists of the main and auxiliary
longitudinal modules (fixed) and a cross carriage(movable).

The

modulesareidentical

andinterchangeable. They can be connected to each other ina wide range of combinations. For the synchronized
two-dimensional skidding motion MCSS employs four
hydraulic driving cylinders of 500 kN.
3. Piling methods
3.1. Classification
In order to unify and typify the technologicalFig. 1solutions, the author proposed to classify the existing

Modular Aggregative Piling System

1 – Piling machine; 2 – Basic module; 3 – Cross carriage;

methods of piling works, by the technological sequence of

4 – Anchor loads; 5 – Concrete pilepiling and the methods of PM positional displacements.
We took into account non-interrupted positioning control

Table 1. MAPS specifications

and non-readjusted technological processes.

Insertion force, max, kN

2300

The classification distinguishes: 1) Point; 2) Lineal

Insertion speed, m/min

1.5 ÷ 3(X); 3) Coordinate (X, Y) piling methods. According to

Displacement speed, m/min

2.1

Positional precision, mm± 10

the classification, three construction piling methods havebeen developed. Each method uses the standard
automated

2.2. Piling machine

pilingequipment

and

new

typicaltechnological processes.

The hydraulic Piling Machine СО-450 (PM) of a

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They were developed taking into account theProceedings of the First International Conference on Press-in Engineering 2018, Kochi

standard geometrical configurations and other parameters
of

pile

foundationsforcivil/industrial

buildings,

The C method is used for a cluster and multi-row
arrangement of piles, including the construction ofproviding the ultimate architecture flexibility.

anti-landslide piling structures. The technological process

3.2. Point method

for C method using two modules with longitudinal

The point (P) method represents the piling machine

connection, as well as point piling method for pile testing,repositioning the to the next operation point by service

was described by Doubrovsky & Meshcheriakov, 2015. It

crane. It is used for installation of single piles, (anchor,

was displayed, that the implementation of the C methodstabilization piles), including the piles of increased

together with the accuracy of the pile installation cutsliability by PM СО-450 in case when the safety of nearby

down the production time providing higher productivity.

buildings is the determining factor. The P method remains

However, in the restricted workspace, reconnection ofindispensable in conducting pile works under conditions

modules is difficult due to the limitations of the serviceof maximum proximity to existing structures, foundations,crane operation area, especially on cites with weak,communications (less than 1m for concrete piles, and lesswater-saturated soils. There is a need for some additional

than 0.5m for steel sheet piles), during reconstruction,

operations rising the machining time, such as therestoration foundations of the historical buildings.

equipment repositioning by a crane into a new working

Average productivity of P piling method is not more thanspace, MCSS remounting, PM reanchoring. Again, there

one installed concrete pile per hour.

is an interruption of the main technological process, and3.3. Lineal method

as a consequence, the impossibility for automation.

The lineal (L) piling method represents the PM
one-coordinated movement along the longitudinal X

3.5. Flow-production method
The new method for a pile foundations construction,

coordinate and along the axis of the pile row, using fixedbased on the modular support system (Meshcheriakov,

longitudinal skid tracks as exemplified in Fig. 2.

2017) of three longitudinal guides and two crosscarriages (the main and auxiliary) processing equipment
for moving along the longitudinal X and transverse Y
coordinates as exemplified in Fig. 3.

Fig. 2

Sheet piling by lineal method

This method is used for single-row arrangement ofbuilding elements: reinforced concrete piles, steel tubes,
sheet piles ets. The advantages of the L method are
obvious for all types of linear works, be it cutoff andretaining walls of sheet pile type or a single-row
anti-landslide

concretepilestructures.

The

labor

productivity is significantly increased in comparison with
the P method, but it is still insufficient for multi-row pile
structures, because of the need for frequent readjustmentof the main technological process.
3.4. Coordinate method
The coordinate (C) piling method represents the PM
two-coordinatedpositional

movement

along

Fig. 3Longitudinal guides; 3 – Main cross carriage (transverse

thelongitudinal X and transverse Y coordinates, using theModular support system: 1 – Piling machine; 2 -guides); 4 – Auxiliary carriage; 5 – Pile; 6 – Carriage slides; 7,
8 – Driving cylinders

cross carriage 3, as shown in Fig. 1.

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Proceedings of the First International Conference on Press-in Engineering 2018, Kochi

Fig. 4The layout of the flow-production piling method by MAPS

This construction method is used for multi-row andcontinuous

arrangement

of

piles

for

large-scale

After installation of all piles in Z1, the PM moves to thenext operating space Z2, as exemplified in Fig. 3, 4.

production. In accordance with the proposed method, theThe main process is repeated: pile installation –assembly of the aggregate module of MAPS (Fig. 3) ismachine displacement. At the same time the PM canperformed

execute the cross slide motion in the desired direction.

first,

includingthemountingofthelongitudinal guides 2 and the cross carriage 3, with slides

The remounting of support system is done

6 and driving cylinders 7 and 8. The main axis (X, Y) of

simultaneously. PM 1 shifts from the auxiliary carriage 4

the modules are controlled, related to the modular

to main cross carriage 3 by driving cylinders 6. The main

coordinating grid of the building/structure. Then thetechnological process is followed inside operating space

mounting of the main cross carriage 3 on the longitudinal

Z3. After installation of all piles in Z3, the PM shifts to theguides 2 is performed. The mounting of the machine 1 on

next working position, depending on the direction of

the carriage 3 is followed. Then we connect the hydraulicpiling. At the same time in prolongation of module 1,

system of the module to the PM and mount anchor loads

module 2 is attached by crane, as shown in Fig. 4.

by a service crane. After anchoring the control of the PM
horizontal position is finally performed.

When installation of piles in the operating space Z3
of module 1 is completely finished, the PM shifts to

The main process (pile installation – machinemodule 2 into Z4. PM movement along the X axis ofdisplacement) inside operating space Z1 is followed. The

building is carried out by a method of modules sequential

mounting

reconnection (Wahler, Meshcheriakov, 2010).

of

the

supportsystemisperformed

simultaneously, without the main process interruption.

At thesame time, auxiliary cross carriage 4 can be used to mountThe additional longitudinal guide 2 and auxiliary

additional technological equipment 10 (Fig. 4) on it:

carriage 4 is mounted by a service crane 6. Coordinating

boring machine, crane manipulator, mechanisms foraxis distance (X - Y) and relations to the modular gridstone-columns, vertical energy wells, «smart piles» etc.

system of the structure are permanently under control.

The functional interchangeability and modular
aggregative principle allows to reuse the standard- 364 -

Proceedings of the First International Conference on Press-in Engineering 2018, Kochi

elements of the MCSS in various combinations. It also
takes into account the standard geometrical parameters ofpile foundations for civil buildings and makes it possible
to cover the entire range of classified piling methods withjust one set of equipment.
4. Construction process
4.1. Layout
Technological process parameters and MAPS
effectiveness can be well illustrated on the example ofthe construction of a residential complex with its
underground space ‘Park Fontanov’, Odessa, Ukraine.
The complex is erected on a land plot of 12.8 hectares
Construction algorithm: 1 – Piles installation by

and consist of ten buildings with nine floors andFig. 5underground car parking.

MAPS; 2 – Piles heads stripping; 3 – Grillage construction

Performed: Sept. 2017 – Feb. 2018.

(underground); 4 – Erection of building (overground)Foundation: more than 1800 installed concrete piles per abuilding. Pile type: reinforced concrete pile С140.35-9
and C120.35-9 with a cross-section 350×350 mm and4.2. Technological process modeling
The technological modeling of the construction

length 14,0 m and 12,0 m.

processes for sections of a pile foundation for a multistory

Site conditions: soil subsidence properties (claybuilding of 126 piles, was performed by three pilingloam with limestone layers) category - ΙΙ. The category

methods, according to the classification: Point (P), Linealof soils is ΙΙ, according to seismic properties.

(L) and Coordinate (C).

Background seismicity of the site - seven points.
Groundwater is at 10.5 m. The project provides the

The main technological processes for three piling
methods have been identified:construction of a pile foundation by installing precast– preparations, major axis control;

piles by sections. Pile heads have to be installed into

– MCSS assembly, mounting, anchoring;prescribed depth (- 3 m) below the ground level without– pile installation (basic automated process);auguring and any soil extraction, in a short time period.

– positional displacement of the machine;

According to the project the full-scale physical modeling,– modules sequential reconnection;

piles installation and testing were made without any– machine unloading, MCSS disassembling.

additional equipment, essentially requiring no temporary

The following parameters have been determined forwork. It was allowed to determine the optimum

the three piling methods: duration, productivity, labor andparameters to realize the flow-production method of

operating cost to the entire scope of piling work and per

construction.

unit of output (one pile). The labor cost for the main

Equipment: Aggregative Piling System; PM SO-450

operating processes are given in table 2.

and a modular coordinating skidding system MCSS.

Table 2. Labor cost, section 126 piles

Piling data: The insertion force was from 1700 kN
to 2000 kN, respectively, for the pile length 12.0 m andProcesses labor cost, man-hour

P

L

C

14.0 m. The insertion speed was from 2.0 m/min to 1.5

Assembly, reanchoring

536.8

16.5

6.7

m/min and the speed of PM positional displacement was

Installation – displacement

54.5

58.7

58.7

Modules reconnection

-

6.0

2.0

Unloading, disassembling

263.4

7.8

4.4

2.1 m/min. The integrated construction process of a piles
installation by MAPS with the flow-production C
method, together with the construction algorithm for a
multistory building by sections is presented in Fig. 5.

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Proceedings of the First International Conference on Press-in Engineering 2018, Kochi

Data given in table 3 display the construction

4.3. Productivity & labor cost
There was a significant decrease in labor cost for theprocess parameters for three piling methods: point (P),identified most labor-intensive operating process, the PM

lineal (L) and coordinate (C) together with thereanchoring by a crane. It is more than twice for C method,flow-production automated (A) method while using thein comparison with L method and more than thirty times

modular support system (3.5). It covers the entire range ofcompared to P method. The process for sequential

classified construction methods with just one set of pilingreconnection of modules by crane decreased three times

equipment.

from 6.0 (L) to 2.0 (C) man-hours, with constant

The use of MCSS decrease the production time sevencharacteristics for the basic process for each method, as ittimes and labor inputs of the crane more than eight times,

is displayed in table 2. The labor cost for the whole scopewith constant characteristics for the basic process, asof piling work was decreased from 856 (P) to 92 (L) andexemplified in Fig. 7. This is the main distinguishingto 77 (C) man-hours, section of 126 piles. It is less thanfeature of the automated construction processes.
The total duration and cost (UAH) of the entire pile

ten times, when using MCSS by C method.
Reducing the labor costs of workers more than ten

work by C method including equipment operational costs,

times, and, respectively, seven times for the crane operator

have been decreased five and seven times, respectively, inas shown in Fig. 6, as well as reducing the operating costs

comparison with the P method, as exemplified in Fig. 8.

of equipment more than seven times, was made possible
by solving the issue of remounting and reanchoringprocesses, Table 2.

Fig. 7

Fig. 6

Machines inputs for three piling methods

Labor costs for three piling methods

It was found that the coordinate piling method, with
the MCSS use, is characterized by an increase in laborproductivity, more than five times, as displayed in table 3.
We took into account direct production time andmachining time for: mounting MCSS, anchoring machine,
reconnection of modules, unloading and disassembly
processes.

Fig. 8

Cost of work

Тable 3. Construction process parameters

Crane operating inputs decreased from 419 t per pile
Parameter \ Method

P

L

C

A

for P method to 8.5 t per pile for C method and almost

Productivity, pile-hour

0.63

3.17

3.52

4.0

two times, in comparison with the L method (16.0 t per

Labor, 1 pile, man-hour

6.8

0.7

0.6

0.5

Movable mass per 1 pile, t

419

16.0

8.5

6.0

pile).

If a flow-production method (A) is used, thisfigure is 6.0 tons per pile (table 3) while the mass of thereinforced concrete pile (С120.35-9) which has to befeeded by a crane is more than 3 tons.

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Proceedings of the First International Conference on Press-in Engineering 2018, Kochi

Initially

both

the

semi-tubes

aredriven5. Pile installation with prevention of the soil plug
The problem of soil plug of open end pile is wellsimultaneously like one solid tube until the soil resistanceknown and there are various proposals to solve theremains low (step 1). After that the semi-tubes are driven

problem. (De Nicola & Randolph, 1997, White et al.,alternatively. Step 2 includes pressing-in of one of the2000). Regarding possibilities of Press-In Method somesemi-tubes (the left one); step 3 includes pressing-in of

innovations were worked out to facilitate tubular piles

another semi-tubes (the right one). Steps 2 and 3 are

driving for hard soil conditions and/or for case of longalternated until the pile reaches the target depth. At thepiles (large penetration depth).

final

step

both

semi-tubes

arepressed-in

again

simultaneously (if necessary).
5.1. Tubular pile formed by “semi-tubes”
Soil plug initiation of open end pile during

only, tubular open end pile is driven without forming of

installation can be prevented by splitting the tube into

soil plug. After achieving the target depth, both thetwo semi-tubes “1” connected by interlocks “2” (similarsemi-tubular parts of the open end pile may be clamped

to sheet piles interlocks) as shown in Fig. 9 [Doubrovsky

rigidly (crimped, welded, etc.) in the interlocks above the& Litvinenko, 2009, Doubrovsky et al., 2011]. Interlock

ground level to provide their simultaneous action andconnections are to be made parallel to the longitudinalrequired bearing capacity.

Therefore, due to semi-tubes penetration at each step

axis of the tubular pile.

Main advantages of this approach are:This design enables a possibility of applying the(a) possibility to achieve large target depth whenpressing force either on the ring cross-section of theother method is not sufficient because of soil

tubular pile at once or alternately by stepping on theplug effects;

semi-ring cross-sections of each semi-tube. In the latter(b)possibility

to

apply

drivingcase less soil plug is initiated because of the(pressing-in) machine of less capacity to reach

open/unclosed cross-section of the semi-tubular pile.

finally the same target depth as using machine ofRegarding the Press-In Method application wegreater capacity (due to possibility to load theassume that clamping ability of press-in machinesemi-tubular piles alternatively and by stepping

provides reliable catching of the semi-tube for its driving.

instead of driving the open end pile at once);

Sequences of technological operations to install the(c)possibility to avoid such press-in

pile of the considered structure is presented in Fig. 10

auxiliary methods as auguring, water jetting,(here and below presented figures demonstrate only idea

etc.;

and principles without real scale and correlations between
sizes of elements; dash arrows show application of thepress-in forces).

(d)energy/fuel saving because of use ofless powerful equipment;(e)positive ecological effect due to useof less powerful equipment, avoiding drilling,jetting, etc.;(f)

simplifying of the pile removal(withdrawing each semi-tube separately alternatively and by stepping).

Fig. 9Tubular pile made of semi-tubes

1 – semi-tubes; 2 - interlocks- 367 -

Proceedings of the First International Conference on Press-in Engineering 2018, Kochi

11

1st step1

1

1

3rd step … and so on …

2nd step

last step

Fig. 10 Installation operations for the tubular pile made of semi-tubes(Fig. 11, application of press-in force is indicated by dot
5.2. Tubular pile with the core bar
The idea of the tubular pile with the core bar isarrows).

based on the following [Doubrovsky & Guseynov, 2015].

pile “1” (Fig. 11, a) to reach target depth and, secondly,

Driving of the open end pile “2” (tube) of designed

pressing-in at once of the open end pile “2” enclosed thediameter “D” follows the driving of the core pile “1” (itcore “1” driven before (Fig. 11, b). So due to advanced

may be tube or any other pile of size/diameter “d”, d<D)core penetration, the tube is driven without forming of

inside the area limited by diameter “D” (Fig. 11, 12).

soil plug. After completing the tube driving the auxiliary

This step includes, firstly, pressing-in of the core

In the case of favorable soil conditions andcore pile may be other removed (withdrawn) as shown in

powerful enough press-in machine, open end pileFig. 11, c (left) or connected with the main open end pile

installation may be provided as just one-step operation

using rigid coupling “3” to increase tube’s strength andbearing capacity as presented in Fig. 11, c (right).

3

1

2

2

2

1

or
1

a

b

Fig. 11cTubular pile with the core bar: one-step installation- 368 -

Proceedings of the First International Conference on Press-in Engineering 2018, Kochi

In the case of unfavorable soil conditions and/or not

After completing tube driving at the last step, thepowerful enough press-in machine, open end pile driving

auxiliary core pile may be either withdrawn as shown in

may be provided as multistep installation (Fig. 12).

Fig. 12, g or connected with the main open end pile using
rigid coupling “3” to increase the tube’s strength andDriving both the piles (core pile first, tubular onenext) is conducted alternately and by stepping until

bearing capacity as presented in Fig. 12, g.

achieving the target depth of open end pile installation.

Regardingpeculiarities

of

the

considered

Step 1 (Fig. 12 a, b) includes driving the core pile “1”technological operations and in order to simplify andand driving the open end pile “2” then. During the step 2

speed up the proposed multistep installation, two drivers(Fig. 12 c, d) the core pile “1” is driven inside the tube “2”can be used simultaneously: press-in piler drives theand then tube “2” is driven along the core pile “1”. Step 3

tubular external pile (pressing force is applied close torepeats the step 2 at the newly achieved depth of driving,

the ground level) while another machine (impact orand the process continues for the following steps.

vibro) hammer drives the internal core pile acting at the

The total number of steps depends on the target

pile head.

depth and the available driving depth of the core and tube

In the general case the described approach may

at every alternation. As the result of the multistep

be successively applied for several coaxial tubular piles

installation process, the tube is driven without forming of

forming the overall tube of the required very large

the soil plug. Additionally, due to the advanced tube’s

diameter. Here every tube, which was an outer one

penetration the core pile driving is facilitated.

relative to the inner core, is used as the core relative tothe following outer tubes of larger diameters.

a

b

c

d

e

f

g

c

2

3

2
2
2

1

2

1

or
1

2

1

1

1

1st step

2nd step

Fig. 12

3rd step … and so on …

Tubular pile with the core bar: multistep installation- 369 -

last stepProceedings of the First International Conference on Press-in Engineering 2018, Kochi

6. Concluding remarks
The piling technology, created by EC Transzvuk,

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