Construction Revolution
Overcomes restrictions on working space to build a continuouspressed-in pile wallwithout constructing temporary facilities
THE FIVE CONSTRUCTION PRINCIPLES
If we analyse all the parties involved in any construction
work, we can categorise them into three main groups: theclient, the contractor and the general public. The ideal
situation is when all three parties are in agreement andsatisfied with the successful outcome of the construction
work. Problems arise when one of the parties becomes a
victim of imbalance in this relationship. The conventional
construction methods based upon principles that "more ispaid for less efficient work" are no longer appropriate topresent-day society. Universally acceptable construction
methods must embody the Five Construction Principles.

Environmental
Protection

Construction work should be environmentally friendly and freefrom pollution.

SafetyConstruction work has to be carried out in safety and comfort witha method implementing the highest safety criteria.

SpeedConstruction work should be completed in the shortest possible
period of time.

EconomyConstruction work must be done rationally with an inventive mind
to overcome all constraints at the lowest cost.

Aesthetics

Construction work must proceed smoothly and the finished productshould portray cultural and artistic flavour.

Construction Solutions Company
GIKEN LTD.

www.giken.com

Global Network : Japan, UK, Germany, USA, Singapore, China

International Business Department
3948-1 Nunoshida, Kochi-shi, Kochi 781-5195, JapanFor more contact information, please visit:

Tel. : +81-(0)88-846-2980 Fax : +81-(0)88-826-5288

http://www.giken.com/en/contactus/groupcompanies

Email : international@giken.com© 2014 GIKEN LTD. All Rights Reserved.

www.giken.com
Ver 2.0EN01 / 28 Feb 2014

Non-Staging Method
GRB System

Construction Revolution

Introduction

Non-Staging Method

Contents

In construction projects, provisional facilities, such as temporary piers, work platforms, and soon, have generally consumed a great deal of money, time and energy, accounting for around
70% of the total construction costs, with only 30% being spent on the target structure.
But the "Non-Staging Method" solves the problem of wasteful temporary measures, byharnessing the superiority of the press-in principle. This method is based on the "GRB system"
which uses the top of completed piles as a work platform to carry out all the steps of thepress-in procedure - transporting the pile, pitching the pile and pressing it in. All of themachinery in the system supports itself by gripping installed piles, which means there is no riskof overturning. Also, the area affected by the work is restricted to the width of the actualmachine, so various restrictions on the working space can be overcome.
This method has no need at all for temporary facilities, such as piers or roadways, even whenworking over water, on sloping or uneven ground, in narrow spaces, or with restricted
headspace. Freed from these temporary measures, the construction work can focus efficiently
on the actual objective, which is building the intended structure. In this way, the Non-Staging
Method achieves a truly excellent balance between the Five Construction Principles:
Environmental Protection, Safety, Speed, Economy and Aesthetics.

■ Overview of Non-Staging Method ‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 1■ System Equipment
Clamp Crane CB1 ‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥
Clamp Crane CB2 ‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥
Clamp Crane CB3 ‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥
Clamp Crane CB4 ‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥
Clamp Crane CB5 ‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥
Pile Runner PR1 (for Sheet Piles) ‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥
Pile Runner PR217 (for Tubular Sheet Piles and Tubular Piles) ‥‥‥‥‥‥‥
Unit Runner UR3, Stage ST17 (for UR3) ‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥■ Applications & Reference
U Sheet Piles ‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥
Zero Sheet Piles (NS-SP-J) ‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥
Concrete Sheet Piles ‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥
Hat Sheet Piles ‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥
Tubular Sheet Piles ‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥
Tubular Piles ‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥

3
3
4
4
4
5
5
5

6
6
7
7
8
8

■ Standard Press-in Procedures
Press-in Procedure Diagram ‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 9
Clamp Crane Self-moving Diagram ‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 10■ Sekisan ‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 11■ Technology : Rail Safe System ‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 11■ Work Management
EMOS Eco Monitoring System

Flood Control Work in a residential area using the Non-Staging Method‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 12

Construction Revolution

Non-Staging Method

Overview of Non-staging Method
A construction system that does away with temporary installations,and the waste they cause in the construction process,and overcomes work space restrictions.

Non-Staging Method

Conventional Excavation Method

No Effect on Water Flow or Neighbouring Area

Water Flow and Water Traffic Cut Off, Oppressive Effect on Surroundings

The Non-Staging Method employs the "GRB system" in which all of the equipment involved in the press-in work
advances along the top of the installed piles. This removes the need for wasteful temporary structures, so that all of
the work is focused efficiently on the wall structure, which is the actual objective. Because the system is light andcompact, it doesn't obstruct water flows or traffic, even when used in water course improvements or trackside
construction work in built-up areas, or road widening on busy highways, etc. This saves both time and money.

■ Standard Components of GRB system
The GRB system is composed of the press-in machine main body, which is the key element that presses the pile into
the ground, accompanied by a power unit providing a source of hydraulic power, a unit runner to move the power unit,a clamp crane to pitch the pile, and a pile runner to transport the pile from the work base.

Piling Direction of Press-in Work
Pile being pressed-in
Silent Piler(Presses in the Pile)

Piler Stage(Work Platform)

Power Unit
(Power Source)

Clamp Crane(Pitches the Pile)

Unit Runner(Transports the Power Source)

Pile Runner(Transports the Pile)

Without using any temporary structures, a revetment is built with an implant structuraldesign of piles that are integrated with the Earth.

■ Features of Non-Staging Method◇ No Temporary Structures are Required
With this system, piling work is carried out on top of installed piles, so no temporary pier is necessary.
(Saves Time and Costs)◇ Work is Possible in Tight Conditions where Conventional Methods
are Difficult
The compact size of the system makes it perfect for working in tight conditions, e.g. over water or on sloping
ground.

◇ Respectful of the Surrounding Area
The press-in method uses static load, so it hardly creates any noise or vibration. The area affected by thepress-in work is restricted to the width of the machinery only, thus protecting the surrounding area.

◇ Excellent Safety with No Risk of Overturning
The press-in machine, clamp crane, and other system equipment are designed to grip firmly onto
completed piles, which means there is no risk of overturning.

Construction works can be carried out with Environmentally-friendly considerations,lower cost and shorter work duration at any work conditions.
12

Construction Revolution

Non-Staging Method

System Equipment
Clamp Crane CB3

②

2000
1700

Clamp Crane CB1

①

5060
10275

3170

③

Model

CB3

Crane Capacity

10.0 ton × 6.5 m

Max. Working Radius

30.0 mCompatible Piles Tubular Sheet Pile φ700-900④

Mass
ModelsCrane Capacity

CB1-7

CB1A

CB1B

2.93 ton × 4.5 m

2.95 ton × 5.0 m

2.95 ton × 5.0 m
15.67 mU Sheet Pile 400-600 pitch
Hat Sheet Pile 900 Pitch

U Sheet Pile 400-600 Pitch
Hat Sheet Pile 900 Pitch

Mass

4500 kg

5170 kg

5200 kg① Width

960 mm

960 mm1000 mm② Main Body Width

810 mm

810 mm

900 mm

③ Height

2475 mm2475 mm2570 mm④ Length5670 mm5690 mm

5800 mm

0
12115

2800

4705

Compatible Piles30

15.67 mClamp Crane CB4
R1

12.0 mU Sheet Pile 400-600 Pitch
Hat Sheet Pile 900 Pitch
Zero Sheet Pile (NS-SP-J)
Concrete Sheet Pile KF100〜150H

Max. Working Radius

18800 kg

Clamp Crane CB2

Model

CB4

Crane Capacity

20.0 ton × 7.0 m

Max. Working Radius

34.0 mCompatible Piles Tubular Sheet Pile φ800-1500
Mass

46300 kg

3300

R9

50

3000

R1

50

0

1870

Clamp Crane CB5

6240
8800
17700

Crane Capacity

2.9 ton × 6.0 m

Max. Working Radius

22.6 mCompatible Piles

U Sheet Pile 400-600 Pitch
Hat Sheet Pile 900 Pitch

Mass

3

12500 kg

* Product specifications may be changed without prior notice.

5780

CB2
4800

Models

3000

980

3230

14700

Model

CB5

Crane Capacity

50 ton × 12 m

Max. Working Radius

47.0 mCompatible Piles

Tubular Sheet Pile φ800-1500

Mass

130000 kg* Product specifications may be changed without prior notice.

4Construction Revolution

System Equipment

Applications & Reference

U Sheet Piles

Pile Runner PR1 (For Sheet Piles)
Rail Support Section

2150

475

Reference

Improvement Work for Coastal Protection Facilities (Tidal Surge Protection),
Kitanoe Aihara District, Embankment Strengthening Project No. 2

Yamaguchi Prefecture

No temporary platform required, resulting in shorter timeframe and reduced costs. Rapid completion with no impact
on the ecosystem, working on the inside of an embankment in an area inhabited by endangered species.

Transporting Rail(Type II Sheet Pile)

670

770

Non-Staging Method

Rail Support

Model

PR1

Carrying Capacity

5.0 t
Towing Rig 645 kg

920

Mass

Carriage

140 kgCompatible Piles

U Sheet Pile 400-600 Pitch
Hat Sheet Pile 900 Pitch
Zero Sheet Pile (NS-SP-J)
Concrete Sheet Pile 500 Pitch

Transporting Rails

U Sheet Pile II

Total Mass

Type Ⅱw Sheet Pile
L = 7.0-11.5 m

Habitat ofhorseshoe crab

785 kgPile Runner PR217 (For Tubular Sheet Piles and Tubular Piles)

2430

Habitat of four-spotmidget damselfly

10660

Model

PR217

Carrying Capacity

15.0 tCompatible Piles

Tubular Sheet Pile
φ700-1200 mm

Transporting Rails

N/A

1400

Total Mass

8900 kg

Zero Sheet Pile (NS-SP-J)
Reference* "NS-SP-J" is a sheet pile made by Nippon Steel and Sumitomo Metal.

Route 10-1-3 Kandagawa District, River Repair Work

Kochi Prefecture

Using the GRB system with its safe and compact machinery, the distance between the sheet pile retaining wall andthe houses was minimized to ensure the largest possible water course.
11290

2430

Unit Runner UR3, Stage ST17 (For UR3)
Soil

7955

3485

2790

1590

Model
Travel Speed

10 m/min.

Min. Turning Radius

11 m

Max. Climbable Step

30 mm

Compatible Piles

U Sheet Pile 400-600 Pitch
Hat Sheet Pile 900 Pitch

Mass

U Sheet Pile
L = 8.5 m

Zero Sheet Pile
(NS-SP-J)

CrushedStone

L = 8.5-9.0 m

2350 kg
Model

1045

UR3

ST17 (for UR3)

Mass

720 kgTotal Mass

3070 kg* Excluding Power Unit

3860
* Product specifications may be changed without prior notice.

56

Construction Revolution

Non-Staging Method

Applications & Reference

Concrete Sheet Piles
Reference

Tubular Sheet Piles

Hiraishiebisuno District, Drainage Channel Section 1

Tokushima Prefecture

By adopting the Non-Staging Method with pre-fabricated concrete sheet piles, the effects on the surrounding area areminimized, and the work time is shortened.

Reference

Ujigawa Bridge No. 1 Revetment Repair Work

The compact equipment built a highly rigid and durable revetment without
obstructing traffic

Kyoto Prefecture
Overhead Obstruction

2000

Existing Bridge Pillar

Reinforced Concrete

Concrete Sheet Piles
L = 6.0 m

Tubular Piles

Hat Sheet Piles
Reference

Tubular Pile φ900
L=14.0 m

Akaike Revetment Construction Work

Ibaragi Prefecture

Due to the effective pile width of 900 mm, the number of piles was cut by 33% comparedto wide sheet piles (600 mm), and when combined with the Non-Staging Method, thisbrought cost savings and faster completion.

Reference

Furukawa River Channel Repairs (1)Tokyo

Tubular piles pressed into mudstone and concrete layer. Work completed in narrow space without vibration andnoise, leaving the surrounding houses and apartment blocks unaffected.
550

4080

Concrete
Hat Sheet Pile
L = 8.5-10.0 m

7

500

2200

Tubular Pile φ1000
L = 8.5 m

Mudstone Layer

8

Construction Revolution

Non-Staging Method

Standard Press-in Procedures
Press-in Procedures Diagram

Clamp Crane Self-moving Diagram

symbol indicates that the pile is gripped by the clamp and chuck.

■ For Sheet Piles
Power Unit

Self-moving
Direction

Clamp Crane
Silent Piler
Clamp No.1

Work Base

The press-in machine main body is set

1 in position and press-in work is started.

When a specified number of piles have been pressed in, the power unit, and clamp

2 crane are moved from the work base and set up on top of the completed piles.

1 Clamp No.1 is opened.

No.1 is raised and2 Clampthe crane body is moved forwards.

3 Clamp No.1 is lowered and closed.

No.2 and 3 are moved
5 Clamps
forwards.

No.2 and 3 are lowered and closed,
6 Clamps
and the self-walking procedure ends.

Pile to be pressed-in

Pile RunnerClamp No.3
Clamp No.2

3 Pile runners are laid down and piles are transported to the next installation point.

No.2 and 3 are opened
4 Clamps
and raised.

■ For Tubular Sheet Piles
Reverse-walk

Self-moving
Direction

Clamp No.1
Clamp No.2

4 When pile installation is completed, the assembly reverse-walks back to the work base.

5 Precast reinforced concrete / fronting panels are transported on continuous pile runners, and set in place by the clamp crane.
9

1 Boom raised.

No. 2 is opened and raised,
2 Clamp3 Clamp No. 2 is lowered and closed.
and the equipment is moved forwards.

4 Clamp No. 1 is opened and raised.

5 moved forwards.

The clamp crane main body is

The clamp crame main body is lowered

6 and the self-moving procedure ends.

10Construction Revolution

Non-Staging Method

Work Management

Sekisan
The technical data published by the Japan Press-in Association can be applied to the Non-Staging Method.

EMOS Eco Monitoring System
Monitoring the behaviour of the machinery during construction andthe accomplishment of reliablesafety within regulatory standards
EMOS : The Eco Monitoring System (EMOS) is an immensely flexible environmental monitoring set-up with all thenecessary measuring equipment mounted in a single custom-designed vehicle. The technical data provided by
EMOS gives a scientific demonstration of the superiority of the construction method and the safety and reliability ofthe procedure, which can be shown to clients, local residents and other interested parties.
Environmental Factors Monitored by EMOS
●Safety (Automatic Control of Machinery)

MeteorologicalObservation Devices

Meteorological
Data

GroundDisplacement

Noise andVibration

Safety Limit(Image Processing)

Safety Indicator●Ground Displacement ●Settlement●Slope ●Noise ●Vibration ●Weather

Standard technical data can be downloaded from the Association's website.

ALL IN ONE

EMOS

http://www.atsunyu.gr.jp

Control Displays

Measuring Devices(left side of vehicle)(right side of vehicle)

VehicleLateral Movement Gauge

Introducing Technology

Inclinometer

Microphone

Rail Safe System

The Rail Safe System can of course be implemented near railway tracks, and due to the superiority of thePress-in Principle, piles can be installed at great speed, without any temporary structures, while maintaining anormal train schedule and ensuring the safety of railway traffic. Using the EMOS Eco Monitoring System (p.
12), every detail of the work environment can be monitored scientifically, even in locations with very strict safety
requirements, such as Shinkansen tracks.
Equipment Layout
Pitching (Pile Setter)

Press-inTransport

EMOS Vehicle

Data Transmitter

Laser Settlement Gauge

Vibration Sensor

Construction machinery stopped automatically by image data processing(Systematic Control of Safety)
EMOS uses camera monitoring equipment and image processing to automatically control the operations of theconstruction machines, so that work is carried out within the established safe area. This safety control systemenables fast and cost-effective work that makes maximum use of the space inside the clearance limits, while ensuring excellent safety with regard to nearby structures, cables, and railway and road traffic.
EMOS Measurement in action

Stop Level
Warning Level
BridgePillarMonitoring Camera

The innovative pile pitching action of the GRB
system, using the pile setter, means even better
work safety.
Warning Level

Movements of the Pile Setter

Stop Level

Working Status
Indicator① Grips the pile to be pressed in

11② Lifts the pile

③ Turns the pile to thepress-in alignment④ Pitches the pile in the piler

Safety Monitor

Working Status Indicator

A warning level and stop level can be set in each of four areas
A warning or automatic stop is implemented, depending on the effect on
existing structures
An image is recorded on the management computer whenever there isan abnormality in the warning and stop level detection

Safety Monitoring Status

Noise / Vibration Monitoring Status

Explaining how it works

12Construction Revolution
Overcomes restrictions on working space to build a continuouspressed-in pile wallwithout constructing temporary facilities
THE FIVE CONSTRUCTION PRINCIPLES
If we analyse all the parties involved in any construction
work, we can categorise them into three main groups: theclient, the contractor and the general public. The ideal
situation is when all three parties are in agreement andsatisfied with the successful outcome of the construction
work. Problems arise when one of the parties becomes a
victim of imbalance in this relationship. The conventional
construction methods based upon principles that "more ispaid for less efficient work" are no longer appropriate topresent-day society. Universally acceptable construction
methods must embody the Five Construction Principles.

Environmental
Protection

Construction work should be environmentally friendly and freefrom pollution.

SafetyConstruction work has to be carried out in safety and comfort witha method implementing the highest safety criteria.

SpeedConstruction work should be completed in the shortest possible
period of time.

EconomyConstruction work must be done rationally with an inventive mind
to overcome all constraints at the lowest cost.

Aesthetics

Construction work must proceed smoothly and the finished productshould portray cultural and artistic flavour.

Construction Solutions Company
GIKEN LTD.

www.giken.com

Global Network : Japan, UK, Germany, USA, Singapore, China

International Business Department
3948-1 Nunoshida, Kochi-shi, Kochi 781-5195, JapanFor more contact information, please visit:

Tel. : +81-(0)88-846-2980 Fax : +81-(0)88-826-5288

http://www.giken.com/en/contactus/groupcompanies

Email : international@giken.com© 2014 GIKEN LTD. All Rights Reserved.

www.giken.com
Ver 2.0EN01 / 28 Feb 2014

Non-Staging Method
GRB System