COMBI-GYRO WALL SYSTEM- High Modulus Steel Combined Wall Ver. Tube / Z Wall Vol.2 Construction

Z Sheet Piles(Intermediate Elements)

WeldingConnection Plates
Tubular Piles(Primary Elements)

Table of Contents
Chapter 1Introduction ······················································································································1

Chapter2

Standard Procedure ·········································································································2
2-1 Overall Procedure ·······································································································22-2 Initial Piling (Sheet Pile) ······························································································32-3 Initial Piling (Tubular Pile) ···························································································42-4 Installation Working Procedure (Sheet Pile) ······························································52-5 Installation Working Procedure (Tubular Pile) ····························································62-6 Extraction Working Procedure (Sheet Pile) ································································72-7 Extraction Working Procedure (Tubular Pile) ·····························································8Chapter3Work Layout ·····················································································································93-1 Standard Operation of Sheet Piling (Above Ground) ·················································93-2 Standard Operation of Tubular Piling (Above Ground) ············································103-3 Standard Operation of Sheet Piling (Above Water) ··················································11
3-4 Standard Operation of Tubular Piling (Above Water) ···············································12
3-5 GRB Operation (Non-staging Method) ·····································································13

Chapter4Machine Specification ····································································································144-1 Machine Specification (for Sheet Piling) ··································································144-2 Machine Specification (for Tubular Piling) ·······························································16

Chapter 1Introduction

The purpose of this document is to provide practical guidelines for the construction of the Combi-GyroWall.
The intended audience for this document is engineers and construction specialists involved in the design,construction, and contracting of foundation elements for infrastructures.
The press-in piling method is commonly used worldwide because of its very quiet operation, ultra lowvibration, and flexibility of sizes to suit different wall properties and subsoil conditions.
The main attributes of the Combi-Gyro Wall are efficiency of physical wall properties and reusability. TheCombi-Gyro Wall comprises steel tubular piles as the primary element and steel sheet piles as thesecondary element. The efficiencies of physical wall properties can be optimised in view of the flexibilityof pile size and the spacing of tubular piles for the ground conditions and the form of the loading. The
Combi-Gyro Wall is installed by the press-in method and pile penetration force is monitored andrecorded throughout the piling operation. This thorough monitoring and recording system alleviates
concerns of quality control, as well as providing a comprehensive quality control method for a
performance-based contracting process.
This document provides a description of construction equipment and procedures of the Combi-Gyro
Wall.

1Chapter 2Standard Procedure

2-1 Overall Procedure
2-1-1 Installation of Sheet Piles
Silent Piler F401-1400
Z Sheet Pile

2-1-2 Installation of Tubular Piles
Gyro Piler F401-G1200

Tubular Pile

Skiplock Attachments

2-1-3 Joining Tubular Piles and Sheet Piles by Welding

Z Sheet Pile

Welding Connection
Tubular Pile2

2-2 Initial Piling (Sheet Pile)

Saddle & Clamps

Chuck
Mast

Reaction Stand

1.Setting of Reaction Stand on level ground2.Fixing of Saddle & Clamps to Reaction StandChuck3(a).Fixing of Mast (or Preassembled Mastand Chuck) to Saddle

Sheet Pile
Counter Weights

3(b).Fixing of Chuck to Mast (if Chuck isseparately assembled)

4.Loading of counter weights

5.Pitching and installation of first pile

6.Installing of piles until Silent Piler can operate
solely on reaction piles

7.Removing of counter weights

8.Removing of Reaction Stand and initial pilingis completed3

2-3 Initial Piling (Tubular Pile)

Saddle & Clamps
Reaction Piles

1.Installing of sheet piles as reaction piles
Note: The sheet pile length for initial reaction
force is determined by site conditions

Reaction Stand

2.Fixing of Reaction Stand to reaction piles
by bolts and welds

3.Fixing of Saddle & Clamps to Reaction StandSaddle & Clamps:
10.25 ton (Ø 800mm)
11.00 ton (Ø 1000mm)
11.00 ton (Ø 1200mm)

Chuck
Mast

4.Fixing of Mast to Saddle

Tubular Pile

5.Fixing of Chuck to Mast
Chuck:
12.80 ton (Ø 800mm)
12.80 ton (Ø 1000mm)
13.20 ton (Ø 1200mm)

7.Installing of tubular pile

8.Completion of initial piling

Mast: 8.80 ton4

6.Completion of assembly of Gyro Piler
F401-G1200
Total mass of Gyro Piler F401-G1200
31.85 ton (Ø 800mm)
32.60 ton (Ø 1000mm)
33.60 ton (Ø 1200mm)

2-4 Installation Working Procedure (Sheet Pile)
Sheet Pile

Silent Piler

Clamps
1.Installing of pile to prescribed depth

2.Pitching and installation of next pile

3.Installing of pile until the pile has
sufficient bearing capacity

4.Releasing of clamps and raisingmachine body

5.Moving of machine body forward

6.Lowering of machine body andgripping reaction piles

7. Completion of pile installation5

2-5 Installation Working Procedure (Tubular Pile)

Tubular Pile
Driving Attachment
Gyro Piler

Chuck1.Pitching of tubular pile into chuck

2.Aligning of pile to installation tolerances

3.Installing of pile until the pile has
sufficient bearing capacity

4.Releasing of Clamps and raisingmachine body

5.Moving of machine body forward

6.Lowering of machine body andgripping Skiplock Attachments

Skiplock Attachment

Driving Attachment

Driving Attachment

7.Pitching of Driving Attachment onto
top of pile and installing pile toprescribed depth

8.Relocating of rear end Skiplock
Attachment to front end

6

9.Pitching of Driving Attachment onto
Skiplock Attachments

Tubular Pile

10.Self-moving of Gyro Piler(Repeating sequence 4-6)

11.Repeat 1-10 until completion

2-6 Extraction Working Procedure (Sheet Pile)

Sheet Pile
Silent Piler
ChuckClamps
1.Partial extraction of sheet pile with
Silent Piler

2.Releasing of Clamps and raisingmachine body

3.Moving of machine body rearward

4.Lowering of machine body andgripping reaction piles

5.Completion of pile extraction

6.Handling and stacking of sheet pile
Repeat 1 to 6 until completion72-7 Extraction Working Procedure (Tubular Pile)

Driving Attachment

1.Pitching of Driving Attachment into
tubular pile

2.Partial extraction of tubular pile with
Driving Attachment

3.Removing of Driving Attachment

4.Releasing of Clamps and raisingmachine body

5.Moving of machine body rearward

6.Lowering of machine body andgripping Skiplock Attachments

Tubular Pile

7.Completion of pile extraction

8.Handling and stacking of tubular pile
Repeat 1 to 8 until completion

8

Chapter 3

Work Layout

3-1 Standard Operation of Sheet Piling (Above Ground)Power Unit
Piling Direction
Sheet Pile

Silent Piler

Trench Excavation
Pile Line

Service Crane

Sheet Pile Bundle

Plan View

Sheet Pile

Power Unit

Service Crane

Silent Piler

Trench ExcavationSectional View

9

3-2 Standard Operation of Tubular Piling (Above Ground)
Skiplock Attachments

Gyro Piler

Piling Direction
Water Lubrication System

Power Unit

Driving Attachment
Service Crane

Tubular Pile

Plan View

Service Crane
Driving Attachment

Tubular Pile
Gyro Piler

Power Unit

Sectional View

10

3-3 Standard Operation of Sheet Piling (Above Water)
Z Sheet Pile

Power Unit

Piling Direction

Crane Barge

Silent Piler

Piler Stage

Welding Machine

Generator

Z Sheet Pile

Plan View

Silent Piler

Z Sheet Pile

Sectional View

11Piler Stage

3-4 Standard Operation of Tubular Piling (Above Water)
Z Sheet Pile

Tubular Pile

Power UnitGyro Piler

Crane Barge
Piler Stage

Welding Machine

Generator

Tubular Pile

Plan View

Gyro Piler
Tubular Pile

Sectional View

12Piler Stage

3-5 GRB Operation (Non-staging Method)
Clamp Crane

Unit RunnerPower Unit

Rail for Pile Runner
Tubular Pile

Pile Runner

Gyro Piler
Piler Stage

Piling Direction

Service Crane

Tubular Pile

Plan View

Clamp Crane

Unit RunnerPower Unit

Rail for Pile Runner
Tubular Pile

Pile Runner

Gyro Piler

Piler Stage

Sectional View

13

Chapter 4

Machine Specification

4-1 Machine Specification (for Sheet Piling)
4-1-1 Silent Piler F401-1400
Super Crush ModeF401 - C1400

F401

SILENT PILERZ Sheet Piles 559 ~ 708 mm

Applicable sheet piles(Super Crush Mode 572 ~708 mm)

U Sheet Piles 600, 700 mm
with WU Chuck Attachment

Max. Press-in Forse
Max. Extraction Forse

Auger Motor
Hose Reel Bracket
33000 (For sheet pile length 24m)

Hose Reel

Casing Auger

Casing Chuck

1200 kN (Super Crush Mode)
1500 kN (Standard / WJ Mode)
1600 kN

Stroke1000 mmPress-in Speed

1.3 ~ 27.0 m / min (Standard Mode)

Extraction Speed

1.0 ~ 20.2 m / min (Standard Mode)Control System

Radio Control

Movement

Self - Moving

Super Crush Mode

30670 kg

Mass Water Jetting Mode

26850 kg

(Main Body, Piler Jet Reel, Casing Chuck)(Main Body, Piler Jet Reel)

Standard Mode

25600 kg

(Main Body)

HR17E

Hose Reel
Mass (Standard)

2770 kg(including Hose Reel Bracket)

Pile Auger
Applicable pile length(Standard)
Mass

F401 - 1400
Piler Jet Reel is an optional item

Piler Jet Reel
JR29

At Extraction

14

Max 24 m*Auger Motor

2540 kg

Casing Auger

18260 kg

Total Mass

Standard / Water Jetting Mode

PA20

20800 kg
*Up to 30m with modification

Piler Jet Reel

JR29

Applicable pile length

Standard 16.0 m

Mass1250 kg

4-1-2 Power Unit EU 300K4Power Unit

EU300K4

Power Source
Rated Output

Diesel Engine

Power Mode

265 kW (322 ps) / 1800 min-1

Eco Mode

236 kW (287 ps) / 1600 min-1

Super Eco Mode

206 kW (250 ps) / 1400 min-1

Fuel Tank Capacity

600 L

Hydraulic Reservoir

Piler Eco Oil 630 L

Urea Additive Tank Capacity

38 L

Moving Speed

1.4 km / h

Mass7250 kg (with 20m Hose)

Leveling JackAt Transportation
2250

4-1-3 Reaction Stand

Reaction Stand (with Leveling Jack)
Mass

3950 kg
The above specifications are subject to alteration without prior notice.

At Transportation 7035

15

4-2 Machine Specification (for Tubular Piling)
4-2-1 Gyro Piler F401-G1200
for Ø 1200mm
SILENT PILER
Applicable sheet piles
Max. Press-in ForceMax. Extraction Force
Chuck Rotation TorqueF401-G1200
Tubular Pile Ø800, 1000, 1200 mm
Tubular Sheet Pile Ø800, 1000 mm*1
with Chuck Rotation*21500 kN

without Chuck Rotation

2000 kN

with Chuck Rotation*2

1600 kN

without Chuck Rotation

2200 kN

900kN・m(Emergency use up to 1050kN・m)

Chuck Rotation Velocity

MAX 11.0 min-1

Stroke1000 mmPress-in Speed

0.7 ~ 4.9 m/min

Extraction Speed

0.7 ~ 3.5 m/min
for 800mm

850 ~ 1320 mm

Applicable Pile Spacingfor 1000mm

1050 ~ 1320 mm

for 1200mm

1250 ~ 1505 mm

Control System

Radio Control

Massfor 800mm

31850 kg

for 1000mm

32600 kg

for 1200mm

33600 kg

*1 For Tubular Sheet Piles (Tubular Piles with external interlocks),
optional Chuck jaws are required.
*2 An external power source is required for Chuck rotation( 200V - 50/60 Hz, 220V - 60Hz, Min. 30KVA, 3 phases )4-2-2 Piler Stage ST48

-18-Saddle Stage

ST48

Piler Stage
Load Capacity

Leader Mast Stage
Saddle Stage

Stroke 900

Stroke 900

Leader Mast Stage

16Mass2035 kg

550 kg (When set both sides)
300 kg (When set one side only)
300 kg4-2-3 Power Unit EU 500C3Power Unit

EU500C3Power Source
Rated
OutputDiesel Engine

Power Mode

377 kW ( 513 ps) / 1800 min-1

Eco Mode

335 kW ( 456 ps) / 1600 min-1

Super Eco Mode

293 kW ( 399 ps) / 1400 min-1

Fuel Tank Capacity

850 L

Hydraulic Reservoir

Piler ECO Oil 660 L

Moving Speed

1.4 km/h

Mass10950 kg (with 30m Hose)

4-2-4 Water Lubrication System OP114A
Lubrication SystemOP114A

Input Voltage (3 phases)

AC200V, 50 / 60 Hz, 24 KVA or more

Water Pump Discharge Rate

Max. 60 L / minWater Pump Discharge Pressure Max. 6 MPa
Outer Tank Capacity (W×D×H)

1505 × 755 × 1230 mm

Water Tank Capacity300 L

Mass (without water)

410 kg

The above specifications are subject to alteration without prior notice.

SwiveWater Hose

Water Pipe
Generator
Tap Water

Submerged Pump
*Water Supply by
Tap Water orSubmerged

Water Outlet(Inside the tubuler pile)17

4-2-5 Driving Attachment
Driving Attachment AM69A
D800mm Form

AM69A

Driving Attachment
Applicable Closure Pile

200 × 200 × t20 - 25

(Equal Angle Section)

250 × 250 × t20 - 25

Mass2000 kg

Driving Attachment AM105D1000mm Form

D1200mm Form

Driving Attachment
Applicable Closure Pile
(Equal Angle Section)
Mass

18

AM105
200 × 200 × t20 - 25
250 × 250 × t20 - 25
3300 kg (D1000mm Form)
4500 kg (D1200mm Form)

4-2-6 Skiplock attachment (AM157)

Tubular Pile

Gyro Piler

Driving Attachment

Skiplock Attachments

4-2-7 Reaction Stand

Sheet Pile
Ø 800/1000/1200

Tubular Pile Ø 800/1000/1200

Bolt Hole Ø 24

Sheet Pile

19

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Ver2.0EN04 / 09 Jun 2023