Pile Head Trimming / Cut Off Method Statement [Template]

pile head trimming method statement

What is the pile head trimming /cut off method statement?

Pile head trimming or cut-off method statement is the documentation requirement related to piling works methodology submitted to the project consultant for approval prior to proceeding with its implementation. Failure to secure this approved document is one of the reasons the contractor will receive an issued nonconformity.

What is pile head trimming/cut off?

Pile head trimming or cut off in the construction sequence is exposing the reinforcement for incorporation into the pile cap. Cast in place bored concrete piles should always be poured to a level above the specified cut-off such that, after pile trimming, a sound concrete connection with the pile can be exposed. To prevent the accumulation of the sediments, impurities, and laitance in immigrating from the bottom of the pile to the top, the pile is concreted above the cut-off level. This in turn is trimmed from the cut-off level to remove this weak layer. Trimming should be carried out without resulting damage to the reinforcement, concrete, and instrumentation of the pile.

Pile head trimming method statement – steps to be undertaken for trimming

  1. Site survey

    The site survey shall be carried out, control points and benchmark shall be determined and verified prior to excavation works of platform level, and survey works for the cut-off level (C.O.L).

  2. Excavation of up to 200 mm below the cut-off level

    After piling work has been completed in the construction areas, pile heads shall be exposed around 200 mm below the pile cut-off level.

  3. Marking the pile cut-off level

    After the pile heads are exposed around 200 mm below the pile cut-off level, the cut-off level (C.O.L.) shall then be clearly marked on each pile.

  4. Pile head trimming using an excavator with a pile head breaker

    Option 1 – After the cut-off-level has been marked on the piles, a special designed hydraulic pile breaker attached to an excavator shall be used to break and remove the concrete above the pile cut-off level as shown in PVC pipes placed over the upper dowel length of the pile cage prior to installation of piles shall help prevent any bonding between pile reinforcement and concrete above the cut-off level which shall facilitate the pile head breaking process. When the pointed tip of the piston starts squeezing the pile head, a horizontal shear will start appearing in the de-bonded area causing to detach the pile head from the pile shaft.

  5. Pile head trimming using handheld pneumatic jackhammer (w/ Compressor)

    Option 2 – After the cut-off level has been marked on the piles, a handheld Pneumatic Jack Hammer with compressor shall be used to break and remove the concrete above the pile cut-off level.

  6. Final chipping

    Final chipping is to be carried out using a handheld electric concrete breaker that will enable finishing the pile top to the allowable tolerance from the design cut-off level and in preparation for the surface to receive pile integrity testing.

Pile Head Trimming / Cut off Method Statement [Template]

1. Description of Works

This pile head trimming/cut-off method statement defines the sequence and describes the control procedures of pile head trimming for xxxxxxx project.

1.1. Introduction

This document explains the strategy for the planned excavation of piles up to 200mm below the cut-off level in preparation for the pile trimming activity. The excavation and pile head trimming method statement shall be in concurrence to the sequence of raft foundation pouring sequence to ensure the smooth movement of equipment to be used.

1.2. Definitions
xxxxx Developer / Client
xxxxx Project Management
xxxxx Supervising Consultant
xxxxx Main Contractor
xxxxx Design Consultant
CM Construction Manager
QC Quality Control
HSE Health Safety & Environment
PPE Personal Protective Equipment
PMV Plants, Machinery & Vehicles
GIS Geographical Information System
LPS Loss Prevention System
MS Method Statement
RA Risk Assessment

1.3. Reference
Approved IFC Drawings
Project Specifications
Welding Procedure
BS EN 1536: Execution of Special Geotechnical Works – Bored Piles
BS 7121
ICE Specification for piling and embedded retaining wall – 2nd Edition
Heat Stress Management Plan
Emergency Response Plan
HSE Plan
Night Work Procedure
Lifting Plan for Installation of Steel Cage for Piles
Logistic Plan

1.4. Responsibilities

Project Manager
Responsible for accomplishing the stated project objectives which include
creating clear and attainable project objectives, building the project requirements, and managing the constraints of the project management triangle, which are cost, time, scope, and quality.

Construction Manager
Responsible for overall construction activities ensuring that all quality and safety procedures are implemented and required approved permits are obtained.

Site Engineer
Supervise operations in accordance with the approved Method Statement, shop drawings, specifications, material submittals, and schedules to achieve the acceptance of the project deliverables.

Site Supervisor
Supervise closely, the activities designated to them and ensure that all instructions and safety procedures are followed and strictly adhered to.

Site Foreman
To liaise with the Site Engineer and Supervisor for the work execution.

QA/QC Engineer
Ensure the proper implementation of the quality system and monitor the overall
quality of the work is maintained. Conduct inspection and monitor tests.
Determine and report any non-conformance and recommended corrective actions. Ensure that all personnel is aware of the quality requirement.
Training of relevant personnel.
Conduct surveillance and inspection duties at various stages to ensure compliance with QA/QC Plan.

HSE Manager
Health, safety, and environmental (HSE) managers generally plan, coordinate, and implement issues and directives within the organization. They ensure safe environmental working conditions for all employees.

HSE Engineer
Ensure enforcement of safety procedures in accordance with the approved HSE Plan.
Will be closely monitoring the site engineer’s strict implementation of the MS and Risk Assessment, the use of proper tools and equipment to maintain safety, certifications of equipment and their adherence to safety regulations, reporting of any unsafe work, or stopping work that does not comply with ES&H procedures. Will advise for Health & Safety requirements and monitor the Hazard controls implemented on-site as per the Method Statement/Risk assessment.

HSE Supervisor/Officer
The Safety Engineer shall be full-time at the site and shall frequently visit all the ongoing works at the site. All safety violations and on-conformance of the HSE.
The plan shall be registered and immediate action shall be done in coordination with the Site Engineer.
Environmental Officer / Manager
Coordinate all relevant Environmental activities associated with the works being undertaken.

Lifting Manager/Lifting Supervisor
Supervise closely, the activities designated to them and ensure that all instructions and safety procedures are followed and strictly adhered to.
Responsible for all lifting operations on site are carried out in a safe manner.
Responsible for preparing, securing, and communicating Lifting Permit, Lifting Plan/Calculation Sheet, Pre-Lift Checklist to all his crew.

Chief Surveyor
Carry out a pre-construction survey to fix the locations and corresponding elevations as per the approved shop drawings.
Ensure the quality and compliance during phases of surveying works and the regular checking of the surveying equipment or periodic calibration from a third party. Ensure the validity and the serial number of calibration certificates are available and posted in the survey equipment.
Ensure proper safety guarding of surveying equipment.
To maintain the records of all surveying equipment handled.

Survey Aide
Maintain and use Surveying equipment. Assist Surveyors in taking measurements, record measurements manually or electronically, and peg out boundaries.
Equipment Operator
The only authorized person to operate any equipment to be used in the project.

Rigger
The rigger assists in the movement of heavy equipment and loads to be lifted. A rigger setups machinery and secures it in place and signals or verbally directs workers engaged in hoisting and moving loads, in order to ensure the safety of workers and materials.

First Aider
The first aider responds promptly when requested, operates with competence, knows how to secure additional help when needed, reports incidents and actions taken, and comply with requirements for certification.

Banksman
The role of a banksman is to provide additional eyes and ears to assist the operator of the equipment to navigate or operate safely.

2. Resources

2.1. Plant and Equipment

Description No. of Units Application
Excavator w/ Hydraulic Pile Crusher
Hand-Held Pneumatic Jack Hammer (w/ Air Compressors)
Various Pile Head Trimming
Hand-Held Small Electric Concrete Breakers
Grinding Machine
Leica TS 15m Total Station
Leica NA2 Automatic Level

2.2. WorkForce

Project Manager        
HSE Manager                      
Lifting Manager                 
Environmental Manager    
Site Superintendent           
Site Engineers                     
Lifting Supervisor               
HSE Officer                            
Safety Officer                      
First Aider                             
QA/QC Engineer                    
Geotechnical Engineer        
Construction Supervisor     
Surveyor                                
Survey Aide                           
Operators, Riggers, and Drivers
Mechanics and Electricians     
Skilled Workers                       
Labors                                    
Banksman                               

3. Materials

Measuring and Marking Tools

4. Site Planning

The duration of work shall be indeterminate but will not critically affect the progress of the project.

4.1. Preparation
Permits from the concerned authority shall be obtained prior to starting work at the site.
The main contractor shall ensure that all gate passes, permits, tools, materials for safety precautions, manpower, and equipment are available before the commencement of work.
The Site Team shall make sure that access roads are always clear from any obstruction and the site is always accessible.
Provision of access and egress such as ladders, steps, ramps, or other safe means of egress and be with reasonable distance.

4.2. Site Clearance
Before commencing the work, the area shall be cleared of all debris, materials, or other obstructions.

4.3. Traffic Management
The Site Team with the assistance of the Safety Officers shall coordinate logistics and materials movement through the site following the direction and road signs displayed on site. The required diversion routes shall be marked on drawings including the required traffic signs.
The Work Permits and Operator Certificates shall be compiled for reference to authorized personnel.

4.4. Pre-construction Safety Meetings
• Meeting shall be scheduled prior to the beginning of the work and before any Subcontractor starts on the project.
• General contractual safety, health, and environmental requirements.
• Traffic safety will be discussed to emphasize these meetings.
• Roles of the contractor, subcontractors, authorized representatives, and all project workers.
Accident reporting requirements.
• Specific details of the work to be performed along with the use of personal protective equipment.
• Emergency procedure.

5. Pile Head Trimming/Cut off Method Statement

The following pre-execution works shall be conducted by the contractor prior to commencement of pile head trimming works for permanent pile at site.

5.1. Site Survey
The site survey shall be carried out, control points and benchmark shall be determined and verified prior to excavation works of platform level, and survey works for the cut-off level (C.O.L).

5.2. Excavation of up to 200 mm below Cut-off Level
After piling work has been completed in the construction areas, pile heads shall be exposed around 200 mm below the pile cut-off level.
The excavation shall be done in concurrence with the raft foundation pouring sequence (see attached Plan in Appendix A) to ensure the work is done logistically.
Considering the minimal distance of each pile in the tower areas as shown in the layout, the excavation shall be done in rows in order to position the pile trimming equipment and move smoothly without damaging the nearby piles. In this method, after excavating the first row of piles and marking of the cut-off level is done, the trimming of the pile head will be done by rows also.
After completing the pile head trimming for the first row of exposed piles, excavation and trimming of piles for the next row will follow. This sequence will be done until completing the excavation and trimming of piles in the tower areas.

5.3. Marking the Pile Cut-Off Level
After the pile heads are exposed around 200mm below the pile cut-off level. Cut-off level (C.O.L.) shall then be clearly marked on each pile.
After the cut-off level has been marked on the pile, a disk grinder shall be used to make a horizontal groove at the pile cut-off level. This groove shall cut the overhanging length of the pile and minimize breakage of concrete below the pile cut-off level when pile head cutting work is undertaken. The minimum groove depth will be 7cm, with a minimum of two perimeter grooves applied above the pile cut-off level.
Reference shall be made to the waterproofing method statement and to the pile layout drawing for the pile head Pile head trimming will be done by one of the methods mentioned in below items of Section 5.4 to Section 5.7 or a combination of them.

5.4. Pile Head Trimming Using Excavator w/ Pile Head Breaker
Option 1 – After the cut-off-level has been marked on the piles, a special designed hydraulic pile breaker attached to an excavator shall be used to break and remove the concrete above the pile cut-off level as shown in PVC pipes placed over the upper dowel length of the pile cage prior to installation of piles shall help prevent any bonding between pile reinforcement and concrete above the cut-off level which shall facilitate the pile head breaking process. When the pointed tip of the piston starts squeezing the pile head, a horizontal shear will start appearing in the de-bonded area causing to detach the pile head from the pile shaft.

5.5. Pile Head Trimming Using Hand-Held Pneumatic Jack Hammer (w/ Compressor) Option 2 – After the cut-off level has been marked on the piles, a handheld Pneumatic Jack Hammer with compressor shall be used to break and remove the concrete above the pile cut-off level.

5.6. Final Chipping
Final chipping is to be carried out using a handheld electric concrete breaker that will enable finishing the pile top to the allowable tolerance from the design cut-off level and in preparation for the surface to receive pile integrity testing. The maximum tolerance for pile head cut-off shall be maintained at +/-2.5cm from the cut-off level upon final trimming, as per project specifications. The necessary safety precautions for these tools are available at Risk Assessment in Appendix B.

6. Risk Assessment Related To Pile Head Trimming/Cut off Method Statement

Risk Assessment is attached as Appendix B of this document.

7. Health and Safety

All Risks are evaluated prior to any works commencing utilizing the matrices to determine the level of significance in terms of likelihood of occurrence and severity of hazard based on the allocated numerical values.
Refer to the Appendices for the risk assessment matrix and for full and detailed Risk Assessments.

7.1 Protective and Safety Equipment (PPE) / Respiratory Protective Equipment (RPE)
All workers Involved shall be equipped with adequate PPE/RPE as stated below:
Mandatory PPE
a. Safety Helmet with Company Logo
b. Safety Boots
c. High Visibility Vest
d. Clear and Dark Safety Goggles
e. Coveralls
Task-Specific PPE
a. Hand Gloves
b. Ear Plug
c. Face Mask
d. Full Body Harness and Safety Lanyards are required for working at heights (if applicable).
e. Respiratory Protective Equipment (RPE) – Breathing mask, Dust mask, could be powered or non-powered depending on the level of hazard and/or site condition.

7.2 Welfare Arrangements
a. Rest Area
The rest area shall be equipped with adequate A/C Units, Tables, Benches, etc. sufficient to cover all workers.
b. Drinking-Water Facilities
Supply adequate quantities of potable drinking water in the immediate work area for all workers.
c. Sanitary Facilities
Supply adequate toilet and washing facilities with hot and cold running water. Separate facilities shall be provided for male and female workers, and shall be located within close proximity to the work area.
d. Mess Area
Provide and maintain Mess Areas free from dust and sand ingress, with A/C units, Benches, Tables, etc.
e. First Aid Station
Availability of Site Clinic with sufficient staff and first aid medicines.
f. Notice Boards
Placed throughout with all current and relevant information displayed.

7.3 Information to Personnel
a. Safety Induction
Establish and implement a health and safety training program and shall provide the resources necessary to ensure adequate and effective training is provided to personnel as required.
b. Job Training
Site personnel shall be provided training on the hazards associated with the tasks they will be conducting and the controls available and/or required by the contractor to perform the work safely.
c. Superintendents Notices/Memos
Site Notices/Memos are issued by the Project Directors for information and full compliance of all staff and workers in the project.
d. Toolbox Talks
Held between Supervisors / Foremen and the Workforce on a weekly basis.
e. START Card
Mandatory Pre-Task Briefing / Safety Task Analysis Risk Reduction Talk prior to commencing the work and ensure all the necessary control measures have been communicated and taken.

7.4 Permits
Work Permit system shall be observed (correctly issued, Signed & Client requirement enforced), along with other related permits required-(if applicable from various service providers and/or Client), when undertaking any work.
• General Permit to Work
• General Lifting Permit
• Temporary Work Permit
• Work at Height Permit
Hot Work Permit

7.5 Site Security
• Information to all personnel on the security systems in force to ensure they comply with necessary requirements.
• Thorough patrols of the project throughout the night, during weekends or holidays concentrating on fire prevention, unauthorized access/entry at work areas, etc.
• All Security Officers will maintain an alert attitude and observe carefully, everything taking place in the assigned area. They will report all witnessed or reported violations to the Security Supervisor who will enforce all orders, rules, and regulations as required by the main contractor.
• Security Officers shall not leave their posts unless properly relieved or unless required to do so in the performance of other assigned functions or in case of an emergency. In such cases, they shall be promptly replaced.

7.6 First Aid Facilities
• The main contractor shall provide first aid and emergency transportation arrangement to employees who sustain injuries or illnesses in any work areas.
• Before work can begin, workers are to have been medically screened and evaluated by the Site Clinic Staff performing a complete evaluation of first aid and medical requirements.
• The HSE Manager notifies the client to arrange ambulance services and emergency helicopter services in accordance with the Emergency Procedures if required.
• A minimum of one (1) first aider shall be provided and at least one additional first aider for every 25 employees thereafter shall be available.
• Individuals who are required to work alone in remote areas must be trained in first aid and provided with an effective means of communication to call for assistance in an emergency.
• A registered nurse (RN) must be assigned on a full-time basis to each Medical Facility.
• Adequate and appropriate emergency response equipment shall be available to medical personnel.
• Designated first responders address immediate first aid needs. First responders may consist of on-site medical personnel or a person certified in first aid.
• All employees must yield to first aid providers in an emergency situation. Untrained employees will avoid providing assistance when a first aid certified employee is present. An untrained employee may assist in an emergency when directed by a supervisor trained in first aid.
• Only first-aid-trained personnel respond to emergency situations that involve potential exposure to bloodborne pathogens. The guidelines for response to emergencies involving sewage, blood, or other potentially infectious materials (OPIMs) are detailed in Bloodborne Pathogens.
• First Aider certificates shall be current and a copy kept for audit in the site office.

7.7 Workplace Access & Egress
• Continuous adequate solid barriers will be placed around a distance of at least 1.2m from the loading edge.
• Where nighttime pedestrian or vehicle access is adjacent to backfilling then all solid barriers will be fitted with warning lights.
• All ladders used on the project will be manufactured in accordance with an internationally recognized standard. Any ladder that is found to be defective will be removed from use immediately.
• All straight ladders will be positioned at an angle to minimize the risk of slipping or falling backward.
• The distance between the base of the vertical plane and the base of the ladder will be 1 unit out for every 4 units in height of the vertical plane.
• Ladders that are used to gain access from one level to another will extend at least 1m above the upper-level surface. Where a general access ladder run extends a distance of more than 6m a landing point with a firm-level platform and fall prevention measures will be provided at each and every 6m.

7.8 Workplace Lighting
• The goal of area lighting should be to produce an overall level of illumination sufficient for personnel and equipment to move around and complete work activities safely.
• Area to be illuminated for the movement of material by hand is much different than the movement of material by crane.
• Parking lots and non-production areas will require lighting based on schedule, the volume of use, and security concerns to the requirements set in the table.
• Setting up lighting, consideration will be given to the layout to ensure that all areas receive light from at least two directions to prevent shadows.
• Lighting will be mounted on poles or towers and spaced for optimal light distribution.
• Bulbs shall be protected from breakage as designed by the manufacturer or as required by regulating agencies.
• Lighting fixtures shall be positioned to prevent employees from coming into contact with the fixtures during work operations.
• Lighting supply cords and cables shall be installed and maintained in a manner consistent with good electrical wiring practices.
• Tower lighting shall be located in a manner that illuminates all work areas.
• Lighting should be provided in confined spaces, and backup lighting shall be provided in case of power failure.
• Lighting poles and other metal poles shall be earthed (grounded) and the circuit fitted with residual current devices.
• Cables supporting temporary lighting shall be routed to ensure they do not present a hazard.
• All lighting fixtures shall be installed in a secure manner to prevent the accidental movement of falling.
• Temporary installations shall meet all the requirements of the applicable local code.
• Temporary lighting strings and extension cords shall be protected by lamp guards.
• Broken or defective bulbs shall be promptly replaced. All lights used for illumination shall be protected from accidental contact or breakage. Metal case sockets shall be grounded.

7.9 STARRT Talks and Briefings

STARRT talks (Safety Task Analysis Risk Reduction Talks)) shall be conducted prior to any work to maintain a high level of safety awareness and to advise employees of changing circumstances. They will be presented by the Works Supervisors or HSE Personnel, in an environment that will ensure good audience reception and allow discussions of raised points. They should address specific work nature and are related to the work activity, project location, the construction industry, and local legislation.

STARRT talk will be conducted on a daily basis per activity per group and a register of attendance and a brief summary of the points raised will be attached with the permits.

7.10 COSHH – Control of Substances Hazardous to Health

Preparation and prevention are the preferred alternatives to control small and common spills that often occur during oil changes and etc. The company shall ensure that each facility and work area is adequately equipped to satisfy the mitigation measures listed below:
Absorptions mats and/or pads shall be placed on the soil surface under the machinery prior to each repair activity.
Routine inspections of the storage tanks in the loading and unloading areas shall be carried out.
Ensure the employees are adequately trained in the provision and use of fire extinguishers and fire-fighting equipment is maintained and in good working order.
Initiate a monitoring and inspection plan to check and record the state of firefighting equipment on a weekly and monthly basis.
Maintain communication and ensure employees are briefed on procedures in the event of an emergency.
Copies of all MSDS forms shall be placed with the chemicals at the COSHH storage areas and maintained by the HSE department.

The following hazardous substances are expected to be in the workplace at the site during these works:
• Fuel
• Oil
• Lubricants
• Diesel
• Marking Paints
• Others
7.11 Emergency Flow Chart
7.12 Emergency Contact Numbers

8. Environment Issues

8.1 General
The main contractor establishes a procedure for identifying and estimating the environmental impact of construction activities, determining control and evaluation of methods in order to minimize the impact of these activities on the environment, and applies to all relevant construction activities that have an impact on the environment.

8.2 Scope
Definition of Environment- Environment is defined as those areas, which are directly impacted by the main contractor Construction’s operations. These are:
• Air / Climate factors
• Water Resources
• Land / Soil
• Natural Resources
• Humans and their interrelation
All precautionary measures shall be briefed to all workers prior to commencing an activity.


8.3 Waste Management
The following rules apply to the construction site in order to countermeasure environmental risks:
• An adequate number of containers (skips, bins, or similar) will be strategically placed throughout the construction areas and temporary facilities.
• The waste containers will be regularly collected and taken to the main waste storage area.
• The Contractor shall remove waste containers from the site as soon as they are full. Waste containers shall not be allowed to overflow.
• Containers will be regularly inspected. Waste receptacles will be kept securely closed during the accumulation
• (except for open-topped trash skips) and storage, except when it is necessary to add waste and will be tightly sealed prior to transportation from the generation area.
Containers will not be opened, handled, or stored in a manner, which may rupture the container or cause it to leak.
• Containers will be lifted using only the designated lifting points.
• The storage containers will be of sufficient size and number to contain all solid wastes generated between collections.
• The contractor will store waste appropriately, depending on the type of waste being stored, with a sufficient number of skips/storage areas for the different wastes.
• Flammable substances will be kept away from sources of ignition.
• The Contractor will arrange for the transfer and transportation of waste consignments with the Regulatory
• Authority approved/licensed Waste Management Contractor (WMC).
• The Contractor will not release the waste if there is concern about the standard of transport or destination of the waste. No waste will be disposed of or removed from the construction site without the knowledge and approval of the Contractor Environmental Representative.

9. Quality Issues

9.1 Inspection, Test, and Sampling for Pile Head Trimming Method Statement
Request for Inspection and Testing will be submitted prior to and after the execution of works.

9.2 Quality Assurance Requirements Table
Ensure that work is executed as per approved shop drawing, method statement, and records are generated referring to approved ITP. All testing shall be carried out by TPL in the presence of the main contractor.
Best management practices shall also be considered which may be stated by product manufacturers or suppliers.
Authority requirements will take precedence over all requirements in case authority approval is to be secured.
For non-authority approval activities, approved the latest project specifications will take precedence.
It is to ensure that regular toolbox training-related work quality is conducted and records are maintained.
Construction department to ensure that next backfilling shall not proceed until testing of the preceding layer is completed by TPL. Only the latest controlled copies of documents including drawings, forms, checklists, etc. shall be used for work execution.

10. List of Appendices

Appendix A: Related Drawings
Appendix B: Risk Assessment
Appendix C: Inspection and Test Plan (ITP)
Appendix D: Equipment Details
Appendix E: Third-Party Certificates

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