NSC N111

ASSESSMENT ON DURABILITY ISSUE

DUE TO LESS CONCRETE COVER FOR REBAR CAGE (P31-1, P31-6)
JULY 2022
1. CURRENT STATUS AND PROBABLE CAUSE OF LESS CONCRETE COVER
1.1 Current Status
1.2 Probable Cause

2. ASSESSMENT AND JUSTIFICATION BASED ON DURABILITY REPORT AND RELEVANT DESIGN CODE
2.1 Reference Made to QPD’s Durability Report
2.2 Assessment and Justification based on Relevant Design Code

3. CONCLUSION AND RECOMMENDATION

4. RECTIFICATION MEASURE IN CASE OF NON-COMPLIANCE TO DESIGN CODE

1.1 Current Status
Status of Bored Piles

 Zap Foundation completed 6 numbers of D1500 bored piles of the Main Viaduct P31 on 14 Sep 2021.
Status  After trimming the pile heads to the cut-off level, it was found that the minimum concrete cover of the 2 bored
piles was 40mm only. (P31-1 & P31-6)

[Location of Affected Bored Pile] [Photo of P31-1] [Photo of P31-6]

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1.2 Probable Cause
Probable Cause
 It is presumed that the upper part of the rebar cages slightly moved toward the soil during removal of casing
Site before concrete started to set.
Observation  Considering the rock coring of 17.5m and 28.05m for P31-1 and P31-6 respectively, spacers at the bottom cages
and casting sequences for bored piles, it is inferred that the concrete cover would increase toward the bottom.
STEEL CASING MIGHT PUSH THE CAGE DURING
REMOVAL BEFORE CONCRETE STARTED TO SET.

BOTTOM PART WAS CONFINED WITH GIV/GIII ROCK

WITH SPACER. PHYSICALLY UNABLE TO MOVE.

TOP CAGE OVERALLY SHIFTED BY 35MM

RESULTING IN 40MM COVER ONLY.

75MM (NORMINAL COVER)

OFFSET OF PILE SURFACE

1ST CONCRETE CASTING

(APPROX 4M HIGH)

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2.1 Reference Made to QPD’s Durability Report
Reference Made to QPD’s Durability Assessment Report
 According to the durability assessment report prepared by QPD (Durability Assessment Report Rev. C, 23 Mar
2020), the external face to bored piles subject to ground environment is classified as AC-2s and DC-2 for
Result of
intended working lift at least 100 years. (XC-2, DS-3, DC-2)
Review
 Given the condition, QPD defined the minimum concrete cover for durability (cmin,dur) as 35mm, nominal concrete
cover (cnom) as 75mm in the report.

PROPERTIES AT LOCATION MAP OF ESN/A012

P31 LOCATION

[Durability Requirement and Recommendation]

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2.2 Assessment and Justification based on Design Code (1)
List of Design Code for Review
Code Description Remarks

LTA CIVIL DESIGN CRITERIA

E/GD/09/106/A1 Tender Specification
(A1)

SS CP65 : Structural Use of Concrete Related to

SS CP4 and SS CP65
SS CP4 : Code of Practice for Foundations LTA CDC A1

SS EN 1992-1-1 Design of Concrete Structure Tender Specification

SS 544:2019 Concrete – Complementary Singapore Standard to SS EN 206-1 Tender Specification

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2.2 Assessment and Justification based on Design Code (2)
LTA Civil Design Criteria (E/GD/09/106/A1)

 LTA CDC A1 specifies that the design details follow the relevant SS CP such as SS CP4 and SS CP65.
Result of  Based on the clause 6.2.3.1 and 8.5.1.2 in the LTA CDC A1, it is inferred that the 75mm cover includes construction
Review tolerance of minimum 35mm.
 Hence, 40mm minimum concrete cover complies with LTA CDC A1.

LTA CDC A1 specifies that the design details follow LTA CDC A1 doesn’t specify whether the 75mm cover includes the construction deviation
the relevant SS CP such as SS CP4 and SS CP65. (tolerance) or not. Considering 40mm nominal cover for members forming external hull of
underground structure, it is inferred that the 75mm cover includes construction tolerance
of minimum 35mm.

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2.2 Assessment and Justification based on Design Code (3)
SS CP4 and CP65 (Related to LTA CDC A1)

 SS CP4 specifies provision of additional allowance for bored piles to ensure a 40mm minimum cover.
Result of
 SS CP65 specifies 35mm minimum cover with 40mm tolerance, totaling to 75mm nominal cover.
Review
 Hence, 40mm minimum concrete cover complies with SS CP4 and CP65.

SS CP4 : CODE OF PRACTICE FOR FOUNDATIONS SS CP65 : STRUCTURAL USE OF CONCRETE

SS CP4 specifies provision of additional allowance to ensure a 40mm

minimum cover.

SS CP65 : STRUCTURAL USE OF CONCRETE

SS CP65 specifies 40mm nominal cover with 5mm allowance.
(35mm minimum cover)

SS CP65 specifies minimum 75mm nominal cover where concrete is

cast directly against earth to ensure the minimum cover.

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2.2 Assessment and Justification based on Design Code (4)
SS EN1992-1-1 (Design of Concrete Structures)

 75mm of nominal cover (cnom) is adopted based on 40mm minimum cover for structural integrity and
Result of durability (cmin), and 35mm additional cover to consider construction tolerance (Δcdev) in accordance with SS
Review EN1992-1-1.
 Hence, 40mm minimum concrete cover complies with SS EN1992-1-1.

The nominal concrete cover (cnom) is comprised of cmin and Δcdev. cmin,b : 40mm (H40) cmin,dur : 35mm (QPD’s Durability
- cmin : the minimum concrete cover for bonding, durability and fire resistance. Assessment Report)
- Δcdev : addition to cmin for the deviation due to construction tolerance/errors.

Nominal concrete cover (cnom) of 75mm is adopted as per

For bored piles, the greater value between cmin,b and cmin,dur shall be adopted. recommendation to allow larger deviation (Δcdev) of 35mm.

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2.2 Assessment and Justification based on Design Code (5)
SS 544:2019 (Concrete – Complementary Singapore Standard to SS EN 206-1)
 Based on SS 544:2019 and surrounding condition, QPD defined the min. cover for durability as 35mm in the
durability assessment report.
 40mm minimum concrete cover could provide more than what is required in the SS 544:2019 in terms of
Result of
durability. Hence, it complies with SS544:2019.
Review
 In fact, despite more favorable conditions in the viaduct area compared to the tunnel area in terms of durability,
the same concrete mix design adopted for diaphragm wall have been used, providing additional durability
against chemical attack.

Concrete Mix Design

Group Tunnel Viaduct
used for Bored Piles

Design Sulfate/Chloride Class DS-4 DS-3 DS-4

Design Chemical Class DC-4 DC-2 DC-4

Design Exposure Class XC3/XC4 XC/2 XC3/XC4

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3. Conclusion and Recommendation
1. Adequacy of 40mm concrete cover observed at the cut-off level of 2 bored piles (P31-1 & P31-6) are assessed
based on the QPD’s durability report and relevant design codes.

2. After reviewing the codes, it has been concluded that the minimum 40mm of the concrete cover complies with the
minimum concrete cover specified in the design codes without compromising the durability and the structural
integrity of the bored piles.

Code Requirement on Minimum Cover Assessment Result

LTA CIVIL DESIGN CRITERIA (A1) 40mm Complied.

SS CP4 and SS CP65 40mm Complied.

SS EN 1992-1-1 40mm Complied.

SS 544:2019 35mm Complied.

3. Although the current condition complies with the minimum concrete cover specified in the design code, it would
always be better to secure nominal concrete covers as it could provide enhanced resistance against
environmental conditions. Hence, it is recommended to install spacers with closer spacing laterally and vertically
especially near the pile cut-off levels for remaining of bored piles and to ensure the casing remains vertical
during extraction process.
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4. Rectification Measure in Case of Non-compliance to Design Code
It has been concluded that 40mm concrete cover complies with all design codes. In case there is a difference in the
interpretation of the design codes between experts, the following is suggested based on SS EN1992-1-1 4.4.1.2 (8) so
that additional strengthening work in terms of durability such as ground improvement can be carried out after the
pile cap is cast. For boring of small diameter holes, a small low-headroom drilling rig or A-frame SI machine, which
is much lighter than the soil weight above the pile cap, will be used.

SS EN1992-1-1 4.4.1.2 (8)

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 Thank You

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