Future Foundations #5 Spring 2021

FUTURE FOUNDATIONS Newsletter of American Piledriving Equipment, Inc.

SPRING 2021 APE Piledrivers’ Classes Drive Unions Kiewit’s David Jack PileBuck Magazine’s APE Interview Aluminum is Cool with Condon Johnson

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American Piledriving Equipment, Inc. • 7032 South 196th Street Kent, Washington 98032

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CORPORATE OFFICE NORTHWEST 7032 South 196th St. Kent, Washington 98032 (800) 248-8498 (253) 872-0141 stevec@americanpiledriving.com kellyg@americanpiledriving.com chrisw@americanpiledriving.com MIDWEST St. Peters, Missouri (855) 303-4580 (636) 397-8400 jakep@americanpiledriving.com WEST COAST Stockton, California (888) 245-4401 (209) 942-2166 chrisc@americanpiledriving.com MID-ATLANTIC Virginia Beach, Virginia (866) 399-7500 (757) 518-9740 jimmyd@americanpiledriving.com GULF REGION Conroe, Texas (800) 596-2877 (936) 271-1044 Gonzales, Louisiana (877) 293-4244 (225) 644-7722 joew@americanpiledriving.com NORTHEAST US EASTERN CANADA Sayreville, New Jersey (888) 217-7524 (732) 432-6604 paulk @americanpiledriving.com billz@americanpiledriving.com SOUTHEAST Mulberry, Florida (800) 570-3844 (863) 324-0378 jimc@americanpiledriving.com jimb@americanpiledriving.com wallyb@americanpiledriving.com APE SOUTH AMERICA (863) 660-8716 jimc@americanpiledriving.com APE MEXICO +1 (786) 991-6875 +1 (936) 207-3366 frankis@americanpiledriving.com APE CHINA Shanghai, China (+86) 21-5677-1221 (+81) 21-3604-0553 ericd@apevibro.com APE CANADA Nisku, AB (855) 328-9888 (780) 474-9888 ericl@americanpiledriving.com

APE TRAINING SUPPORTS PILEDRIVERS Training is at the core of APE’s history and the future of the industry.

Leadership and learning are indispensable to each other.

-John F. Kennedy It doesn’t show up in the financial report or the other measurements used to determine how a company stands in the industry - market share or any fancy metrics like that. But when it comes to availability to Piledrivers, APE is, uncharacteristically perhaps, a quiet leader.

“The APE Pilebuck Equipment class was extremely interesting! It was exciting to see and learn how the different types of hammers work! Dan Corp is very knowledgeable and made it easy to understand while attending the class. Had an amazing time at APE!!!” says 4th year Apprentice Joe Brady of the Local 196 Piledrivers, Divers, Bridge, Dock & Wharf Builders.

Many apprentices of the 196 attended APE’s Piledriver’s class held this spring, run by APE’s National Equipment Manager Daniel Corp and Northwest Carpenters Institute’s Marc Carey, Pile Driver Coordinator/ Instructor. “APE teamed up with NWCI to get this program back to full bore. That was the mission.” - Daniel Corp.

APE has a long history of partnerships around the US and Canada of bringing

A good visual inspection can avoid many complications.

KNOW your hammer’s parts and pieces. expert training to apprentice and journeymen level Piledrivers - since the earliest days of APE when it was apparent that well trained Pilebucks operated and maintained and understood the capabilities and limits of the equipment they were using.

sites are often remote and support or service can be a big challenges. Reid continues, “A fuel pump is one of those things you pull apart and go ‘what the @#$%... but when you have the confidence to put it back together? Invaluable.”

“It all goes back to Dave Yingling” says Steve Reid, Assistant Training Coordinator for the Piledrivers Local 2404 in Delta, BC Canada. “He’d come up every year and teach level I and level II. He had a way. He’d keep them engaged and entertained.”

“The Level I Training was something the apprentices looked forward to completing, achieving a level of confidence and technical expertise. The Fuel Pump class grew out of that.”

The 2404 covers Alberta, Saskatchewan and Manitoba and the Territories; i.e.

Yukon, Northwest Territories, and Nunavut. Work-

Eric Legault, APE’s Canadian Regional Manager adds another point of view, “The ability to be able to work on hammers on the job site is

“Down time is a huge constraint on any job, and clients are relentlessly on the hunt to find workers that are not only familiar with piledriving equipment, but to also be able to service them.”

- Eric ‘Wiggy’ Legault, APE Canadian Regional Manager

ON-LINE APE Pile Buck School Educational Tools: School Part 1 - Romans, Pile Types, Pile Points School Part 2 - Pile Driving Lead School Part 3 - Air Hammers School Part 4 - Diesel Hammers School Part 5 - Vibratory Hammers, Power Units, Clamps, Underwater School Part 6 - Noise and Hammers Replacing the Piston Rings. Good solid compression keeps the hammer running cooler with more energy. definitely a high requirement and sought out from many of our clients. Our Classes teach the knowhow of function, set up, and repairs to our Equipment. This will drastically reduce or eliminate down time to equipment & and increase the safety to workers for any job site. If its set up properly, and serviced properly it will perform the way it is designed and intended to perform. This knowledge is an asset to the piledriver and a skill-set that our clients are very interested in.” Win-Win. The Southwest Carpenter’s training Fund’s Matt Dunphy, Coordinator out of Whitter, CA reached out to APE in early 2021 when they realized they needed refresher training on equipment they had in their yard an APE Diesel and APE Vibro. The SWCTF covers training for the Local 562 Southern California Carpenters Piledrivers.

“We went up for a Train-

ing session in Stockton, CA and just got a full-on meat and potatoes everything you need to know if you’re running a diesel piledriver or Vibro. We’ve been working with APE for years

“Great class with a knowledgeable Instructor (Dan Corp) and hands on instruction and functions” - 3rd year Apprentice, Frank Pineda, Local 196 Piledrivers, Divers, Bridge, Dock & Wharf Builders. and they’ve always been a great resource. Its the equipment our guys end up using in the field, so it makes sense that’s what they train on. We train Apprentices to Journeymen on this equipment - so getting this complete rundown ourselves was exactly what was needed.

School Part 7 - Hydraulic Hammer Types School Part 8 - Wick Drains APE Hydraulic Motor Identification for Vibros and Drills APE Lead Types APE Diesel Hammer Drive Caps Press Pile Drivers Cost Effective Driven Piles Quad Kong Presentation How to Drive Steel Sheet Piles APE Hydraulic Impact Hammer Education - HIH 101 APE Service of Solenoids for Directional Valves APE Basic Hydraulics Training Pile Driving Equipment Book of Knowledge APE Quad Kong Project Questions for APE Basic Hydraulics Diesel Hammer Inspection Procedure VISIT:

AMERICANPILEDRIVING.COM

NEED TRAINING? CONTACT APE AT:

(800) 248-8498

FUTURE FOUNDATIONS FEATURE: KIEWIT’S DAVID JACK A career defined by Deep Foundations

David Jack has been working for Kiewit 33 years specializing in managing structures and deep foundations of large infrastructure projects. David is currently working as the piledriving sponsor on the Calcasieu Pass LNG in Cameron Louisiana.

On a cut and cover tunnel project 40’ below grade in the heart of downtown San Francisco, 18” concrete squares were driven to cutoff elevations at an elevation 60’ below grade.

An elaborate setup made it work. Vibro 36” casings into ground. Evacuate 60’ of material from the can: bay muds and sand.

The casing was installed by a Vibro Hammer and cleared by a hydraulic drill that were in leads of one crane. In another crane, a 60’ follower below a D62 hammer would drive the precast piles to the design elevation. “Drive the pile, fill the casing with sand then extract casing. This Muni Metro project was an all-around tough job. To pull this idea off we needed a big vibro – but what was big enough to do the job?

It was 1994 and John White of APE convinced me that APE’s prototype “Model 400” could do the job. The challenge was that APE had never built a hammer this big for production. We

agreed - as long as they built two and we had a spare. Just in case.”

“With more than 11,500inch lbs. of eccentric moment, the APE 400, (known as the King Kong)

vibro worked great.” This is where innovation meets demand in construction and then experience paid dividends. In 2020 history repeated itself in Louisiana and Dave and his Kiewit

APE’s first Model 400 King Kong.

Sharing power unit and leads with APE built Auger.

team were able to use the same technique at Calcasieu Pass LNG. One of the benefits of a 30+ year old toolbox.

Muni Metro was the job that really started the Kiewit - APE relationship.

At the time APE was barely 3 years old and Kiewit had a new Manager of their Northern California District, David Jack.

Graduating 10 years earlier with a Construction Engineering Degree from Cal Poly, Dave had slugged it out with Kiewit learning to build Bridges, Dams, Buildings, Water Treatment Plants - all of them with deep foundation elements.

Kiewit has driven a ton of Cast in steel shell piles particularly for Union Pacific Railroad and Caltrans. U.P. understood the importance of the driven pile having been the originators of the H-pile. That history is interesting - they needed to have a pile they could drive and achieve a bearing capacity in any soil profile.

The H-pile was transportable, stackable and you could splice it till you had a pile that would hold the load. Great for the railroad construction because you could stockpile material for when you needed it. And it would go through most soil profiles. It’s different today but H-piles have gained widespread use in the industry – because of the Union Pacific Railroad. UP still drives lots of H-piles, but also cast in steel shell piles as well.

Work north of the border in Canada, in the Alberta

oilsands has shown Dave different looks at the industry. Differences in field operations, equipment, trends in the market. Lots of the smaller Canadian piledriving companies are using “all in one” Piledriving Rigs like the Junttan or Liebherr. They have limitations on what you can drive, but roll in, stand it up – you’re driving that morning. But beyond driving 15 m piles, you needed the standard large crane setup, leads, spotter, hammer, Big Hammers! That’s good for Kiewit. Good for APE too.

Kiewit’s travels to work in Alberta and British Columbia showed the APE equipment off to the Canadian market. “Nobody had used APE products in Alberta at that point – now they’re everywhere.”

Dave encouraged APE’s fledgling helical pile (Now PileWorks) program in the 2000s, noting to APE’s Dan Collins, “’You guys gotta get

into this.’ “The Canadian market was years ahead of the US when it came to Helicals. It was up and coming market and APE was in the fetal stages of developing its own HD Driver helical installation system. In the past 20 years the helical market has been growing rapidly, and APE now has a nice material product, versatile equipment and a major player in the US helical market.”

On the site today vs. 30 years ago? The most, limber, the most athletic PileBuck would be sent to the top of the leads to service any hammer issues or grease the shives. Whereas today Kiewit will use a JLG service boom in the interest of safety. First came Hip belts and clip on/clip off. Then came the yo-yo lanyard style tie-offs, then the full body harnesses became the standard until boom lifts took the place of all that. This is a major

difference. We are totally focused on safety.

One of the biggest challenges we face today is that many of the crane operators with experience are retiring. You need to be able to chew gum and walk at the same time. You need to be able to boom up, cable up, swing all at the same time in order to be a productive operator. Not to diminish safety, because you can’t, but one side effect of the emphasis on safety is some operators today cannot multitask a crane the way the last generation could. Mistaking a good productive skilled operation for safe operation is not necessarily the case.

We need qualified help.

We need to have productive operators in a competitive environment like we have now in both the States and Canada. It’s a huge opportunity right now for kids who don’t know how great and important

this job is.

Another difference is in equipment. Hydraulic hammers technology and engineering have finally caught up with each other.

30 years ago, if you brought out a hydraulic hammer, half the owner’s engineers would have no idea how to work out the energy, capacity, etc. Everybody at that time had grown up on diesel hammers and the difference between calculating energy on diesel hammers and hydraulic hammers is like night and day and engineers struggled early on with the differences in energy transfers with the two hammer types as hydraulics came into more common use.

The lesson being, if I could work with the engineers ahead of time, making sure whoever I was working with was up to speed on the equipment technology, it could save a headache later. It’s really the contractor’s responsibility to make that happen. You just need to make sure you have engineers and inspectors on site that are up to date with the equipment and technology out there.

As an industry we have to make sure we do one thing - educate, educate, educate. Sometimes you’ll get with an owner that has no clue about foundation work. Then it’s my job is to get them up to speed.

What would I tell the young up and coming engineer, contractor? Understand every type of deep foundations out there.

Con’t pg 9

Pile Buck’s interview with Steve Cress, VP of APE (American Piledriving Equipment), the world’s leading manufacturer of deep foundation construction equipment was published on Pilebuck.com on April, 27, 2021. Republished with permission.

APE: Good maintenance practices!

Keeping a close eye on the hammer while in operation for loose bolts.

Low pressure fuel injection w/ Impact AtomizaPB: APE has an impressive tion. line-up of deep foundation Single acting, self-conequipment–the diesel ham- tained operation. mers, in particular. Diesel Using the hammer within hammers obviously operthe operating parameters. ate under extreme pressure Did I mention “Good and are driven, literally, to Maintenance Practices”? their max. What makes a good diesel hammer that PB: When did APE start will last? manufacturing diesel hammers? How have diesel hammers evolved over the years?

APE: APE started manufacturing diesel hammers in 1997 and have advanced them from the older 32 series hammer into what they are today in the 52 series hammers with all the “Piledriver Desires” added like the oversize fuel and oil tank that enable you to run an entire shift without having to stop and fill up, or the advanced Octagon shaped Lower cylinder with “Vortex Cooling” charac-

teristics that keeps the hammer running cooler longer. APE has integrated the “Pusher Style” Hydraulic tripping system that doesn’t require any addition welding and one of the awesome features that came from “Pilebuck Minds” is the “APE Bolt on Flare Kit” that enables the quick adaptation from smaller leads to larger leads simply by bolting the flare kit to the existing lead guides on the hammer.

Bottom Line: APE doesn’t stop making advanced changes to our diesel hammers just because we think we have the best Single Acting Diesel Hammers on the market. APE continues to listen to Piledriving Contractors when they have an idea, we infuse those ideas into our equipment for the piledriving industry. From the contractor to the foundation equipment manufacturer, APE is dedicated to bringing the very best to the end user, the Piledriving Contractor!

PB: What are the benefits of using a diesel hammer on a project? Correct me if I’m wrong, but diesel hammers do not require additional equipment making them more cost-effective?

APE: You are correct. The Diesel hammer is a selfcontained unit that requires no addition outside power for it to operate.

In addition to being fully self-contained, the APE single acting diesel hammer fires from “Impact Atomization”, which means less chance of pre-ignition prior to impact and a higher “Peak Force” of energy delivered when the piston strikes the impact block.

One of the greatest advantages to using a diesel hammer over a hydraulic impact hammer is the power to weight ratio.

When using a diesel hammer a contractor can get the energy needed to drive the pile with a diesel hammer that is a fraction of the weight of a hydraulic impact hammer.

PB: What would you say is APE’s most popular diesel hammer model and application?

APE: APE has a wide range of single acting diesel hammers ranging from a piston weight of 1,760 lbs in the little D8-42 up to the massive D320 with a piston weight of 70,550 lbs.

With that said APE has a couple of unique hammers

that would qualify for the most popular.

The APE D50-52 would be a close runner due to its slightly larger piston weight than the D46-42, yet the D50 piston fits in the same housing as the D46 but gives just a tad bit more energy per stroke, and that is desirable on those tough driving jobs.

But the bread winner would be the APE D70-52 that fits the same body as the D62-42. The D70 has a piston weight of 7 metric tons (15,435 lbs) compared to the D62 with a 6.2 metric ton piston (13,671 lbs) which gives the D70 the clear advantage with a whopping 9,500 ft-lbs of energy per stroke over the D62.

PB: I’m assuming APE’s vibratory hammers are just as popular? Tell us about the different models that APE offers.

times just two Kong’s isn’t enough. APE then jumped up to the “OctaKong”, meaning eight Super Kong Vibros, assembled together to drive some 72’ diameter casings to build a couple Islands in China for the Hong Kong Macao Bridge, which by the way is 34.5 miles long going from Macau to Hong Kong. We’ll talk a little more about the Dodecakong project in a bit.

PB: What are the advantages of using a vibro hammer on a project? When is it best suited?

APE: Vibros are used for many different projects driving many different types of piles from Sheet piles to H-Beam to Pipe and even Concrete sheet piles.

APE Has attachments for just about any pile you may have.

When extracting piles, you will always need to use a vibro. It is the vibro’s job to “Wake Up” the piles to get APE: Thanks for asking! APE them in motion and then offers a full line-up of vibra- the crane takes over with tory hammers ranging from line pull. As long as the the little guy called the APE vibro has the pile in motion model 6 vibro, otherwise you can pull the pile. known as “The Chimp”, all the way up to the massive Using a vibro to drive a 600 vibro known as “The pile is the fastest most efSuper Kong”. ficient way to drive piles.

If you drive the pile out of APE has mated two vibros plumb, you can just pull it together calling them a out, correct to get the piles “Tandem” set-up which we plumb and start driving do quite often when one again. You cannot do that vibro just is not enough. with an impact hammer.

We have also mated four However, there are limitavibros together calling it tions to driving piles with a the “Quad Kong” set up. vibro with some of the facWe did this because some- tors being certain soil con-

Con’t ditions, weight of the piles or if the pile needs to be tested for capacity. There is not formula that will tell you the capacity of the pile when driven with a vibro.

You must use other means of testing the pile capacity such as hitting it with an impact hammer after it has been driven with a vibro.

2017. The world’s largest pile driven by the APE DodecaKong. A record 30 meter (98 foot) diameter steel pipe pile was driven

by First Harbor Engineering Company of China and APE near Hainan Island for the new international airport for Sanya, China. The massive pile is 30 meters in diameter, 34 meters long

and weighs over 600 metric tons. The previous record pile, 22 meters in diameter, was driven by APE’s Octakong on the Hong Kong– Zhuhai–Macau Seaway Project in 2011.

PB: In our Mar/Apr 2017 issue, we covered APE’s Dodecakong project in China. Is this still APE’s most impressive feat yet?

For those who are unaware of the project, can you give us some highlights?

APE: Indeed! APE accomplished the incredible when asked to build not one, but three Dodecakongs in as little as three months. Each Dodecakong consisted of 12ea of the Mighty APE 600 “Super Kong” vibros, all interlinked together with gearboxes, drive shafts and electrical components.

With each vibro there was a 1200 HP power unit making this vibro set up operational with a whopping 14,400 HP. The build of the Dodecakongs maxed out APE’s suppliers! It was an incredible feat how all our vendors ramped up their production to help make this happen for APE. Our assembly crews worked around the clock in three different shifts to meet the deadline, and we did!

Each of the twelve APE “Super Kong” vibros has an eccentric moment of 17,200 in-lbs with a centrifugal force of 445 Tons.

With the dozen Super Kong’s combined, we have a super powerful 5,340 tons of drive force coupled

Cress

with 206,400 in-lbs of eccentric moment. These Dodecakong assemblies are driving 98’ diameter caissons. Piles of this size aren’t driven every day, but when they are, they are driven with APE Dodecakong!

The next APE Dirty Dozen being assembled along with a half dozen of the massive piles ready to be driven!

PB: What other APE products should our readers know about?

APE: APE is excited for the future of piledriving with our NEW 300 series line up of vibros starting with the 300-2 and moving up into the 300-4 and on to the 300-6 vibro. These Vibros are state of the art and were introduced to the foundation piledriving industry in late 2019. They are hitting the ground running hard with more drive force per pound than any other vibro available to the foundation industry. The APE 300 series Vibros are sporting advanced cooling aluminum bearing covers giving the contractor longer

run times with 20% more cooler running operations.

All the NEW features and benefits of the 300 series vibro line up are geared towards the benefit of the foundation contractor who can always use the extra “Go Get It” when needed.

The state-of-the-art Tier 4 APE Power Units push the 300 series vibros to an unparalleled performance with the use of High-Pressure Piston Pumps. With the 300 series vibros and the award winning T4 APE Power Units you can rest assured that at the end of the day you have the latest foundation equipment technology working for you to get your piles into the ground.

Also look for APE’s NEW line up of the Dash 5 Hydraulic Impact Hammers coming to you in June 2021 sporting all the great benefits that you have been enjoying in the Dash 4 and Dash 3 series HIH hammers! And like our low headroom models, these New 5’ stroking hammers will still be the shortest hammer on the market. With ram weights from 30,000 lbs in the New 15-5 HIH up the 30-5 HIH with a ram wight of 60,000 lbs The APE HIH gives you more bang for the buck.

These new APE Hydraulic Impact Hammers use the time proven hydraulics system that has made APE Hydraulic Impact Hammers desirable for their ease of use and lasting durability.

DAVID JACK Con’t

We need to train these guys, on all these types of systems and installation methods: Micropiles, Drilled Shafts, Driven Piles, Auger Cast, Rigid Inclusions, Displacement pile, Helicals, etc. etc. etc. In my role I need to know the advantages of each – to those that will occupy my role 10-20 years from now, “You better be well versed on every method of Deep Foundations. There’s a huge variety of piling we can do. Engineer or contractor – it’s an important knowledge set of extremely high value and essential in this industry.

Peter Kiewit Company started in 1884 as a small regional masonry outfit in Omaha. As they grew, they took on more and more DOT work until they were eventually referred to as the “Colossus of Roads.” At one time they had built more miles than any other contractor, and they still do a ton of public road work, including I-10 in Baton Rouge, LA, I-70 in Denver. Today they dominate 4 major markets: Civil & Highway, Oil & Gas, Power Generation and Wastewater. Kiewit Foundations works with all these groups, fulfilling the piling scope for the many projects these markets generate. In particular, Kiewit is focused on construction of the signature bridges.

“When Kiewit gets involved

with one of these projects, I usually get brought in to work with the design and estimating team to come up with the foundation solution.” Kiewit is looking to self-perform more and more and with the increasing capabilities of Kiewit Foundation Co. “One of the great things about Kiewit has been the support in ‘having the right tool for the job. We didn’t have to use a 150-ton crane when a 200-ton crane was needed. I was always told, ‘get the crane you need, we’ll figure it out.’ So as for looking back, I’m pretty lucky.”

Today, Dave works out of Omaha and lives in Lake Tahoe, NV. When in Tahoe he tries to get out there and ski every day regardless of the conditions.

“When you can ski ice, crud, powder, whatever, you build up your conditioning to ski anything, when you have a blue bell day, you can just run.”

Dave applies this same philosophy to piledriving.

You can’t be a fair weather piledriver and cherry pick jobs. The tough jobs keep you sharp. “Yeah this job’s tough and it’s in the middle of nowhere but we got to bid it. Protect our market share. Otherwise, next job, that bid winner will show up on your front door.”

APE WEST COAST

EQUIPMENT

APE Innovation Keeps it Cool in Cali

PROFILE typical, 20-30 minutes of max RPM/VPM/PSI is all it takes to get any hammer up to 200* degrees.

The 300-4 with aluminum bearing covers driving next to it, hasn’t had to stop for a cooldown yet. In fact, its asking for more, and complaining about the chilly weather!

PS I forgot to mention the need for the crowd winch, which could easily add 30 tons of energy to the hammers’ centrifugal drive force. This is an “addon” boost as a contingency plan, since impacting was restricted from the job.

When tough driving and stiff soils demand more out of standard vibratory hammers, steel bearing covers just won’t do… they hold onto radiant heat much longer than aluminum, and thus limiting the amount and/or duration of vibration, before the bearings in the equipment heat up to what we call its “stopping point” (200o degree temp at the bearing cover = roughly 220o degrees at the bearings behind them, with the brass race becoming pliable at 230o degrees, which could result in damage to the gearbox = expensive repair and even more costly downtime!)

APE Innovates!

To combat this problem and add for more efficiency

in our ever-changing industry, we have machined and cut grooves into aluminum bearing covers (the ridges and valleys cut in, add more surface area to allow faster cooling…anyone who owns a motorcycle knows this) This combined with the science of the metallurgy, allow the aluminum to take much longer to heat up, and when it does, it gets rid of the heat much faster. All of this simply meaning, you can go back to work, or you don’t have to stop at all!

On this particular jobsite with Condon Johnson, we have another APE hammer with standard covers (250VM) on the same fixed lead setup, and as the industry already knows as

- West Coast Regional Manager Chris Corp

APE VIBRO MODEL 300-4

• Highest driving force in its class • 2 stage suppressor • Variable deceleration stops vibro faster, minimize stress on the crane • Silverback™ - radiant technology • Balanced and blueprinted design • State of the art design to maximize vibro performance and efficiency • 2 stage suppressor with 133 tons of line pull and you don’t need no stinking dampener • Eccentric moment: 5,300 in-lbs • Drive force: 258 tons

Corp

• Variable vibration speed on demand

Contact Chris Corp: chrisc@whenyourbeardislongerthanyourleads.com or chrisc@americanpiledriving.com

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