The Flexi-Pile Cap is a remedial solution for 610 & 762 diam

Stage 2: The Cutting (Cont)

Stage 3: The drilling template

Stage 2: Cutting

Stage 3: The drilling process

Form 003 signed off for the Flexi-Pile Cap. On-site the pile is cut off at the required level. Holes are then drilled to suit the template provided by FLI.

For speed and accuracy a disk cutter is used

Cutting of the pile: <60 minutes

The drilling template is used to mark drill holes

Profiling for welded bosses & hot works negated

Completion of template: <4 Minutes

Stage 1: Marking up

Stage 4: Bolting up

Marking of the pile: <5 Minutes

Drill mount is attached to pile

Drilling: <30 Minutes

Adjustment Features of FLI Flexi-Pile Cap

LEVEL - Pre set cut down positions with pre drilled holes for coarse level adjustment extra row of drillings for further adjustment. Levelling nuts for fine adjustment

PLAN – Coarse adjustment via beam mounted across top of pile. Fine adjustment via oversized holes on column base plate then clamped with oversized washers

ROTATIONAL - Coarse rotational adjustment by additional columns of holes around pile perimeter. Fine adjustment through kidney shaped holes in cap plate.

PLUMB – Corrected by levelling nuts using prefabricated and drilled packers as necessary

Each tab is fitted with two M36 bolts

Flexi-Pile Cap tabs fitted & ready for the structure

Completed remedial solution: <2 Hours

Completed remedial solution: <2 Hours

Solution – FLI Flexi-Pile Cap

Each tab is fitted with two M36 bolts

Flexi-Pile Cap tabs fitted & ready for the structure

• Providing Solutions to:

• Damaged bosses.

• Piles hitting refusal

• Installed at incorrect rotation

• Large mast requiring

interface/plate

• Flexi-Pile Cap retro-fits

to standard 610 piles

• 60 Year Design Life

Tube drilled and cap fitted

610 pile refused/out of rotation

Structure fitted to pile cap

Principles of the FLI Flexi-Pile Cap

• Bolted pile
• Easy to adapt on site
• Improved QA
• No bosses or butt welding
• Adjustability in position, level and rotation
• Simple tabs to u/s of base plate if pile is in tolerance
• Standard tabs/ caps for different structures
• Different methods of installation available

P A T E N T P E N D I N G

Adaptor Plate Replacement

For use with

Four angled fabricated masts

Double channel masts

Challenges on site

Angle of Deviation

Incorrect Orientation

Correct Orientation

Installed out of rotation

Challenge No 4

Challenges on site

Adaptor Plate Replacement

Offset Deviation

Finish Position

Design Position

Final Position

Design Depth

Set Back From Track

Depth Refusal

Challenge No 2

Challenge No 3

Challenges on site

Adaptor Plate Replacement

Damaged on installation

Challenge No 1

610mm pile overdriven/set back from track

Standard caps/stubs to fit all structure types

Adaptor beam for services or portals

FLI Flexi-Pile Cap

The Flexi-Pile Cap is a remedial solution for 610 & 762 diameter piles, in particular those piles that refuse early in hard ground and do not achieve full depth, or are out of rotational tolerance. 

The Flexi-Pile Cap provides a quick and efficient cutting down solution that negates the need for hot works and re-welding new bosses in-situ. The solution helps to improve the completed productivity of 610 pile installations and enables higher output of piling activity, so more piles can be installed per shift, saving time and money. View our storyboard for more detail on how the Flexi-Pile Cap overcome pile challenges.

P A T E N T P E N D I N G

Summary

Identify risk

Design for it up front

A suite of solutions

Overall design input reduced to limit stop flows

Overall manufacturing timeframe reduced

Overall installation timeframe reduced