Ductile Iron Piles


The Ductile Iron Pile is a driven pile system, utilising high strength ductile cast iron. Pile sections are connected together by a unique spigot and socket joint, which offers speed of connection together with a high degree of stiffness. The piles are installed in quick succession using an Excavator with a Hydraulic Hammer, to both pitch and drive each pile section.

Technical Information:

Manufactured as Ductile Cast Iron, also known as Spheroidal Graphite Cast Iron, the system is immensely strong and offers superior durability over conventional tubular steel piles. Additional compressive strength is provided by the concreting or grouting of the bore, to form a composite pile.

Installed as an End-Bearing Pile (dry driven to a set, followed by concreting of the bore) or a Skin Friction Pile (simultaneous drive and grout, with an oversize shoe), the Ductile Iron Pile can accommodate a range of different ground conditions.

Key features include:

  1. Spigot and Socket Joint   
    Unique design (with internal shoulder) ensures a very
    stiff joint, with high resistance to bending.
  2. No Breakdown of Pile Head
    There is no breakdown of the pile head as in CFA or Precast
    concrete piles. The pile is simply cut to level with a disc
  3. Pitch and Drive Speed
    Piles can be pitched and driven in quick succession. The
    connection of each new section is made easy with the spigot
    and socket joint.
  4. Installation by Excavator
    Considerably lighter and far more versatile than
    conventional piling plant, excavators offer greater
    flexibility and faster rates of installation.
  5. Composite Pile
    Ultimate pile strength is a combination of the strength from
    the ductile iron pile, together with the concreted bore.

Advantages and Characteristics

The pile system consists of driven ductile centrifugally cast pipes with conical couplers. Depending on the soil conditions, the ductile cast iron piles will be used as peak pressure or frictional piles.

  • Very fast and almost vibration less pile production, no waste cuttings. 
  • Control of load capacity through correlation with driving rate.
  • Can be used as permanent pile.
  • Easy adaption of the pile length to different soil conditions.
  • No reworking of the pile heads necessary.
  • Light and easily moveable equipment allows pile production under limited space conditions, small site equipment enables fast use. 

Diagram Shows Excavator Driving TRM piles

Driven Piles (with concreted bore) – End Bearing

Driven installation using the Ductile Iron Pile is one of the quickest and simplest piling methods available. The pile is driven to a “set” in dense gravel or on to bedrock. Concrete is then placed into the bore of the pile to give additional strength.
An end plug or rock point is fitted to the lead section, which is then driven to its full length, with additional sections added as required. The set is defined as the reduced rate of pile penetration, in relation to a sustained driving energy (of the hammer), over a given time. Achievement of the set, demonstrates the pile’s ability to sustain its design load on a long term basis.
The value for the set (i.e. penetration rate in relation to sustained driving energy) is determined from empirical data, correlated with static load test results, in a range of different ground conditions over many years.

Concreting of the Pile Bore

For dry driven piles, the bore of the pile is concreted after driving, at the end of the shift (to limit standing time for concrete delivery trucks). The mix is discharged via a chute into the top of the pile. A high slump cohesive mix (piling mix), with 10mm aggregate and high fines content is typically used to concrete the bore of the pile. Slump of 150 to 175 or collapse, ensures full placement in the bore.

Coffeys Experience:

Green Park, Limerick – we used the piles to support the sewer pipeline that was laid to a particular gradient for the development of the land. The existing ground conditions were very peat and a lot of running sand was present and there was a major issue with pipeline deflecting. A solution was to drive the piles down to the bedrock and then place a saddle to carry the pipeline. The spacing between the piles was 5 meters.

Two Mile Inn, Clare - A new pumping station was constructed for the existing hotel to overcome the issue they were having with the sewage from the hotel. A new concrete pumping station had to be constructed at the back of the site to pump the sewage to the mains at the head of the road. The existing ground conditions were very peat and a lot of running sand was present and the only option was to pile the foundation of the pumping station. The simplest method was to use the Ductile Iron Piles due to ground conditions and site restrictions.

Coffey Group, Athenry, Co. Galway, Ireland Tel: +353 91 844356 Fax: +353 91 844519 Email: info@coffeygroup.com