In addition to structural support, driven piles provide lateral support for retaining walls. The piles are advanced to design tip depth or nominal resistance using an impact or vibration hammer and are typically installed in groups and tied into a pile cap. When penetration of dense soils is necessary, pre-drilling is required for the pile to achieve the specified design depth. Driven piles can be made of timber, pre-cast concrete, steel H-piles, steel sheet piles, or pipe piles.
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Piles can be installed as a single length or spliced for extremely deep piles. Driven piles do not create spoil, and since no curing time is required, they can be installed in sequence, speeding up the overall production time. The completed pile element resists compressive and lateral loads and uplift forces.
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In order to achieve shortest down time, project engineers are requesting to explore the possibility of installing precast pile cap on a group of piles. Pile cap size will be quite large - over all size may be 3m x 14m.
I designed pile caps before but never used a precast pile cap. A theoretical solution may be possible, but installation of the concept in real life could be a real challenge.
Any suggestion / advise on this matter will be of immense help to me.
Possible but not much potential savings in cost, some savings in time is possible. The amount cost for formwork, concrete and rebar installation is similar whether or not done in the factory of in the field. Prestressing can be easily done in the field.
The difficulty is not on the cap design, is at the pile-cap interface. Connection details (such as special reinforcing/embedments/grouting) and feasibility/ease of construction are the keys. If there is no one in the company has done it before, suggest to talk to a few experienced contractors during the project development stage.
I have a drawing that I can post when I get back to the office in a day or so. It's a precast cap beam for a pile bent. It's been a while but I'd say it's about 5' wide x 4' deep x about 70' long - it two pieces. It sits on 5' diameter drilled shafts.
It's for a bridge over a waterway; it you think it'll be useful let me know.
Anyway, if your cap is 3 x 14 x D, it's not exactly the easiest thing to ship and lift. ON my bridge job, everything is shipped by barge from fabricator to erector.