App 13.A01 - Annex 13-1-Process Installation Screws - 20150916 PDF

Project: El Romero Chile
Customer: ACCIONA Energa

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Process of installation of ground screws Annex of contract 13.1.
General
The ground screws is the base and anchor in the ground of the module table, hence its the
most important piece of the whole table rack.
To know more about the ground of the construction site where the ground screws are
installed, sample test on geologic composition and drill and load test with foundations was
carried out. This researches gave a general overview about the different conditions and there
approximately lying areas, because of the big size of the construction field only on some
areas test cloud be survived.
Without knowing exactly the soil under your feet, the installed ground screw comes every time
with overdimensions in terms of safety, stability and live time.
Scope
Scope of this text is to describe in the best possible way the steps of preparation and
installation of ground screws from its first preparation till to be ready for the rack montage.
We will try to describe the different installation methods, but because of the on wide areas
unknown ground some installation method might be modified during works in order to reach
the best anchor in the ground.
Edited by: RN Date: 16/09/2015

Annex 13-1 Procedure Krinner_Romero_Process of
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installation of ground screws _20150916 Page 1
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Preparation
By Acciona a topographic scan of the relief of terrain was made by a drone based scan system. As
a result a topographic layout plan with height scales of 0,25m was calculated and drawn.
The scan resolution of the ground, number of measuring points per hectare is not known.
According to this plan Acciona determined and planed the areas where ground works of dismantling
and refill is required, dismantling of areas of the hills and peaks and backfill of canyons and fosses.
Acciona plans to start this activities in October December 2015 before begin of construction
works.
Krinner uses the topographic layout plans to design table types, and exact positions and number of
ground screws.
In the head office the layout data will be computed together in a 3D design, generating a digital
height module of the construction field surface.
Based on the model and on the type of tables to install the technician calculate and define the
foundation depth.
We like to point out that between two measurement points the height level is extrapolated,
exceeding and undercut of real heights will appear, means the real depth of ground screw in the soil
may deviate.
The works of Krinner on site will start with the control and review of the ground relief with the KRM.
This machine will check the height of ground on given X-Y coordinates; especially a review will be
done on areas where ground leveling work was done.
All generated data will be upload in a cloud computer based data base.
Previously Krinner headoffice
The aim of the review and control is to make sure that the planned layout consist with the real
ground conditions on site.
Once that the controls and reviews are completed the 3-D model of the layout plan is safe on the
cloud data base by Krinner headquarter.

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installation of ground screws _20150916
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Positioning
The KRM machine, a modified chain Bobcat drive equipped with GPS can be used also for the
marking of positions of ground screw. Therefore the machine downloads the positioning data of the
layout plan and controlled by the GPS drives on each position of the ground screws, row by row.
There on each screw position the machine marks with white color the exact point of screw, pressing
with a chisel a hole in the ground.
Once that the position if painted and marked on the ground the team of setting of screws comes
with a telescopic fork lift load with a pallet fo ground screws. The fork lift follows row by row the
marked positions of the ground screws while one or two men take the screws from the pallet in put
these in the holes of screws.
Installation of ground screws directly in ground
The installation of the ground screws will be done with the machine KRD 60.
These machine with a combined drill and percussion hammer for the screw installation is further
more equipped with GPS system and laser height control.
All installation data are download from the cloud by a GSM local hot spot. For the construction site
of El Romero it`s pending to check the mobile phone grid intensity and capacity order to see if the
previewed cloud technology can be used.
To install the screws in an area, a reference height will be set and programmed on the height laser.
The installation of the screw runs nearly automatically. The KRD 60, operated by an machinist
drives to the set ground screw, the machine starts drilling automatically with an fixed feeder speed
and force. The ground screw is installed according to the set height level of the laser.
In case of hard ground and therefore too low feeder speed the KRD 60 switches on automatically
the drill hammer.
The drill hammer destroys the local stones or hard layer and continues the montage. The operator
who supervises the installation process can adapt and change the programmed drill forces and can
control the machine manually.
In case of solid rock or non-destroyable hard layers the operator decides or machine will stop the
installation process. There the Im-loch driller is used.
All screws have to be installed with a minimum torque which has to be defined at the beginning of
the project. To ensure that all ground screws are correctly installed the final installation torque is
recorded.
All screws what dont archive the minimum torque will be removed and reinstalled with chipping till
getting the required strength.

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Predrilling of holes of ground screws
In solid rock, hard layers or layers of boulders a predrilling will be carried out.
For the area of Z4 of the El Romero project Krinner estimate 20% of the ground screws need
predrilled holes. The holes will be made with common drill machines what comes with carriage of
the drill rod and compressor for the blast of furnace.
This work will be executed by an external chili drill company, subcontracted by Krinner.
The size of the drill rod will be choose according characteristics of the local ground conditions
(ground composition and hardness), adapted to the different areas of the field.
If some single or individual bore holes are need these are drilled with the machine KR55 equipped
with a driller type Im-loch-driller with compressor. Also here the size of the driller will choose on site
adapted to the local ground conditions.
Installation of ground screws in predrilled holes
There where the predrilling of bore holes was necessary the installation of ground screws will be
done with the KR 55 with normal drill head for screws.
The predrilled bore hole of diameter 90mm is partly filled with fine chippings. Than the ground screw
will be turned in the hole, turning into the chipping. The chipping is compressed between screw and
wall of bore hole, creating high torque and stability on the ground screw.
Installation of ground screws when longer (or shorter) shaft is needed
Because of the unequal terrain and the high distance between 2 topographic measurement points
the real ground relief can differ from the supposition (extrapolation) of the 3D layout model and on
the heights of tables on the ground.
There where the minimum installation depth of the ground screws is not reached (in order to keep
the height on screws head), the standard screw will be substituted by a longer one (or shorter one).
The not deep enough (or too deep) installed screw is drilled out by the KRD60 operator just after its
montage, or alternatively marked with red-white plastic strap on the head of screw.
Than it is removed or drilled out by the KR55.
After this the operator of ground screw installation check the ground condition and decide if chipping
and how much of it may be add to the hole in the ground. The chipping backfills the hole and create
by lateral compression of the soil that the new screw get high stability in the ground.
With the machine KR55 the longer (or shorter) ground screw will be installed in the chipping and in
virgin and untouched ground till reaching the needed height.

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Controls to ensure the quality of installation
The first control to ensure the installation quality of ground screws in the soil is the mounting and
monitoring of a minimum required installation torque. The final installation torque will be sent from
the installation machines via GSM and hotspot to the cloud. Krinner office controls and supervises
the data of installation torque.
The second step is a permanent visual control of installation position or tilt angle of ground screw.
This check is needed because boulders, massive rock and roots can displace the screw while its
installation process.
If the problem cant be solved by pre-drilling and installation of new ground screw the obstacle must
be removed out of ground.
The third step of control is carried out in parallel the second step. During the same visual control the
technician in charge proves the height of screw above ground level with a meter scale. By knowing
the total length of the screw he can easily calculate the depth of the screw in the ground
In case of non-conformity the screw has to be removed, see installation of ground screw when
longer shaft is needed.
The third step of quality control is the zinc touch up. See procedure Zinc touch up on ground
screws.
Actions to ensure the quality of installation
Reasons for actions of correction on ground screws lays in the inhomogeneous ground conditions
and the non-leveled ground.
Because of hidden obstacles in the ground like big stones, solid rock or big roots of trees the ground
screw can be deviated, set inclined and displaced.
By these obstacles during the installation the ground screw is moved from its planned position, the
threat is thigh turned in the underground that the guided shaft of ground screw is elastically bended.
At finishing of turn in the shaft of the ground screw is take off the drill in machines head, lead to
feathering back in a inclined position of the ground screws shaft.
Other correction reasons on the ground screw might be zinc damages by transport or montage.

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For the correction of correct ground screws with light side inclination the machine KR 55 will be
used.
Ground screws with high deviation and strong side inclination has to be dismantled and reinstalled
with chipping.
Considering the installation and montage tolerances of the ground screws most of the screws
wouldnt need a correction, but good vertical installed foundation makes the assembly of the tables
much easier.
Because of the two different used table types in the El Romero project, we like to point out that
ground screws for FLEX III even need less precision than ground screws on Flex V. Due to its
design the FLEX III table is more adaptable on unequaled and difficult ground, accepting higher
ground screw deviations.
Work steps
A team of 2 men equipped with drill in machine KR55 realizes the correction of the ground screws.
The worker in charge of the control of ground screws is placed approximately 5 till 10m away of the
operator of the KR 55 and the machine, staying in line with the installed ground screws. By visual
control he checks the alignment and position of ground screws, comparing this with the others.
Randomly or in special cases he counter check the alignment with the digital scale.
At the visual control ground screw by ground screw the controller indicates the operator of the
machine by hand signals the instruction of correction.
The operator guides the machine close to the ground screw, pulling or pushing them with the
support feet of the KR55 just over the ground level. At this work a bending force act on the free
staying shaft and the thigh installed ground screw thread. In the area of the top soil where the
horizontal support on the ground screw is less, the tube of the screw will be lightly bended.
By repeating the process of pushing and pulling the top of the ground screw will be corrected till the
required exactitude is reached.
Because of the high distance between acting force and the thread as well as the high installation
deepness of the ground screw in the ground, the stability of the thread is not affected.
During the correction process in some cases the zinc layer might be scratched or locally removed.
These small defects will be revised and corrected in the following working step by the team of zinc
touch up painting.
See the corresponding procedure.
For small corrections on single ground screws what shows deviations of height during the assembly
process of rack / table Krinner designed a hand ground screw wrench. This hand moved wrench is
used for esthetic adjustments on table heights and inclinations as well as to enhance the installation
process.
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Safety and Health
Instructions and safety and health proceedings of the former named works and activities are descript
in the general safety and health plan of El Romero project of Krinner.
Environmental risks
For general or specific environmental risks see Project ambience and environmental plan.
Example pictures
Picture: Bobcat based KRM Picture: Sample view on pos. of screws in

digital layout plan

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Picture: Ground screws with KRD 60 machine.

On left side and middle, ready installed screws, on the right corner of loose just set screws.
Picture: Machine KRD 60 with vertical Picture: Hand ground screw wrench with 2 levers
set carriage of combined driller-hammer.

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Picture: Screen shot cloud of installed ground screws. The different colors show the machine what
installed the screw. Each dot symbolize a screw, installation torque can be read.
Picture: Ground screws with small Picture: Controller men give hand signs to the machine
inclination or deviation. operator.

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Picture: Correction of the tube of ground screw close over the ground level by pushing with the
support feet
Picture: Correction by pulling Picture: check of inclination angle with digital scale

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App 13.A01 - Annex 13-1-Process Installation Screws - 20150916 PDF

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Project: El Romero Chile

Customer: ACCIONA Energa

Edited by: RN Date: 16/09/2015

Edited by: RN Date: 16/09/2015

Installation of ground screws directly in ground

Edited by: RN Date: 16/09/2015

Predrilling of holes of ground screws

Installation of ground screws in predrilled holes

Installation of ground screws when longer (or shorter) shaft is needed

Edited by: RN Date: 16/09/2015

Controls to ensure the quality of installation

Actions to ensure the quality of installation

Edited by: RN Date: 16/09/2015

Safety and Health

Picture: Bobcat based KRM Picture: Sample view on pos. of screws in

Edited by: RN Date: 16/09/2015

Picture: Ground screws with KRD 60 machine.

Edited by: RN Date: 16/09/2015

Edited by: RN Date: 16/09/2015

Edited by: RN Date: 16/09/2015

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