METHOD STATEMENT FOR BORED CAST INSITU PILE

Prepared By: - Piling Division

Reviewed & Approved: - Vice President (Structures)

1) PURPOSE

The purpose of this procedure is to describe the system to be followed for construction of bored
cast in-situ piles. This procedure is intended to summarize DBLs proposal for the construction of
pilling work. The construction of Bored Cast-in-situ piles in land shall be completed with the
Hydraulic Piling Rig. The area in which piling rig will work in land shall be suitably levelled
Compacted and made secure. Necessary services such as Service crane, Trailer/Dumpers
Loader
Welding generators, Lighting arrangements, Transit mixtures, etc., shall be provided to complete
the piling works. Area for steel reinforcement cage fabrication shall be provided close to rig
working location.

2. WORKSCOPE
The scope of the work shall the following activities.

a) Layout of structure and control of alignment

b) Positioning of the piling rig
c) Installation of Temporary casing
d) Boring of pile and disposal of bore muck/spoil
e) Termination of bore
f) Cleaning of Bore
g) Cutting bending, and tying of reinforcement cage as per approved drawings.
h) Transporting Rebar cage to site
i) Placing & lowering of reinforcement cage by using Crawler crane.
j) Lowering of Tremie pipe and flushing
k) Producing and transporting the concrete to site as per the approved mix design
l) Concreting of bore hole

3. REFERENCE:
a) IS: 2911 Part: 1 Section – 2
b) Project technical specifications
c) Approved drawing of pile

METHOD STATEMENT FOR BORED CAST IN-SITU PILE

4. LIST OF EQUIPMENTS:-
As attached with separate Sheet.
*Note: All of the above equipment will be dedicated to construction of Pile works and
Requirement depends on scope and site Condition.

Office: G-13 (Ground Floor), Centurion, Plot no. 88 to 91, Sector-19A, Nerul, Navi Mumbai – 400706, India
Phone no.: +91 9004242674 / 9167110702
Email: [email protected] | Website: www.globalarcher.in
5. RESPONSIBILITY AND AUTHORITY

 Project Manager: - The overall responsibility pertaining to construction of main

and temporary works for the entire contract.

 Construction Manager: - Responsible for the availability of required resources, monitoring

of progress and quality of work for construction of Bored Cast In-Situ Piling.

Sr. Engineer: - Overall responsibility to execute the work at site and day to day
monitoring of site activities.
 Foreman/ Supervisor: - The supervisor will be responsible for managing all plant,
machinery and Labour, recording of data and supervision works.

 QA/QC: - The QA/QC engineer will be responsible for ensuring the quality of work as per
the specifications.

 Safety Officer:- Responsible for Risk assessment, Risk identification, safety inspection,
Traffic diversion and traffic safety etc pertaining to the construction of Bored Cast In-situ
Piles.

 Surveyor:- Responsible for setting out of Piles and other surveying works like line and level
checking and layout.

 Site Engineer:- He will be responsible for the overall works to be executed as per the
Methods specified and also for submitting the records and documents pertaining to the
works.

6. CONSTRUCTION PROCEDURES:-

i) Installation of Bored Cast in Situ Pile in Land:-

A). Layout of Structure and Control of alignment:-

Construction of piling shall start by carrying out survey for alignment and levels in accordance
with approved drawings. Control pillar shall be constructed at suitable location and reference for
installation of piles shall be taken from the control pillar. Then each pile location shall be marked
at ground before starting the pilling work for the location.
 Set out the positions of Bored Piles as per Approved Construction Drawings.
 Mark the pile positions with pegs
 Survey the existing ground level at the pile positions.

Office: G-13 (Ground Floor), Centurion, Plot no. 88 to 91, Sector-19A, Nerul, Navi Mumbai – 400706, India
Phone no.: +91 9004242674 / 9167110702
Email: [email protected] | Website: www.globalarcher.in
b) Installation of Liner:-

Liners are pre-fabricated as per the depth shown in the drawing & keeping liner top level 30cm
above ground level. This liner driving by using Hammer adaptor with the help of Rig. Crane (If
required) will be centered properly at the pile point. Two reference pegs are driven at right angle
to the pile point at a known distance away from the centre of pile (say 1.50m). Once the liner is
centered properly above the pile point and checked from the reference point (i.e. outer of the
Liner shall be 1.5 – ½ the diameter of pile) the liner will be driven with the help of Rig with
hammer adaptor. After driving bottom piece as above the pile will be bored up to the liner bottom
and the second piece will be joint vertically above the bottom and will be driven to the required
level) . Care shall be taken that the liner is driven vertically within the tolerance limit of 75mm as
per specification & IS Code 2911 (Part I –Sec 2).

c) Positioning the Piling Rig

Pilling rig shall be mobilized to the pile location and rig shall be positioned and centered with the
liner driven at pile location by keeping Kelly bar true to vertical at the pilling location.
 Position the piling rig to the intended pile point as per GFC drawing.
Permissible horizontal tolerance in any direction is not more than 75mm as per contract
specification.
 Placing the auger/bucket exactly above the pile point.
 Check the verticality of Kelly bar before boring commences
 Offset two reference points perpendicular to each other from the pile position.

d) Boring of pile and disposal of bore muck/spoil:-

After installation of liner, boring shall commence further with soil barrel bucket and soil auger up
to the design depth. Size of the cutting tools shall not be less than diameter of the pile by more
than 75mm as mentioned in IS: 2911 part 1 sec 2. Bentonite/Polymer (If required) solution will
be used for stabilizing the bore hole.

Office: G-13 (Ground Floor), Centurion, Plot no. 88 to 91, Sector-19A, Nerul, Navi Mumbai – 400706, India
Phone no.: +91 9004242674 / 9167110702
Email: [email protected] | Website: www.globalarcher.in
If hard materials are encountered during boring and if doesn’t penetration through Hydraulic Rig
will be replaced by Conventional tripod method (Winch machine).
Frame with suitable winch

Machine
(F50/F75) with Rock chisel & Bailer to boring in to the hard
Stratum as shown below,

Disposal of bore muck/spoil will be in tipper to the designated locations as directed by the
Employer’s/Engineers Representative as per Environmental specification & policy.
 Continue boring with an Auger or boring bucket depending on the soil conditions.
 Continue to check the verticality of Kelley bar till the completion of bore hole.
 Carryout Boring as per drawings specification
 If hard material is encountered during boring, use chisel or rock tools to penetrate into
the hard stratum as shown in the figure.
 Carry-out boring as per drawing specification.

Office: G-13 (Ground Floor), Centurion, Plot no. 88 to 91, Sector-19A, Nerul, Navi Mumbai – 400706, India
Phone no.: +91 9004242674 / 9167110702
Email: [email protected] | Website: www.globalarcher.in
d.1) Drilling Mud (Bentonite/Polymer Solution):-

For stabilizing sides of bore hole, drilling fluid of required specification (as per IS 2911) shall be
used, during boring the level of Bentonite/Polymer solution shall be kept minimum 1.5m above
the existing ground water table. Fresh Bentonite/Polymer solution will be supplied to pile from
Bentonite storage tank where Bentonite solution will be allowed to saturate for minimum 24
hours.
Recycled Bentonite solution will also be used in pile. For this the provision of setting pits in
Vicinity of piling location will be kept. A pit shall be excavated to collect the overflow Bentonite
from pile bore, where the sand and other material coming out of the bore along with Bentonite,
shall be allowed to settle or filtered through a desander. Once the heavier materials are settled or
filtered, the clear Bentonite shall be pumped into the feeding tank for reuse. A schematic diagram
for Bentonite feeding in pile bore is shown in Appendix 01. Bentonite/Polymer shall be tested as
per QAP.

d.2) Termination of Borehole:-

On completion of pile boring borehole depth shall be checked jointly with sounding chain and
bore shall be terminated as per the approved drawing and specification or as directed by the
Employer’s/Engineers Representative.

d.3) Cleaning of Bore Hole:-

Cleaning of bore holes shall be carried out with a cleaning bucket Air Flushing. Density of
Bentonite/Polymer shall be checked after adequate flushing and after lowering of cage and
Tremie pipe.

e) Cutting bending and tying of reinforcement cage as per approved drawings:-

The reinforcement of grade Fe 500 (As per Specifications) conforming IS 1786 shall.
Be used for pile cage. Rebar Steel shall be as per approved Design, GFC Drawing & IS Code
specification. The bars shall be stacked in lot and dia. Wise. Cutting bending and tying of
reinforcement shall be as per approved BBS/ drawings for the intended pile. Necessary welding
will also be done as per requirement as per IS 9417 - 1989. Then cage for the piles shall be
prefabricated in advance as per the schedule and stacked on wooden sleepers well above the
Ground Level with proper identification tag, same grade concrete circular cover blocks
Shall be fixed to obtain a cover of 75mm as per approved drawing to the rebar cage. Cover
blocks shall be made as per project technical specification. All the reinforcements shall be
corrosion resistant thermo mechanically treated and binding wires shall be used as per
specification. It shall be ensured that the cage shall be intact without distortion during storage.

e.1) Transporting Rebar cage to Site:-

The cage shall be fabricated in the nearby vicinity of piling area and lifted and transported to the
pile with the help of crane. Lifting hooks will be provided as per approved drawing. If the cage is
fabricated at Yard the same shall be shifted to the pile location by trailer.

e.2) Placing & lowering of Reinforcement Cage:-

Reinforcement cage fabricated at the site shall be checked for the intact & dimensions including
diameter and cage length of different pieces as per approved bar bending schedule & Schematic
diagram of different cage arrangement, cover blocks, etc., and are appropriate to the intended
pile. Sufficient preventive care shall be taken for the handling disturbances. Then the cage shall
be hoist to the service crane and gently lowered in to the bore hole. The cage shall be rested on
the top of pile liner with the help of rebar, thereafter additional cages is to be hoisted with the
help.

Office: G-13 (Ground Floor), Centurion, Plot no. 88 to 91, Sector-19A, Nerul, Navi Mumbai – 400706, India
Phone no.: +91 9004242674 / 9167110702
Email: [email protected] | Website: www.globalarcher.in
Of service crane and brought to the location and positioned on top of previous anchored cage.
Then the cages shall be lapped together firmly by help of threaded coupler and the full cage
Shall be hoisted to the service crane. Anchoring arrangements shall be removed and the full
cage be lowered up to the pile base by keeping the cage top at prescribed level as per approved
drawing.

f). Lowering of Tremie pipe and flushing:-

After placing the reinforcement cage Tremie pipe of appropriate dia i.e. 250mm shall be lowered
into the pile bore. Flushing shall be started with fresh drilling fluid by using adequate capacity
pump for 1 to 1½ hour (As per specifications). Bentonite sample shall be collected from the
bottom of the pile with double door sampler. Before starting the concrete, the specific gravity of
Mud suspension near about the bottom of bore hole shall be checked and lowered it within
suitable limit as per IS Code.

 Check & Ensure the reinforcement and dimensions of cage are appropriate for the
Intended pile as per approved drawings, BBS and schematic cage arrangement.
 Ensure that the cage is intact for handling.
 Ensure the cover blocks are in position.
 Hoist the reinforcement cage to the service crane.
 Verify lower the reinforcement cage into the bore hole to the base of bore hole or to
the cut –off-level.
 Ensure that the cage is maintained at the cut off level during concreting.

The specific gravity should not be more than 1.20. After completing the
Flushing of bore, hopper/ funnel of suitable capacity shall be connected with Tremie pipe.
The gap
Between the base of pile bore and bottom of the Tremie shall be kept 300mm.

g) Producing and transporting the concrete to site as per the approved mix design: -
Office: G-13 (Ground Floor), Centurion, Plot no. 88 to 91, Sector-19A, Nerul, Navi Mumbai – 400706, India
Phone no.: +91 9004242674 / 9167110702
Email: [email protected] | Website: www.globalarcher.in
grade of concrete are required for the pile shall be produced as per the approved mix
design. Concrete shall be produced in centralized batching plant. Then the concrete
Shall be sampled for its slump, the concrete shall be transported to the site by means of transit
mixers. The capacity of the transit mixers shall be 6m3/8cum.

h) Concreting of bore hole:-

After satisfactory flushing of the bore, concrete with adequate slump (range
150mm to 180 mm at the time of pouring) shall be poured into the bore hole through hopper
attached at top. The plug shall be placed in the hopper opening before charging the Tremie with
concrete. After filling the Tremie hopper with concrete then the plug shall be removed with the
help of service crane. The concreting shall be done continuously up to 750mm above pile cut off
level for the contaminated concrete i.e. concrete mixed with Bentonite with witness of Employer’s
Representative. The Tremie pipes will be removed one after one while the concreting is going on
but in any case the Tremie should be embedded into the concrete a minimum length of 2m. In
case of withdrawal of Tremie out of the concrete, either accidently or to remove a choke in the
Tremie, the Tremie may be re-introduced in the manner to prevent impregnation of laitance or
Scum lying on the top of the concrete already deposited in the bore. (As per IS 2911 Part 1 Sec2
Pt. 7.5.2)

After casting, alignment & position of pile will be done to check allowable limits before placing
precast unit.

7. HEALTH SAFETY AND ENVIRONMENT:-

Barricade shall be erected around the location of pile and the area shall be properly
illuminated. All site personnel should wear safety helmet, safety shoes and other safety
devices as required, proper precautions and safety arrangement shall be used as per
approved safety plan for activities like excavation, fabrication, handling of electrically
operated equipments, hydraulic pile rig, lifting of cage with crane, etc.
All employees shall follow the health safety policy of the company and environment policy
& plan of HSE. Bored Pile will be covered during idle hours. The area surrounding to the
Office: G-13 (Ground Floor), Centurion, Plot no. 88 to 91, Sector-19A, Nerul, Navi Mumbai – 400706, India
Phone no.: +91 9004242674 / 9167110702
Email: [email protected] | Website: www.globalarcher.in
pile will be barricaded.

8. RISK INVOLVED:-
 Working with heavy machinery Cranes and Vibrio hammer and other equipment’s.
 Shifting of Liner, positioning and driving.
 Swing of Boring Rig during Boring.
 Shifting of Rebar Cage & Jointing.
 Insert the concrete plug at the bottom of the Tremie hopper.
 Lower the Tremie above 300mm above the toe of the borehole.
 Discharge concrete directly from the transit mixer in to the hopper and fit it.
 Remove Tremie plug with the help of service crane.
 Fill concrete from the bottom of bore hole which displace the sludge as
concrete rises to the top.
 Withdraw the Tremie pipe as concrete rises upwards.
 Always maintain minimum 2m-3m length of Tremie is embedded in to the
concrete during concreting works.
 When concrete has reached minimum 750mm above the cut off-level withdraw
Tremie pipe.
 Ensure that the sound concrete has reached above the cut off level.

9. QUALITY ASSURANCE AND QUALITY CONTROL:-

Construction of pilling shall be done with the approved methodology. All quality and Equipment
related check list attached here with.

10. ATTACHMENTS:
i) Bentonite Flow & Recycling Plan
ii) QC Checklist Format iii) Equipment Check List to setup site

Office: G-13 (Ground Floor), Centurion, Plot no. 88 to 91, Sector-19A, Nerul, Navi Mumbai – 400706, India
Phone no.: +91 9004242674 / 9167110702
Email: [email protected] | Website: www.globalarcher.in
 RFI No.

BORIHG DEPTH
CUTTING CLEANING
LEVEL
START EWD START END START END

Office: G-13 (Ground Floor), Centurion, Plot no. 88 to 91, Sector-19A, Nerul, Navi Mumbai – 400706, India
Phone no.: +91 9004242674 / 9167110702
Email: [email protected] | Website: www.globalarcher.in
Office: G-13 (Ground Floor), Centurion, Plot no. 88 to 91, Sector-19A, Nerul, Navi Mumbai – 400706, India
Phone no.: +91 9004242674 / 9167110702
Email: [email protected] | Website: www.globalarcher.in