HARYANA CONSTRUCTION COMPANY

Methodology for
Construction of Pile

Project : Central Park II

Construction of Pile

Revision No.: 1
Date of Revision: 14.01.2016

DOCUMENT RELEASE AUTHORIZATION

Prepared by : Mr. Mukesh Agondh (Civil Engineer)

Approved by :

Reviewed by IMS Representative: ________________________

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HARYANA CONSTRUCTION COMPANY

A1/88 First floor ,sushant lok-2 ,Gurgaon

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 HARYANA CONSTRUCTION COMPANY

Methodology for
Construction of Pile

I. History of Revisions

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Reason for revision
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Methodology for
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II. TABLE OF CONTENTS

Clause
Description Page
No
1.0 PURPOSE 4
2.0 SCOPE 4
3.0 DEFINITION 4
4.0 RESPONSIBILITY 4
5.0 CROSS REFERENCE 5
6.0 FLOW CHART 5
7.0 CONSTRUCTION METHODOLOGY 5-10
8.0 INSPECTION AND TESTING 10
9.0 OCCUPATIONAL HEALTH, SAFETY & ENVIRONMENTAL PLAN 11-13
10.0 ATTACHMENTS 13
11.0 DISTRIBUTION LIST 13

1.0 PURPOSE

This Segment Quality Plan provides details of the Engineering, Procurement

and Construction activities of Piling

2.0 SCOPE

 Pile Construction ( 1200 mm Dia.)

3.0 DEFINITION:

MoRTH : Ministry of Road Transport & Highways

IRC : Indian Road Congress
IS : Indian Standards

4.0 RESPONSIBILITY:

The responsibilities and authorities for the execution of Piling are as per the following
matrix:

Responsible person
SI
Activity
No Checking /
Performing Approving
Verifying
Preparation of Construction QM Manager /
1 SIC WM
Methodologies Client
Identification of source for SIC / Site In charge QM Manager /
2
construction Materials Engineer QA/QC Client
Testing of sample& Trial mix In charge QM Manager /
3 QC Engineer
& approval of the same QA/QC Client

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Methodology for
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Section In Works Manager /

4 Site clearance Site Engineer
Charge Client
Section In Chief Surveyor /
5 Survey & Setting out work Survey Engineer
Charge Client
Section In Works Manager /
6 Excavation Site Engineer Charge Client
Section In Works Manager /
7 Piling Site Engineer
Charge Client
Clearance to release / final QA /QC Works Manager /
8 Site Engineer
approval Engineer Client
Implementation of risk
Site engineer /
control measures & Safety Manager /
9 Section In SIC
Environmental Mitigation Engineer / Client
charge
measures during execution.

5.0 CROSS REFERENCE:

 Standard MORTH specifications Rev. 4.

 Contract specifications.
 IS CODE 2911 (Part-IV).

6.0 FLOW CHART

Nil

7.0 CONSTRUCTION METHODOLOGY

7.1 Plant & Machinery for piling works:

TMR rig
Bentonite tankers ,if required
Hydra
Tremie Set
Dumper
JCB /Loader
Pump (for bentonite slurry pumping) ,if required
One store cum office container

7.2 Material requirement:

 Reinforcement Steel – Client

 Concrete of required grade or as approved by Client
 Bentonite - Self arrange

7.3 Time cycle:

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The Following are the expected time cycles for the activities pertaining to construction
of pile foundations: -
A. For 750 mm dia up 26 mtr pile length,
Piling rig centering and placing 0.30 hr
Boring up to founding level: 1.30 hrs
Cage is lowering: 1.00 hrs
Concreting including removing of tremie: 3.00 hrs

Total time cycle for 750 mm dia piling work: 6 hrs (Caging and transportation
shall be done in advance)

7.4 Construction Methodology:

1. Setting Out Done

2. Fabrication Of Cage
3. Boring for Pile

7.4.1 Setting out:

Prior to the installation of the piles the site will be prepared at the design location. The
preparation will be sufficient size to allow piling equipments access to each pile
location. The preparation will be carried out and installation of working piles shall take
place from the working platform. Survey pillars shall be constructed on either direction
of the alignment and points marked by total station from control points. Center of the
pile will be marked or verified from those points before placing the pile boring
equipment. All setting out job in scope of Client .

7.4.2 Fabrication of cage:

 If length of the cage is more than 12 mtr. The lap will be provided in vertical rods or
couplers may be used for joining the bars as necessary. The lap length shall be as
per drawing

 Reinforcement cage making shall take place at the pilling site by HCC.

7.4.3 Boring for the pile:

The Pile excavation can be dry bore or by wet boring with soil support bentonite slurry
to prevent collapsing / caving in of soil depending upon the actual soil conditions and
ground water table at site.

Bentonite shall be in accordance with the requirements of MORTH specification and IS

2911. To assure that the bentonite slurry is in accordance to IS 9556 the quality of the
bentonite used for the excavation will be verified during preparation, during excavation
and prior to concreting.

 Density
 Marsh Viscosity

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 Sand Content
 PH value

7.4.3.1 Setting out of Pile point

The setting out of pile positions will be carried out by a qualified surveyor for every
location. The piling in charge will be informed of the setting out and will be requested
to check the pile locations in advance of any piling work being carried out. The setting
out pegs will consist of steel reinforcing bars or the nails as required will be driven
slightly below the working platform level of the piling rig so that they will not disturbed
by the piling activities. These pegs will be marked so that they can be easily located.

7.4.3.2 Operations of drilling pile hole

The TMR moves to the position of the pile to be installed, the pile point will be made
visible by hand excavation. From the center point of the pile, two reference pegs are
set at 900 to each other at a distance equal to 1 mt. From the outside of the temporary
casing to be installed.

7.4.3.3 Temporary casing installation

The temporary casing of required diameter ( 750 mm ) and at least 2 mtr. Long,
depending on the soil and other conditions are pitched and centralized over the center
point of the pile as a guide for the auger. Temporary casing will be installed using a
vibrator hammer or by the drilling rig. The vertically will be controlled by means of long
base level alternatively positioned in two mutually perpendicular directions on the
casing or with two plumb lines located on perpendicular axis. The casing will extend
about 0.5 mt. above working platform.

7.4.3.4 Boring

Once the temporary casing has been installed, boring of the pile will commence. The
material contained in the temporary casing will be removed by the rig. The boring will
be done both in dry condition and wet condition (in presence of bentonite solution)
depending upon the ground condition, soil characteristics and presence of ground
water table. During wet boring the bore shall be kept filled with bentonite slurry of
optimal density and viscosity by regularly feeding it from the storage tank, installed on
the site and poured inside the hole stirring by using a pump to provide the required
support and protection to the sides of the borehole .We shall do the dry boring if soil
is not collapsible. Drilling rig will remove the soil from inside the hole and deepens
the bore hole. The drilling tool when filled with the soil is lifted up and the soil is
dumped outside. The whole process continues till the desired stratum or depth of the
hole is achieved.

7.4.3.5 Reinforcement Installation

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Methodology for
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The ready made reinforcement cage, fabricated according to the design requirement
and specifications, will be slowly and carefully lowered into the hole and centralized by
means of roller spacer blocks which are located along the cage periphery. The
installation of reinforcement will be performed by using crawler / mobile crane with
proper lifting capacity.

7.4.3.6 Pile Flushing ( Reverse mud circulation method )

1) After completion of cage lowering the flushing of the pile shall be started by
operating the vertical pump and Tremie pipe will be connected by hose pipe.

2) The outlet of tremie is attached to PVC hose of DIA grater or equal to the DIA of
tremie.

3) The density of mud slurry (bentonite slurry) shall be regularly checked at the outlet
point throughout the flushing operation.

4) The flushing operation shall be stopped when the density of bentonite reaches the
value less than 1.20 gm/cc.

5) The concrete operation shall be started within 30 min after completion of Flushing.

7.4.3.7 Tremie pipe installation

The tremie pipe with funnel shaped hopper will be placed in position at the top of
casing to transport the concrete to the base of the pile. Generally the tremie pipe
elements will be lowered in the center of pile shaft for its full length. The number of
tremie pipe sections will be determined by the depth of the pile to be concrete.

7.4.3.8 Concrete

Concreting of the pile is done by the use of a tremie pipe using high slump concrete as
allowed by the specifications, general codes of practice and IS 2911. Concrete will be
supplied in transit mixers. Before being poured, the supplied concrete will be submitted
to workability check, verifying that actual characteristics suit the Technical
Specifications. Should the excavation is left open for more than 12 hours before
starting the concrete placement, the bore hole will be re–cleaned. Concrete can be
poured directly from the transit mixer into the tremie pipe or if required as per site
condition concrete pump may be used to pour the concrete. The matter shall depend

Solely on the accessibility of pile locations. Concrete will be continuously poured

throughout the whole placement process to ensure a smooth operation. In order to

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assure continuity of the casting tremie pipe column will be shortened element by
element, while proceeding upwards to the cutoff level. The bottom of the tremie pipe
will be kept at least 2.0 meters into the rising concrete. The tremie pipe will have a
minimum diameter of 20 cm and shall be clean and water tight. To shorten the tremie
pipes they will be lifted from the pile shaft by the service crane and stopped on the
casting platform by special forks made up of channels which insert below the coupling
enlargements of the pipes, the extra elements will be removed and the topping
element replaced on the shortened column in order to continue the pouring. In order to
achieve the green concrete at the top concrete will be over poured at the working
platform level.

7.4.3.9 Extractions of temporary casing

On completion of casting operations the temporary casing will be removed by means

of vibrator or the rig rotary head. This operation will be performed while the concrete
within the casing remains sufficiently workable.
RECORDS

For each pile the following data will be recorded:

 Pile reference number

 Pile type
 Pile diameter
 Date and time of boring
 Date and time of concreting
 Working platform level
 Pile top and toe level
 Pile depth
 Pile cut – off level
 Length and detail of reinforcement
 Concrete mix
 The volume of concrete supplied
 Concrete records, slump etc.

7.4.3.10 Disposal of Excavated Material

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The excavated material will be temporarily stocked, and subsequently loaded on trucks
and transported to proper disposal areas. If the slurry has been contaminated or is
otherwise not suitable as a drilling fluid it will be delivered to the proper disposal area
according to the legal requirements.

7.4.3.11 Piling Records

Piling records will be kept as per the specification requirements. These records will be
submitted to the Engineer on the next working day after the pile is installed. Any
unexpected drilling conditions encountered will be noted briefly in records and will be
brought to the attention of the Engineer immediately. A daily report shall be submitted
to the Engineer specifying the work progress at this specific day and man – hours and
equipment involved. A daily program shall be submitted to the Engineer daily
specifying the work planned for the next day.

7.4.3.12 Pile overflow dismantling

Piles will be dismantled only after concreting plain cement concrete. It provides a good
working platform for dismantling and a datum for cut-off level. Similarly the damage to
the pile below cut-off level is also avoided. It is generally 50 mm above leveling course
top level. Hence untoward dismantling of piles gets automatically avoided. Cut off
levels are marked on all piles. Pile concrete above cut-off level will be dismantled by
chipping the concrete in cover portion then opening the reinforcement and wedging out
the PCC shaft, overturning and disposing off. If any hoop rings/spiral bars are there,
these will be removed for ease. After dismantling the pile, the pile tops will be dressed
properly. The debris from the leveling course will be disposed of as directed. The
leveling course will be cleared to make it ready to receive the reinforcement layout of
pile cap. If by chance there is any excess dismantling of the pile has taken place it will
not mended then and there. It will be kept as it is. It will be built-up with pile cap
concrete.

8.0 INSPECTION AND TESTING :

All the Inspection and Test requirements as per Technical Specifications and other
Codes/Standards as mentioned in References Chapter are identified and placed in
Inspection and Test Plans. These Inspection and Test Plans shall consist of type of
Inspection and the name of the test to be conducted for product realization, frequency
of testing, acceptance criteria and category of Inspection as mentioned in the legend of
ITP. Inspection and Test Plans shall be revised whenever there is any change in
methodology and specifications etc. Field Test Format referred in Inspection and Test
Plan shall be maintained as per the frequency mentioned in respective ITP’s for
various activities. All the Records shall be properly controlled and maintained in easily
identifiable and traceable manner.

Any Non-Conformity observed during Field Inspection and also during Testing of
Materials the same Non-Conformity shall be recorded in the specified Format and
necessary Corrective/Preventive actions shall be initiated to prevent such things in
future.

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9.0 OCCUPATIONAL HEALTH, SAFETY & ENVIRONMENT MANAGEMENT PLAN:

9.1 Hazard identification and controlling measures.

Occupational Health Hazards and Control Measures

Sl.
Activity Operational Control
No Hazard & Risk
Measures
1 Site clearance,  Personal injury due to  Cordoned off the area by
clearing & unsafe movement of providing barricades, traffic
grubbing vehicles and the signs and flagmen.
equipments. The road users
as well as workers may be  Trained drivers or
hit by vehicles equipment defensive driving including
and machinery. knowledge of safety
features of vehicles.
 Ensure speed within
specified limits.
 Biological/Health  Assess the work place,
Hazards (Insect/snakebite). collect the information
about snakes/insect
available on site, and
accordingly provide
awareness and suitable
control measures to the
workers.
 First aider with Anti
Venom medicine.
 Provide suitable water
sprinkler system and
personnel protective
equipments.
2 Transportation of  Personal injury due to  Follow safety
materials improper loading / procedures and provide
unloading of materials. suitable equipments for
loading/unloading of
materials.

 Injury to other road  Cordon off the work

users during area by providing proper
loading/unloading of barricades, traffic signs and
materials. flagmen.
3 Concrete  Personal injuries due to  Providing proper
contact of person with guarding to all rotating
rotating parts of Batch parts and safe operating
mixers. procedure to be followed.

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 Physical injury & back  Avoid heavy manual

pain due to incorrect lifting lifting and follow kinematics
procedure. principle of weight lifting.
 Skin burns and  Avoid direct contact of
dermatitis caused due to concrete with skin by using
direct contact with concrete. personal protective
equipment.
4 Boring / Drilling Falling of person into the  Nobody should be
bored pit. allowed to go near the
boring area. If any body is
required should be
provided with a safety belt.
After boring a fall
protection guard should be
placed on it.
Defective Wire rope of bore Only tested & certified wire
rig rope should be used. Any
Signage should be tagged
on the rope for proper
identification.

9.2 Environmental Management

The Environmental aspects involved in the construction activities shall be
assessed before execution and accordingly provide suitable Mitigation
measures as per PROJECT ENVIRONMENTAL MANAGEMENT PLAN: .

Sl. Activity Environmental Mitigation Measure

No Aspect
1 Site Clearing Effect on flora and 1. Only ground cover/shrubs that
and Grubbing fauna impinge directly on the
permanent works or necessary
temporary works will be
removed with prior approval
from the Client.

2. The waste shall be disposed

of as per the Environment
norms.

2. Excavation 1.Natural soil 1. Topsoil shall be stripped and

profile disturbance preserved for turfing purpose.
2.Contamination of
the stream 2. Debris shall not be dumped in
the watercourse.

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3. Transportation 1. Emission from 1. Ensure that all vehicles,

of material construction vehicle equipment and machinery used
2.Noise generation for construction are regularly
of vehicles, Plant maintained and conform to
and Equipment pollution emission levels.

2. All plants and equipment used

in construction shall strictly
conform to the Noise Pollution
(Regulation & Control) Rules
2000.

3. All vehicle and equipment

used in construction will be fitted
with exhaust silencers

4. Maintenance of vehicles,
equipment and machinery will be
regular And effective to control
unwanted sound

10.0 ATTACHMENTS:

ITP for Inspection of Piling works.

ITP for Material testing of piling works.

11.0 DISTRIBUTION LIST

Client : For approval

Works Department: For execution
QA/QC: For Material testing
Survey: For survey job
Doc Controller: For Documentation
HSE: To inspect the Safety and environmental mitigation measures.

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