JOB EXECUTION PROCEDURE FOR DRIVEN

CAST IN-SITU PILES DOC. NO:

PLL/IOCL/EPC/PEIN
LOA No. PJ / HAL / LSTK – 1 / 11 Dt. 01.01.04 02/JP/C-002
PROJECT : MSQ UPGRADATION PROJECT REV. NO.: 0
CLIENT : INDIAN OIL CORPORATION LIMITED DATE : 05/02/2004
PUNJ LLOYD LTD CONSULTANT : Lurgi India Company Limited

JOB EXECUTION PROCEDURE

FOR DRIVEN CAST IN-SITU PILES

ISSUED FOR LURGI

00 05/01/2004
COMMENTS
REV. APPROVED
NO. DATE REVISION DESCRIPTION PREPARED BY CHECKED BY
BY
 JOB EXECUTION PROCEDURE FOR DRIVEN
CAST IN-SITU PILES DOC. NO:
PLL/IOCL/EPC/PEIN
LOA No. PJ / HAL / LSTK – 1 / 11 Dt. 01.01.04 02/JP/C-002
PROJECT : MSQ UPGRADATION PROJECT REV. NO.: 0
CLIENT : INDIAN OIL CORPORATION LIMITED DATE : 05/02/2004
PUNJ LLOYD LTD CONSULTANT : Lurgi India Company Limited

1.0 SECTION 1: PURPOSE

The purpose of this procedure is to ensure that the Driven Cast-In-Situ Pile construction , workmanship and
its testing can be achieved up to the satisfaction of Client / Consultant at IOCL Site, Haldia.

2.0 SECTION 2: SCOPE

This procedure is applicable to the execution team. It intends to co-relate and control all the tasks need to be
done in order to achieve satisfactory completion Driven Cat-In-Situ Pile construction and testing.

3.0 SECTION 3: REFERENCES

DOCUMENT TITLE DOCUMENT NO.

1. Lurgi Spec. for Construction and Installation of Driven Cast In Situ 4 LI SP
Piles.
2. Design and construction of Pile foundation Section-I Driven Cast In IS 2911(Part-I/Sec I)
Situ Concrete Piles
3. Standard Specification for testing of concrete piles 4 LI SP 22 , IS 2911
( PART IV)
4. Standard Specification for Material for concrete 4 LI SP 21
5. Standard Specification for Plain and Reinforced cement concrete 4 LI SP 03
4.0 SECTION 4: TERMS AND DEFINITIONS
All terms used in the development of this procedure are defined in Item specifications and Detailed
drawings
For the purpose of this document the term “shall” mean mandatory requirement and “should” mean
recommended practices.
5.0 SECTION 5: RESPONSIBILITY
Following are the responsibilities and reporting structure of personnel involved in the scope of the
procedure:

Resident Construction Manager - Shall report to the Project Manager.

- Shall be overall responsible for management of the
project .
Construction Manager - Shall report to the Resident Construction Manager.
- Shall be responsible for control, supervision and
direction for implementation and execution of
construction plans .
- Shall develop construction schedules , Procedures
and prepare progress and accomplishment reports .
Site Engineers - Shall report to construction Manager.
- Shall be responsible for day to day planning of site
activities and preparation of construction records .
QA / QC Manager - Shall report to RCM at site.
- Shall be responsible compliance of this Procedure.
- Shall provide all necessary resources to implement
this procedure .
- Shall periodically audit the compliance of the
procedure .
6.0 SECTION 6: METHODOLOGY
(A) MATERIAL
 Coarse Aggregate Conforming to IS 383

ISSUED FOR LURGI

00 05/01/2004
COMMENTS
REV. APPROVED
NO. DATE REVISION DESCRIPTION PREPARED BY CHECKED BY
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 JOB EXECUTION PROCEDURE FOR DRIVEN
CAST IN-SITU PILES DOC. NO:
PLL/IOCL/EPC/PEIN
LOA No. PJ / HAL / LSTK – 1 / 11 Dt. 01.01.04 02/JP/C-002
PROJECT : MSQ UPGRADATION PROJECT REV. NO.: 0
CLIENT : INDIAN OIL CORPORATION LIMITED DATE : 05/02/2004
PUNJ LLOYD LTD CONSULTANT : Lurgi India Company Limited

 Fine Aggregate Conforming to IS 383

 OPC Cement Conforming to IS 455
 HYD Bars Conforming to IS 1786

(B) WORK SEQUENCE

1. The survey work and the marking of the center point of the pile shall be completed as per AFC Drawings.
The Center location of pile shall be firmly fixed by driving the pieces of Reinforcement into the Ground.
2. The survey and the location of the pile shall be cross-checked and approved by LURGI.
3. The pile driving shall be done by the mechanically driven Rigs ( METCO ) or Hydraulically driven Rigs
( D 408 , D-308 ).
4. Pile shoe shall be MS fabricated double collar shoe . Fabricated shoe shall be painted with anti corrosive
paint. Now these shoes shall be setout on surveyed pile point and leveled properly.
5. The piling rig shall be brought to the pile location and casing pipe shall be lifted and properly aligned on
the pile shoe. The joint between the pile shoe and casing tube shall be sealed with bitumen and jute rope
(Bitumen-Mastic) to make it water tight.
6. Alignment of rig and verticality of the guide frame shall be ensured. For guide frame, a deviation of
maximum of 1.5% for the vertical piles shall be permitted.
7. In case of Mechanically driven rigs Drop Hammer and winch should be operated through mechanical
device. In case of Hydraulic rigs winch should be operated by hydraulic means . The casing tube shall be
driven into the ground with fall of hammer.
8. Number of blows of hammer shall be noted per running meter depth of the penetration of casing of casing
tube.
9. Set Criteria / penetration for 10 blows shall be recorded before final depth is achieved as established by
driving empty casing tube .
10. M-25 Grade Concrete shall be used for the concreting. Workability of the concrete shall correspond to a
slump of 100 mm to 175 mm. Mix design of concrete shall be established prior to start of pouring in
accordance with IS : 456 , IS : 2911 , Lurgi Code 4LI SP21 , IS : 10262 .
11. If the measured underground water above the inner surface at the tip of the shoe is more than 150 mm
then the concreting shall not be commenced. Also while withdrawing the casing , the head of concrete in
the hole shall always be more than the head of ground water table outside the casing to prevent inflow of
water inside .
12. It shall be ensured that the volume of concrete poured is at least equal to volume of pile shaft being
concreted and the rate of concreting should match with the rate of withdrawal of casing tube. It shall also
be ensured that the minimum 1meter height of concrete shall be maintained in the casing pipe.
13. In a pile group, the sequence of installation of piles shall normally be from the center to the periphery of
the group or from one side to the other.
14. The top of concrete in a pile shall be brought above the cut off level to remove all laitance and weak
concrete before capping and to ensure good concrete below the cut off level. The reinforcement cage shall
be left with adequate protruding length above the cut off level for proper embedment into the pile cap
foundation.
15. The concrete shall be cast to a minimum of 300 mm above the COL.
16. All the data in connection with Pile from starting time to the completion time shall be recorded .After
completing the concrete , the top level of concrete has to be checked .
17. The casing tube has to be taken out immediately & rig shifted to next pile point.
18. Sample of concrete cubes shall be marked clearly with date of concreting .

ISSUED FOR LURGI

00 05/01/2004
COMMENTS
REV. APPROVED
NO. DATE REVISION DESCRIPTION PREPARED BY CHECKED BY
BY
 JOB EXECUTION PROCEDURE FOR DRIVEN
CAST IN-SITU PILES DOC. NO:
PLL/IOCL/EPC/PEIN
LOA No. PJ / HAL / LSTK – 1 / 11 Dt. 01.01.04 02/JP/C-002
PROJECT : MSQ UPGRADATION PROJECT REV. NO.: 0
CLIENT : INDIAN OIL CORPORATION LIMITED DATE : 05/02/2004
PUNJ LLOYD LTD CONSULTANT : Lurgi India Company Limited

7.0 SECTION 7: TESTING OF PILES

7.1 Scope : This specification will cover the requirements and methods of testing of a single pile for
evaluating its safe capacity in
 Vertical loading ( Compression )
 Lateral Loading
 Pull Out
 Combined Vertical and lateral loading
 Special type of loading such as vibratory loadings
7.2 Requirements
Full details of the equipment proposed to be used and the test setup shall be submitted with detailed
sketches for approval . Approval shall also be obtained after the test setup is complete prior to
commencement of loading .
All measuring devices shall be tested for satisfactory performance and accuracy at an approved institution
and a certificate to that effect shall be obtained and shall be submitted to Lurgi prior to use .
The test pile shall be constructed using same equipment and technique as for the working piles.
A minimum time period of four weeks shall be allowed from the time of casting in case of cast in-situ
piles or as per the direction of Engineer in charge .
7.3 VERTICAL LOADING TESTS
7.3.1 Loading system :
 Loading shall be applied by the reaction method consisting of an hydraulic jack centrally against a
loaded platform (Kentiledge Load ) .Supports of the platform shall be suitably designed .
 The loading system shall be adequate to ensure that the test can be carried out up to the specific
limits .The reaction to be made available for the test shall be at least 25 % greater than the
maximum jacking force required .
7.3.2 Method of Conducting Test
 The around the test pile is to be suitably excavated . The bottom of the pit shall be below the cut-off
level .
 The pit shaft is to be chipped off at the cut off level and the projecting reinforcement shall be cut off
at this level . The top surface of the pile shaft is to be plastered to a smooth finish . Alternatively the
pile can also be built up and finished smooth at level higher than the COL .
 Wooden sleepers are to be placed on the two sides of the pit . The main girders are to be placed over
wooden sleepers such that the C.G of the girders is exactly over the centre of the pile . A gap of about
100mm has to be maintained between the bottom of the main girders and the top of the jack in the
zero position .
 On the width sides of the pit , two rows of sand bags are to be placed parallel to the main girders
along the entire length of the girder. Wooden planks are to be placed on the top of the sand bags .
 All the cross girders are to be placed at equal spacing at right angles to the main girders
 Sand bags are to be placed along the periphery of the platform up to required height so as to make a
wall . The inner space is to be filled up with sand bags .
 The datum bars are to be fixed on either side of the pile in the ground along the length of the pit so
that they rest on immovable supports at a distance of 3D from the edge of the pile, where D is the
diameter of the pile or 1.5m whichever is more.
 A square mild steel plate is to be placed on the top of pile such that the centre of the plate is over the
centre of the pile.
 The jack of required capacity is to be placed over the mild steel plate. The jack is connected with
hydraulic pump.
ISSUED FOR LURGI
00 05/01/2004
COMMENTS
REV. APPROVED
NO. DATE REVISION DESCRIPTION PREPARED BY CHECKED BY
BY
 JOB EXECUTION PROCEDURE FOR DRIVEN
CAST IN-SITU PILES DOC. NO:
PLL/IOCL/EPC/PEIN
LOA No. PJ / HAL / LSTK – 1 / 11 Dt. 01.01.04 02/JP/C-002
PROJECT : MSQ UPGRADATION PROJECT REV. NO.: 0
CLIENT : INDIAN OIL CORPORATION LIMITED DATE : 05/02/2004
PUNJ LLOYD LTD CONSULTANT : Lurgi India Company Limited

 The gap between the top of the jack and the main girders is filled up by providing packer plates.
 Four nos. of dial gauges are to be placed on the M.S. Plate by magnetic bases on diametrically
opposite sides of the pile so that its needles are resting on glass plates on the datum bars.
 The first increment of load (equal to or les that 20% of the test load (Initial / Routine) is to be applied
and this load is to be maintained till the settlement rate is not more than 0.20mm per hour or until 2
hours whichever occurs later. The readings are to be recorded at 2,4,8,15,30,60 min & every two
hours interval.
 The next increment of load is to be applied and settlement readings are to be recorded as above.
 For loading application of load is continued until the maximum load on the pile is reached or the
settlement exceeds 10% of the pile dia. , whichever is earlier.
The final load is to be maintained for 24 hours and readings are to be recorded on 6 hours interval.
 The load is then started to be released in the same sequence as when the load was applied. Each load
is to be maintained for 30 min and the corresponding dial gauge readings are to be recorded. When
the entire test load has been removed, the final rebound shall be recorded after six hours.
 A graph is to be plotted showing load on X axis and settlement on Y axis.
 All the data are to be recorded in the specified pile load test record from.
 Assessment of safe load :- The safe capacity of the pile shall be the least of the following values :
I)2/3 of the final load at which the total displacement attains a value of 12mm unless otherwise
required , in a given case on the basis of nature and type of structure in which case a safe load should
be corresponding to the stated total displacement permissible .
II)50 % of the final load at which the total displacement equals 10% of the pile diameter in case of
uniform diameter piles .
7.4 Lateral Load Test

7.4.1 Loading system :

 Loading shall be applied by an hydraulic jack of adequate capacity , abutting the pile horizontally
and reacting against a suitable system . The reaction shall be provided by the wall of the excavated
pit when the test is being conducted below ground level or by a neighboring pile in which case thrust
pieces shall be inserted on either end of the jack to make the gap .
7.4.2 Method of Conducting Test
 Test and working piles shall be decided by the Engineer - in - charge. It may be one of the working
piles or a separate test pile .
 the area around the test pile is to be excavated for exposing the pile completely and exposing the
reaction pile only half the surface facing the test pile leaving the soil behind the reaction pile intact so
as to generate additional resistance. Excavation depth shall be below the cut-off level, the ground
between the test pile and the reaction pile is to be levelled and the exposed surface of the piles are
cleaned off.
 Wooden sleepers are to be placed tightly touching each other at end to end between the test pile and
the reaction pile along the line joining the centre of two piles.
 A girder (ISMB)of required cross-section and length is welded at one of the ends with a M.S. plate of
required thickness and suitable length and breadth.
 The other end of the girder is to be welded to semi circular plate of required thickness.
 The ISMB girder is to be placed horizontally on the wooden sleepers in line with the cut-off level test
pile with the semi-circular plate placed tightly against the exposed surface of the reaction pile.
 The hydraulic jack is to be placed on its side on the ISMB so that the base of the jack is toughing to
face of steel plate welded to be ISMB. Mild steel packer plates are to be placed between the steel plate

ISSUED FOR LURGI

00 05/01/2004
COMMENTS
REV. APPROVED
NO. DATE REVISION DESCRIPTION PREPARED BY CHECKED BY
BY
 JOB EXECUTION PROCEDURE FOR DRIVEN
CAST IN-SITU PILES DOC. NO:
PLL/IOCL/EPC/PEIN
LOA No. PJ / HAL / LSTK – 1 / 11 Dt. 01.01.04 02/JP/C-002
PROJECT : MSQ UPGRADATION PROJECT REV. NO.: 0
CLIENT : INDIAN OIL CORPORATION LIMITED DATE : 05/02/2004
PUNJ LLOYD LTD CONSULTANT : Lurgi India Company Limited

and the base of the jack so that the ram of the jack touches the test pile and is in line with the COL of
the test pile.
 Two datum bars are to be fixed at about 300 mm distance from the edge of the test pile at right angle
to the axis of the jack and diametrically opposite to the jack. The datum bars are to be rest on
immovable supports spaced at a distance of 3D from either side of the pile.
 The dial guage are to be spaced at 3.0 M and kept horizontally, one above the other on the test pile
when COL is ot approachable. For approachable COL one dial guage will be placed diametrically
opposite to be jack at COL.
 The hydraulic pump is to be connected with the jack.
 The first increment of load is to be applied till the displacement is not more than 0.20mm/hr or one
hour, whichever is greater.
 Next increment of loads are to be applied and the corresponding readings are to be recorded.
 For initial test, the final load shall be 3 times the safe load. For routine test the final shall be 1.5 times
the safe load.
 The final load is to be maintained for 24 hours and readings are to be recorded at every 6 hours
interval.
 The load is gradually to be released in the same sequence as the load was applied . Each load is to be
maintained for 30 min. and the corresponding dial gauge readings arre to be recorded . When the
entire test load has been removed , the final rebound shall be recorded after 06 hrs.
 A graph is to be plotted showing load on X-axis & Settlement on Y-axis .
 All data are to be recorded in the specified pile load recorded format .
 Assessment of safe load :- The safe capacity of the pile shall be the least of the following values :
I)1/2 of the final load at which the total displacement attains a value of 12mm. II)Load corresponding
to 5 mm total deflection .

7.5 PULL OUT LOAD TEST

This section deals with the testing of piles for vertical uplift force by application of an axial load or force .
Maximum test load for vertical uplift load test shall be as follows.
a. Initial pull out load test : Load corresponding to thrice the estimated test load or until load
displacement curve shows a clear break ( Downward trend )
b. Routine pull out load test : Load corresponding to one & half times the estimated safe load or 12 mm
total displacement which ever is earlier .
7.5.1 Loading system :
Load shall be applied using an approved reaction system . Uplift force on the pile shall be applied directly
to the test pile or through a lever system . The reaction shall be provided by neighbouring piles or blocks
may be constructed for the purpose . A hydraulic jack shall be used for load application ,
7.5.2 Method of Conducting Test
 Supervision.
All the tests shall be carried out only under the direction of an experienced and competent supervisor
conversant with the test equipment and test procedure . All personnel operating the test equipment
shall have been trained in its use .
 Construction of A pile for initial test
The test pile shall be built up to the proper length & the head provided with suitable arrangement for
anchoring the load applying system .

ISSUED FOR LURGI

00 05/01/2004
COMMENTS
REV. APPROVED
NO. DATE REVISION DESCRIPTION PREPARED BY CHECKED BY
BY
 JOB EXECUTION PROCEDURE FOR DRIVEN
CAST IN-SITU PILES DOC. NO:
PLL/IOCL/EPC/PEIN
LOA No. PJ / HAL / LSTK – 1 / 11 Dt. 01.01.04 02/JP/C-002
PROJECT : MSQ UPGRADATION PROJECT REV. NO.: 0
CLIENT : INDIAN OIL CORPORATION LIMITED DATE : 05/02/2004
PUNJ LLOYD LTD CONSULTANT : Lurgi India Company Limited

 Loading system
Load shall be applied using approved reaction system . Uplift force on the pile may be applied directly
to the test pile or through a lever system . The reaction may be provided by neighboring piles or
blocks may be constructed for the purpose . A hydraulic jack shall be used for load application ( if
required ).
 Measuring system
Load applied by jack shall be measured by a calibrated pressure gauge with a least count of 05
Kg/Sq.cm. . Movement of the pile shall be measured by dial gauges fixed to datum bar having at
least count of 0.1mm. A minimum of two dial gauges placed diametrically opposite shall be used .
Datum bars shall be provided with rigid supports.
 Method of conducting test .
The test shall be conducted as outlined below .
Loading shall be applied to the pile top in increment of 1/5 th. the rated capacity of pile .Each stage
shall be maintained for a period till the rate of the movement of the pile head is not more than .2
mm/hr. or one hr. Whichever is greater .
 Loading shall be continued till one of the following occurs .
a. Yield of soil pile system occurs causing progressive movement of the pile exceeding 12 mm.
b. The loading on the pile top equals twice the estimated safe load or as specified .
 Assessment of safe load .
The safe capacity of the pile shall be the least of the following .
a. 2/3 rd. of load at which the load displacement is 12 mm or the load corresponding to a specified
permissible uplift . and
b. ½ of the load at which the load –displacement curve shows a clear break . ( downward trend )
 Process of unloading
Unloading will be done in each n30 min. & reading will be taken simultaneously . Decrease of load
will be in the same cycle i.e. 20% in each 30 min .After full unloading the rebound will be observed .
So deduct the rebound from the uplift in full load , we will get the final uplift of the pile . One load
vs. uplift curve will be given along with the test report .
 Completion of a Test.
On completion of a test eqpts . & measuring devices shall be dismantled , checked & stored so that
they are available for further tests.
Kentledge and its supporting structures shall be removed from the test pile and stored so that they are
available for use in further test . Ground anchors , if any shall be cut off below GL , removed from the
site and the ground made good with approved material .
 Presentation of results
The test data shall be recorded sequentially in an approved format along with the information about
the pile. The data may be suitably presented by curves. The completed schedule of recorded data shall
be submitted to the Engineer-In charge.
7.6 COMBINED VERTICAL AND LATERAL LOADING
7.6.1 Loading system :
Loading system shall be similar to the loading system required for the lateral loading . In addition a
platform shall be constructed above the pile top and loaded as per the specification / practice in vertical
loading .
The pile load test subjected to the full vertical load and lateral load shall commence after all settlements
due to the vertical load have ceased and when the full vertical load in position .
7.6.2 Method of Conducting Test
ISSUED FOR LURGI
00 05/01/2004
COMMENTS
REV. APPROVED
NO. DATE REVISION DESCRIPTION PREPARED BY CHECKED BY
BY
 JOB EXECUTION PROCEDURE FOR DRIVEN
CAST IN-SITU PILES DOC. NO:
PLL/IOCL/EPC/PEIN
LOA No. PJ / HAL / LSTK – 1 / 11 Dt. 01.01.04 02/JP/C-002
PROJECT : MSQ UPGRADATION PROJECT REV. NO.: 0
CLIENT : INDIAN OIL CORPORATION LIMITED DATE : 05/02/2004
PUNJ LLOYD LTD CONSULTANT : Lurgi India Company Limited

Detailed procedure along with full details of the equipment proposed to be used and the test setup shall be
submitted with detailed sketches for approval . Approval shall also be obtained after the test setup is
complete prior to commencement of loading .
Only experienced agencies having proven track record shall be awarded the job and intimation shall be
given prior to starting the job.
7.7 SPECIAL TYPE OF LOADING SUCH AS VIBRATORY LOADINGS
For the purpose very skilled and experienced agency like IIT shall be hired . Their methodology shall be
submitted for approval prior to starting the job .
8.0 SECTION 8: DOCUMENTATION AND RECORDS
1. Record for Survey approval for Piles as per Format-PLL/IOCL/EPC/PEIN-02/JP/C-002/F-01
2. Pile driving record as per Format - PLL/IOCL/EPC/PEIN-02/JP /C-002/F-02
3. Pile reinforcement / concreting details in Format - PLL/IOCL/EPC/PEIN-02/JP /C-002/F-03
4. Pile load test record as per Format - PLL/IOCL/EPC/PEIN-02/JP /C-002/F-04
5. Cube strength report as per Format - PLL/IOCL/EPC/PEIN-02/JP/C-002/F-05
6. Concreting ( Check for Slump )/ Design Mix - PLL/IOCL/EPC/PEIN-02/JP /C-002/F-06, Rev.0
9.0 SECTION 8: HEALTH, SAFETY AND ENVIRONMENT
Following measures but not limited to here under shall be taken for the execution of Driven Cast In Situ
Pilling Works. Risk Assessment of all activities associated with this procedure shall be done before
starting any activity.
1. Entire working area shall be within the plant boundary limit .Only authorized equipment/
personnel will be allowed within the working area.
2. All utilities shall be identified and protected.
3. All lifting tools and tackles shall be periodically inspected against any damage.
4. All equipments shall be maintained in good working condition as per maintenance schedule.
5. All workmen supervisors and engineers shall use proper personnel protection gears.
6. All employees shall follow the employee Health & Safety Rules

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COMMENTS
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NO. DATE REVISION DESCRIPTION PREPARED BY CHECKED BY
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