METHODOLOGY

SETTING OUT:
Necessary survey is to be completed and pile points marked. The pile location is set out
with respect to the control points by suitable pin marked at location and checked by
Engineer’s representative. The permission to start boring will be obtained in writing as per
the checklist. The guide points (min. 2 nos.) as per enclosed sketch are fixed at suitable
location outside the casing for future reference and the reference points are guarded.
Recording of Ground levels shall be taken prior to starting of work jointly with GC Engineer.
The setting out of each pile shall be agreed with the Engineer prior to commencement of
work.
Prior to starting piling work, pile cap diagonal trenching shall be done at each pile location
to identify the underground utilities. If any utilities are found the same shall be reported to
GC/NMRCL immediately.

Procedure for Checking of Verticality:

Check the mast of Hydraulic Rig by Spirit level to ensure that Hydraulic Rig shaft is vertical.
For conventional winch verticality shall be checked by plumb bob from top of pully of
Tripod.

DRIVING OF TEMPORARY CASING:

Tripod Rig to be positioned at the pre marked pile point. After necessary checks for
verticality of the Tripod Rig, boring will be started by bailer and Chisel. On completion of
boring up to about 2m on top, temporary steel casing pipe will be installed in position using
Tripod Rig. The casing pipe will be gradually pushed to the required depth &
simultaneously boring will be done; ensuring verticality. Casing shall be driven preferably
in one piece. The diameter of cutting tool shall in no case be less than the diameter of the
pile minus 75 mm. The working level should be 0.3m to 0.5 meter above ground level. Top
level of the casing shall be recorded along with GC Engineer. The centre line of the casing
pipe is then checked with respect to the reference points with total station. Care shall be
taken during driving to keep shift and verticality with in specified limits that is for verticality
1.5% and 75mm for shift. After concreting the casing is extracted.
BORING:

Boring operation will be done by Hydraulic rotary rig with the help of Kelly and bucket.
The size of bucket shall not be less than 1125mm for 1200mm dia pipe. After completion
of boring, founding level will be checked with sounding chain. Immediately after completion
 of boring the R/F cage fabricated as per the detailed drawing and approved BBS is
lowered. If, due to any reason starting of R/F cage lowering is delayed 2hrs, the borehole
will be clean by cleaning bucket and founding level is checked at 4 locations inside
circumference of pile with sounding chain again.

In case of end bearing piles founded in rock, minimum socketing length shall be followed
as per approved by designer.

Excavated material from pile boring should be directly loaded to the trucks and transported
to dumping areas. It should not allow being stacked at site.

Polymer
Use of polymer in stabilizing of pile borehole may also necessary together with temporary
or permanent casing wherever sub soil and ground water conditions are likely to case
instability of pile bore or sand boiling. However, this will be permitted only when deemed
necessary by Engineer. In such situations, the properties of polymer slurry used & quality
control shall be as per requirements given below. After installation of temporary casing,
the drilling operation will continuously proceed together with the application of polymer
slurry. The polymer shall be mixed with water in proportion according to manufacturer in
separate tank. The capacity of mixing tank shall be more than 1.5 times of volume of the
bore hole for which the polymer is to be used. For mixing and application of polymer with
water, agitator & pumping arrangement fixed with mixing tank shall be used. Prior to
preparation of mixture, care shall be given to cleanness of storage tank and PH value of
fresh water is to be between 7 to 9.

Properties of Polymer

REQUIRED
SL NO TYPE OF TEST EQUIPMENT TO BE USED
VALUE

1 Specific Gravity 1.00-1.05 g/cc Hydrometer

Marsh Funnel Value

2 60-70 seconds Marsh cone viscosity apparatus
Viscosity

CHECKING BY GC/NMRCL:

After achieving initial rock level & quality of rock is checked by GC/NMRCL. After approval
 further boring in rock is started by Tripod winch.
Chiseling by Tripod Winch:

Chiseling by using Tripod Winch is done upto desired depth in rock as per approved
drawings by using suitable capacity of chisel and Polymer Slurry. Cleaning will be done
by bailer at suitable intervals. One extra safety rope shall be used long with the Chisel.
REINFORCEMENT CAGE LOWERING:

Before cutting and bending of reinforcement, protective coating of reinforcement rods

against corrosion shall be done according to Contract document. The bar bending
schedule based on approved drawing is prepared and got approved from GC/NMRCL.
Reinforcement is cut and bent to required size and shape. Reinforcement cage shall be
fabricated at fabrication yard and transported to location and not at site/near pile location.
Specified cover blocks shall be provided to reinforcement cage for the pile. Reinforcement
cage shall be lowered in 1 piece or more depending on the available length of steel bars
& length of pile. Bottom cage is lowered inside the borehole and temporarily supported on
the casing pipe top, keeping the dowel length projecting above and second cage is lifted
and lapped as per approved drawings or construction drawings. Helicals / rings are tied
as per approved drawing and main reinforcement laps are properly welded to provide
more rigidity to the cage. The cage is further lowered in the borehole. MS Pipe of 2.9 mm
thick 50 mm outer dia shall be installed according to drawing for Cross hole sonic test.
Also earthing rod shall be provided as per approved drawing.

COVER BLOCK:

Circular Cover Block of 150mm dia shall be made with the same grade of concrete as that
of pile concrete and fixed to either the main bar or to helical as mentioned in drawings.
The cover block shall be provided at approximately 1.2 to 1.5 meters intervals and suitably
staggered. The strength of concrete cover blocks will be same as that of concrete in pile.

CONCRETING:

Funnel shall be attached on top of the tremie pipe for pouring of concrete. The concrete
shall be placed in the bore through the tremie. The bottom of the Tremie shall be 300
mm (approx) above the bottom of the bore. Before the first charge of concrete is placed
in the funnel, a floating plug will be inserted in to the tremie pipe and a suitable plate will
close the mouth of the tremie at top. During concreting care has to be taken to see that
the tremie pipe is always embedded in concrete by 1.0 to 1.5 m.

If Cut off level (COL) is less than 1.0 m below the ground level, concrete shall be cast at
top of the piling platform level and overflow the concrete. In case COL of Pile is more than
1.0m below working level then concrete shall be cast to a minimum of one meter above
 COL.

On completion of concreting to the required elevation, temporary casing will be withdrawn

by tripod rig. Lowering Reinforcement Cage, lowering Tremie pipe, pouring concrete &
extraction of tremie will be done Tripod or suitable crane. Tripod rig then will be shifted to
next pile location.

Workability of concrete; Concrete cubes will be casted as per specification requirements

and test cubes for 7 days and 28 days strength on a regular basis

Preparation of concrete graph indicating the theoretical and actual quantity of concrete
used at various depths to determine the extent at location of over break. Incase of
chocking of tremie the additional set of tremie to be used so that the same can be inserted
in the concrete by more than one meter.

Material Used:

Prior to utilization of materials needed tests has to be done in the laboratories in the
presence of GC/NMRCL.

(A) Concrete
 Grade of Concrete As per drawing
 Slump of concrete 150 to 175 mm
 The maximum size of Coarse aggregate shall not exceed 20mm
 The cement used for piling work as per IS:455 specification for Portland Slag
Cement and IS 269 Ordinary Portland cement or any other cement as per technical
specification and directions of Engineer.
 Minimum cement content for design Mix shall not be less than 400kg/m3
 For Piling, quantity of cement shall be as per the Design Mix or the min. cement
content whichever is greater.
 Concrete cube shall be tested as per specifications.

(B) Reinforcement steel:

 Fe 500D bars shall be used
 18 gauge G.I. wire shall be used for binding reinforcement
 Bending of reinforcement shall be as per IS:2502
 The reinforcement shall extend as specified in the drawing
 Only circular cover blocks threaded on the helix of the pile cage.
EQUIPMENTS
 S. No. DESCRIPTION TYPE CAPACITY NO.
1. Hydraulic Rig - - 1
2. Vertical Pump with __ Suitable 1
Tripod
3 Service Crane __ Suitable 1 (if required)

4 Excavator JCB 0.25 cum 1

5 Dumpers Tata / AL 4 cum 1

6 Batching Plant Automatic 30 & 60 cum/hr 1 each

7 Transit Mixers __ 6/4 cum 3

8 Welding Rectifier __ 400 Amps 1

9 Tremie Pipe __ Min 200 Dia 20 – 25 rm

10 Hopper __ __ 1 nos.

11 Trailor __ __ 1 nos.

12 Water Tanker __ __ 1 nos.

13 Compressor __ __ 1 nos.
14 WILDEN Pump __ __ 1 nos.
15 NW2E Pump __ __ 1 nos.

As per actual site condition the number of equipment mentioned above may increase or decrease.
Any other equipments, machinery, tools and plants etc. whenever required to complete the work
successfully shall be deployed.

1. HEALTH, SAFETY AND ENVIRONMENT

Barricade having suitable width and length shall be erected at construction work location. Suitable
reflectors, blinkers, diversion board, proper illumination, painting of barricade etc. shall be
provided to caution the road users and their safety.
All site personnel shall be provided with PPE’s.
Proper precautions and safety devices shall be used for activities like excavation, fabrication,
handling of electrically operated equipments etc.
All site personnel shall follow the health and safety policy of the company and environment policy
and plan of NMRCL.
Traffic shall be diverted as per approved scheme wherever and whenever required.

2. QUALITY ASSURANCE AND QUALITY CONTROL

Quality control and assurance shall be strictly followed as per proforma attached.

3. ENCLOSURES:

A. INSPECTION AND TEST PLAN

B. PERMANENT CASING CHECKLIST
C. REINFORCEMENT CHECKLIST
D. BORING PERMISSION SHEET
E. PRE POUR CHECKLIST
F. PERMISSION OF CAGE LOWERING
G. TREMIE CHECK LIST
H. CONCRETE POUR CARD
I. POLYMER SLURRY TEST
J. SETTING OUT PILE LOCATION
K. SAFETY CHECKLIST
L. HIRAC FOR PILING ACTIVITY
M BORE LOG SHEET