LARSEN & TOUBRO HYDROCARBON ENGINEERING

LIMITED
CRYOGENIC ETHANE RECEIPT & STORAGE FACILITY

RIL- DAHEJ

METHOD STATEMENT FOR INITIAL PILE LOAD TEST

Doc. No: LTHE/CERSF/C/MS/001

For RIL Review &

0
Approval
Rev Purpose of issue Date of issue Prepared by Checked By Approved by

Reviewed by RIL Approved by RIL

Signature:

Name:

Date:

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 METHOD STATEMENT FOR PILE LOAD TEST

Table of Contents

Section No. Description Page No.

1 Scope Of Work 3

2 Definitions
3

3 Test Plan 4

4 Controlling Specification
4

5 Test Procedure 5

5.1 Vertical (Compression Load Test) 5

5.2 Lateral Load Test 11

5.3 Pull Out Test 15

6 Test report 20

7 Annexures 21

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 METHOD STATEMENT FOR PILE LOAD TEST

1. SCOPE OF WORK:

Dia of the pile Type Nos

Compression 1
1000 mm
Lateral 1
Pull out 1
2. DEFINITIONS:

Cut-off Level: The level where the installed pile is cut- off support the pile caps or
beams or any other structural components at that level
Initial Test: It is carried with a view to determine Ultimate Load Capacity and the Safe
Load Capacity.
Factor of safety: The ratio of the Ultimate Load Capacity of pile to the Safe load of a
pile.
Routine Test: It is carried out on a working pile with a view to check whether pile is
capable of taking the working load assigned to it
Test pile: A pile which is meant for initial test.
Datum Bar: A rigid bar placed on immovable supports.
Total Displacement: The total movement of the pile top under a given load.
Cut-Off Level: The level where the installed pile is cut-off to support the pile caps or
beams or any other structural components at that level.
Working Pile: A pile forming part of foundation of a structural system which may be

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 METHOD STATEMENT FOR PILE LOAD TEST

used for routine load test.

Working Load: The load assigned to a pile according to design.
Safe Load: It is a load on a pile derived by applying a factor of safety on ultimate load
capacity of pile as determined by load test.
3. TEST PLAN :

TP - 1
TP – 1: Lateral Load Test Pile

TP - 2 TP – 2: Tension Load Test Pile

TP – 3: Vertical Load Test Pile

TP - 3

4. CONTROLLING SPECIFICATION:
 Specification 10110-PS-CMG-100-001 Rev 02
 AFC Drawings
 IS: 2911 (Part4) – Load Test on Piles

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5. TEST PROCEDURE:
5.1 VERTICAL (COMPRESSION LOAD TEST)
5.1.1 SPECIFICATION CLAUSES
 It is essential that all equipments and instruments are properly calibrated
(Calibration Certificate Placed as ANNEXURE- I & ANNEXURE-II) both at the
commencement and immediately after the completion of tests, so that they
represent true values.
 The complete jacking system including the hydraulic jack, hydraulic pump and
pressure gauge shall be calibrated as a unit. The complete unit shall be calibrated
over its complete range of travel for increasing and decreasing loads same as that
of test loads. The calibration certificate shall be submitted to the Engineer-in-
Charge.
 The reaction load to be made available for the test shall be at least 25% greater
than the maximum jacking force. The reaction system as relevant shall be
designed for the total reaction load. All reaction loads shall be stable and
balanced during all operations of testing. During testing, stability of reaction
system shall be ensured.
 The load applied on the pile shall be measured by a calibrated pressure gauge
mounted on the jack with a least count of not more than 10% of the safe load.
 The displacement of pile shall be measured using Dial gauge having a least count

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 METHOD STATEMENT FOR PILE LOAD TEST

of 0.01 mm.
 Load test shall be conducted at pile cut of level (COL). If the water table is above
the COL the test pit shall be kept dry throughout the test period by suitable de-
watering methods. Alternatively the vertical load test may be conducted at a
level higher than COL. In such a case, an annular space shall be created to remove
the effect of skin friction above COL by providing an outer casing of suitable
diameter larger than the pile diameter.
 Full details of the equipment proposed to be used, the test setup and pile testing
scheme along with detailed design, drawings shall be submitted to the Engineer-
in-Charge, before making arrangements to carry out the tests, for his approval.
Approval of the Engineer-in-Charge shall also be obtained after the test set up is
complete prior to commencement of loading.

5.1.2 PREPARATORY WORKS

 Load test can be carried out if the specified concrete strength is achieved at the
day of testing. However, the strength shall be checked before loading the pile.
 Area around pile shall be excavated for working space to a depth of 1.0 to 1.5 m
below the existing ground level or 20 cm above ground water table whichever is
encountered first. Necessary dewatering arrangements shall be done during
testing. Adequate side slope shall be provided.
 Pile shall be exposed and the Pile head chipped off upto the sound concrete level

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 METHOD STATEMENT FOR PILE LOAD TEST

followed by building up of the same with fresh levelling concrete of same grade
as that of pile concrete for 30 to 40 cm length upwards to accommodate MS
angle for contact of Dial gauge and resting of MS test plate.
 Adjoining ground surface shall be checked on which load will be transferred
through secondary joists. Primary joists on steel section / plate shall be placed at
the ends.
 Secondary joists shall be placed on top of the primary joists spanning over brick
work / concrete blocks supports. The platform shall be properly levelled for
ensuring stability.
 All setup is as per approved drawing 10110-C-73-GUT-192-100-172 Rev 0 (Placed
as ANNEXURE-III)
 Datum bars are to be fixed rigidly to support the dial gauges. The support for
datum
Bars must be at a minimum distance of ‘three times the diameter’ of pile from
the face of the pile.
 Dial gauges are used for measuring deflection.
 The least count of the dial gauges shall be at least 0.01mm. These dial gauges
must be set up in such a way that any tilting of test pile will not cause errors in
the measurements.
 Four dial gauges are used and positioned at equal distances around the pile and

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 METHOD STATEMENT FOR PILE LOAD TEST

normally held by datum bars resting on immovable supports at a distance of 3D

from the edge of the pile, where D is the diameter of the pile.

5.1.3 EQUIPMENT AND TEST SETUP

List of equipment’s and test setup to be deployed is as under:

S. No. Description Quantity

01 Jack with Pump 01 No

02 Settlement Measuring Instrument 04 No

03 Pressure Measuring Instrument 01 No

04 Primary Joists As Per Drawing

05 Secondary Joists As Per Drawing

06 Plates, Accessories, etc. As Per Drawing

5.1.4 LOADING SYSTEM

 Vertical load test shall be as per specification for 1000 mm diameter pile.
 The maximum axial load to be applied on test pile shall be the predicted ultimate
pile Capacity (so to induce failure) but shall not exceed 3 times Qsafe.
 2.6 Qsafe was considered as the maximum load of the second cycle in order to
reach the predicted ultimate pile capacity and not to exceed the capability of the

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loading system (900Tons).

 For the first cycle, the applied load will be 1.4Qsafe. This will allow to better
assess the yield load when processing the results.
 These loads shall be carried out by applying a series of vertical downward
incremental load.
 Each increment is to be about 20% of the design working load on the pile.
5.1.5 TEST PROCEDURE

 The increment of test load in each stage shall be maintained till rate of
displacement of the pile is either 0.25mm in one hour or till 2 hours, whichever
occurs first.
 If failure occurs, maintain the failure load, or the maximum load possible, until
the total axial movements equals 15% the pile diameter.
 If failure does not occur:
 And settlement is not greater than 0.25mm/hr, remove the total test load
after 12 hours of overall test duration.
 And settlement is greater than 0.25mm/hr allow the total test load to
remain on pile for24 hours.
 After completing the final load increment, remove the load in increments of 25%
of maximum test load with 1hr between decrements.
 Final rebound shall be recorded 12 hours after the entire test load has been

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removed.
 After noting the total settlement, the load is released in full and the residual
settlement is measured.
 Loads shall not be sustained over long periods, in order to avoid the effect of
creep and consolidation.
 The detailed loading steps for loading and unloading is according to the
specification 10110-PS-CMG-100-001 REV 2( Placed as ANNEXURE-IV)
5.1.6 SETTLEMENT RECORDING
 Test readings shall follow the requirement described in section 8.2 of the ASTM
D1143/D1143M-07 [2]. It shall include but not limited to the following
requirement:
 Record test readings taken before and after the application of each load
increment or decrement.
 During each load interval, provided that the test pile has not failed, record
additional readings taken at 5, 10 and 20 min following application of the load
increment, and every 20 min thereafter as needed.
 After applying the maximum total load of each cycle, provided that the test pile
has not failed, record additional readings taken at 5, 10 and 20 min, then every
20 min upto 2 hrs, then every hour from 2 to 12hrs, and then every 2 hrs from 12
to 24 hrs as needed.

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 If pile failure occurs, also record readings taken immediately before removing
the first load decrement. During unloading, record readings taken at time
intervals of 20 min for each unload interval. Record readings at 1, 2, 6 and 12 hr
after removing all load.
5.1.7 Record of Readings:
 The load settlement response shall be recorded along with the complete
information about the pile in LTHE/ERSF/IR/C-017(Placed as ANNEXURE V)
5.2 LATERAL LOAD TEST:

Lateral Load Test on piles will be conducted as per requirement described in section 8.2
of the ASTM D3966/D3966M-07 [3].

5.2.1 PREPARATORY WORKS

 Load test can be carried out if the specified concrete strength is achieved at the
day of testing. However, the strength shall be checked before loading the pile.
 Pile up to the COL where possible and the adjacent piles to be used in the test for
reaction purposes shall be excavated. The area around test piles shall be
excavated to allow working space ensuring adequate side slope. Wherever it is
not possible to excavate up to the COL due to the presence of ground water table
or involving deep and unstable excavation, test shall be conducted above the
COL. Thereafter, test pile concrete shall be checked for soundness and
reinforcement in the test region.

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 Pile surface shall be cleaned, levelled and dressed at level of testing.

 Datum bar shall be fixed with supports at specified distance away from pile face
not less than 3 times the dia of test pile.
 Hydraulic jack of suitable capacity shall be placed at COL on the dressed level
between the test pile and the reaction piles. Suitable mild steel extension / test
piece shall be provided to make up the space between piles after the jack is
placed in the line along pile centres. Necessary steel packing shall be provided for
a tight fit of the assembly.

5.2.2 EQUIPMENT AND TEST SETUP

List of equipments and test setup to be deployed is as under:

S. No. Description Quantity

01 Jack with Pump As Per Drawing

02 Crane(Capacity1: 50 Tonnes) 01 No.

03 Displacement Measuring Instrument 04 No.

04 Pressure Measuring Instrument 01 No.

05 Steel Plates, Accessories, etc. As Per Drawing

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5.2.3 LOADING SYSTEM & TEST PROCEDURE

 This test shall be conducted as far as possible at the cut off level of the Piles.
 The total test load shall be estimated ultimate lateral capacity. So either 500KN
or 10 cm of pile head deflection whichever occurs first.
 The test shall be conducted by introducing a hydraulic jack, with gauge between
two piles under test or the reaction may be suitable obtained, otherwise these
tests may also be done by applying Lateral pull by a suitable set up. If it is
conducted by jack located between two piles, the full load imposed by the jack
shall be taken as the lateral resistance of each pile.
 The Lateral loads shall be applied without shock.
 The loading should be applied in increments and time duration as mentioned in
specification 10110-PS-CMG-100-001 Rev 2( ANNEXURE VI)
 Displacements shall be measured by using at least two dial gauge spaced at 30
cm and kept horizontally one above the other on each pile. Where it is not
possible to Locate one of the dial gauges in the line of jack axis then the two dial
gauges may be Kept at a distance of 30 cm at a suitable Location from similar
triangles.

5.2.4 MEASURING SYSTEM

 The deflection shall be measured at a point diametrically opposite to the point of

Load application. Use of LVDTs placed on opposite side of the load application as

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mentioned elsewhere shall be done to measure deflection.

 Deflection of the pile at the level of load application shall be measured. The
datum bar shall rest on immovable supports.
5.2.5 SETTLEMENT RECORDING
 Test readings shall follow the requirement described in section 8.2 of the ASTM
D3966/D3966M-07 [3]. It shall include but not limited to the following
Requirement
 Record test readings immediately before and after the application of each load
increment and the removal of each load decrement.
 Record additional test readings at 5-min intervals between load increments and
load decrements.
 While the total test load is applied, record test readings at not less than 15-min
intervals. Record test readings 15 min and 30 min after the total load have been
removed. If pile failure occurs, record test readings immediately before removing
the first load decrement.
5.2.6 Record of Readings:
 The lateral load vs displacement curve shall be recorded along with the complete
information about the pile in LTHE/ERSF/IR/C-017.

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5.3 PULL OUT LOAD TEST:

 INTRODUCTION

Pull out load test on piles will be conducted as per requirement described in section 8.2
of the ASTM D3689/D3689M-07 [4].

5.3.1 SPECIFICATION CLAUSES

 It is essential that all equipments and instruments are properly calibrated both at
the commencement and immediately after the completion of tests, so that they
represent true values.
 The complete jacking system including the hydraulic jack, hydraulic pump and
pressure gauge shall be calibrated as a unit. The complete unit shall be calibrated
over its complete range of travel for increasing and decreasing loads same as that
of test loads. The calibration certificate shall be submitted to the Engineer-in-
Charge.
 The reaction load to be made available for the test shall be at least 25% greater
than the maximum jacking force. The reaction system as relevant shall be
designed for the total reaction load. All reaction loads shall be stable and
balanced during all operations of testing. During testing, stability of reaction
system shall be ensured.
 The load applied on the pile shall be measured by a calibrated pressure gauge

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mounted on the jack with a least count of not more than 10% of the safe load.
 The displacement of pile shall be measured using LVDT's having a least count of
0.01 mm.
 Load test shall be conducted at pile cut of level (COL). If the water table is above
the COL the test pit shall be kept dry throughout the test period by suitable de-
watering methods. In such a case, an annular space shall be created to remove
the effect of skin friction above COL by providing an outer casing of suitable
diameter larger than the pile diameter.
 Full details of the equipment proposed to be used, the test setup and pile testing
scheme along with detailed design, drawings shall be submitted to the Engineer-
in-Charge, before making arrangements to carry out the tests, for his approval.
Approval of the Engineer-in-Charge shall also be obtained after the test set up is
complete prior to commencement of loading.
5.3.2 PREPARATORY WORKS
 Load test can be carried out if the specified concrete strength is achieved at the
day of testing. However, the strength shall be checked before loading the pile.
 It is to be checked that test pile shall have adequate reinforcement to withstand
pilling.
 Area around test pile shall be excavated for working space to a depth of 1.0 to
1.5 m below the existing ground level or 20 cm above ground water table
whichever is encountered first. Necessary dewatering arrangements shall be

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done during testing. Adequate side slope shall be provided.

 Test pile shall be exposed and the test pile head chipped off upto the sound
concrete level followed by building up of the same with fresh levelling concrete
of same grade as that of pile concrete for 30 to 40 cm length upwards to
accommodate MS angle for contact of LVDTs and resting of MS test plate.
 Concrete pad for supporting reaction system for dispersion of load through MS
joists. Size of pad and grade of concrete shall be decided based on the load to be
applied and soil bearing capacity.
 Concrete shall be cured for 10 days, and the area shall be levelled and dressed up
for the test.
 On top of levelled pile concrete fix MS plate with slots at predetermined location
for pile reinforcements.
 MS pipe sleeve shall be welded to pile reinforcements on top of MS plate.
 Secondary steel girders shall be placed on concrete pad followed by placement of
the main steel girders across the secondary ones.
 Steel plate shall be placed over main girders followed by placement of hydraulic
jack on this plate.
 Steel plate shall be placed above jack by fixing steel bolts between top plate and
the plate over test pile head to make the assembly complete.

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5.3.3 EQUIPMENT AND TEST SETUP

List of equipments and test setup to be deployed is as under:

S. No. Description Quantity

01 Jack with Pump As Per Drawing

02 Crane 01 No.

03 Displacement Measuring Instrument 04 nos

04 Pressure Measuring Instrument As Per Drawing

05 Plates, Accessories, etc. As Per Drawing

5.3.4 LOADING SYSTEM

 Test load shall be as per the specifications for 1000mm dia pile
 Uplift force on the piles shall be applied with hydraulic jacks with calibrated
Gauges and using suitable set up, approved by the Engineer
 The test pile shall have adequate steel reinforcement to withstand pulling Loads.
Additional reinforcement may be provided in the pile for this purpose.
 The pull out load increments and consequent displacement readings shall be read
as in the case of vertical load test
 The increment of test load in each stage shall be maintained till rate of

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Displacement of the pile top is either 0.25 mm in one hour or till 2 hours,
whichever occurs first.
 1)- If failure occurs, maintain the failure load, or the maximum load possible ,

Until the total axial movement equals 15% the pile diameter.
 2)- If failure does not occur :
 2.a)- and settlement is not greater than 0.25mm / hr, remove the total test
load after 12 hours of overall test duration.
 2. b)- and settlement is greater than 0.25mm / hr., allow the total test load to
remain on pile for 24 hours.
 After completing the final load increment, remove the load in increments of 25%
of the maximum test load with 1hr. between decrements.
 Final rebound shall be recorded 12 hours after the entire test load has been
removed.

5.3.5 TEST PROCEDURE

 The loading steps shall be as per specification 10110-PS-CMG-100-001 Rev

(ANNEXURE VII)
 Pull out loads shall be applied without shock.

5.3.6 Record of Readings:

The pull out load vs displacement curve shall be recorded along with the

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complete information about the pile in LTHE/ERSF/IR/C-017.

5.3.7 SAFE LOAD :

 Test readings shall follow the requirement described in section 8.2 of the ASTM
D3689/D3689M-07 [4]. It shall include but not limited to the following
requirement:
 Record test readings taken before and after the application of each load
increment or decrement.
 During each load interval, provided that the test pile has not failed, record
additional readings taken at 2, 4, 8, 15, 45, 60, 80, 100, and 120 min following
application of the load increment, and every 60 min thereafter as needed.
 If pile failure occurs, also record readings taken immediately before removing
the first load decrement. During unloading, record readings taken at time
intervals of 30 min for each unload interval. Record readings at 1, 2, 6 and 12 h
after removing all load.
 A graph of pull out force and corresponding rise of pile top shall be plotted.
6 TEST REPORTS

 One report shall be made for each test (totally 3 reports).

 Test report of each test shall include but not limited to the requirements
described in section 10 related to test report of each corresponding ASTM
standards. ASTM standards used for compressive load, tensile load and lateral

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 METHOD STATEMENT FOR PILE LOAD TEST

load are respectively ASTM D1143, ASTM D3689 and ASTM 3966
 Test Report of each test shall be in accordance with the specification 10110-PS-
CMG-100-001 Rev 02
6 ANNEXURES

 Annexure A - Check List

 Annexure – I Calibration Certificate of Pressure Gauge
 Annexure – II Calibration Certificate of Dial Gauge
 Annexure – III Test Scheme
 Initial Vertical Load Test on 1000mm Dia Pile ( Test Load 900T)
Drg No: 10110-C 73- GUT192-100-170 Rev 0
 Initial Pull out Load Test on 1000mm Dia Pile ( Test Load 500T)
Drg No: 10110-C 73-GUT192-100-171 Rev 0
 Initial Lateral Load Test On 1000 mm Dia Pile
Drg No: 10110-C 73-GUT192-100-172 Rev 0
 Annexure – IV Loading System- Vertical Load Test
 Annexure – V Pile Load Test Format LTHE/ERSF/IR/C-017 rev 0
 Annexure – VI Loading System- Lateral Load Test
 Annexure – VII Loading System- Pull Load Test
 Annexure B – Test Pile Location Drawing.

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ANNEXURE – A Check Sheet

S Remark
Check List Item Yes No
No. s

1 Desk Study

a) Method Statement for pile load test available .

Availability of design calculations for the kentledge, reaction

b)
supports -ensure the safe design for conducting load test

c) Specification of materials and test results

d) Soil investigation and subsurface profile study

e) Construction drawings

f) Pile installation record

2 Reaction Frame Setup

Stability of reaction piles / support – structural and geotechnical

a)
capacity

b) Reaction supports – arrangement and tilting of ground support

c) Pile head preparation – smoothness and levelled surface

d) Stability of packing between main girder and jack plates

3 Loading Components

a) Condition of hydraulic jack and hydraulic pump

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S Remark
Check List Item Yes No
No. s

b) Calibration certificate for hydraulic jack and pressure gauge

Ensuring non-availability of oil leakages and pressure leakages

c)
in the system

4 Pile Head Monitoring

a) Ensuring sufficient number of working dial gauge / LVDTs

b) Availability of calibration certificate

Ensure attachment to datum bar and seating of needle point in

c)
the glass plate

d) Ensure coincidence of diagonal distance

e) Ensuring suitable pump for pumping drilling mud

5 Loading Sequence

a) Follow loading sequence as per procedure

6 Requirement of Facilities

a) Head clearance availability in the testing pit

b) Sufficient area lighting

c) Stop watch

d) Levelling equipment (optional)

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S Remark
Check List Item Yes No
No. s

e) Safety arrangements

7 Records

Ensure continuous monitoring and recording of settlement and

a)
loads

Ensure Client and Engineer-in-Charge representative to sign on

b)
field sheet record

c) Safe custody of records and storing it in safe place

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