Akashganga Infraventures India Limited

PILING WORKS-II, A & B FOR RESIDUAL UTILITIES
AND OFFSITE (RU&O) FACILITIES FOR HRRL PROJECT
JOB PROCEDURE FOR PILING WORK

DOCUMENT NO: AGIIL/QA-QC/EIL/B229/JP-06 REV. No. 0
AKASHGANGA INFRAVENTURES INDIA LIMITED
Rev-00
Issued for
Review &
Approval
Rev. Date Description Prepared Checked Reviewed Approved

By AGIIL By AGIIL By EIL By EIL
PILING WORKS-II, A & B FOR RESIDUAL UTILITIES AND OFFSITE (RU&O) FACILITIES FOR HRRL PROJECT
Document No: AGIIL/QA-QC/EIL/B229/JP-06 , Rev-00 Page 1 of 12


Table of Contents
1) PURPOSE...........................................................................................................................................3
2) SCOPE.................................................................................................................................................3
3) REFERENCES...................................................................................................................................3
4) RESPONSIBILITY............................................................................................................................3
5) Methodology........................................................................................................................................4
 Construction material:..........................................................................................................................4
 Procedure:.............................................................................................................................................4
 Reinforcement Steel.............................................................................................................................5
 Reinforced Cement Concrete...............................................................................................................5
 Detailed Construction sequence...........................................................................................................6
 Quality Assurance and Quality Control...............................................................................................8
6) Pile Testing..........................................................................................................................................9
7) HEALTH, SAFETY AND ENVIRONMENT..................................................................................9
 Safety Procedure of Boring Rig & Lifting by Crane..........................................................................10
 Safety Procedure of Night Work.....................................................................................................10
 Risk Identifications...........................................................................................................................10
 Risk Management.............................................................................................................................11
8) DOCUMENTATION & RECORDS..............................................................................................11
9) ITP’S / FORMATS...........................................................................................................................11


1) PURPOSE
This procedure is generated in part conformance of purpose to follow proper activities to carry out the
sequences involved in piling works for Residual Utilities and Offsite (RU&O) for Rajasthan Refinery
project of HRRL.
2) SCOPE
The scope covers the execution of load bearing reinforced concrete 500 mm dia bored cast in situ pile at
proposed location. Installation of Bored Cast in situ piling works involves various activities like boring,
liner installation, cage lowering, tremmie lowering, concrete etc. Including co-ordination of activities.
3) REFERENCES
Following documents in totality or in part shall form the reference documents:
 EIL’s specification/Guidelines (i.e. 6-74-0006 Rev.03, 6-74-0011 Rev.03, 6-74-0013 Rev.03)
 Contract (Bid), AFC Drwaings etc
 Relevant/Applicable IS codes IS:2911 (relevant parts), IS 456:2000, ASTM D-5882, ASTM D-
4945, IS 383:2016, IS 1786:2008, IS 6186:2010, IS 9103:1999, IS 455:1989
4) RESPONSIBILITY
Following are the responsibilities and reporting structure of personnel involved in the
of the procedure:
Resident Construction Manager-

• Shall be responsible for overall control of this procedure.
Site QA / QC In charge-
 Shall report to RCM at site
 Shall be responsible for overall implementation & control of this Procedure.
 Shall ensure proper implementation of this procedure.
 Shall checks and verifies the activities.
Site Safety Manager -

 Shall report to Resident Manager (Administratively) & Project HSE Manager
(Technically)
 Manages the implementation of all safety requirements during piling operations.


• To verify and ensure that the communication system is working properly and that
emergency equipment is in place.
5) Methodology
 Construction material:
 Concrete-As per approved design mix production of piles.
 Steel-Reinforcement steel shall comply the requirement of IS 1786:2008. The stresses
Allowed in steel should confirm IS:456-2000
 Water-Clean water conforming IS:456
 Procedure:
 The piles shall be installed as accurately as possible according to AFC drawing.
 The pile is going to be founded on competent strata with cut-off level as mentioned in the
respective drawings
 The location of the pile will be marked using Total Station with utmost care.
 The hydraulic rig will be cantered over the designated pile location.
 The pile hole will be bored continuously with regular draw out of drilled or cut soil.
 The hydraulic rig/TMR will be placed at the pile location after that we will start the initial
boring as required depth. Then place the permanent liner in the bore hole and push with
hydraulic rig rotary till required level.
 Permanent liner depth shall be insured during lowering the same and maintaining the
record before concreting started.
 Temporary casing will be used from col to ground level.
 All along this process do it as per site condition, the pile shaft will be kept dry bore or
filled with bentonite fluid for stabilizing the hole and the bore will be flushed to the bottom
before concreting by using bentonite slurry.
 The density of the bentonite will be maintained as 1.03g/cc to 1.10g/cc during boring
operation and <1.25g/cc prior to concrete pour.
 Pile shall be terminated in hard silty clay/clay silt/very dense sand/rock strata with
minimum pile length of 15m below COL.
Note
1) If rock layer (SPT-N value>100) is encounter in pile shall be terminated by embedding
2500mm inside rock.
2) Hard Silty Clay/Clay Slit/Very Dense sand (SPT-N value>50) will be confirmed as per
Engineer in Charge.


 Reinforcement Steel
 Check the reinforcement cage as per AFC drawing before lowering cage in the bore. 18
gauge SWG binding wire shall used for cage fabrication.
 Stiffener ring and laps shall be welded as per standard working practices to keep the cage
intact as per requirements.
 Check cover block to reinforcement, sufficient no. of blocks to be provided to ensure the
specified cover.
 Reinforcement cage should not be dropped during lowering down.
 Reinforcement cage to be kept hanged with in bore during concreting. During extraction of
casing the wire shall observed to avoid the lifting cage.
 Reinforced Cement Concrete

 The pile bore shall be free from water any other foreign materials.
 As per approved design mix concrete shall be produced in batching plant.
 The grade of concrete shall be used as mentioned in AFC drawing.
 The following points shall be taken care off:-
The concrete should be start as soon as possible after driving is completed. Pile
concrete shall be uninterrupted only fresh concrete shall be used.
Ensured equipment/material available is sufficient for a continuous concreting. The
extraction of casing shall not cause any necking or shearing of poured concrete.
The slump of concrete shall be as design mix concrete. Casing shall be extracted in
stages by pull and push movement followed by moderate tapping of casing after
sufficient height of pouring the concrete in the casing.
Concrete shall mix thoroughly so that no segregation takes place during pouring of
concrete from top casing. The reinforcement/concrete shall not get lifted along with
the casing. The bottom casing shall always be inside the concrete. One time of
pouring concreting shall not exceed 25% of pile length.
Check the volume concrete placed in the bore to theoretical volume, actual concrete
volume shall not be more than theoretical volume. Concrete shall be continued till
pile reaches required level above the cut-off level. The concrete shall reach at least
1000mm above cut off level.
Check Volume concrete placed initially. Cast piles and obtain average figure to
check for undue variation in concrete consumption for subsequent piles. The slump
of concrete shall be in the range between 150mm to 180mm
For the concrete, water and aggregate section lay down in IS:456, shall be followed
in general. Specified works cube strengths at 28 days and aggregate more than
20mm shall not be used.


1.Casing
2.Drilling
3.Cleaning 5. Concrete Pour
4.Cage lowering 6. Pile Cast Finish
& Ben. flushing
 Detailed Construction sequence

 Formation of Borehole
Setting-out pile Position: Pile positions shall be set by the surveyor, and checked by Site -
Engineer, before commencement of piling. The existing ground level at the pile position shall
be measured and recorded.
Set boring unit: Prior to boring, the following steps shall be carried out.
 Offset surveyed pile position in two perpendicular direction by placing 2 offset markers at
appropriate distances from the pile position, to facilitate the installation of temporary steel
casing. The offset distance will be such that these markers shall not get disturbed during
installation process.
Adjust or extract the casing in case of deviation and reinstalling it unit the spirit level vertically
in two direction of the casing .


PILE POSITION
Figure 1: Vertically check during casing installation

Take and record the top level of permanent steel casing to enable measurement of pile depth.
Typical pile boring record will be maintained at site.
 Verticality Check
The verticality of the pile bore will be ensured by checking inclination of installed casing. It
will be checked by using spirit-level as mentioned in above sections, simultaneously, plumb
bob setup will be placed in two perpendicular directions of casing circumferences and
alignment will be checked while driving the casing to control verticality of guide / permanent
casing, since it is proposed to use permanent liner, the Kelly of piling rig will not get deviated
from the vertically installed liner alignment which will ensure the verticality of pile beyond the
liner depth.
The tolerances shall be as per, IS 2911, Part 1 Section 2: 2010 or as specified in technical
specifications.
 Cleaning of Bottom of the Pile Bore

Clean the base of the borehole to remove any loose, disturbed or remolded soil with a cleaning
bucket, stabilizing fluid solution is free of sand and hence keeps the pile base cleaner.
Measure the depth from the base of the borehole to the top of the casing.
 Tremie Pipe Lowering:

Use a tremie pipe of appropriate diameter (150 mm & 200 mm) for concreting bored pile.


Joint the sections of the tremie pipe prior to lowering it into the borehole.
Lower the tremie pipe into the borehole unit 200-300 mm above termination level to
facilitate flow of concrete.
 Flushing:
Before concreting, flushing will be carried out based on the site conditions to ensure the
cleanliness of the pile bottom, Generally, flushing will be carried out if sand layers are
noticed in the pile bore.
Hoses will be laid for bentonite flow from mixer point to pile point and separate bund will
be prepared adjacent to pile with proper flow channel from it. The bund capacity will
accommodate to the bentonite discharge volume.
All circulation of bentonite fluid will be carried by flexible pipe to avoid disturbance of
working platform.
Tremie top will be fitting to flushing head in order to commence flushing by direct
circulation process.
Table 2 Properties of Bentonite Slurry at The Time Of Boring
Tests/Properties Range of Results Test Method

Density 1.03 to 1.10 g/cc Mud Density Balance /
Hydrometer
 Quality Assurance and Quality Control

All the necessary concrete pour cards and checklists will be filled up during pre-pouring,
during pouring and after pouring.
The concrete cubes will be cast In frequencies based on the concrete quantity, as per the Field
Quality Plan.
The acceptability criteria of concrete cube in 28 days as per the given tender specifications.
6) Pile Testing
Pile load test such as (Vertical, Lateral, Pull out, Cyclic test) will be carried out in accordance with


contract conditions and as per IS 2911-2013 Part 4.

PIT and Pile dynamic load test shall be conducted as per relevant ASTM code.
7) HEALTH, SAFETY AND ENVIRONMENT
Contractor shall ensure that the machine operators involved must be an experienced /competent
person.
All PPE is a must in this activity.
It is to be noted that the special care to be adopted against snake / insect bite.
During the movement of equipment, the operator must blow horn to caution the people around.
All Measuring & Test Equipment's used must be well maintained.
All lifting devices & Tolls used shall be well maintained.
It is to be taken care that no spillage of fuel or lubricants is allowed at site.
Contractor shall arrange Regular Tool-Box Meeting.
Contractor shall arrange First Aid Box at site.
Safety is essential and imperative part of the construction process. All relevant personnel who are involved in
the piling activity will be issued with personnel protective equipment (PPE) such as safety boots, hard hats
and high visibility vests / clothing will be provided
Safety Supervisor will carry out and adhere to the following activities during execution:
Conduct toolbox meeting once or twice in a week prior to commencement of work.
Conduct safety inspection and safety meetings.
Arrange safety induction for new workers who enters first time into the site.
Issue PPE for all workers and maintain record for the same.
Keep appropriate equipment and machinery certificates on site.


Record accidents in "Accident Report Form".
Ensure good housekeeping on site
 Safety Procedure of Boring Rig & Lifting by Crane
The following safety procedures will be adopted at site:

Inspect the boring rig & service crane by the lifting supervisor and operator with the provision of
checklist.
Make sure that the working area is cordoned off with red-white safety tape when the boring rig /
service crane is in operation.
Ensure that no personnel other than the crane operator, safety supervisor and lifting supervisors are
allowed to engage in the lifting works.
Keep unauthorized personnel out of the lifting works area.
 Safety Procedure of Night Work
Sufficient lighting will be provided for night shift at working area.
All night shift employees will wear reflective jackets.
All activities will be under closed supervision.
Lighting will be provided for night shift works.
 Risk Identifications
Risk of damage to "live utilities".
Risk of public wandering into the work area.
Risk of accident during installation of the temporary steel casing using Rig
Risk of site personnel falling into boreholes.


Risk of traffic accidents within the site.
 Risk Management
Mark and display clearly the type of utilities.
Allow only authorized persons with permission.
Use appropriate PPE before entering work site.
Cover the borehole with steel mesh and cordon off the area around the opening.
8) DOCUMENTATION & RECORDS
Documentation shall be in the line with approved inspection / test plans. Quality document will be
maintained by systematic implementation of this procedure and generating necessary quality records.
Inspection reports in approved formats shall be raised upon carrying out the work.
9) ITP’S / FORMATS
 ITP’s
SrN DESCRIPTION Annexure

o
1. ITP For PILING I
SrNo DESCRIPTION Annexure
1. Record for approval of sources for aggregate II
2 FORMAT FOR POUR CARD III
3 IV
FORMAT FOR CONCRETE CUBE TEST
4 FORMAT FOR SEIVE ANALYSIS OF COARSE V

AGGREGATE (10MM )


5. FORMAT FOR SEIVE ANALYSIS OF COARSE VI

AGGREGATE (20MM)
6. FORMAT FOR SEIVE ANALYSIS OF FINE VII

AGGREGATE ( SAND )

Akashganga Infraventures India Limited

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PILING WORKS-II, A & B FOR RESIDUAL UTILITIES

AND OFFSITE (RU&O) FACILITIES FOR HRRL PROJECT

JOB PROCEDURE FOR PILING WORK