A

PROJECT REPORT

ON

COMPLETE PROCEDURE

OF

BORED CAST IN-SITU RCC PILING

Prepared By: - Submitted To:-

AMIT KUMAR MISHRA (ROLL NO. 09) PROF. N.K.MISHRA

NITIN KUMAR JOSHI (ROLL NO. 24) (Prof.Track I)

Special Course for Executive of DFCCIL Gr. II Phase II

(Course No. 23903)

 INDEX

S.No. Description Page No.

1 Site Location 1-2

1.1 Name of Work 1

1.2 Bridge Overview 2

1.3 Contractor 3

2 Boring Procedure 2-6

2.1 Boring Machine and Tools 3

2.2 Depth Check 5

2.3 Liner 5-6

3 Reinforcement of the Bore 6-9

3.1 Reinforcement Detailing 6

3.2 Steel Register 7-8

3.3 Binding and Welding 8-9

4 Pile Concreting 10

5 Pile Chipping 10-11

6 PCC Work 12

7 Pile Integrity Test 13

8 Pile Cap 14-15

8.1 Reinforcement 14

8.2 Pile Cap Concreting 15

1. Site Location:- Site is located near Makar Pura Railway Station. This is at a distance of 12
Km from Vadodara main city. Fig. 1(a)

Fig. 1(a) Site Location

1.1 Name of Work- Construction of Road Over Bridge (ROB) including approach complete in
lieu of Crossing No. 228 at Railway KM 386/834 [ DFCC Ch: DN-6458.139, UP-5927.1027] of
Surat-Vadodara [B.G.] section

1
1.2 Bridge Overview-

 It is a T-beam RCC girder bridge.

 For the turning portion, solid slab is casted of span 12x4m on both the approach side.
 For the railway portion, three composite girders are approved for the total span of 78m.
(18x1m, 21x1m and 36x1m)
 For the remaining portion, casting of deck slab on the RCC girder was in progress for the
total span of 24x12m.

1.3 Contractor- M/S Rachana Construction Company, Ankleshwar, Bharuch. Fig.1(b)

Fig. 1(b) Company’s Logo

2. Boring procedure :- First of all, a detailed survey of the location was done with the help
of the Total station and the exact boring location was marked by a steel peg mark.

2
2.1 Boring Machine and Tools-

 The boring work for piling was executed by using MAT Machine or Hydraulic Rig
Machine. Proposed diameter and depth of boring was 1200mm and 30m respectively.
The MAT Machine took 4-5 hrs. to complete one boring operation of a given
dimension. Fig.2(a)

Fig. 2(a) MAT Machine

 This is a boring tool which is used to drill in the hard rock mass which is found generally
near the ground surface. Fig.2(b)
 This drilling bucket is used when the rig reaches the loose soil strata. It has a jaw-like
structure at its bottom. Water is used to facilitate the excavation process.
 After 4m-5m boring, casing is lowered to avoid the collapse of bore due to loose soil
surroundings. Casing is 6m long.
 After 15m-20m boring, bentonite soil is mixed with water to stabilize the bore. Fig. 2(c)

3
Fig. 2(b) Drilling Auger

Fig. 2(c) Drilling Bucket

4
2.2 Depth Check –

 Boring depth can be checked by manually or from the display unit of the MAT
Machine.
 After completion of boring, depth is checked manually. For this a chain of 34m length
was lowered into the bore. Fig.2(d)
 Also, the same depth can be checked from the MAT Machine Display Unit. Fig.2(e).

Fig. 2(d) Manually Boring Depth Fig. 2(e) MAT Machine Display
Measurement Unit

2.3 Liner-

 Just after verifying the required depth, a permanent liner was lowered into the bore. This
is done to avoid the collapse of the bore due to the loose soil near the ground surface.
 Liner has 6m length and 1200mm diameter. Fig.2(f)

5
 Fig. 2(f) Permanant Liner

3. Reinforcement of the Bore:- For reinforcing the bore, steel bars are used of the grade
Fe 500D.

3.1 Reinforcement Detailing

 A complete reinforcement cage was prepared before the completion of the boring.
 For that particular site, three cages were prepared viz. bottom, middle and top cage. 
 Reinforcement detailing was as per approved drawing. Fig.3(a)

6
 Fig. 3(a) Reinforcement Cage

3.2 Steel Register-

 A steel register is prepared having all the details of the reinforcement for each pile.
Fig.3(b)
 Same executed details must be entered in this register which is checked (calculation
check) by the Finance Department during payment.

7
 Fig. 3(b) Steel Register

3.3 Binding and Welding-

 Cages were lowered into the bore by the crane of capacity 50 tonnes. Fig.3(c)
 Each three cages are bounded by transverse reinforcement in spiral at the ends. 
 Proper lap length are given. Some portion of lap length is welded. Fig.3(d)
 Main reinforcement and transverse reinforcement are tightened together by the binding
wire.

8
 Fig. 3(d) Binding and Welding of
Fig. 3(c) Cage lowering process Two Cages

 Reinforcement cage should be 1500mm below the

ground level as per drawing. Fig.3(e)

Fig. 3(e) cage in Bore

9
4. Pile Concreting Procedure:-

 After this, concreting of pile was done. For this,

tremie pipes are used. Fig.4
 Before concreting, slump value of concrete was
checked and it was found 180mm
 15 numbers of cubes were casted for cube test.
 Capacity of transit mixture was 7m3.

Fig. 4 Concreting Pouring

5. Pile Chipping:-
 Pile chipping process was done after 48 hrs. 
 Chiping was done to remove the bad quality of concrete from the top of the pile.
 For this hand breaker and tractor breaker was used.

10
  This chipping was done by using hand breaker.
Fig.5(a)
 It requires more time than tractor breaker.
 It ensures the minimum damge of the
reinforcement.

Fig. 5(a) Hand Breaker Chiping

 This chipping was done by using tractor breaker.

Fig.5(b)
 It requires lesser time.
 But this method can damge the reinforcement if
care is not taken.

Fig. 5(b) Tractor breaker Chiping

11
6. PCC Work:-
 From the cut-off level, 250mm of PCC was made of the grade M-15. Fig.6
 After setting off the PCC, reinforcement was bent for 1500mm length from the top of the
bar.

Fig. 6 PCC for Pile Cap

12
7. Pile Integrity Test:-
 After ten days, the Pile Integrity Test was done.
 Pile Integrity Test refers to qualitative evaluation of the physical dimensions, continuity
of a pile, and consistency of the pile material. Fig.7

Fig. 7 Pile Integrity Test

13
8. Pile Cap:- Pile cap laid over all the pile bored having sufficient cover along the sides. For
railway portion, a pile cap combine 8 no. of piles and for others it is of 6 no. of piles. Pile cap
dimension was 5.1mx8.7m (for 6 piles) and 5.1mx12.3m (for 8 piles). Thickness was 1.8m in
both the cases.

8.1 Reinforcement

 After ensuring proper piling work through the Pile Integrity Test, the pile cap
reinforcement process started. Fig.8(a)
 Fe 500D reinforcement was used.
 Reinforcement detailing was as per approved drawing.
 During this process, reinforcement for the pillars were extended outside.
 For this, reinforcement for the pillars was bounded from the reinforcement of the pile
passing through the bent portion. Fig.8(b)

Fig. 8(a) Reinforcement for Pile

Cap 14
 Fig. 8(b) Reinforcement for Pile
Cap

8.2 Pile Cap Concreting-

 After completion of the reinforcement procedure, concreting of the pile cap was
done.Fig.8(c)
 For this M-35, grade concrete was used.

Fig. 8(c) Pile Cap Concreting

15