Project Mumbai Coastal Road Project North – Versova to Dahisar Package A

(From Versova to Bangur Nagar) (Chainage – from Ch. 0+000

To Ch. 4+540)
Client Brihanmumbai Municipal Corporation

PILE BORING AND CONSTRUCTION METHODOLOGY OF PILE CONSTRUCTION INCLUDING THE DETAILS
OF BORING RIGS.

Versova Dahisar Coastal road Package Page | 1

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 Project Mumbai Coastal Road Project North – Versova to Dahisar Package A
(From Versova to Bangur Nagar) (Chainage – from Ch. 0+000
To Ch. 4+540)
Client Brihanmumbai Municipal Corporation

TABLE OF CONTENTS

1) PURPOSE

2) SCOPE OF WORK

3) PILE FOUNDATION
 Bentonite Installation
 Bentonite powder
 Bentonite mixing
 Bentonite slurry feeding, recycling and replacing
 Reinforcement cages
2) Piling by Rotary Rig
3) Layout
 Guide casing placing
 Pile excavation
 Reinforcement cage lowering
2) Tremmie lowering
3) Flushing pile hole
4) Concreting pile
5) Guide casing withdrawal
6) Shifting rig, next location
7) Routine pile tests

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 Project Mumbai Coastal Road Project North – Versova to Dahisar Package A
(From Versova to Bangur Nagar) (Chainage – from Ch. 0+000
To Ch. 4+540)
Client Brihanmumbai Municipal Corporation

1. PURPOSE :
The purpose for the details is to understand the pile foundation and its implication on the work.

• SCOPE OF WORK:
The work consists of executing piles & pile cap. Required initial vertical & horizontal pile load test shall
be carried out to confirm the design parameters. Initial pile load test shall be executed as detailed
in Annexure. On approval of the initial pile load test, regular piling shall be taken up. Piles are
bored cast in-situ type of 1000mm, 1200 mm,1500 diameter & 2000mm diameter.

3. PILE FOUNDATION

 Bentonite Installation
Piles being uncased are planned to be constructed using bentonite for side stabilization.
Bentonite installation including layout is as per annexure. After mixing fresh bentonite it will be to
gel at-least over 24 hrs. Then properly prepared bentonite will be transferred to storage
tank. Bentonite feeding will be done from storage tank by gravity to pile. The returned
bentonite during concreting will flow through an open channel and will be collected in a
tank & will be pumped back to used bentonite tank for desilting through Desander.

 Bentonite powder
Bentonite powder purchased should be along with manufacturers test certificate. As soon as
the delivery has reached the site, the consignment should be weighed and number of bags be
counted. Each bag normally weighs about 40 Kgs. immediately the samples from the
consignment be tested for (1) Silt content (2) pH value (3) Swelling index and (4) Liquid limit.
All these test results be satisfying the requirements. Only bentonite satisfying all
requirements should be used.

Versova Dahisar Coastal road Package Page | 3

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 Project Mumbai Coastal Road Project North – Versova to Dahisar Package A
(From Versova to Bangur Nagar) (Chainage – from Ch. 0+000
To Ch. 4+540)
Client Brihanmumbai Municipal Corporation

 Bentonite mixing
Bentonite will be mixed with the help of Bentonite mixer. The mixed slurry will be
transferred to the gelling tank. The slurry will be checked for its specific gravity (1.08 to
1.12). Then it will be allowed to jell over next 24 hours. Such bentonite slurry will be pumped to
bentonite storage tank and from the tank, the jelled bentonite shall be taken by gravity to pile
locations.

 Bentonite slurry feeding, recycling and replacing

Bentonite slurry shall be fed in to the pile by gravity from bentonite storage tanks and shall
always be maintained 1 to 1.5 times above the ground water table, or within the casing
depth whichever is higher. The return bentonite coming out of the pile during concreting shall
be collected in a pit at ground level and pumped to used bentonite tank. Bentonite from the
used bentonite tank shall be passed through desanders and then stored in storage tanks for
reuse. Before the bentonite is pumped into the storage tank, sand content to be checked and
ensured to be less than 2%, otherwise to be recycled through the desanders until the sand
content is less than 2% and then sent to storage tanks.

 Reinforcement cages
Reinforcement cage fabrication is an independent and parallel activity. Cages will be
fabricated as per approved drawings/schedules by straightening, cutting, bending, tying, and if
required welding reinforcement bars against jigs supported on elevated platform. The
cages will be fabricated in the vicinity of piling activity. Stiffener rings as per GFC drawings shall be
provided along the length of pile cage to retain it’s circular shape while handling the cage.
Circular cement mortar clear cover blocks of 50 mm thickness with central hole of 12 for 10 mm
bars, shall be threaded through hoop rings/spirals at suitable spacing to maintain required clear
cover of 75 mm on reinforcement as per specification. The top and bottom cage shall have “L”
shaped vertical bars at its end of 300 mm dia.. The top portion over the overlap length shall be
without hoop rings/spirals. Cages will be fabricated in two lengths considering the pile length of
22m and pile cap depth of 1.8m. The overall length of the cage

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 Project Mumbai Coastal Road Project North – Versova to Dahisar Package A
(From Versova to Bangur Nagar) (Chainage – from Ch. 0+000
To Ch. 4+540)
Client Brihanmumbai Municipal Corporation

shall be 23.725m, the length of bars considering ‘L’ at the ends to be 12.162 m. Lapping of
cages shall be with couplers.

 Piling by Rotary Rig

a. Layout
With respect to longitudinal and transverse centrelines, co-ordinates for individual pile will
be worked out. With respect to reference lines, pile location will be marked to begin with piling
work. Take up piling work in pre-decided sequential order.

b. Guide casing placing

After completion of pile point survey, road crust is to be dismantled if existing with
a pneumatic breaker to the outer diameter of the casing pipe+50mm. Erect the
casing in position and drive down by pushing until the casing top is 250 to 300 mm above
the working platform level. While driving the casing, measurements with respect to
reference shall be continuously taken and the casing alignment corrected if found
necessary.

c. Pile excavation
Excavation shall be carried out using Rotary Hydraulic Rig piling rigs. The Boring bucket with
cutting tool will have external diameter equal to the diameter of pile less 75 mm. For pile
diameter of 1200 mm, the tool diameter shall be 1125 mm and so on for various diameter.
As the boring is carried out by the bucket, simultaneously bentonite shall be filled in the
pile, to maintain the head. Boring/excavation shall be carried by a boring bucket mounted
on a belly. Bored muck shall be directly unloaded in to tipper and disposed at suitable
designated areas. Boring shall be continued till the founding level. On reaching foundation
level, depth of borehole will be measured by taking sounding. Measurement for pile length
will be got certified from the client and secured clearance for cage lowering and
concreting. On approval of the founding level, the pile shall be cleaned with a cleaning
bucket.

d. Reinforcement cage
lowering

Versova Dahisar Coastal road Package Page | 5

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 Project Mumbai Coastal Road Project North – Versova to Dahisar Package A
(From Versova to Bangur Nagar) (Chainage – from Ch. 0+000
To Ch. 4+540)
Client Brihanmumbai Municipal Corporation

Pre-fabricated, pre-certified and pre-recorded reinforcement cage will be lowered in

borehole by the rig /service crane in one piece. Whenever reinforcement cage top is below
operating floor level of piling equipment, provide temporary suspenders in the form of 4
Nos of 16 mm dia rods at the top of reinforcement cage by welding. Maintain cage top at
design level only.

Measurements will be written for reinforcement in approved bar consumption schedule &
got certified from the client.

e. Tremmie lowering
Pre-calculated, pre-assembled and pre-recorded in sequential order, tremmie will be
lowered through reinforcement cage with the help of rig / service crane, keeping 300 mm
clearance from bottom of pile borehole & supported against guide casing through fork. If
required adjustable tremmie pieces will have to be replaced in place of full pieces. Funnel
should always be hanging & supported from fork only. Taking support of rods/guide
casing/pile bore base will harm the quality of pile so constructed.

f. Flushing pile hole

Pile flushing is not required as pile is cleaned on completion of boring. In the event of pile
boring being completed and the time lag between completion of boring and start of
concrete is more than 12 hours, the bore shall be cleaned by Air flushing before start of pile
concreting.
Airline shall be lowered through the Tremmie pipe, and flushed. Simultaneously it shall be
ensured that fresh bentonite is pumped in to the pile to maintain head otherwise the sides
can collapse. The bentonite coming out of the tremmie shall be collected in a steel tank and
pumped to used bentonite tank and then to desander and finally to storage tank. Flushing
shall be continued till the bentonite coming out of the borehole is same as the being fed
bentonite.

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 Project Mumbai Coastal Road Project North – Versova to Dahisar Package A
(From Versova to Bangur Nagar) (Chainage – from Ch. 0+000
To Ch. 4+540)
Client Brihanmumbai Municipal Corporation

g. Concreting pile
Concrete will be mixed either in mini batching / regular central batching plant/s.
The concrete will be transported through transit mixers if it is from regular central
batching plant. Concrete will be poured into concrete funnel directly from mini batching
plant/transit mixer. Concreting must be completed in a continuous operation.

Remove bentonite-flushing arrangement from tremmie. Place-concrete funnel and snap-out

plug (MS circular plate) in funnel opening with one end of the wire rope connected with
plate and other end with funnel top edge. The quantity of first charge of concrete shall be
such that the weight of column of green concrete formed is more than the hydrostatic head
of bentonite standing inside the borehole. In the case of first charge the capacity of funnel
should be calculated accordingly, in this case it shall be at least of 1.2 cum. After placing
first charge continue concreting and withdrawal of tremmie pieces in between, so
that at no point of time the tremmie embedment is less than 1.2 m inside concrete.
Concrete pile up- to cut-off level, allow concrete to over-flow equivalent to
overflow height as per specification. On completion of the pile all tremmie pieces,
funnel and fork be cleaned and stored properly.

h. Guide casing withdrawal

As soon as concreting is over, remove the guide casing.

• Shifting rig, next location

As soon as pile guide casing is withdrawn service crane/rig will be shifted to the next pile
location as per pre-decided sequence.

h. Routine pile tests

As per specifications and approved methodology, routine vertical/lateral pile load tests will
be conducted and detailed test report will be submitted to the clients to secure
clearance for further activities like pile cap. Routine Pile Load Test shall be carried out
as detailed in the annexure.

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 Project Mumbai Coastal Road Project North – Versova to Dahisar Package A
(From Versova to Bangur Nagar) (Chainage – from Ch. 0+000
To Ch. 4+540)
Client Brihanmumbai Municipal Corporation

1. HEALTH, SAFETY AND ENVIRONMENT:

Underground utilities shall be detected before commencement of the work to avoid damage to the
underground services.
Housekeeping shall be done regularly and if contaminated waste is there it will be disposed off in
environment friendly manner.
It shall be ensured that everyone wears the necessary personal protective equipment’s like safety
helmets, shoes, reflective jacket, eye protection, ear protection, hand gloves, safety belt etc.
No loose clothing will be worn where there is a potential risk to ones hand.

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