SEMAC CONSULTANTS LTD

METHOD STATEMENT FOR CONSTRUCTION OF BORED CAST IN-SITU PILE

PROJECT-PEPSICO GF PROJECT NALBARI, ASSAM

CHECKED BY
APPROVED BY
REV DATE
PREPARED Sr. Manager LTTS
PROJECT QA/QC
BY Coordination
MANAGER MANAGER REPRESENTATIVE

KULDIP MODI BASANT K JHA B.Nanda

R0
Gopal

METHOD STATEMENT
FOR
CONSTRUCTION OF BORED CAST IN-SITU PILE
 SEMAC CONSULTANTS LTD

METHOD STATEMENT FOR CONSTRUCTION OF BORED CAST IN-SITU PILE

PROJECT-PEPSICO GF PROJECT NALBARI, ASSAM

Contents
1. Introduction................................................................................................................................
2. SCOPE........................................................................................................................................
3. REFERENCES...........................................................................................................................
4. RESPONSIBILITIES.................................................................................................................
5. METHODOLOGY.....................................................................................................................
6. HEALTH, SAFETY AND ENVIRONMENT...........................................................................
7. QUALITY ASSURANCE AND QUALITY CONTROL.........................................................
8. ENCLOSURES:.........................................................................................................................
 SEMAC CONSULTANTS LTD

METHOD STATEMENT FOR CONSTRUCTION OF BORED CAST IN-SITU PILE

PROJECT-PEPSICO GF PROJECT NALBARI, ASSAM

1. INTRODUCTION
This method statement covers the methodology of piling work for foundations works are coming in
PepsiCo GF Project Nalbari, Assam Site. The proposed type of pile is 450mm dia. Bored cast-in-
situ concrete pile.

2. SCOPE

Method for Piling by using suitable capacity Hydraulic Rig in soil as well as Tripod Winch in rock
using partial depth casing and thereafter chiseling in hard rock. Concreting of pile as per approved
drawings including reinforcements, compaction etc. all complete.

3. REFERENCES
a) Contract documents
b) Good for Construction drawing of pile
c) IS:2911 1979 Part 1 Section 2 and IRC 78
d) IS: 2911 1985 Part 4
e) Bar bending schedules as prepared by Contractor as per IS 2502
f) Quality assurance manual
g) Quality system manual
h) Health, Safety and Environment plan.

4. RESPONSIBILITIES
Following are the responsibilities and reporting structure of personnel involved in the scope of the
procedure:
SL. Responsible Person Responsibilities
NO.
1 Sr. Manager  Shall report to management
Coordination
2 Project Manager  Shall report to the Project Manager.
 Shall be responsible for control, supervision and direction for
SEMAC CONSULTANTS LTD

METHOD STATEMENT FOR CONSTRUCTION OF BORED CAST IN-SITU PILE

PROJECT-PEPSICO GF PROJECT NALBARI, ASSAM

implementation and execution of construction plans.

 Shall also be responsible for supervision of construction
activities and preparation of construction records, Develop
construction schedules, procedures and prepare progress and
accomplishment reports.
3 Site In charge  Shall report to Deputy Project Manager.
 Shall be responsible for day to day planning of site. Piling
activities and preparation of construction records.
4 Surveyor  Shall report to Project Manager

5 QA/QC Engineer  Shall report to Project Manager.

 Shall be responsible for overall control of QC activities and
sub-contractors QC activities, implementation of QAM and
Quality Plan
 Shall be responsible for carrying out Inspection as per the I &
TP and/or this procedure
6 Site Supervisor  Site supervisor shall report to site engineer and shall be
responsible for supervision of all works as guided by site
engineer.

5. 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 LTTS 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 LTTS
immediately.
 SEMAC CONSULTANTS LTD

METHOD STATEMENT FOR CONSTRUCTION OF BORED CAST IN-SITU PILE

PROJECT-PEPSICO GF PROJECT NALBARI, ASSAM

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 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 800mm for 450mm 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 suckering 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.
 SEMAC CONSULTANTS LTD

METHOD STATEMENT FOR CONSTRUCTION OF BORED CAST IN-SITU PILE

PROJECT-PEPSICO GF PROJECT NALBARI, ASSAM

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 LTTS
After achieving initial rock level & quality of rock is checked by LTTS. After approval
further boring in rock is started by Tripod winch.

Chiseling by Tripod Winch:

SEMAC CONSULTANTS LTD

METHOD STATEMENT FOR CONSTRUCTION OF BORED CAST IN-SITU PILE

PROJECT-PEPSICO GF PROJECT NALBARI, ASSAM

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 LTTS. 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:
 SEMAC CONSULTANTS LTD

METHOD STATEMENT FOR CONSTRUCTION OF BORED CAST IN-SITU PILE

PROJECT-PEPSICO GF PROJECT NALBARI, ASSAM

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 LTTS.
(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 specifica-
tion and directions of Engineer.
SEMAC CONSULTANTS LTD

METHOD STATEMENT FOR CONSTRUCTION OF BORED CAST IN-SITU PILE

PROJECT-PEPSICO GF PROJECT NALBARI, ASSAM

 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 con -
tent 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.
 SEMAC CONSULTANTS LTD

METHOD STATEMENT FOR CONSTRUCTION OF BORED CAST IN-SITU PILE

PROJECT-PEPSICO GF PROJECT NALBARI, ASSAM

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.

6. 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 PEPSICO & LTTS.
Traffic shall be diverted as per approved scheme wherever and whenever required.

7. QUALITY ASSURANCE AND QUALITY

CONTROL
Quality control and assurance shall be strictly followed as per preformed attached.
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
SEMAC CONSULTANTS LTD

METHOD STATEMENT FOR CONSTRUCTION OF BORED CAST IN-SITU PILE

PROJECT-PEPSICO GF PROJECT NALBARI, ASSAM

i) POLYMER SLURRY TEST

j) SETTING OUT PILE LOCATION
k) SAFETY CHECKLIST
l) HIRAC FOR PILING ACTIVITY
m) BORE LOG SHEET