STANDARDSPECIFICATIONS

CONSTRUCTION AND INSTALLATION OF RCC BORED CAST-IN-SITU PILES

RecordofAmendments

A RevNo

02 Nov. 2010 Date

Issued for review Description

Munish Gaur Preparedby

Arif Siddiqui Checkedby

S C Lee Approvedby

ThisdocumentisexclusivepropertyofPoscoE&CIndiaPvtLtdItistobeusedonlyforthepurposewhichitislentandmustnotbe copiedorusedinanyway,detrimentaltotheinterestofthiscompanyandsubjecttoreturnondemand

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DESIGN SPECIFICATIONS FOR BORED RCC CAST-IN-SITU PILES

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Table of Contents
1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0

Page no

SCOPE.................................................................................................................... 3 CODES ................................................................................................................... 3 MATERIALS ......................................................................................................... 3 DESIGN CONSIDERATIONS.............................................................................. 4 EQUIPMENT AND ACCESSORIES ................................................................... 5 PILING INSTALLATION ....................................................................................... 5 CONCRETING OF PILES....................................................................................... 6 DEFECTIVE PILES .............................................................................................. 7 RECORDING OF DATA ...................................................................................... 7

10.0 SITE EXECUTION, WORKMANSHIP, QAP/ITP & TESTING OF MATERIALS .................................................................................................................. 7 11.0 SEQUENCE OF ACTIVITY AT SITE ................................................................ 8 12.0 MINIMUM REQUIREMENT OF PILING EQUIPMENT ............................... 10 13.0 INSTALLATION ................................................................................................ 10 14.0 MEASUREMENT OF PILES ............................................................................. 11 15.0 PILE TESTING ................................................................................................... 11

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DESIGN SPECIFICATIONS FOR BORED RCC CAST-IN-SITU PILES 1.0 SCOPE

This standard specification covers the construction bearing reinforced concrete bored cast-in-situ piles and

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2.0

CODES
2.1 IS: 2911 (Part I /Sec.2) - Indian Standard Code of Practice for Design and Construction of pile foundations for Bored Cast-in-Situ Piles shall be referred to in conjunction with these specifications during the entire design, construction and installation work. 2.2 Further the following codes shall be referred for design: 1. IS:1893-Part-l 2. IS:1893-Part-2 3. IS:1893-Part-4 4. IS:456-2000 The design document shall carry clause-wise references to applicable codes. 2.3 Reference to any code shall always mean reference to the latest revised edition of the code including all its amendments upto date, unless otherwise specified. In the event of any conflict between the requirements of this specification and those of the referred codes, the former shall govern. 2.4 The piling operations shall be carried out strictly in line with IS: 2911 (PartI /Sec.2).Major clauses are reproduced herein for purpose of ready reference and guidance only. In case of any typographical errors & mistakes, the corresponding reference in IS: 2911 (Part I /Sec.2) shall prevail.

3.0

MATERIALS
All materials, viz. cement, steel, aggregates, water, etc. which used in the construction work, shall conform to respective BIS codes. 3.1 REINFORCEMENT are to be

Reinforcement shall conform to IS: 1786 (latest version) grade Fe-415 or Fe-500 for mechanical properties. The reinforcement shall be tested for quality before use. 3.2 CONCRETE Methods of the manufacture of cement concrete shall in general, be in accordance with IS: 2911 (Part I /Sec.2) and as per following clauses: The grade of concrete shall be M-25 with a minimum cement content of 400 kg/m3 and water cement ratio of 0.5. 3.3 SLUMP OF CONCRETE Slump of concrete shall range between 100 to 180 mm depending on the manner of concreting. The table below gives the general guidance.

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Table-1 Slump of concrete for Piling work PILING TYPE SLUMP IN MM Min. Max. TYPICAL CONDITIONS OF USE

100

180

Pouring into water-free unlined bore having widely spaced reinforcement. Where reinforcement is not spaced widely enough, cut-off level of pile is within the casting and diameter of pile less than or equal to 600mm, higher order of slump within this range may be used. Where concrete is to be placed under water or drilling mud by tremie or by placer

150

180

4.0

DESIGN CONSIDERATIONS
4.1 Structural Design The piles shall have necessary structural strength to transmit the load imposed on it, to the bearing/termination strata. Relevant part of IS: 2911 (Part 1/ Sec.2) and other applicable codes shall be considered for assessing the structural capacity of piles. 4.2 Reinforcement The minimum longitudinal reinforcement shall be 0.4% of the cross sectional area of the pile. Clear cover to the main reinforcement shall be 50 mm. This shall be increased to 75 mm in case of aggressive soils and ground water conditions The minimum clear distance between the two adjacent main reinforcement bars should normally be 100 mm for the full depth of cage. The bars shall be so placed as not to impede the placing of concrete. The lateral ties in the reinforcing cage shall be preferably spaced not closer than 150 mm centre to centre. The minimum diameter of the lateral ties shall be 6 mm.

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5.0

EQUIPMENT AND ACCESSORIES

The equipment and accessories for installation of bored case-in-situ piles shall be selected giving due consideration to the subsoil conditions and the method of installation, etc. These shall of standard type and shall have the approval of the Engineer-in-Charge. The capacity of the rig shall be adequate so as to reach the desired depth. Provision shall be kept for chiseling within the borehole in case of any underground obstruction/hard strata. However, chiseling shall be carried out only with the approval of Engineer-in-Charge. In case pile is required to be socketted in medium or good quality rock strata, the equipment mobilized shall have adequate capability to do so upto the required socket length.

6.0

PILING INSTALLATION
6.1 Control of Alignment The piles shall be installed as accurately as possible as per the designs and drawings. The permissible positional deviations shall be governed by IS: 2911 (Part I /Sec.2). In case of piles deviating beyond such permissible limits, the piles shall be replaced or supplemented by additional piles, as directed by Engineer-in-Charge at no extra cost to POSCO E & C. 6.2 Boring The boring shall be done by one of the following methods: (a) Direct mud circulation (b) Reverse mud circulation (c) Bailer bentonite. The actual method of construction to be followed shall be as per the decision of POSCO E & C in this regard shall be final and binding. In very soft soil a permanent liner shall be installed to ensure stability of borehole. A liner shall be used to protect the green concrete where a high hydrostatic pressure exists in the subsoil or where an underground flow of water exists and which is likely to damage the concrete on withdrawal of casing. Use of temporary liner only in lieu of bentonite to stabilize sides of boreholes shall not be permitted. Properties of bentonite used and quality control shall be as per IS: 2911 (Partl/Sec.2).

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DESIGN SPECIFICATIONS FOR BORED RCC CAST-IN-SITU PILES 7.0 CONCRETING OF PILES
7.1 Reinforcement

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The reinforcements shall be made into cages sufficiently rigid to withstand handling without damage. In case the reinforcement cage is made up more than one segment, the same shall be assembled by providing necessary laps preferably by welding. Stirrups/lateral ties/spiral ties to the main bars shall be welded. Care shall be taken to ensure that the reinforcement bars do not come closer while the cage is lowered down the hole. Proper cover and central placement of the reinforcement shall be ensured by use of suitable concrete spacers or rollers, case specifically for the purpose. Welding shall be done by qualified welders and approved by POSCO E & C. The welding shall be done such that the reinforcement bars are not undercut. The welding shall be done using approved grade electrodes manufactured by M/s. Advani Oerlikon or ESAB or D&H Secheron. 7.2 Concreting Concreting shall not be commenced until the Engineer-in-Charge satisfies himself that at final borehole depth the soil is not weaker than that taken as the basis for pile design. If necessary, SPT or similar test shall be conducted to ensure the above. Borehole bottom shall be thoroughly cleaned to make it free from sludge or any foreign matter before lowering the reinforcement cage. The full length of reinforcement cage shall be in position before start of concreting. Concreting shall be done by tremie method. The operation of tremie concreting shall be governed by IS: 2911 (Part I / Sec.2). The concrete placing shall not proceed if specific gravity of fluid near about the bottom of borehole exceeds 1.2. Determination of the specific gravity of the drilling mud from the base of the borehole shall be carried out by taking samples of fluid by suitable slurry sampler approved by the Engineer-in-Charge, in first few piles and at a suitable interval of piles thereafter and the results recorded. Control of consistency of drilling mud shall be carried out throughout boring as well as concreting operations. Care shall be exercised to preserve correct cover and alignment of reinforcement and avoid any damage to it throughout the complete operation of placing the concrete. Concrete shall be placed as per Clause 7.8 of IS:2911(partI/Sec2).

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DESIGN SPECIFICATIONS FOR BORED RCC CAST-IN-SITU PILES 8.0 DEFECTIVE PILES

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Defective piles shall be removed or left in place, as judged convenient by the Engineer-inCharge, without affecting the performance of adjacent piles of capping above and additional piles shall be provided to replace them.

9.0

RECORDING OF DATA
9.1 A competent supervisor shall be present to record the necessary information during the installation of piles. The data to be recorded shall include: a) The dimensions of the piles, including the reinforcement detail and the mark of the pile. b) The boring method employed. c) The type of soil in which pile is terminated. d) The depth bored. e) The depth of water table. f) When drilling mud is used, the specific gravity of the fresh supply and contaminated mud in the borehole before concreting is taken up, in case of first few piles and subsequently at suitable interval of piles. g) The time taken for concreting. h) The cut-off level/working level, and i) The consumption of cement. j) Any other important observations. 9.2 Typical data sheets of recording piling data shall be as given in Appendix-D of IS: 2911 (Part 1/Sec.2). 9.3 Any deviation from the designed location, alignment or load carrying capacity of any pile shall be noted and promptly reported to the Engineer-inCharge.

10.0 SITE EXECUTION, WORKMANSHIP, QAP/ITP & TESTING OF MATERIALS

a) It shall be the sole responsibility of the Contractor to ensure proper end termination, sound workmanship and construction of RCC piles & pile caps in accordance with design issued by POSCO E & C Contractor shall also submit his QAP/ITP and obtain approval for same from POSCO E & C. Contractor shall submit, test at POSCO E & C approved laboratory and obtain POSCO E & C approval for source & sample of water, coarse aggregates, sand, cement and Reinforcement steel. Contractor shall carry out design mix at POSCO E & C approved laboratory for Piles and Pile cap separately; formulate the recipe; test the ingredients, carry out trial mix & test the cubes and confirm the design requirements. For this purpose l-day/3-day and 7-day
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b) c)

d)

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e)

f) g)

accelerated strength results may also be obtained. However it shall be the sole responsibility of the Contractor to ensure that the 28-day results are satisfactory. In case of failure/inadequacy of 28-day test results, dismantling/abandonment of the piles/pile cap or any other RCC work shall be carried out by the Contractor at no extra cost to POSCO E & C. Alternately, if Concrete is sourced from RMC (Ready Mixed Concrete) Plant, then, RMC Plant shall also be inspected and approved by POSCO E & C. Further, the design mix being adopted by RMC for the particular grade shall be verified through a POSCO E & C approved Third Party like local Government engineering College or Expert of POSCO E & C 's choice and based on the finalized mix and recipe, test cubes shall be cast and l-day/3-day and 7-day accelerated results shall be obtained as soon as possible. Contractor shall ensure that the RMC Plant adopts the finalized recipe as directed by POSCO E & C. The materials used by RMC shall also be drawn and tested by the Contractor at an independent laboratory of POSCO E & C choice for conformity to BIS codes. In the absence of adequate test results job concrete can be carried out with proven design mix for one higher grade at no extra cost to POSCO E & C. All required statutory and safety regulations shall be fulfilled

11.0 SEQUENCE OF ACTIVITY AT SITE

Hold points required to be witnessed by POSCO E & C shall be indicated in the QAP/ITP by the Contractor. 11.1 Initial load tests:

POSCO E & C proposes to carry out initial vertical & lateral load test. Contractor shall carry out initial two-three piles at such points where the kentledge required for carrying out the initial load tests can be arranged safely based on discussions with POSCO E & C. On completion of these two-three piles, further piling work will not be taken up till the test results are available. Load tests will be carried out after minimum 28 days curing for these piles. 11.2 Installation of Piles: POSCO E & C shall provide the exact location of the piles either in the form of coordinates or physical location. Further to mobilisation of required manpower, equipments & tools and tackles by the Contractor, the following sequence of activities shall be followed by the Contractor: a) b) c) d) Contractor shall carry the levels in the area @ 5m c/c and determine the average NGL(Natural Ground level). The Contractor shall mark the location of the piles and pick the co-ordinates through Total Station. Setting up of Rig and Piling operation shall be carried out for providing RCC bored cast in situ piles. Termination of the pile shall be as per the termination criteria set out in this section.
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DESIGN SPECIFICATIONS FOR BORED RCC CAST-IN-SITU PILES

e) Depth as per sounding to be recorded. f) Preparation of reinforcement cage & lowering same. g) Bore is kept in re-circulation & verification of borewash. h) Concreting of the pile. i) Shifting of Rig 11.3 For Routine Pile load test for Job Piles: POSCO E & C shall mark out the test piles. The following activities shall be carried out by the Contractor:

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Required preparation of the pile head shall be done by the Contractor. Mobilisation of Kentledge/any other loading arrangement and instruments required for the test(s). c) Carry out the Test. d) Document the readings and prepare reports. 11.4 For Pile caps & grade/plinth beams: a) b) c) d) e) f) g) h) i)

a) b)

duly

calibrated

Excavation. Back chipping of the piles up to required level. PCC bed concrete. Mobilisation of materials, fabrication & providing approved quality shuttering & supports required for Pile cap concreting. Placement of reinforcement. RCC work for Pile cap. RCC work for grade/plinth beams . Disposal of the bored muck shall be done by the contractor as per purchase order. Demobilisation shall be completed by the Contractor on completion of all the works. Design data & soil Investigation Report:

11.5

POSCO E & C shall provide a copy of the geotechnical investigation report to the contractor for ready reference . 11.6 Termination Criteria:

The soil profile encountered in the borehole are furnished in the report. However, POSCO E & C bears no responsibility for variation in strata. If desired, contractors are free to carry out their soil investigations at the site at their own cost. It is anticipated that rock may be encountered at approx. 13-15 meters below FGL. Piles shall be terminated with a minimum embedment of 300mm of the pile inside the hard rock layer. For the first two piles, upon identification of disintegrated rock strata with spt n value > 100,further chiseling shall be done with chisel(only chisel wt will be considered;wt of dmc rods will not be considered) of wt. Of 1.15 mt with a drop of 1m & rate of progress of chisel shall not be more than 200mm with 44 blows In case, the penetration with 44 blows using 1200 kg chisel exceeds 200 mm, then the subject strata shall not be considered as hard rock and further chiselling shall continue till appropriate strata as per specifications is encountered.
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DESIGN SPECIFICATIONS FOR BORED RCC CAST-IN-SITU PILES

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With the above chiseling criteria, hard rock strata is identified. Thereafter, socketing to an extent of 300mm shall be done. In all cases it shall be the sole responsibility of the contractor to ensure proper end termination, socketing, sound workmanship and construction of rcc piles in accordance with the relevant design issued by POSCO E & C and complying with the relevant specifications. In the event, contractor is required to use chisel weighing more weight than the chisel wt given above, the same shall be resorted to by the contractor at no additional time and cost implications to POSCO E & C. The hard rock layer shall be identified by the value of SPT N value greater than 100. The pile shall be terminated with an embedment of minimum 300mm inside the strata. The level of encountering the rock layer and termination depth in all cases shall be certified by Engineer-in-Charge. However, the number of blows required shall be theoretically calculated by the Contractor based on the energy required. For the purpose of facilitating the bidders to provide their technocommercial offer the diameter of piles have been assumed as 600 mm dia and quantities in the BOQ are worked out. However, the diameter of Pile and size of pile caps may vary at the time of design finalization. The quantities mentioned in the schedule of rates are approximate and actual payment shall be made basis the actual executed quantities based on the approved design. However the contractor is expected to quote for this tender based on the information provided herein and other sections of this tender document including the Schedule of Quantities.

12.0 MINIMUM REQUIREMENT OF PILING EQUIPMENT

Sufficient no. of manual rotary piling rig to complete the entire job as per the time schedule provided in this tender document. The Contractor shall mobilize sufficient spares and cutting tools (e.g. flat teeth bits, round shank bits, holders, etc) to avoid any stoppage of work. 12.1 Bidder shall submit the following information as part of their technical bid: a) Number of piling rigs proposed to be deployed for the Pile installation b) Full Technical details of piling rigs and accessories in the form of catalogues, data sheets, etc. c) Piling procedure.

13.0 INSTALLATION
a) Installation of piles shall be carried out in accordance with the pile lay out drawings which shall be available to the contractor at the time of execution of work. b) Cut-off level of the piles shall correspond to those given in the Issued for Construction drawings.

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c) No extra payment shall be made for concreting done above Cut-Off Level and quoted rates shall be inclusive of this. d) In case the reinforcement cage is made up of more than one segment, the same shall be assembled by welding only, before lowering, by providing necessary laps. e) The vertical reinforcement shall project above the cut-off level as per code requirements. f) Concrete shall be placed by tremie. All precautions for obtaining clean and sound pile shaft shall be strictly observed. g) For Tremie concreted piles, a sample of drilling fluid shall be taken from the base of the borehole by means of an approved sampling device in the first few piles and at suitable interval of piles thereafter. Concreting shall not proceed if density of fluid exceeds 1250 kg/cu.m. The sand content in the fluid shall not exceed 7 percent.

14.0 MEASUREMENT OF PILES

a) The piles shall be measured and paid for the actual pile length from pile tip to the cut off level, as per the drawings or as indicated by the Engineer-inCharge. No extra payment shall be made for empty boring. b) Payment for routine load tests which shows unsatisfactory results shall not be made. c) Piles showing unsatisfactory results shall be treated as defective piles. Defective piles shall be removed or left in place and replaced by additional piles as directed by engineer-in-Charge at no additional cost to the owner. d) Reaction piles, if required for the purpose of conducting load tests on piles shall not be paid extra. Quoted rate for tests shall be inclusive of this. However, for routine lateral and uplift tests, if required, job piles may be used as reaction piles.

15.0 PILE TESTING

15.1 Routine Load Test

Routine load tests shall be carried out as per IS specifications. The piles for the test shall be randomly selected by the Engineer-in-Charge. 15.2 Pile Load Test Details

a) For pile load tests, the test set-up shall be as per IS 2911 Part IV and specifications for testing of concrete piles. b) All testing shall be done by Direct method of loading in successive increments as per the relevant clauses of IS: 2911 Part IV & Standard Specifications for testing concrete piles forming a part of tender. c) Test shall be carried out at the cut-off level. d) Maximum test loads shall be as per Code
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e) The number of tests required shall be as per BOQ. f) A full record of pile load test results shall be submitted in triplicate to the Engineer-in-Charge immediately on completion of each test. The record shall also include the plots of load-settlement (for various stages of loads) characteristics of pile and also the interpretation of the pile load test curve as per criteria for safe loads mentioned in the specifications for testing concrete piles forming a part of this tender. Any special observations shall be duly explained by the contractor.

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