MWPP Accss Civ PRD 0004 RG Eddited

Page No: Page 1 of 235
Method Statement for Construction MWPP-ACCSS-CIV-

Date &Revision: 01 August 2019, Rev. G
of Bored Cast In Situ Piles PRD-0004
Prepared By: Access Engineering PLC
METHOD STATEMENT FOR CONSTRUCTION

OF BORED CAST IN SITU PILES
CONSTRUCTION OF 100MW SEMI DISPATCHABLE WIND

FARM IN MANNAR ISLAND SRI LANKA
Client: Main Contractor: BoP Sub Contractor (Civil):
Ceylon Electricity Board Vestas Asia Pacific A/S Access Engineering PLC
Version History
Revision Date Changes Overview Remarks
A 10/01/2019 Initial issue
B 18/01/2019 ITP included.

Document no. changed as per Aconex
C 23/03/2019
numbering.
D 23/04/2019 Addressed Vestas comments
E 06/05/2019 Addressed Vestas comments
F 02/06/2019 Addressed CEB comments in DTS 33
G 01/08/2019 Addressed Vestas comments
This Version,
Dinidu Priyankara QA/QC Manager

BoP Civil Contractor Checked By:
(Access Engineering Dasun Rukmal HSE Manager
PLC)
Approved By: Achala Kalinga Contractor’s Representative
Main Contractor Checked By: Ononbaatar Jigjidsuren Civil Engineer
(Vestas Asia Pacific
A/S) Approved By: Syed Sadathulla Nizamuddin Construction Manager
Paper size
Main document A4
Contents
Comments Reply Sheet .......................................................................................................................................... 7
1. Introduction ..............................................................................................................................................16
2. Scope of Work .........................................................................................................................................16
2.1. Construction Sequence .................................................................................................................................. 17
1.1.1. Test pile ............................................................................................................................................... 17
3. Resource Requirement ...........................................................................................................................17
3.1. Machinery and equipment list per team ........................................................................................................ 17
3.2. Manpower list per team .................................................................................................................................. 19
4. Construction Methodology ......................................................................................................................19
4.1. Drilling Sequence of Single WTG Foundation .............................................................................................. 20
4.2. Preliminary Survey &Driving temporary steel casing ................................................................................... 20
1.1.2. Ground Preparation and Setting Out ................................................................................................. 20
1.1.3. Pre-Drilling and Driving Temporary Casing....................................................................................... 21
1.1.4. Maximum Permitted Deviation ........................................................................................................... 21
1.1.5. Verticality ............................................................................................................................................. 22
4.3. Pile Boring ....................................................................................................................................................... 22

1.1.6. Pile Boring with Bentonite Slurry........................................................................................................ 22
1.1.7. Drilling Fluid ......................................................................................................................................... 22
1.1.8. Boring Near Recently Cast Pile ......................................................................................................... 22
1.1.9. Properties of Bentonite Slurry ............................................................................................................ 23
1.1.10. Drilling Termination ............................................................................................................................. 24
4.4. Preparation of the Reinforcement Cage ....................................................................................................... 24
1.1.11. Reinforcement Cages ......................................................................................................................... 24
1.1.12. Concrete Spacer blocks Details ......................................................................................................... 25
1.1.13. Placement Rebar cage ....................................................................................................................... 25
4.5. Cleaning and Concreting Bored Pile ............................................................................................................. 26
1.1.14. Cleaning Pile Toe ................................................................................................................................ 26
1.1.15. Working sequence of pile base cleaning in flushing stage .............................................................. 27
4.6. Bentonite Handling System ........................................................................................................................... 27
1.1.16. Typical Layout of a Bentonite Handling System ............................................................................... 28
1.1.17. The Mixing Unit ................................................................................................................................... 28
1.1.18. The De-sanding Unit ........................................................................................................................... 28
1.1.19. The Storage Unit ................................................................................................................................. 28
1.1.20. De-sanding .......................................................................................................................................... 29
4.7. Placing Concrete ............................................................................................................................................ 31
4.8. Prevention of Cage Uplift during Concreting ................................................................................................ 32
4.9. Pile Head Casting Level tolerance ................................................................................................................ 33
4.10. Tremie Pipe System ....................................................................................................................................... 33
4.11. Pile Head Preparation and Concrete Trimming ........................................................................................... 34
1.1.21. Preparation Works .............................................................................................................................. 34
1.1.22. Setting Out ........................................................................................................................................... 34
1.1.23. Pile Hacking ......................................................................................................................................... 34
1.1.24. Pile Head Treatment ........................................................................................................................... 35
1.1.25. Safety ................................................................................................................................................... 35
1.1.26. Protection ............................................................................................................................................. 35
4.12. Inspection & Test Plan ................................................................................................................................... 37
4.13. Health & Safety ............................................................................................................................................... 38
1.1.27. Emergency Management Plan ........................................................................................................... 39
1.1.28. Heat Stress Emergency Preparedness and Response Plan ........................................................... 39
1.1.29. Lightning Emergency Preparedness and response Plan ................................................................. 39
1.1.30. Fire Emergency Preparedness and Response Plan ........................................................................ 40
1.1.31. In case of fire ....................................................................................................................................... 40
1.1.32. Snake Bites Emergency Preparedness and response Plan ............................................................ 41
1.1.33. Plan Major Accident (Vehicle and Machinery) Emergency Preparedness and Response plan.... 41
1.1.34. Fuel/ Oil split Occurrence Emergency Preparedness and Response plan ..................................... 41
1.1.35. Risk assessment ................................................................................................................................. 43
ANNEX – A: TECHNICAL SPECIFICATIONS OF BG MACHINES .................................................................. 52
ANNEX – B: QA/QC PLAN ................................................................................................................................... 71
1. Introduction ..............................................................................................................................................72
2. Quality Control Hold Points.....................................................................................................................72
3. Material Testing .......................................................................................................................................72
3.1. Bentonite Testing............................................................................................................................................ 72
1.1.36. Bentonite Density Test (According to BS1888 Specifications) ........................................................ 72
1.1.37. Bentonite Viscosity Test (According to BS1888 Specifications.) ..................................................... 73
3.2. Testing For Concrete ..................................................................................................................................... 73
1.1.38. Workability of the Concrete ................................................................................................................ 73
1.1.39. Compressive Strength Test ................................................................................................................ 75
3.3. Steel Testing ................................................................................................................................................... 76
3.4. Pile Testing ..................................................................................................................................................... 76
3.5. Pile Defect Rectification ................................................................................................................................. 77
3.6. QA/QC Formats .............................................................................................................................................. 77
ANNEX – C: SAFETY PLAN ................................................................................................................................95
1. General Safety Work Provisions ............................................................................................................97
1.1. Personal Work Provisions .............................................................................................................................. 97
1.2. Safe Plan According with the Piling Activities .............................................................................................. 97
1.2.1. Pile Driver Assembly ........................................................................................................................... 97
1.2.2. Erection ................................................................................................................................................ 97
1.2.3. Moving the Rig .................................................................................................................................... 98
1.2.4. Driving Piles ......................................................................................................................................... 98
1.2.5. Concreting ........................................................................................................................................... 99
1.2.6. Welding and Cutting............................................................................................................................ 99
1.3. Machine ......................................................................................................................................................... 100
1.4. Fire ................................................................................................................................................................100
1.5. Electrical ........................................................................................................................................................ 100
2. Operators and Maintenance Personnel ...............................................................................................101
3. Equipment Application and Safe Condition .........................................................................................101
4. Danger Zone and Safety Clearance ....................................................................................................102
4.1. Danger Zone ................................................................................................................................................. 102
4.2. Safety Clearance .......................................................................................................................................... 102
5. Personnel Handling ...............................................................................................................................102
6. Tipping and Damage Prevention ..........................................................................................................103
6.1. Operating and Travel Practices ................................................................................................................... 103
6.2. Operation in Vicinity of Unstable Ground ................................................................................................... 103
6.3. Travel Routes ............................................................................................................................................... 104

7. Signalmen and Hand Signals for Controlling Operations ...................................................................104
8. Operation in Vicinity of Underground Lines .........................................................................................106
9. Operation in Vicinity of Overhead Power lines ....................................................................................107
10. Accidents with Electricity -First Aid ......................................................................................................108
11. Leaving the Equipment Unattended .....................................................................................................109
12. Load Handling........................................................................................................................................109
13. Assembly, Maintenance and Repair ....................................................................................................109
13.1. General.......................................................................................................................................................... 109
13.2. Supervision ................................................................................................................................................... 112
13.3. Stability .......................................................................................................................................................... 112
13.4. Drive Engine ................................................................................................................................................. 112
13.5. Work Equipment ........................................................................................................................................... 112
13.6. Protective Parts ............................................................................................................................................ 113
13.7. Hydraulics and Pneumatics ......................................................................................................................... 113
13.8. Welding, Cutting and Grinding .................................................................................................................... 113
13.9. Electrics ......................................................................................................................................................... 114
13.10. Noise .......................................................................................................................................................... 114
13.11. Oils, Greases and Chemicals ................................................................................................................... 114
13.12. Replacement Parts .................................................................................................................................... 115
14. Travelling ................................................................................................................................................115
14.1. Towing ...........................................................................................................................................................115
14.2. Transporting .................................................................................................................................................. 115
14.3. Transport Route ............................................................................................................................................ 116
15. Routine Inspections ...............................................................................................................................116
16. Test Inspections ....................................................................................................................................116
17. Personal Protective Equipment ............................................................................................................117
18. Environment Protections .......................................................................................................................117
18.1. Storage of Equipment / Plants ..................................................................................................................... 117
18.2. Transporting .................................................................................................................................................. 118
18.3. Assembly / Disassembly, Service, Maintenance ....................................................................................... 118
18.4. Biodegradable Oils and Greases ................................................................................................................ 118
18.5. Disposal of Waste Oil, Filters and Auxiliaries .............................................................................................118
18.6. How to Response to an Accident with Water Hazardous Materials ......................................................... 119
18.7. Fuel / Refueling ............................................................................................................................................ 119
18.8. Fuel Consumption, Emissions ..................................................................................................................... 119
18.9. Contaminated Areas .................................................................................................................................... 120
19. Specific Requirements for Safe Operation ..........................................................................................120
19.1. Rotary Drill Rigs ............................................................................................................................................ 120
20. References .............................................................................................................................................125

ANNEX – D: SEQUENCE OF PILING PROCESS ...........................................................................................129
ANNEX – E: OTHER DOCUMENT FORMATS ................................................................................................135
ANNEX – F: MSDS OF BENTONITE ................................................................................................................137
ANNEX – G: CROSS HOLE SONIC LOGGING TEST FOR BORED PILES.................................................144
ANNEX – H: LOW STRAIN PILE INTEGRITY TEST (PIT) .............................................................................177
ANNEX – I: HIGH STRAIN DYNAMIC LOAD TEST (PDA) .............................................................................184
Comments Reply Sheet

Ref CEB Comments Access Reply
DTS 033 COMMENTS AND REPLY
Method statement 1. Execution of bored piles shall be as per 1. Noted, BS 8004 and also
for bored cast BS EN 1536:2010. CIDA/SP/101 will also be applicable
insitu piles for some situations.
Table 1: scope of 2. Scope and type of tests for the test pile 2. Sonic Logging and PDA shall be the
work(2) shall be included in the MS. test for test piles. Test method for
Verify the design assumptions about each has been added as annex G
resistance between the concrete piles and and.
the soil layers, as the soil alone the piles Verification of Skin friction, end
might be disturbed during the construction bearing and settlement shall be get
of the pile. from the PDA test.
Further upper part of the piles shall acct This argument is not accepted. Our
as laterally loaded piles, and the lateral load resisting mechanism as
horizontal lade taken by resistance from follows
the soil. This part of the piles should not i.) Passive resistance of surrounding
be used for taking the vertical load soil
simultaneously. ii.) Friction of base
Tension and compression (Beyond the tip iii.) Lateral capacity of piles.
resistance) in the piles should be taken as However pile has been design to take
resistance along the piles by considering all lateral loads.
soil layers below the part of the piles If it assume that all lateral force will be
working as a lateral loaded pile taken by the piles, one face of the pile
Considering above, the test on pile to be under active condition while other
decided. face passive condition. Hence vertical
load carrying capacity will not change.
Anyhow we have disregard the soil
vertical carrying capacity up to 1m
from the WTG foundation base
Table 1: Scope of 3. As per CIDA/SP/101, specification 3. Noted. I PDA test for each WTG
work(5) minimum requirement of PDA test is 5% location
of the total numbers of piles. So, it is 4. It is proposed to do lateral load test
recommended to carry out one PDA test for test pile and test
each foundation.
4. Propose the test frequency for lateral load
test on working piles, refer comment (2)
above.
3. Resource 5. Resource allocation shall be revised when 5. Changed accordingly
requirement two boring rigs are engaged at different
locations.
4. Construction 6. The MS testing piles shall be approved 6. Pile testing method statement shall be
methodology prior to construction of piles. submitted separately. Which shall be
approved for conducting the pile test
4.2.1 Ground 7. Detail of the temporary flat form shall be 7. Overcasting of the pile shall not be
preparation and specified including length, width, height less than the diameter of pile from the
setting out above the ELG, height of the temporary cut of level of the pile as per the
casing EGL etc. for safe and effective design decision is to be the natural
pilling construction. ground level in each position.
However it might be varied. In such
case temporary platform height also
depend on pile cut off level. Platform
height shall be minimum 800mm from
the design cut-off level. It is to be
spreaded around 30m area for one
side.

4.2.2 Pre Drilling 8. As per Doc.No.MWPP-ACCESS-DWG- 8. Noted.it should be a temporary casing
and driving WFN-001 Rev B, it is mentioned as not a permanent casing. Design team
temporary casing permanent casing revise accordingly. will change it accordingly.
9. As per Geotechnical investigation, loose 9. We have done pilling for peat soil with
layer SPT N < 10 encountered deeper SPT 1-2 areas without permanent
than 6m (7.5m to 12m). Clarify how to casing. Maintaining proper bentonite
stabilize the borehole using 6 m casing. density and circulation method, the
10. Remedial actions should be proposed wall collapsing prevented. In this bore
when in case the soil from the side has holes it was found that lesser SPT
slithered into the borehole. layer which consist of clayey sand
11. Thickness and diameter of casing shall be around 1m thickness. Hence we
specified. believe that we could achieve the
boring without any issue. Anyhow the
behavior of soil varying from site to
site and hence this will be checked
during the test pile boring stage and
required modification will be done
accordingly.
10. Prior to place the rebar cage, depth
measurement shall be collected and it
is to be tally with the actual boring
length. Bentonite flushing shall be
done after lowering the rebar cage. If
there is any collapse soil from wall of
the bore shall be removed with this
flushing and it can be encountered by
using depth measurement.
11. Thickness shall be 10mm and the
diameter shall be same as to the pile
diameter. Tolerance of casing shall be
20-30mm to the positive side
4.2.3 Maximum 12. The MS shall include the fact that, the 12. Noted for this work. However
permitted deviation exact position of the pilling shall be Qualified and experienced surveyors
confirmed by the licensed surveyor prior will be deployed for all the survey
to start the pilling work and shall be work relevant to piling and licensed
checked during the boring once after 60% surveyor confirmation will be obtained
of the boring depth is complete. for the exact position of each pile
4.2.3 Maximum 13. If the allowable tolerance is exceeded, the 13. At the first, it shall be made a third
permitted deviation alternative technical proposal including party verification for the subjected pile
rectification methodology shall be with the witness of
submitted with justifiable proof by the Engineer/Employer. Situation is same
independent competent professional in as in internal check, we need to
the industry with an agreement of the inform this deviation to the designer
Employer. an then he can show that due to
deviation there is no any impact to the
foundation by calculation.
Third party checking and verification
from consultant side also be better in
this case
4.2.4 Verticality 14. Methods for verify the verticality of the pile 14. Described in section 4.2.4
bore after boring prior installation of the
reinforcement cage to the pile shall be
specified.
4.3.1 Pile boring 15. Boring tools required for actual site 15. Casing tube, core tube, drilling bucket
with bentonite condition shall be specified in MS. and augur drill
slurry

4.3.2 Drilling fluid 16. The testing frequency for drilling fluids 16. Bentonite quality will check prior to
shall be mentioned in MS. boring (fresh stage), before flushing
17. Drilling fluid shall be mixed with pure and prior to concreting only.
water. 17. Mixing water shall be selected as per
the specification given in EN1538.
Also to be considered the requirement
given in CIDA appendix 2.2
4.3.3 Boring near 18. A minimum period of 3 days shall be 18. As per CIDA guidelines, minimum
recently casted provided before boring adjacent cast piles period of 3 days shall be provided
pile otherwise provide reference document. before boring near recently cast piles,
but as per the BSEN 1536 clause 8.1,
it has mentioned that to avoid
damage to the unset concrete in the
pile or piles recently installed nearby.
In that sense we are selecting it as 2
days from the date of casting. We got
2 day cube strength results of pile mix
design as 18MPa. It is very close to
the 50% of day strength. So that the
minimum distance between two
adjacent piles which are recently
casted should be 5 x (pile diameter).
According to that, piling sequence
shall be decided. A minimum period
of 48hours shall be provided before
boring near recently cast piles, unless
otherwise agreed with the Engineer
4.3.5 Drilling 19. Pile load bearing capacity calculation 19. Pile termination length shall be
termination shall be submitted based on sample according to the construction drawing.
recovery, rate of penetration, bore hole Calculation sheet only be submitted if
data and adopting the relevant soil bored soil layers are differ from
parameters prior to termination with relevant bore hole report
satisfying the design requirements and 20. Calculation sheet only be submitted if
justifications. Considering above, bored soil layers are differ from
acceptable termination criteria for pile relevant bore hole report
shall be submitted.
20. In case unfavourable ground condition is
observed in the design bearing layer
level, the termination criteria shall be
specified.
4.4.1 21. Detail shall be provided for jointing the 21. Lap length shall be selected as
Reinforcement caged, lap length, method of welding or mentioned in the drawing, it shall
cages jointing, method of placing the cage etc. generally be 52 times diameter bar.
22. Boring shall not be started until required Binding wire shall be used to fabricate
length of reinforcement cage is available rebar cage overall and only at the
at site. jointing place tag welding is permitted
23. Detail of access ducts for ultrasonic cross to ensure proper fittings with each
hole testing shall be specified including other. See section 4.4.1 for more
fixing method with reinforcement cage. details.
24. Rebar cage shall be fabricated only at 22. Prior to complete the boring of each
yard and brought location prior to boring. pile location rebar cage fabrication
shall be finished and inspection shall
be approved as per the drawing
23. See Annex G, clause 7 of this MS
24. Rebar cage will be fabricated in the
platform close the WTG location and
that area shall be demarcated. See
section 4.4.1 for details

4.4.2 Concrete 25. Spacer Blocks shall be made same or 25. Incorporated with comment
Spacer block higher grade of pile concrete.
details
4.5.1 Cleaning of 26. As per pile design calculation, piles are 26. Bottom cleanliness will check with the
pile toe designed as friction + End bearing piles. sand content test, as per specification
Provide method to verify the bottom sand content of the pile prior to
cleanness. pouring shall be less than 4%, See
27. Specify the method of measuring the section 4.5.1 for more details.
sedimentation and recommended 27. Common check is to find out the pile
sediment thickness for the pile bottom at toe cleanliness is sand content test
the concreting stage. prior to concreting. Bentonite flushing
shall be done around 1 hour prior to
collect the sample from the toe.
Also the depth of boring after cleaning
and after lowering the rebar cage
shall be check to verify that there is
any sedimentation at the pile toe. See
section 4.5.1 for more details
4.7 Placing of 28. Concrete slump shall be revised as per 28. Corrected
concrete Mix design. 29. Backup batching plant will be ready
29. Alternative arrangements shall be for feeding the concrete in that kind of
specified in case of brake down of situation. In addition we have skilled
batching plant or power interruptions. technician to settle majority of incident
without any delay.
For small production, portable mixer
available at batching plant can also
be used if consented.
4.12 Inspection 30. State the acceptance criteria for following 30. Refer annex G,H, and I for pile testing
and test plan tests since ASTM doesn’t give details
acceptance criteria Included. When the depth of pile is
Pile integrity test greater than 20m, sonic logging test is
Sonic logging test applicable otherwise PIT is
Pile dynamic analysis applicable. No need to do both.
Include checking of casing top Level. Included
Include checking of casing top level
General 31. MS shall include an alternative plan for 31. Extra piling position will be depended
extra pilling position in case the on the pile testing results. If sonic
acceptance criteria not fulfilled for logging test results is not satisfactory
constructed pile. level, it will go for PDA test then the
result is same we can go for another
advance test like pile load test. All
the test results are in worst position,
then it shall be ask from designer to
take decision to check whether there
is a requirement to cast another pile
or not. If required the location, sizes
and other details will be decided by
the Designer. Decision will be taken
according to the site condition.
General 32. Grouting of access ducts for sonic logging 32. We will provide separate mix design
test shall be submitted with approved for sonic tube grouting. Supporting
grouting materials. technical data will also be attached
with that document for approval
General 33. The Contractor shall submit the work 33. This will be submitted separately
programme for complete the pilling work.

Annex B: QA/QC 34. Number of PDA test shall be revised as 34. 5% of total amount of the pile and
Plan per above comment (3) however number of pile to be tested for PDA
3.4 Piling requirement may increase as per PIT will be changed according the
result. integrity test results obtained from
sonic logging test or PIT test
Annex B: QA/QC 35. Checklists are based on rock in borehole. 35. Rearranged accordingly
Plan So, modify the checklists for actual soil
3.6 QA/QC conditions.
formats
Annex B: QA/QC 36. Pile verticality check and flushing time for 36. Included both items
Plan bottom cleaning shall be included. 37. Revised accordingly
Checklist for bored 37. Number of test cube shall be revised as
cast insitu piles per specified in clause 7.6.1.13.2
Annex B: QA/QC 38. Calculation sheet for estimate for load 38. Calculation sheet to estimate load
Plan carrying capacity before boring after carrying capacity is shown in each
boring shall be submitted. So include and every WTG foundation location
sample format for calculation sheet. design report. Calculation sheet will
be submitted after boring only if bored
material differ from the Borehole
report.
Annex B: QA/QC 39. Bentonite slurry properties shall be 39. Revised accordingly
Plan revised as per specified in Table 7.6.8
Bentonite slurry
record
Annex B: QA/QC 40. Cube strength results, PDA and other pile 40. Rearranged the check sheet
Plan test shall be included. accordingly
Check sheet for
obtain final
approval of pile
Annex D: 41. The maximum permitted deviation of the 41. Revised accordingly
Sequence of piling pile from the vertical is 1 in 75 revise the
work figure specified in MS (1 in 100)
accordingly.

Requested CVs of surveyors, qualified personal engage for the work and sample load bearing calculation
sheet at site shall be submitted separately for approval.
Document Comments (by CEB) Access Reply

Description
Method 1. As specified in the contract document 1. CVs of required persons will be
Statement for volume 10, chapter 7, clause 7.6.3.2, submitted accordingly.
construction of qualification and experience shall be
Board cast In-Situ provided of personnel those who are
Piles supervising the piling construction.
Table 1: Scope of 2. As per CIDA/SP/101 clause S1.8 (a), 2. As per the soil investigation, ground
Work number of preliminary test pile shall be 1 conditions (Soil type at a particular
preliminary pile test per 250 piles since depth, SPT values etc.) are almost
the risk level is high in this regards, the same in all the locations. So the
contractor shall be constructed two test ground condition can be considered
pile at two different locations. The as consistent, as there isn’t significant
locations shall be decided by the different in those parameters in
employer. boreholes. Therefore as per
CIDA/SP/101 clause S1.8 (a), the risk

Description
level shall be medium. So one
preliminary test pile is enough in this
regards.
3. As per CIDA/SP/101 clause S1.8 (b), Static 3. Our Testing Plan as follows.
load test shall be done 1% of the total  One instrumented SLT will be
number of piles and detail description of done as the preliminary test pile.
SLT shall be submitted.  Every pile will be tested for
integrity by CSL method.
 One PDA scheduled on every
wind tower location. (Nearly 7%
of total number of piles)
1.1.1 Test Pile 4. It is recommended to perform at least 02 4. Please refer the answer for the item
instrumented pile load test including no 03.
compression, tension and lateral load
5. Static load test shall be done as per

CIDA/SP/101 and details description of 5. Noted. Test will be conducted as per
SLT shall be submitted. the specifications. Method Statement
for the SLT will be submitted
separately.
6. Only minor part of the foundation will be
Lateral load below the ground, passive resistance 6. Noted
resisting from surrounding soil shall not be
mechanism considered since high possibility of soil
moving away during high wind season.
7. Friction of base: lateral load transferring
mechanism for long pile shall be
considered. 7. Noted
8. Deformations are required to develop

active and passive pressure during the
lateral loading. The 1m length allocated 8. Active and passive condition will be
in this design for deformations has to be developed if piles are moved
rechecked for adequacy of deformation considerable amount to mobilize it.
length with appropriate load modeling. There is considerable lateral load
Further it is recommended to exclude the carrying capacity during structure is
bearing capacity for skin friction for this on at-rest condition also. This will be
part (subject to deformation) of the soil further verified during actual lateral
lateral forces. load test at site.
1.1.2 Ground 9. Overcasting shall not be less than 1.4m as 9. We will take the concrete level up to
preparation and per Employer’s specification (7.6.3.3.5.d). 1.4m from the cut off level or up to
setting out and Thus, temporary platform is essential for the existing ground level. In an event,
4.9 pile head efficient and safe piling work. Revise the the clearance between, cut off level
casing level description accordingly. & existing ground level is lesser than
tolerance 1.4m, pile has flushed with adequate
volume of concrete in order to verify

Description
the fresh concrete remain at cut off
10. Place where the rebar cage fabrication is level.
done shall be selected so that to avoid
rust formation on rebar cage, once it 10. In generally fabrication of rebar
ready for installation. cage will be done in suitable ground
near the pile location in order to
avoid damages to rebar cage in
handling.
1.1.3 Pre-Drilling 11. The behavior of soil different from 11. It is not recommended to extend
and Driving location to location. So temporary casing the temporary casing over 6.0 m in
Temporary is recommended in the very loose sand. general since during the withdrawal
casing Thus temporary casing at least 10m of process of the casing pile might get
length has to be kept at site prior to damaged. Therefore, in principle we
boring. will maintain the temporary casing
height at 6 m and the balance portion
will be stabilized by bentonite.
In any requirement where necessary

temporary casing height may change
as per the scenario.
1.1.4 Maximum 12. Qualification and experience of the 12. Noted. This will be submitted Commented [M1]: @ Achala
For your necessary action please
permitted surveyor who will do the setting out separately.
Deviation works shall be provided with the MS.
1.1.5 Verticality 13. Method of verticality check shall be 13. BG machine has the facility to check
specified after boring prior to rebar cage the verticality of the borehole, it self.
installation. MS only described verticality
check for temporary casing.
1.1.8 Boring Near 14. Additional test cube shall be made for 14. Noted and will do accordingly.
Recently Cast pile verification of strength in early boring
situation.
1.1.10 Drilling 15. Drilling termination criteria shall be 15. This has been discussed and agreed
Termination revised if pile design depth is more than during the discussion had with CEB on
borehole investigation minus 4D. …………..
16. On site calculation shall be submitted for 16. Noted.

each and every pile with considering
sample recovery and rate of penetration
etc.
1.1.11 17. Number of welding tags shall be 17. We will provide a shop drawing.
Reinforcement specified.
Cages
18. Completely description shall be specified 18. Sonic ducts will be fastened to the
for installation and maintenance of rebar cage in order to maintain its
vertically of the access duct and size of verticality. Detailed shop drawing will
the duct shall be specified. be provided.

Description
1.1.13 Placement 19. As specified in contract document 19. Noted and will do accordingly.
of Rebar cage volume 10, chapter 7, clause 7.6.3.3.5 C,
Spacers shall be spaced at interval not
exceeding twice the pile diameter.
1.1.14 Cleaning 20. Methodology shall be provided to ensure 20. Depth of boreholes will be
Pile Toe the bottom sedimentations. And measured in 05 different places
thickness of the sediment to measure including the center and 04 edges to
physically at site. ensure the design depth.
14.12 Inspection 21. Acceptance criteria shall be specified 21. Already submitted as a separate
and Test Plan and clearly. MS.
Annex G, H
22. Check of elevation of pile shall be 22. Top levels of Access ducts will be
Achieving design included. measured prior to the test and that
depth has been included to the CSL check
list.
23. Acceptance criteria shall be based on site 23. Not clear

calculation.
Alternative plan 24. The PDA or Static Load Test provides the 24. In an uncertain situation as
for extra piling load carrying capacity only and does not specified, we will get opinion from
provides the clear indication for integrity, independent professional/
hence to confirm the integrity of the pile consultant.
PDA or MLT is not accepted. Since all pile
are in the overburden soil layer and no
rock socketing is encountered. Thus pile
integrity is very crucial. Hence integrity
should be verified in addition to the load
carrying capacity of the pile. However,
compensation with the same pile without
additional pile should be confirmed by an
independent consultant.
Annex – B: 25. Defective pile should not be included in 25. Noted.
QA/QC Plan 5% of the PDA test requirement.
Section 3.4 pile
testing
Annex – B: Check 26. Casing levels (top and bottom) and 26. Noted.
list “ Bored pile planned toe level shall be included.
records”
Annex- B: Check 27. Following items shall be included in check 27. Noted.
list “ Bored In list
situ Pile”  Planned level of pile top and toe
 Length of steel casing

Description
Annex- B: 28. The list shall be in accordance with Hold 28. Noted.
Checklist for and Witness point and refer to actual
obtain final check form.
approval for pile
29. The following items should be included 29. Noted.
approval of the pile
 Elevations (Top and Toe)
 PDA
 Other pile tests
30. Above items shall include fulfilling the 30. Noted.

acceptance criteria.
Annex – B: 31. Calculation sheet for estimate for load 31. Noted. Separately submit for
QA/QC Plan carrying capacity before boring and after approval
boring shall be submitted. So sample
format for calculation sheet shall be
included.
Annex - G 32. Pile testing organization shall be 32. Noted and the company profile of
acceptable to Employer. the testing agent will be submitted.
33. Qualified authorized person and 33. Will be included in the company
acceptable to employer shall be engaged profile.
for recommendation for the test results.
34. Calibration reports for the testing

equipment shall be submitted prior to 34. Will be included in the company
testing. profile.
35. The initial test reports and raw data

(water fall and wave speed) shall be 35. Will submit accordingly.
submitted to employer at end of each
day after testing.
36. The minimum gap including allowable
limit of the sonic tube bottom and pile 36. 150mm
toe shall be specified.
37. Final reports of the CSL test shall be

included the applied filter value for 37. Final waterfall diagrams will be
energy and wave velocity. Otherwise generated through CHA-W software.
report will not be accepted. Software will include those filter
values in the graphs and it’s a default
format of the software.
1. Introduction
Ceylon Electricity Board plans to implement 100 MW Mannar Wind Power Project phase 1 in the southern coast of
the Mannar Island which is located in the North province of Sri Lanka 300 km from commercial capital, Colombo.
Vestas Asia Pacific A/S (main contractor) have been awarded to design, supply and install wind farm in Mannar
Island. Access Engineering PLC will be the BoP sub-contractor for civil works.
This method statement is intended as a guideline for CEB (The Employer) Personnel &Vestas Asia Pacific A/S and
Access Engineering PLC site staffs to ensure a safe and efficient piling works of Mannar Wind Power Project. This
should be read in conjunction with the applicable approved drawings, specifications and relevant designs.
BS 8004 and also CIDA/SP/101 will also be applicable for some situations.Execution of bored piles shall be as per
BS EN 1536:2010.
2. Scope of Work
 Scope of the project consists of the followings,
 Pile setting out
 Mobilizing the Boring machinery
 Boring machine placement
 Pre-boring up to require depth (at least 2/3 rd length of temporary casing)
 Temporary casing installation
 Rechecking of position and casing verticality
 Pile boring up to design depth plus required tolerances
 Removal and transferring of soil
 Bentonite circulating system for drilling process (density, viscosity, pH, sand content etc.)
 De-sanding
 Borehole depth reading
 Washing the pit and lowering of submersible pump
 Pile toe cleaning
 Fabricating and bar bending
 CSL access tubes installation and attached to rebar cage
 Rebar cage installation
 Tremie pipe lowering
 Check bentonite properties before concreting (density, viscosity, pH, sand content)
 Test cube casting
 Concreting process
 Removal of temporary casing
 Waiting for strength gain
 Pile head treatment and hacking
 Pile testing(CHSL or PIT,PDA)
This method statement covers for providing bored cast-in-situ reinforced concrete pile foundation including boring
work, steel reinforcement, concreting, pile head treatment, pile testing and all other work as required.
Table 1: Scope of Work
Item Description Unit Quantity
1. Bored Piles – 800mm diameter No’s 450
2. Bored Piles – 800mm diameter- Test pile No’s 1, as finalized by design
3. Pile Integrity Test (PIT) ,if pile length <20m No’s All Piles
4. Cross hole sonic logging test, if pile length >20m No’s All Piles
5. PDA test No’s 1 test for each WTG location
Item Description Unit Quantity

6. Pile Head Treatment No’s All Piles
Note: IF the pile length is more than 20m from the cut off level, sonic logging test shall be carried out instead of low
strain integrity test. Contractor shall include the pipes as appropriately.
One instrumented SLT will be done as the preliminary test pile. Instrumented test pile method statement
will be submitted separately.
As per the soil investigation, ground conditions (Soil type at a particular depth, SPT values etc.) are almost same
in all the locations. So the ground condition can be considered as consistent, as there isn’t significant different in
those parameters in boreholes. Therefore as per CIDA/SP/101 clause S1.8 (a), the risk level shall be medium. So
one preliminary test pile is enough in this regards.
2.1. Construction Sequence
i. Mobilization & Ground Preparation
ii. Construction of Bored Cast Piles
iii. Pile Head Treatment
iv. Testing of Piles
2.1.1 Test pile

Overall pile testing scope is as per below
• One instrumented SLT will be done as the preliminary test pile.
• Every pile will be tested for integrity by CSL method.
• One PDA scheduled on every wind tower location. (Nearly 7% of total number of piles)
Only one test pile in the scope. Sonic Logging and PDA shall be the test for test pile. Procedure for each test has
been added as annex G and I
Verification of Skin friction, end bearing and settlement shall be get from the PDA test.
Lateral load resisting mechanism considered in the pile design is as follows
i. Passive resistance of surrounding soil
ii. Friction of base
iii. Lateral capacity of piles.
Pile has been design to take all lateral loads.
If it assume that all lateral force will be taken by the piles, one face of the pile under active condition while other
face passive condition. Hence vertical load carrying capacity will not change. Anyhow we have disregard the soil
vertical carrying capacity up to 1m from the WTG foundation base
Active and passive condition will be developed if piles are moved considerable amount to mobilize it. There is
considerable lateral load carrying capacity during structure is on at-rest condition also. This will be further verified
during actual lateral load test at site.
3. Resource Requirement
3.1. Machinery and equipment list per team
Table 2: Machinery and Equipment list
Item No. Description Unit Quantity
1 Boring rigs Nos 02
2 Mobile crane Nos 01
3 Crawler crane Nos 02
Item No. Description Unit Quantity

4 Excavators Nos 02
5 De-sander Nos 03
6 Bentonite Silos Nos 04
7 Generator(10kW or More) Nos 03
8 Welding Plant Nos 02
3.2. Manpower list per team

Table 3: Manpower list
Designation No’s
Site Manager 02
Assistant Engineer 02
Technical Officer 04
Supervisor 02
Lab Technician 04
Store Keeper 01
Surveyor 02
Material Technician 02
Safety Officer 03
Foreman 04
Lab Helper 04
Store Helper 02
Surveyor Helper 06
Electrician 02
Welder 04
Labour 34
BG Operator 02
Crane Operator 03
Excavator Operator 03
Number of teams allocated for the project will be decided according to the construction programme.
4. Construction Methodology
The construction methodology which will be adhered to this project is descriptively illustrated in this chapter. Annex
D consist a summary of this chapter. Typical piling methodology consists following key processes which includes
various sub processes.
i. Preliminary Survey & Driving Temporary steel casing
ii. Pile Boring
iii. Preparation of the R/F Cage
iv. Cleaning and Concreting the Bored Pile
v. Testing of Piles
First four key processes are described in this chapter with various sub processes relevant to them. See the annex
G, H and I for testing details
4.1. Drilling Sequence of Single WTG Foundation
Figure 1: Sequence of pile foundation construction of single WTG location
4.2. Preliminary Survey &Driving temporary steel casing

4.2.1 Ground Preparation and Setting Out
The pile locations shall be set out in accordance with the bored pile foundation layout plan. Clearing, grubbing
&levelling shall be done before drilling the bore pile. Identifying tree and bushes before clearing etc., barricading
the entire area of works. All setting out reference points and related contract drawings shall also be referred. Setting
out of pile location, ground level and ancillary control points shall be checked and confirmed with the Engineer prior
to commencement of piling works. Once the first section of pile casing is erected, the setting out with all ancillary
control points and the verticality of the pile will be re-checked with the Engineer before piling works proceeds further.
We will take the concrete level up to 1.4m from the cut off level or up to the existing ground level. In an event, the
clearance between, cut off level & existing ground level is lesser than 1.4m, pile has flushed with adequate volume
of concrete in order to verify the fresh concrete remain at cut off level.
In generally fabrication of rebar cage will be done in suitable ground near the pile location in order to avoid damages
to rebar cage in handling. In such case temporary platform height also depend on pile cut off level and the natural
ground level. Platform height shall be minimum 1m to 1.5m from the design cut-off level. The area of platform is to
be spreaded around 25m length for one side. Rebar cage fabrication can be done on this platform.
Figure 2: Working Platform Preparation for piling work
4.2.2 Pre-Drilling and Driving Temporary Casing

A temporary 6m steel casing will be driven by casing driver attached to the boring rig or vibratory hammer if required.
Before casing driving, the alignment and verticality of the casing shall be checked to ensure that there is no deviation
from the original point.
In cases where the maintenance for stability of borehole is difficult by drilling fluid (SPT N<10) such as peat layer
(weak layer) or in the places where there is aggressive action of ground water and constant change of external
ground water level. In such situation case by case, situation will be informed to engineer for further instruction.
Furthermore important to noticed that, we have done pilling for peat soil with SPT 1-2 areas without permanent
casing. Maintaining proper bentonite density and circulation method, the wall collapsing prevented. In this bore
holes it was found that lesser SPT layer which consist of clayey sand around 1m thickness. Hence we believe that
we could achieve the boring without any issue. Anyhow the behavior of soil varying from site to site and hence this
will be checked during the test pile boring stage and required modification will be done accordingly.
Further, it is not recommended to extend the temporary casing over 6.0 m in general since during the withdrawal
process of the casing pile might get damaged. Therefore, in principle we will maintain the temporary casing height
at 6 m and the balance portion will be stabilized by bentonite. In any requirement where necessary temporary casing
height may change as per the scenario.
It is recommended that a tolerance of ±3mm allowed during Setting-out and ±15mm after casing installation.
Thickness shall be 10mm and the diameter shall be same as to the pile diameter. Tolerance of casing shall be 20-
30mm to the positive side.
4.2.3 Maximum Permitted Deviation

The maximum permitted deviation of the pile center from the center point shown on the setting out drawing shall be
+ or -75mm in any direction. The maximum permitted deviation of cut of level shall be +or - 10mm. This shall be
check prior to rebar cage installation, after temporary casing installation and after hacking completion. After 60% of
the boring completion shall also be checked if required by the Engineer/Employer.
Noted for this work. However Qualified and experienced surveyors will be deployed for all the survey work relevant
to piling and licensed surveyor confirmation will be obtained prior to concreting work.
At the first, it shall be made a third party verification for the subjected pile with the witness of Engineer/Employer.
Situation is same as in internal check, we need to inform this deviation to the designer an then he can show that
due to deviation there is no any impact to the foundation by calculation.
However, third party checking and verification from consultant side also be better in this case.
4.2.4 Verticality
During and after installation of the temporary casing also it required to check the position of the boring, in that case
perpendicular offset two points shall be placed 1m (between 1000mm-2000mm) from the center point. After
installation temporary casing, offset distance from each point to casing shall be measured and the values shall be
same or within the allowable limit (±75mm) (Reference BS 8004:1986 clause 7.4.2.5.4). However it is better to
reduce this deviation as much as possible without depending on the tolerances.
During installation verticality shall be checked with 600mm or 1000mm length spirit level from two positions which
locations are perpendicular to each other. If 1m sprit level used to check the verticality, the deviation shall not be
greater than 10mm.
After intermediate checking of the position and verticality temporary casing shall be stay align with the support of
boring machine and drive through the soil.
The maximum permitted deviation of the finished pile from the vertical is 1 in 75
BG machine has the facility to check the verticality of the borehole, itself to check the verticality of bore at the end.
4.3. Pile Boring

4.3.1 Pile Boring with Bentonite Slurry
Boring of the piles shall be carried out by a rotary boring rig, using special types of boring tools depending on the
soil conditions encountered. The position and inclination of the pile have to be checked and documented. In case
tolerances are exceeded, the design engineer has to be consulted before constructing the next neighboring pile.
The excavated material in the bore hole is taken out by boring bucket, cleaning bucket and the drilling fluid. The
excavated material has to be documented by a drawn borehole profile with classification of the excavated material
according to the exploration profiles. (Soil samples and Rock particles from each bore hole shall be taken and
packed in polythene bags. Bags shall be labeled with pile reference number, depth, date of sampling etc.).
Especially the depth of the surface of un-weathered rock (fresh rock) and the rock socketing shall be documented
(only if applicable)
Casing tube, core tube, drilling bucket and augur drill will be used specifically for sandy soil which are available in
this site.
4.3.2 Drilling Fluid

Bentonite slurry shall be prepared at site using a mixture and stored in silos to maintain an uninterrupted supply.
The quality of the Bentonite shall be checked in following stages and the results shall be within the limits given in
table 4.
.Bentonite quality will check prior to boring (fresh stage), before flushing stage and prior to concreting only.
Mixing water shall be selected as per the specification given in EN1538. Also to be considered the requirement
given in CIDA appendix 2.2
4.3.3 Boring Near Recently Cast Pile

Piles shall not be bored so close to other piles which have recently been cast and which contain workable or unset
concrete that a flow of concrete could be induced from or damage caused to any of the piles. Minimum distance
between two adjacent piles which are recently casted should be 5 x (pile diameter). According to that, piling
sequence shall be decided. A minimum period of 48hours shall be provided before boring near recently cast piles,
unless otherwise agreed with the Engineer.
As per CIDA guidelines, a minimum period of 3 days shall be provided before boring near recently cast piles, but
as per the BSEN 1536 clause 8.1, it has mentioned that to avoid damage to the unset concrete in the pile or piles
recently installed nearby. In that sense we are selecting it as 2 days from the date of casting. We got 2 day cube
strength results of pile mix design as 18MPa. It is very close to the 50% of day strength which is shown that there
is no unset concrete when it is old 48 hours from the date of casting.
Additional test cube shall be made for verification of strength in early boring situation.
4.3.4 Properties of Bentonite Slurry
Drilling fluid shall be checked for following properties, during the soil boring stage and the flushing stage of a pile.
Table 4: Bentonite Slurry Properties (Reference: BS 8004: 1989 clause 6.5.3.8.2 and clause 7.4.5.4.3)
Characteristics for Bentonite Suspensions

Stages
Property Unit Ready for Before Test Equipment
Fresh
Re-use Concreting
Density g/ml <1.10 <1.25 <1.15 Mud Balance
Marsh Viscosity
sec 32-50 32-60 32-50 Marsh Funnel
(946ml)
Sand Content % n.a n.a <4 Sand content set
pH 9.5 to 12 9.5 to 12 9.5 to 12 PH indicator or Paper strips
In order to check the quality of the slurry the following equipment shall be used:
 Marsh funnel
 Mud balance
 Sand Content Kit
Prior to concreting of a pile, Bentonite samples will be taken from the bottom of the pile bore to test the actual
properties of the Bentonite slurry. A Bentonite sampler which allows collecting slurry at any depth will be lowered
to pile bore in order to collect Bentonite samples. It consists of a tube and two balls on top and bottom of the tube.
All the test equipment shall be calibrated and back up testing equipment for this kind of compulsory and urgent test
shall be available at site to use in case of emergency
Figure 3: Bentonite Slurry Sampler and Working Principle
4.3.5 Drilling Termination

The pile boring can be terminated upon reaching the design depth. The engineer/engineer’s representative shall be
consulted to obtain permission to terminate the drilling operations. Information for inspection as usual will be done
through RIF supplemented with direct communications with counterpart Engineer’s representative. If hard rock is
encountered, it will be separately addressed case by case.
Drilling termination criteria shall be revised if pile design depth is more than borehole investigation minus 4D. On
site calculation shall be submitted for each and every pile with considering sample recovery and rate of penetration
etc.
4.4. Preparation of the Reinforcement Cage
4.4.1 Reinforcement Cages
Rebar cage fabrication location can be varied as per the site condition. It can be either in one single outside yard
or in foundation area according to the convenience during construction. The reinforcing cages shall be checked to
ensure that they are in accordance with the approved construction drawings. Following parameters shall be
complied with the approved construction drawings.
 Dimension of reinforcement bars
 Geometry, completeness and stability of reinforcement cage
 Spacing, material, dimension and position, fastening
Lap length shall be selected as mentioned in the drawing, Binding wire shall be used to fabricate rebar cage overall
and only at the jointing place tag welding is permitted to ensure proper fittings with each other. Joints between
sections of reinforcement cages can require additional fixing, (e.g. by clamps or tack welding). Refer BSEN 1536,
clause 8.2.2.2 and 8.2.2.3. Number of welding tags shall be specified with shop drawing.
However reinforcing bars shall not be welded at or near bends.
Prior to complete the boring of each pile location rebar cage fabrication shall be finished and inspection shall be
approved as per the drawing.
Reinforcement cages shall be suspended or supported so as to maintain their correct position during concreting.
Sonic ducts will be fastened to the rebar cage in order to maintain its verticality. Detailed shop drawing will be
provided.
4.4.2 Concrete Spacer blocks Details
75 mm
General Notes:
Y
15 mm
Y
75 mm : Cover
165mm : Outer Diameter of the
75 mm
Spacer Blocks
50 mm : Height
Location of Spacer blocks shall be
decided as per the construction
drawing
Figure 4: Cover Block Details – Plan View

50mm
165 mm
Figure 5: Cover Block Details – Section Y-Y
The reinforcement cage will be hanged by a steel stiffener welded in girder casing to ensure 100mm gap between
the bottom of the reinforcement and the toe of the pile. Grade of spacer block shall not be less than the grade of
pile concrete.
4.4.3 Placement Rebar cage

Prior to complete the boring of each pile location rebar cage fabrication shall be finished and inspection shall be
approved as per the drawing.
Spacers shall be arranged symmetrically around the cage with
- At least 3 number at each level and as specified in contract document volume 10, chapter 7, clause 7.6.3.3.5 C,
Spacers shall be spaced at interval not exceeding twice the pile diameter.
- Sufficient tolerance to the inner wall of a casing or the wall of the pile bore to allow safe installation and avoid
damage to the bore walls.
Rebar cage shall be lifted by mechanical means (crawler crane) and lowered into the borehole very carefully without
damaging to the walls. Excess length shall be cut off from the rebar cage after the installation. 100mm gap to be
maintained between pile toe and rebar end which is maintain by using calculation considering the borehole length
from the casing top and total rebar cage length.
The reinforcement shall be installed as soon as possible after the cleaning of the pile bore.
The installation of the reinforcement has to provide for its alignment with the pile axis and maintain the correct
concrete cover over its full length.
4.5. Cleaning and Concreting Bored Pile

4.5.1 Cleaning Pile Toe
Bottom cleanliness will check with the sand content test, as per specification sand content of the pile prior to pouring
shall be less than 4% as per the specifications.
Initially, bore-hole base shall be cleaned by boring rig using cleaning bucket. If the depth and the sand content of
the bore-hole attain to satisfactory level, concreting operation will be commenced.
Common check is to find out the pile toe cleanliness is sand content test prior to concreting. Bentonite flushing shall
be done around 1 hour prior to collect the sample from the toe.
Also the depth of boring after cleaning and after lowering the rebar cage shall be check to verify that there is any
sedimentation at the pile toe.
Depth of boreholes will be measured in 05 different places including the center and 04 edges to ensure the design
depth.
However, after lowering the rebar cage the bore-hole will be measured and verified again prior to concreting. If
there is major soil collapse encountered, rebar cage will be lifted up and the bore-hole will be clean again. The
Bentonite slurry properties will satisfy the requirements mentioned in table no 04.
4.5.2 Working sequence of pile base cleaning in flushing stage

Case 01
Step 01 Clean the pile toe and shaft with the aid of cleaning bucket of boring rig
Step 02 Insert reinforcement cage to the pile.
Case 02
Step 01 : If a hard layer is encountered in the pile toe at the termination, flushing operation will take place
Step 02 : Bentonite will be pumped to the borehole through the tremie to remove sludge.
Step 04 : Discharged Bentonite will be collected and sent for de-sanding process
Step 04 After attain the sand content of the pile to satisfactory level, ready the pile for concreting.
Figure 6: Bauer De-Sander BE 170 and Bentonite Mixer BM 10

By considering the distance from the machinery supply location and the preparation for contingency situation, back
up de-sander will be available at site.
4.6. Bentonite Handling System

Bentonite slurry is required to stabilize the bore hole. During the drilling process fresh Bentonite is pumped to the
borehole to keep it full (inside the casing should be kept always at least 1.0m above ground water level) in order to
guarantee its stability. Prior to concreting the bore, Bentonite that is charged with particles of soil must be cleaned
or replaced. The System is made up of several components.
4.6.1 Typical Layout of a Bentonite Handling System

A. Flow circuit for stationary handling system
A leveled area of about 40 x 20 m is required. The storage volume is substantial and is made up of a series of
tanks, silos or can be in the form of earth ponds. The system consists of
 1 no. de-sanding unit (typically BE 100 to BE 250),
 Bentonite mixing unit, pumps and pipelines.
Figure 7: Bentonite Mixing Unit, Pumps and Pipelines
4.6.2 The Mixing Unit

An efficient mixing unit (fully automatic or manual operation mode) mixes Bentonite powder with water. The freshly
mixed slurry is pumped to a holding and hydration tank where the slurry is kept in motion. Hydrated Bentonite slurry
is then transferred by a pump to the main reservoir/ pile.
4.6.3 The De-sanding Unit

The de-sanding unit separates from the slurry all particles down to a cut point d50 of 60 microns and is made up of
four main items: one or more hydro cyclones, driers, distribution boxes and pumps. De-sanded slurry is pumped
back to the storage reservoir for reuse.
4.6.4 The Storage Unit

The storage unit can be made up of a series of ponds excavated in the ground, steel tanks stacked parallel or on
top of one other or, if space is at a premium, a series of silos. The layout can have different configurations to best
suit the geometry of the site but it is important, in order to guarantee continuity in the work that the total capacity of
storage is at least 1.5 x the volume of pile. In the design of storage capacity, consideration should be given to the
local geology.
If there are indications of the presence of formations that could lead to a sudden loss of Bentonite during the boring,
that might be affected to the stability of the bore hole. The size of the storage basins should take into account a
surplus supply that can be used in these emergency situations.
4.6.5 De-sanding
Prior to concreting, Bentonite in the bore hole must be sampled and checked to ensure that it satisfies the minimum
criteria for concreting. When this is not the case, Bentonite in the bore hole is circulated through the de-sanding
plant; alternatively it may be partly or completely replaced by fresh Bentonite so that its characteristics satisfy the
contract requirements. The decision on whether to circulate or to replace the slurry is a function of the properties of
the slurry in the bore, the contract specifications that characterize this material, the availability of fresh Bentonite
and time.
Figure 8: De-sander
Flush out Pump

Bentonite will send Bentonite to
to De-sander for the borehole
recycling
Step 02 Step 03 Step 04

Step 01
Figure 9: Working Sequence of Pile Base Cleaning

Bentonite IN – Circulate the Bentonite slurry
Bentonite IN from
the Silo OUTPUT Send to the De-Sander
Section View of the Cleaning

Process - Pile base shall be cleaned
using fresh Bentonite slurry
circulation though tremie pipes
Figure 10: Bentonite Circulation System & Cleaning Process
4.7. Placing Concrete

Concreting the fluid filled bore hole is carried out using a “Tremie pipe” that introduces fresh concrete to the bottom
of the bore and allows it to rise upwards displacing the fluid in the bore hole. Tremie pipes will be installed into
the pile bore up to the pile toe. The tremie pipes will be internally free of any old and hardened concrete as to
allow for a smooth concreting procedure. O-rings may have to be inserted to the joints of the tremie pipes to
ensure adequate water tightness.
Concreting shall only commence once a sufficient number of loaded mixer trucks are available on site ready to
discharge the concrete and all other trucks are confirmed for arrival. The slump of the piling concrete shall be
200± 25 mm before the discharge into the pile bore.
At the commencement of concreting, the bottom of the tremie shall be placed between 100-150mm from the
bottom of the borehole. The funnel with appropriate capacity shall then be filled with concrete up to brim level.
The concrete shall be released by removing the lid fixed at the bottom of the funnel and the concrete shall be
discharged without interruption in one operation unit. Then the tremie pipe is raised and the concrete is placed at
the bottom of the pile if needed only. Whilst concreting, the tremie pipe shall be raised in such a manner so that
the embedded Tremie length in to the concrete is at least 3.0 m of fresh concrete.
The concrete may be retarded to ensure that setting does not commence within four (04) hours of arrival at site.
A retardation of 4 hours is recommended to avoid technical problems during concreting. When concrete mix is
supplied to the site, uniformity, temperature (should be less than 32°C) will be checked.
On-site sampling and testing of concrete usually consists of taking:
Sets of cubes - The amount and frequency of sampling and testing are specified in the contract specifications.
(Clause7.6.1.13.2)
Clause 7.2 project quality plan MWPP-ACCSS-QUA-PLN-0001
Cubes to be casted for testing purpose each mix. For each 15 m3 of concrete 3 set of cubes to be casted each
set having 3 no of cubes (total of 09 test cubes). 7 days strength and 28 days strength to be checked compulsory
and other set is to check the strength in any time as the requirement. In 28 days concrete shall be achieved its
full strength and in 7 days 65% of it.If the concrete amount is less than 15m3 for each concrete supply it should
be maintained minimum 9 no of cubes.
Three cubes out of 9 cubes so collected shall be tested at seven (7) days and further three cubes shall be tested
at twenty eight (28) days. The remaining three cubes shall be retained as reserve and tested if and when required
by the Employer.
Slump tests - carried out regularly on site to check consistency in the workability of the concrete.
During the concreting process the actual consumption of concrete is plotted against the theoretical volume and is
included as part of the panel records. This information will enable the identification of zones of necking or over
break
Backup batching plant will be ready for feeding the concrete in an emergency situation. In addition skilled
technician shall be available to settle majority of incident without any delay.
4.8. Prevention of Cage Uplift during Concreting

Prior to concreting, guide bars in the reinforcement cage shall be tag to the casing in order to prevent any uplift
of the cage during concreting.
Guide Bars
Steel Tag
Casing
R/F Cage
Figure 11: Guider Bars shall be welded to the steel

casing in order to prevent of Cage Uplifting
4.9. Pile Head Casting Level tolerance

Minimum overcast of 1 D (D-Diameter)/ 1.4m will be done from the cut-off level
4.10. Tremie Pipe System
Figure 12: Tremie Pipe System

4.11. Pile Head Preparation and Concrete Trimming

Bored cast in situ piles generally cast above pile cut off level, in order to maintain sound Concrete on pile cutoff
level. The purpose of this method statement is to describe the procedure of trimming the excessive slurry concrete
above the pile cutoff levels.Pile hacking method statement shall be subjected to change any time according to the
actual site condition where construction going on. This is general guide line to prior to construction work
commenced.
Table 5 : Pile Hacking Methodology
No Methodology Application
1 Breaking of Piles by Hand Held Pneumatic breakers Reinforced concrete portion
2 Using hand held small chipping Hammers 200mm above Pile cutoff level.
3 Using wedges [A crack will be induced at the cut-off level of the This will be used case-by case
pile head to separate the mass of concrete above, which led to where application of this is
its easy removal in one piece to be lifted away.] appropriate with other parameters
4.11.1 Preparation Works

 Concrete Strength: Concrete strength of the piles should be checked prior to pile hacking and should be
satisfied that the required strength as per mix design has been achieved.
 Supports and Ladders: Ladders or scaffoldings will be provided to make easy access to the workmen
to the pile top, in case of deep excavation.
 Dewatering: Standby water pumps will be provided for dewatering the area if necessary. (Not considered
in the scope)
 Excavation: The entire foundation area will be excavated up to its final excavation level in accordance
with lines and grades specified in the approved construction drawings. (Not considered in the scope)
4.11.2 Setting Out

 The working drawings will be used for setting out work.
 The pile hacking level will be same as the pile cutoff level. The levels will be checked by Engineer after
excavation and marked.
 As built top levels will be recorded before starting pile-hacking.
4.11.3 Pile Hacking

 Tools and Equipment: Pile hacking will be done by hand-operated tools or Jackhammers (pile hacking
level will be finished at 1m height from the pile cutoff level). Skilled operators will carry out the work under
supervision of technical officer.
 Methodology: Mark a line 200 mm above the pile anchor length. Break the upper part of the pile up to
marked line and remove debris from the area. Then the balance portion will be chip by using jack
hammers. OR
Mark a line 200 mm above the pile cut off level. Two opposite sides of the pile will be chip off for gain a
wedge shape after the cutting is completed. After using pneumatic tools, wedges will be inserted to the
pile in four locations to have a horizontal crack in above marked line. Using crane or boom truck this
cracked part will be lifted and remove from the area. The balance 200 mm portion will be chip manually
using jack hammers. OR
After the level of cutting has been cut by using cutting grinder, continue the pile chipping work using hand
held pneumatic breakers up to cut off level.
 Levels: Pile hacking will be carried out from top of casted pile up to sound concrete with conformity to the
cut-off level.
 Rebar Protection: Extra care will be adhered for the rebar while hacking to avoid deformation.
 Hacking below Cut-off Level: In case sound concrete is encountered below cut-off level, then the pile will
be re-built up to cut-off level.
 Engineer’s Confirmation: Joint Inspection with the Engineer’s representative will be performed upon
completion to confirm the levels.
 Disposal of Waste Material: Non usable concrete pieces and soil will be removed from the Site premises
immediately.
4.11.4 Pile Head Treatment

 Cleaning: After hacking completed, the top of the pile will be cleaned up properly by removing any
concrete debris, dust, oil and any remainders by flushing with clean water.
 Rebar Fixing: Hooking or bending of rebar will be adhered if necessary or as per Engineer’s requirement.
Rebar shall be rust-free or clean to the satisfaction of the Engineer/Engineer’s representative.
 Pile Built-up: If hacking reached below cut-off level due to actual sound concrete obtained, it is necessary
to build up the pile. Rebar arrangement will be prepared in accordance with approved construction
drawings. Steel casing will be used for shuttering the pile to cast the concrete. Same concrete grade of
the pile will be used to build up the pile.
4.11.5 Safety
 All the site staff and workers should wear ear plugs, safety eye glass, safety helmets and shoes (PPE)
 All the dangerous areas must be barricaded & demarcated
 All the electrical wires and sockets must be covered to safety regulations
 All the site staff and workers must be alert when working near heavy machineries
4.11.6 Protection
 The excavated area will be demarcated using barricade tapes stretched on support bars, around the
perimeter of excavation.
Figure 13 : Pile hacking using hand held pneumatic breakers
Figure 14: Pile crushing to gain a wedge shape

Re-Bar after hacking
Cut off level

Lean concrete
Pile toe level
4.12. Inspection & Test Plan

Hold Point [H]
A designated point during or following a specific activity at which inspection or examination cannot be by-passed
through next work without designated inspector's witness or any prior written
Witness Point [W]
A designated point during or following an important activity at which inspection or examination is required in
accordance with the relative procedure. Work may proceed through the designated witness point if the inspector
is not present for the previously established activity.
Review Point [R]
It is processed through reviewing any result of inspection or test report as a method of ensuring that the inspection
or test is performed in accordance with any approved drawing, procedure, specifications or acceptance criteria
Surveillance [S]
It is processed through the routine act of monitoring or observing to verify an item or activity conforms to specified
requirements
Item Description of Test/

Inspection Frequency Acceptance criteria
No. Inspection
1. Checking casing center by H Prior to install and after As described in method statement
surveyor installation clause 4.2.3
2. Bentonite test (Density, H Prior to boring, Prior to Within the specified limit as
Viscosity, Sand content) rebar cage installation mentioned in the method statement,
and prior to concreting table 4 clause 4.3.4
3. Checking socketing H At the time of Depth to be as per the drawing or as
length(if applicable) and pile termination mentioned in the clause 4.3.5
depth after termination
4. Achieving of design depth H After completion of the Shall be as per the drawing or as
boring and pile toe mentioned in the clause 4.3.5
cleaning
5. Inspection of rebar cage H Prior to placing All the details shall be as per
prior to place drawing and items in the relevant
check sheet shall be fulfilled.
6. Level and position of rebar W After placement As per drawing(Relevant lap length
cage form the cutoff level shall be there)
7. Desired degree of cleaning H Prior to concreting As specified in the method
statement, Bentonite property shall
be as per table 4
8. Slump test W Prior to concreting As specified in method statement
and project specification and as per
relevant mix design
9. Truck mixers’ details W After completion of With delivery reports
pouring
10. Testing of 7 days cube H After 7 days of concrete 65% of Specified target strength
strength placement shall be achieved
11. Testing of 28 days cube H After 28 days of Specified cube strength in the mix
strength concrete placement design shall be achieved
12. Bored pile record W After completion of Attached check sheet to be available
casting with complete data entry
13. Pile Integrity Test (PIT) H For each pile As per the requirement of ASTM
D5882
14. Sonic Logging Test H If required (when pile As per the requirement of ASTM
length more than 20m) D6760
15. Pile Dynamic Analysis H Specified pile As per the requirement of ASTM
(PDA) D4945
16. Pile eccentricity checking H For each pile after Need to state within the specified
hacking finish tolerance in the method statement
4.13. Health & Safety

 Personal Protective Equipment (PPE) shall be worn by all staff or workers.
 Hard Hat
 High visibility vest
 Gloves (when required)
 All operatives shall be inducted before entering the site.
 Tool box talk shall be conducted before the activity.
 AE shall be provided adequate lighting, task lights, navigational lights etc.
 AE will made available adequate volume of water for the investigation team.
 Barricade to be placed around working location.
 AE will maintain proper housekeeping around the work area
 During piling works flagman shall be provided to guide other equipment’s movement
4.13.1 Emergency Management Plan

Communication Plan
If there will be a first aid case, HSE Manager and/ or first aider will arrange necessary first aids according to the
injury. If the injured person required further medical attention, HSE Manager will contact Mannar General Hospital
or Pesalai Divisional Hospital according to required medical need.
4.13.2 Heat Stress Emergency Preparedness and Response Plan

a. If a worker suspect heat exhaustion, below will be the action plan.
b. Move the person out of the heat and into a shady or air-conditioned place.
c. Remove tight or heavy clothing.
d. Have the person drink cool water or other nonalcoholic beverage without caffeine.
e. Then Monitor the person carefully.
f. As final step Safety Manager or Responsible safety officer will Contact a doctor if signs or symptoms
worsen or if they don't improve within one hour.
4.13.3 Lightning Emergency Preparedness and response Plan

1. Following Instructions shall be provided to all staff and guest.
a. Don’t work or move around on open ground area while lightning.
b. Don’t work or stay at heights during lightning.
c. Don’t hold any iron rod or material affected by lightning.
d. Turn off and refrain from using all lightning affected electronic items and accessories such as television,
radio, mobile phones, wired network connections etc. At lightning condition.
2. Details of contact personal and agencies shall be displayed to inform emergency situation Ex: Hospitals.
3. Lightning arrestor shall be installed at the concrete batching plant, asphalt plant & at height ground.
4. Emergency evacuation path shall be sign posted.
5. Ignitable materials and steel shall be stored separately.
6. Lightning prevent guidance shall be prepared and displayed for all employees and visitors.
7. Welding done workshop and yard shall be stopped during lightning.
8. All lightning prevention equipment shall be checked and tested regularly and failure shall be corrected by
qualified person.
4.13.4 Fire Emergency Preparedness and Response Plan

a. Assign a site emergency response team members and aware & training.
b. Displaying the details of contact persons and agencies to inform the emergency situation.
c. Providing fire controlling facility and equipment needed at identified fire points.
d. Guidance to use the fire equipment are displayed at fire point.
e. Evacuation plan shall be prepared and displayed for all employees and visitors
f. Assembly point shall be identified, displayed and communicated.
g. All the rubbish and easily burnable items has been removed from all places with high risk for fire, such as
fuel stores.
h. Naked flame shall be prohibited and there should be notice at fuel store and other store of flammable
items to aware about fire hazard and prohibition of naked flames.
i. Smoke area shall be reserved at office premises and outside of the working location.
j. All the naked flames used in workshop or machinery repairing shall be safe guard with proper manner.
k. Old electricity wiring system and their all equipment shall be checked, tested regularly and failure shall
be corrected by qualified person if necessary.
l. All electricity generators and their wiring shall be checked regularly to prevent fire due to electrical leaks.
m. Explosive used in site shall be stored in special safe condition approved by explosive controller.
n. There should be monitoring plan to ensure proper function of all arrangement and equipment shall be
checked and tested periodically and record shall be maintain as per the established monitoring schedule.
o. Effective of the planned system shall be tested by rehearsal.
p. Easily flammable items shall be stored in separately.
q. Gas cylinders & oxy-acetylene tank shall be avoided from exposing to excess heat.
r. During long vacations electricity connection, vehicle batteries shall disconnected.
4.13.5 In case of fire

a. Inform the situation to any responsible person as soon as possible
b. Inform to site emergency response team
c. Inform to fire brigades or nearest police station
d. Use the fire extinguishers properly
e. Minimize the property and human damages

f. Using correct evacuation plan and assembling to the assembly point
g. Getting the head count
h. Not getting permission to go out till all are assemble
i. Check and confirm all of site and get action to give first aid or medical treatment those who wanted
4.13.6 Snake Bites Emergency Preparedness and response Plan

1. Instruction to all staff and guest shall be provided on.
a. Use snake bite protection & preventive PPE
2. Details of contact person and agencies shall be displayed to inform emergency situation Ex: Hospitals.
3. Snake bites controlling facilities shall be installed at plant complex. Ex: Lights
4. Internal roads and accommodation surrounding area shall be cleaned.
5. Emergency response team has been aware and train for First aid and other necessary actions in emergency
snake bites.
6. Immediately admitted to the hospital
4.13.7 Plan Major Accident (Vehicle and Machinery) Emergency Preparedness and Response plan
1. Instruction to all staff and guest shall be provided on.
a. Protect major accident of vehicle and machinery.
2. Vehicle internal speed control level shall be provided and displayed.
3. Machinery operating manuals and safety manuals shall be provided to the machine operators.
4. Heavy vehicle running and operating areas shall be displayed and prohibited unauthorized entrance
5. All vehicle and machinery shall be maintained and services on time for their safety operation.
6. At the major accident situation first aid and immediately admitted to the hospital.
4.13.8 Fuel/ Oil split Occurrence Emergency Preparedness and Response plan
1. Assign a site emergency response team members and aware & training.
2. Adequate communication facilities shall be established and emergency contact numbers shall be given to the
work force. (Details of contact persons and agencies to inform the emergency situation)
3. Providing oil distribution controlling and collecting facility and equipment needed (PPEs, Oil absorb pads and
alloy wool, Water barriers, compressors and bowsers)
4. Urgent action shall be taken to not blend oil with natural water paths
5. There should be monitoring plan to ensure proper function of all arrangement and equipment shall be checked
and tested periodically
6. Effective of the planned system shall be tested by rehearsal
 District General Hospital, Mannar
023-2222261
023-2222349
 Divisional Hospital, Pesalai
023-3232679
4.13.9 Risk assessment

Risk Assessment criteria
Value Estimation
1 Injuries or illnesses requiring no treatment or first-aid only
2 Injuries or illnesses requiring medical treatment beyond first-aid
Severity
3 Temporary impairment, causing lost-time or job restriction
4 Permanent/prolonged impairment
5 Fatality
Value Estimation
1 Foreseeable, very low probability , might be seen once during working life
2 May have occurred in past, expects to see several incidents during working life
Probability
3 Occurred in past, expected one per year, would not be surprised by incident
4 Occurs frequently, expect significant number of incidents each year
5 Occurs very frequently, expect significant number of incidents each month

Original Risk Revised Risk

Sr.No. Activity Hazard Involved Risk Rating Mitigation Action Rating
P S V P S V
1.  Site cleaning and  Dust energize  Respiratory 3 5 15  Use water bowser to spray water to control dust 2 2 4
grabbing at pilling  Exceeding noise level  Noise  Using ear plugs to reduce sound
locations
 Snakes bites  Fatality  TBT ,Mockup drills , EPRP
 UXO at site  Explosions  Detect un exploded bombs and explosives before start
2.  Surveying  Awkward posture  Neck/ body pain 2 5 10  Provide proper PPE 1 2 2

 Slip/ trips/ falls  Fracture  Tool box talks
 Exposure to sun light  Major injury
 Biological hazards  headache
3. Site cleaning and  Snakes around the  Fatality 5 5 25  Using emergency vehicle to send the victim to hospital 5 2 10
grabbing environment / Snake biting  Keep anti- venom stock at site
4.  Mobilizing  Hit by moving object  Crushing injuries 4 5 20  Use speed limits at site area 2 3 6
machinery  Un-controlled speed  Fatal
 Tripping hazard
 High volume of vehicle
movement
 Un even and muddy ground
condition
5.  Placement of the  possible to be struck or  Injuries 4 5 20  Use PPEs 2 3 6

Machine punctured  Fatal  Awareness programs
 worker movement at the  Use check list to ensure safety
site
6.  Placement of the  sharp edges and angular  Injuries 4 5 20  Use PPEs 2 3 6

Machine parts that protrude (stick  Fatal  Use check list to ensure safety
out) from the machine

P S V P S V
7.  Loading and  Contact lubricant with eyes  Eye irritant 1 5 5  Proper planning 1 2 2
unloading  Awkward posture  Muscular pain  Instruction and supervision
machinery and
 Use of unsafe lifting gears  Awareness
equipment
and non-inspected cables
8.  Laydown yard  Traffic flow  Vehicle accident 3 5 15  Traffic Control 2 4 8

preparation  Speed /Slip, trip, Falling  Working sign board
 Unauthorized visitors  Fire  Proper PPE
 Equipment operation  Major Injury  Conducting awareness program
 Buried utilities  Check the site condition and search for buried utilities
 Reversing equipment/  Use flagmen and signalmen
Vehicles  Fire extinguisher placement
 Fuel storage/ refilling  Dip trays and traps for fuel leaks
 Material storing  Store in even surfaces and use 5s concept
9.  Assemble and  Manual handling  Leg and hand 4 4 16  Provide PPE 2 2 4

dismantle  Hit by moving object injuries  Competent mechanics
machinery and
 Crush by machine parts  Back pains  Site supervision
equipment
 Machinery overturn  Crushing injuries  Demarcation of hazards area
 Contact with the hydraulics  Minor fractures  use fire safety precautions ( fire extinguishers )
 Hospitalization
 Fatal- Major
injury.
10.  Removing &  Defective and unsafe  BG machine or 5 4 20  Take all necessary safety precautions to avoid personal 3 3 9
replace tools of BG equipment inexperience ground instability injury or damage to equipment
Machine operators of mechanical  Workers will be made aware of the dangerous working
failures around necessary equipment

P S V P S V
11.   Overloading  Collapsing cables 5 4 20  safety precautions to avoid personal injury or damage to 3 3 9
 Mounting rotary boring rig equipment
12.  insertion of the  toppling  injuries 3 4 12  safety precautions to avoid personal injury or damage to 2 2 4
temporary casing  damage to the machines and  fatality equipment
surround objects  Use experienced signalmen
 Miscommunication
13.  Removal Of Soil  Dust emission  Injuries to eyes 4 3 12  Use safety glasses and eye protector 2 2 4
14.  removal and  Soilcontamination  Ingestion and 3 3 9  Always educate workers to wear adequate PPEs 2 2 4
transferring of  Direct contact with inhalation
soil potentiallycontaminated ofsoils, dusts
soils and vapors
 Heavy vehicle movement
15.  mixing bentonite  Direct contact of site  Injuries to eyes 4 3 12  Use safety glasses and eye protector 2 2 4
workers and others  Use dust mask when mixing the bentonite
with contaminated
soil
16.  Excavations  Deep holes at the site  Injuries 4 5 20  Hard barricading the deep holes / excavated locations 2 2 4
locations  fatal
17.  Excavation  Expose to dust  Occupational 4 3 12  Spray water 2 2 4

 Collapse of spoil soil asthma  Excavation with proper manner
 Hit by moving object  Major injury  Demarcate water area
 Machinery overturn  Hospitalized  Tool box talk
 Fatal

P S V P S V
18.  Case Placement  Falling object from cages  Injuries 4 4 16  Don’t work under carne operations 2 3 6
 Cage falling or slipping  Fatal  Use PPEs
19.  Concrete pouring  Falling from height  Major injury 3 4 12  Warn safety harness if work at more than 2m height 2 1 2
 Protruding reinforcement  Hospitalization  Make proper access and egress
 Foot damage
20.   Concrete contamination eyes  Eye injury 3 3 9  Provide proper PPE 2 1 2

and skin  Skin irritation
21.   Contact with live electricity  Electrocution 4 4 16  Make proper access 2 2 4
22.  washing the pit  Environment hazards  Environment 4 4 16  Stop splitting bentonite to the environment 2 2 4
contaminate with bentonite pollutions
23.  Temporary  Possible electrical shocks  Uncontrolled 2 3 6  Proper electrical wiring 1 2 2

electricity lighting  Temporary electrical supply released of  Approved power tools
energy
by unskilled labours  Grounding shall be provided on all electrical equipment
 Usage of direct current  Electrocution fuel for protection of workers
leakage
 Uncertified power tools  Use of lockout and hold tags as necessary
 Personal injury
 Damaged wire code  Inspection of power tools and equipment shall be done
 Fire and burning
 Unknown cable, suspected periodically

P S V P S V
24.  Pile breaking  Noise exposure  Long term 4 3 12  Use ear plugs 2 2 4
 Dust hearing losses  Use dust marks
 Vibration of pneumatic  Occupational  Supply 15min rest break per every working hour
asthma
breaker  supervision
 Awkward posture  Neck/ body pain
 Work at height  Major injury
 Fatal
25.   Hit by machinery  Major injury 4 3 12  Use PPEs 2 2 4

 Hit by particles  Fatal
26.  Pile rectification  Hit by machinery falling from  Major injury 3 4 12  Use PPE 2 1 2
height falling into pit  Fatal  Display sign board
 Chemical usage  Hospitalization  Conduct awareness program
 Spillages  Tool box talk
 Keep MSDS on site
27.  Bar bending  Bar bending and bar cutting  Major fracture 3 2 6  Use competent person to operate the machine 2 1 2
machineries  Multiple crushing  Proper insulation for electrical code
 Contract with live wire  Cutting injuries  Providing inspection for machines
 Current due to faulty  Foot damage
equipment
 Electrocution
28.  Welding of  Spark & toxic gas from  Hospitalization 3 3 9  Wear eye protection. 2 2 4
extension piles. welding works  Wear gas mask.

P S V P S V
29.  Electrical wiring  Damage wire codes  Personal injuries 1 5 5  Qualified electricians shall maintain temporary and 1 2 2
and supply  Unskilled workers  Fire and burning permanent electrical codes and wiring
 Heated surfaces  Electrocution  Proper warning signs
30.  Power generation  Ground contamination with  Damage to the 3 3 9  Regular maintenance of machinery & gen set. 1 2 2
oil. environment  . Provide drip tray.
 Piling machine / generator
set leaks oil onto ground
31.  Hand tools  Split of wooden handles  Impact with body 4 4 16  Renew wooden handles 2 1 2
 Sharp edges  Cut wound  Hammer head tightly wedged on their head keep tools on
 Scrap tools  Minor injury boxes or racks when not in use
 Always use right tool for the job
32.  Use of power tools  Short circuit  Electrical shock 4 3 12  Check foe defective cables, plugs and sockets 2 2 4
 Damage sockets  Fire  Use corned fuse plug, cables
 Damage wire codes  Burn  Switch off before making any adjustment
 Personal Injury  Ensure that all electrical equipment are periodically
checked and tested
 Make sure that the power cable is long enough reach
your working place without straining it
 Power tools should be regularly inspected and maintain
by competent person.
33.  Sign Board Fixing  Cutting injury hit by moving  Tetanus crushing 4 3 12  Providing PPE 2 1 2
object manual handing  Cutting injury  Good supervision
awkward posture.
 Law back pain  Employ skilled persons
 Cut/bruises

P S V P S V
34.  Access and Egress  Exposure to dust  Occupational 5 3 15  Providing PPE 4 2 8
 Vehicle accident asthma  Traffic control plan
 Fatal or Major  Good supervision
Injury
35.  Machinery  Contact with lubricant  Moderate eye 3 2 6  Use proper PPE 2 1 2
breakdown and  Contact with sharp edge irritant  Competent Mechanic
repair edges  Skin irritant  Demarcate working area
 Static Postures  Deep cut wood  Conduct tool box talk
 Impact with moving parts  Temporary  Taking frequently brakes
discomfort on
 Good supervision
pain
 Major Injury
 Minor bruise
36.  Manual Handing  Lifting unbalanced  Major Injury 3 4 12  Frequently change the postures 2 2 4
 Risk of back strain from  Educate by training
lifting awkward heavy weight
37.  During adverse  Occupant will be face to  Major Injury 4 5 20  Immediately evacuate workers from site as soon as 3 1 3
weather condition thunder- bolt and get  Fatal. possible
like Lightning, clammy.  Reschedule activity carry out according to weather
thunder showering,  Working on rainy conditions condition.
Heavy rain fall and expose to lightning
conditions
38.  night work  Poor visibility  Major Injury 3 5 15  Flash lights and adequate lighting system install to visible 2 1 2
 Impact with tools  Property Damage working area and traveling route.

P S V P S V
39.  Rebar unloading  Awkward posture  Deep cut wound 4 3 12  Providing proper PPE 3 2 6
 contact with shape edges  Fatal  Inspect lifting slings/belts regularly
 Collapsing of rigging rebar  Hospitalization  Use experienced Crain operators
 Hit by moving trucks and  Use competent riggers
machineries  Barricade operation area
 Falling objects from the  Don’t stay under the suspend load
carne operation
 Get third party certification for cranes and lifting cables
40.  Welding/ gas  Fire risk, Electric shock,  Major Injury 3 5 15  Use full face welding shield, welding gloves, apron, fire 2 3 6
cutting works Explosion, Welding fumes,  Burn extinguishers and fire blankets.
expose to high intensity light,
 Eye injury  Using flash back arrestors
Create welding sparks, Arc
 Fatal
rays, Acetylene leakage
41.  Steel element  Impact with steel element,  Physical injury 3 5 15  Use special PPE relevant to the welding and drilling work 2 5 10
welding, drilling and fire, with burned skin other than the common safety items, especially eye
the other associate  eye contact with welding  abrasion protection glasses should be warn, sufficient number of
activities. helping person shall be allocated to assist skill workers.
flame directly,  Major injury
Entire work will be executed with proper planning.
 burning of skin,
 electrical shock
ANNEX – A: TECHNICAL SPECIFICATIONS OF BG

MACHINES
ANNEX – B: QA/QC PLAN

1. Introduction
This QA/QC plan consists of the criteria of determining the quality standards and methodologies of verifications
of each quality parameter in different stages of project development. The system of routine technical activities, to
assess and maintain the quality of the piling works is documented in the QA/QC plan.
2. Quality Control Hold Points

The Client & Engineers Representative shall inspect all the Hold Points Activities which are mentioned in the
QA/QC Manual and once they grant the approval, construction process will be started.
Hold Points are mentioned below.
i. Setting out the Pile Center
ii. Checking the Casing Center
iii. Testing Bentonite in Boring Stage
iv. Checking Rock Samples
v. Checking Socket Length
vi. Checking the Fabrication of the Rebar cage
vii. Cleaning of the Pile Toe
viii. Testing Bentonite prior to the concreting
ix. Testing Concrete (Slump)
3. Material Testing
3.1. Bentonite Testing
As per the Project Specification, Bentonite slurry should have following properties.
Table 6: Bentonite Slurry Properties – QA/QC Plan
Compliance values measured at 20 °C

Property to be
Slurry Pumped to the Slurry in the Pile Bore prior Test Method
Measured
Pile to concreting
Density < 1.10 g/ml < 1.15 g/ml Mud Density Balance
Viscosity 30 – 50 seconds 30-50 seconds Marsh Cone Method
Wet sieving through
Sand Percentage <4% ≤4%
210 BS Mesh
pH 9.5-12 9.5-12 pH indicator
3.1.1 Bentonite Density Test (According to BS1888 Specifications)

The mud balance consists of a mud cup attached to one end of a beam, which is balanced on the other end by a
fixed counterweight and a rider free to move along a graduated scale.
A level bubble is mounted on the beam. Attachments for extending the range of the balance may be used.
Figure 15: Mud Balance
3.1.2 Bentonite Viscosity Test (According to BS1888 Specifications.)

Cover the funnel orifice with a finger, and pour freshly sampled drilling fluid through the screen into the clean,
upright funnel. Fill until fluid reaches the bottom of the screen.
Remove finger and start stopwatch. Measure the time for filling up mud to the 1 qt (946 cm3) mark of the cup.
Report the measured time to the nearest second as Marsh funnel viscosity.
Figure 16: Marsh Funnel Viscosity
3.2. Testing For Concrete

3.2.1 Workability of the Concrete
Slump Cone test shall be done to determination of workability on fresh concrete at the site. The slump test result
is a slump of the behavior of a compacted inverted cone of concrete under the action of gravity. Required range
of slump shall be mentioned in the project technical specification.
Testing Procedure: -
a. Slump cone
b. Tamping procedure
c. Removing cone
d. Height measurement
3.2.2 Compressive Strength Test

Sample preparation
Samples are taken from the concrete as it is cast into the pile bore, prepared specimens under the standard
conditions which are mentioned in BS 1881-101 or BS 1881 – 125.
Testing Procedure:-
A. Testing Equipment
Following equipment will be used from the sample preparation to carry out the compressive test at the site.
 Testing machine
 150×150 mm cubes
 Steel Tamper
 Scoop
 Auxiliary platens
B. Testing Procedure
 Samples are taken from the concrete as it is cast into the pile bore, cured under the standard conditions
which are mentioned in BS 1881-116 and SLS 1144 part II clause 11, crushed to determine the maximum
compressive strength. The first step, sample preparation from the fresh concrete as follows.
 Place the mould on a rigid horizontal surface and fill with concrete in such a way as to remove as much
entrapped air as possible (without significantly reducing the amount of entrained air, if present) and to
produce full compaction of the concrete with neither excessive segregation nor laitance. For this purpose,
by means of the scoop, place the concrete in the mould in layers approximately 50 mm deep and compact
each layer by using tamper (compacting bar).
 When the compacting each layer with the compacting bar, distribute the strokes of the compacting bar in
a uniform manner over the cross-section of the mould, and ensure that the compacting bar does not
penetrate significantly any previous layer nor forcibly strike the bottom of the mould when compacting the
first layer. The number of strokes per layer required to produce full compaction will depend upon the
workability of the concrete but in no case shall the concrete be subjected to less than 35 strokes per layer
for 150 mm cubes. Record the number of strokes. After the top layer has been compacted, smooth it level
with the top of the mould, using the plasterer’s float, and wipe clean the outside of the mould.
 Immediately after making specimens store them in a place free from vibration and in conditions which will
prevent loss of moisture. Specimen stored in water shall be tested immediately on removal from the water
and while they are still in the wet condition. Surface water and grit shall be wiped off the specimens and
any projecting find removed specimens when received dry shall be kept in water for sufficient time before
they are taken for the testing.
 Demould specimens to be tested at greater ages within the period 16 h to 28 h, just before testing. If the
concrete has not achieved sufficient strength to enable specimens to be demoulded during this period,
demoulding should be delayed for a further 24 h. The dimensions of the specimens to the nearest 0.2mm
and their weight shall be noted before testing. Do not test cubes which have been made in badly
assembled moulds or which are clearly misshapen.
 Placing the specimen in the testing machine, the bearing surface of the testing machine shall be wiped
clean and any loose sand or other material removed from the surface of the specimen, which are to be in
contact with the compression platens. Carefully center the cube on the lower platen and ensure that the
load will be applied to two opposite cast faces of the cube. If auxiliary platens are being used, align the
top auxiliary platen with the cube.
 Without shock, apply and increase the load continuously at a nominal rate within the range 0.2 N/ (mm2·s)
to 0.4 N/ (mm2·s) until no greater load can be sustained. On manually controlled machines as failure is
approached the loading rate will decrease: at this stage operate the controls to maintain as far as possible
the specified loading rate. Record the maximum load applied to the cube.
3.3. Steel Testing

Samples of reinforcing steel which is used in pile construction should be tested in an independent approved
laboratory and reports submitted on the request by the employer / engineer. Following tests shall be conducted
for each steel consignment or per 100 ton.
 Tensile Strength Test
 Re-Bending Test
 Rib Geometry Test
3.4. Pile Testing

During the project piles shall be subjected to two types of integrity tests in order to verify the integrity as well as
the load bearing capacity. Following tests shall be done in this project.
 Pile Integrity Test (PIT) – See Note Below
 Cross Hole Sonic Login Test – See Note Below
 High Strain Dynamic Test (PDA) – 5% of the piles shall be tested.
Descriptive methodologies of the each test are mentioned in Method Statements which will be submitted
separately for each test if applicable.5% of total amount of pile.
Note: If pile length more than 20m (from cut off level) sonic logging test shall be carried out instead of low strain
Integrity test (PIT), the Contractor shall appropriately install pipes when constructing the piles. Please incorporate
this requirement with testing section.
3.5. Pile Defect Rectification

Based on the analysis of above test results, the pile category will be identified. If any defect pile is observed,
suitable rectification method shall be conducted. If any requirement, detailed method statement will be submitted.
3.6. QA/QC Formats

QA/QC Formats are attached to the document separately.
ANNEX – C: SAFETY PLAN

Foreword
Scope, Purpose and Application

In order to prevent accidents it is very important to identify hazards which create accidents. Access Engineering
PLC is highly committed in this regard and also ensures safe work conditions for employees. Our Objective is to
identity hazardous conditions which cause accidents in workplaces and to apply strategies to minimize the effects
of such hazards.
It is the policy of AE (PLC) to perform work in the safest manner possible in accordance with the factories
ordinance. Safety must never be compromised or challenged. To fulfill the requirements of this policy, an
organized and effective safety program must be carried out at each location where work is performed.
We believe that all injuries are preventable, and we are dedicated to the goal of a safe work environment. To
achieve this goal, every employee on the program must assume responsibility for Safety. Every employee is
empowered to:
1. Conduct their work in a safe manner
2. Stop work immediately to correct any unsafe condition that is encountered
3. Take corrective actions so that work may proceed in a safe manner
Safety, occupational health, and environmental protection will not be sacrificed for production at any instant. These
elements are integrated into quality control, cost reduction, and job performance, and are crucial to our success.
The purpose of this safety information is to inform of responsibilities, operating practices and work habits which
will aid in providing safe working conditions.
1. General Safety Work Provisions

At the onsite of a job, an officer in charge should conduct a safety meeting wherein safety rules are explained to
all employees. In this tool box meeting, the engineer/ Technical officer/ Supervisor should obtain telephone
numbers of those to be contacted in emergencies, check that a fully stocked first-aid kit is onsite, and assure that
a trained first-aid person or hospital is nearby in case of an emergency.
1.1. Personal Work Provisions

 Personnel to work on/with the equipment must read the manual and this safety information before they
start; they must completely understand all safety instructions.
 Persons who will work only temporarily (such as rigging personnel and service men) must also be familiar
with the equipment, the manual and the safety information.
 Personnel should be checked from time to time for safe working practices, and that they are fully aware
of the safety hazards involved and that they follow the instructions in the manual.
 Personnel at work shall not wear long hair loose, loose-fitting clothing, necklaces, bracelets or rings
because of the danger of being caught by protruding parts or being drawn into machinery.
 Personnel shall wear the appropriate personal protection required for the job and always wear mandatory
PPEs at the site
1.2. Safe Plan According with the Piling Activities

1.2.1 Pile Driver Assembly
Prior to unloading the rig, a Technical Officer must insure that adequate handling equipment is available, with
slings and other rigging in good working condition. A firm, level site which is free of overhead power lines is optimal
for rig erection.
All equipment that arrives and is unloaded should be inspected for cracks, signs of overstressing, and deterioration
that could limit functionality. All wire rope, including hoisting lines, pendants, and slings, should also be inspected,
along with head blocks, fairleaders, and other fittings.
While workers are bolting up leaders, the rig operator should conduct a detailed inspection of the crane or hoist.
All controls should operate properly, with the operator adjusting clutches and brakes, checking the operation of
swing and travel locks.
When lifting equipment, ensure adequate size slings are utilized and properly tied down to the transport in order
to prevent shifting. Additionally, use tag lines to prevent loads from uncontrollably swinging, and provide blocking
to allow loads to land safely.
1.2.2 Erection
Before raising leaders, a Technical Officer and operator should ensure that:
 TBT has done and persons who engaged in operations ,fully understand the procedures
 Carnes have all the documents (third-party certification, valid licenses to the operators)
 Adequate tag lines are provided

 No tools or extra bolts have been left on the boom or leaders
 Hammer extensions and sliding frames are cabled securely
 Steam, jet, and hydraulic hoses have been inspected; if connected to the boom tip, these hoses must
have safety chains secured to the boom
 All joints are safely tied down
 Lower hose ends and boom safety cables are wired to the boom
 Availability of the appropriate check lists.
 If operation is doing at night time , should ensure the adequate lighting is available
When erecting, do not attempt to add additional counterweight or tie down the back of the crane. Doing so can
cause gantry and topping lift failure.
After raising the leaders, attach the sliding frame to the spotter and connect the boom safety cables. Once the
hammer is lifted, lower its extensions and cable them off. As hoses are attached, ensure safety chains are
secured.
1.2.3 Moving the Rig

Operating over unstable ground represents the most hazardous aspect of moving the rig. As a rule, avoid moving
a rig over areas where the ground is soft or compacted. Areas above old sewers or underground structures that
will not support the rig, or areas adjacent to excavations, should also be avoided when possible. If crossing over
an old sewer or freshly backfilled trench, double matting represents the simplest precaution.
Only the supervisor, or a trained signalman, should sign to the operator, with standard hand signals being utilized.
Additionally, the supervisor should ensure that all workers are clear before giving a signal to move, swing, pick
up, or lower a load. The hoisting or swinging of loads over areas where typical work operations are conducted
should be avoided.
1.2.4 Driving Piles

Pile driving is complicated, yet common sense and general safety rules – combined with a knowledge of pile-
related problems – can equate to safe working conditions during operations. Safety rules to adhere to include:
 Availability of check lists, work permits
 Lift piles with proper slings or other equipment, with workers properly trained in their use
 Pick up piles from the side opposite of other operations
 Clear workers when piles are hoisted into the leads

 Do not undermine the rig or an adjacent structure when jetting or pre-excavating for piles
 Clean augers of clods of earth and rocks as they are hoisted out of the ground
 Holes made in advance should then be covered or barricaded to prevent a possible fall
 Instruct workers to never be under the hammer or core at any time
 Release the core sling on both sides when changing cap blocks or a hammer cushion
 Keep workers away from leads when cap blocks or a hammer cushion is being changed
 Keep the hammer under control during driving, via slight pressure on the hammer drum brake
 Shut off the hammer immediately if the pile should break or start running into the ground
 Watch the hammer hose closely when lifting the hammer at the end of driving, ensuring it does not catch
 Hold any hose loop below the leaders away from them until the hose is clear
 If workers are engaging any work near to the borehole unprotected, he should wear a full body harness
which is attached to safe and strong enough anchor point. and also if any worker engaging any height at
work related to pile driving machine , he should have fall protection system
1.2.5 Concreting
Pile driving and concrete operations should be coordinated so that piles are not dragged and the rig is not swung
over an area of concreting in progress.
The principal cause of concreting accidents is associated with the use of narrow or unstable runways. When
runways are more than three feet above ground, duckboards should be used. Because cement can be irritating
to the skin, workers should be fitted with rubber-coated gloves.
Vehicle management plan (Ex: truck mixtures) system should be maintained and vehicle washing inside the site
area is completely prohibited and designated place should be maintain adequate safety precautions should be
applied to prevent environmental hazards and pollution.
1.2.6 Welding and Cutting

Essential aspects of pile driving operations, welding and cutting can be conducted safely via several precautions.
General welding and cutting recommendations include:
 Don’t permit anyone to strike an arc on a compressed gas cylinder (should have hot work permit)
 Flashback arrestors are compulsory to the torch and cylinder side

 Don’t weld near flammable or combustible materials
 Avoid welding on containers that have held combustible or flammable materials
 Avoid welding in confined spaces without adequate ventilation (if it is a confine space confine space
permit should be maintained.)
 Hot objects should not be picked up
 Delay chipping or grinding without suitable goggles
 Avoid dropping or abusing cylinders
 Confirm cylinders are well fastened in their stations

 Avoid using a hammer or wrench to open cylinder valves
 Never interfere with fuse plugs
 Protect the hose from being trampled on
 Avoid tangles and kinks
 Don’t leave the hose unattended, as it could turn into a tripping hazard
 Protect the hose from sparks, hot slag, hot objects, and open flames
 Don’t allow the hose to come in contact with oil or grease
 Ensure that connections between the regulators, adaptors, and cylinder valves are tight
 Determine if acetylene is escaping by smelling for odor. Additionally, test with soapy water, but never with
an open flame
 Don’t hang a torch with its hose on regulators or cylinder valves
 Don’t cut material that would permit sparks, hot metal, or severed sections
1.3. Machine
 Operator's cab and machine inside must be kept clean and tidy and be free of objects which do not belong
there. Operator's personal belongings shall be stored in such a manner that they do not interfere with
access or operation. Tools, oil cans and other necessary articles shall be stored in the tool box or storage
area of the machine and not lie about in the cab.
 All caution and danger signs on the machine must be observed.
 All caution and danger signs, decals and nameplates must be maintained legible and installed. If a sign
is defaced or removed, it must be replaced immediately.
 Should there be any doubt as to safety of the machine, the work equipment or the operating practice, the
machine shall be shut off immediately and the case be reported to the appropriate authority or appointed
person.
 Modifications or additions which could affect the capacity or safe operation of the machine or work
equipment shall not be made without the manufacturer's written approval. The same applies to installation
or readjustment of safety devices or pressure relief valves and welding on load-bearing members.
 New parts must conform to the specifications made by the equipment manufacturer; with genuine spare
parts there will be the guarantee that they conform.
 No changes may be performed on the programs (software) of programmable control systems in the
machine.
 Hydraulic hose assemblies must be replaced in the stated or properly safe intervals and this also when
there is no evidence of a safety impairing defect.
 The inspection and maintenance intervals prescribed in the manual must be followed.
 To perform maintenance and repair, the appropriate tools and appliances required for the action must be
at hand and be in good working order.
 Machine condition should be monitored by marking checklist and it should be practice every shift start.
 After any repair or any modification the machine which is under third party inspection process, such
inspection must be done before starting work
 Machine repairing should be done at designated place and should use LOTO systems for repairing
1.4. Fire
 Personnel shall be informed of the placement of fire extinguishers and be familiar with their use.
 Personnel shall be familiar with the fire preventing and suppressing possibilities on the jobsite and also
with the alarming and alerting measures to take in case of fire.
 Availability of EPRP and should display emergency contact numbers at site locations
1.5. Electrical
 Like other equipment, electrical tools should be inspected regularly for defective or frayed cables. Points
where cables enter tool housings and switch boxes should particularly be checked and repaired
immediately. Under no circumstances should a defective device be utilized by substituting a larger fuse
or bypassing the overcurrent device.
 Power tool should be undergone to the monthly color cording system. All power tools should be double
insulated and powered trough GFCI units. Proper and adequate current should be supplied through
industrially accepted cables and sockets.
2. Operators and Maintenance Personnel

Personal qualifications, responsibilities and assignments:
 Only the persons who have the following qualifications may be assigned and designated responsibility to
perform on their own on the equipment.
o They must be at least 18 years old.
o They must be physically and mentally fit.
o They must have been trained for the job, be familiar with the equipment and have given the
contractor proof of their competence.
o They must be dependable and conscientious in their work.
 Operating, rigging, maintenance and repair assignments shall be clearly designated by the contractor.
 It must be ensured that performance on the equipment be carried out only by the assigned and designated
persons.
 The operator shall be responsible for those operations which are under his direct control. Therefore, he
must also have the authority to stop operating or to refuse orders from third persons should there be any
doubt as to safety or violation of a la (e. g. traffic regulations).
 Apprentices or persons undergoing training, or personnel taking part in a general training program, may
practice on the equipment only under direct supervision by a skilled and experienced operator.
3. Equipment Application and Safe Condition

 Precautions must be taken that the equipment be used only when it is in a safe operating condition; any
defects found on the equipment which could be a danger to safe operation must be repaired before
operations are begun.
 Store in charge should be responsible to issue a perfect tool to the requester. And it is the responsibility
of receiver to assume a perfect tool for his job.
 The equipment may be used only when it is fitted with all its safety devices (such as removable guards,
emergency stops, limiting devices, exhausts, sound insulation, etc.) and when they are all in proper
working order.
 The equipment must not be used in any practices which could be a danger to safe operation.
 The equipment shall be controlled from the operator's position only and this only by the assigned operator.
 All controls, indicators and displays must be tested by the operator at the start of a new shift. If any of
them do not work properly, they must be repaired before operations are begun.
 Start and stop performances must be carried out in compliance with the instructions in the manual. Before
the operator starts the machine, he must satisfy himself that no person will be endangered thereby.
 Control levers may be moved by hand only and control pedals by foot only.
 If there is any doubt as to safety of the equipment, the work tools, the operating practice or the stability of
the ground, the operator must promptly stop operating, shut down the equipment and report the case to
the appropriate authority or appointed person.
 The machine and the work equipment must be inspected for evidence of damage or defects at least once
a work shift. Any changes found (machine's performance included) must promptly be reported to the
appropriate authority or appointed person. It may be required that the machine and work equipment be
shut down and secured in the meantime.
 If adjustments or repairs are necessary, the equipment must be shut down and the faults corrected without
delay.
 Smoking, sparks and open flame are forbidden during machine refueling and in the proximity of batteries.
The engine must be off during refueling.
 Work tools and equipment parts which have been put down on the ground must be safely secured against
movement, to prevent personal accident.
4. Danger Zone and Safety Clearance

4.1. Danger Zone
 No person shall be allowed to stay in the danger zone of the equipment while work is in progress. The
danger zone is the machine surrounding area in which the machine or its work equipment or a suspended
load could hit a person by motion or accidental dropping, and where objects could fall.
 The machine shall be fitted on two sides with permanent, clear and legible danger signs to alert persons
to keep out of the danger zone. The location of the signs must be such that the signs are visible at all
times when work is in progress. Their size, colors, symbol and wording must conform to the country's
safety standards laid down forth for this type of equipment.
 The operator may start to move or operate the machine only when he is sure that there is no person in
the danger zone.
 The operator must warn persons exposed to danger; in general he can do so by audible signals (sounding
the horn).
 Where the surrounding noise level is high, established hand signals must be used instead of horn signals.
 The operator must promptly stop operating if a person does not keep out of the danger zone despite
warning signals.
 With hydraulic machines of this type, personnel (and especially those who are required near the machine
to assist the operator!) must take into consideration at all times that the operator's view to the rear and
the right side of the machine is obstructed; not to keep out of the danger zone or travel path of the machine
when it starts moving, or while it is in motion, is very dangerous.
4.2. Safety Clearance

 No part of the machine and the work equipment shall be capable of coming closer than 0.50 m to fixed
objects (such as buildings, pit sides, scaffolds, other machines), so that persons may not be trapped or
crushed.
 Where this safety clearance is not practicable, the zone of the machine operating area and the fixed object
shall be barricaded.
5. Personnel Handling
 The operator may pick up passengers with the machine only on seats built-in by the manufacturer.
Equipped seatbelts or slings must be worn.
 Passengers may mount the machine only with the operator's permission.
 Mounting or dismounting the machine may take place only when the engine is off and the machine is out
of motion.
 Persons must never ride on the machine or be transported on the work equipment.
 Hoisting equipment must not be used as a personnel lift.
6. Tipping and Damage Prevention

6.1. Operating and Travel Practices
The equipment must not be used in situations or practices which could endanger its stability. Factors which could
reduce stability are, for example:
 Machine on unstable, uneven and sloping ground.
 Overloading the machine (see Load Capacity Charts).
 Exceeding the machine's safe operating range (see Operating Range Diagrams).
 Sideways dragging of a load.
 Sudden acceleration or deceleration of a moving load.
 Sudden starts and stops.
 Abrupt turns and swings.
 Excessively slowed down operating and travel performances.
 The carrier machine used for the BAUER work equipment must be designed with adequate capacity so
that its stability can be guaranteed at all times.
 The machine's capacities must never be exceeded! Be aware that moving a load over the side of the
machine will reduce the machine's capacities.
 The ground must be safely and uniformly supporting; if excavator mats are used, they shall be wider than
the machine undercarriage by 1 meter at least and be fitted with proper attachments for hoisting
equipment.
 While in transit from one place to another on a jobsite, the upper carriage of the machine must be
interlocked with the undercarriage to prevent rotation, and the work equipment must be kept as close to
the ground as possible.
 Before travelling, even a short distance, any external power sources used must be disconnected from the
machine. They must be properly reconnected again before operations are resumed.
 The operator must adapt the travel speed to the given conditions.
 To travel up or down a slope, the work equipment must be on the uphill side of the machine and the boom
or mast must point straight to the grade.
 Travel straight to the grade only -never zigzag!
 Travelling in reverse over longer distances must be avoided.
 SWL, and hoist limit of the crane should not bypass or removed. And it should be verified by the operator
before starting the work. if two machines work too close to each other , it should have accepted safety
method to prevent collide each other
6.2. Operation in Vicinity of Unstable Ground

 Where possible, the machine must be kept at a safe distance from the edges of slopes, banks, uneven
ground, pits, etc. Where work near such areas is necessary, special safety precautions must be taken:
The contractor or his agent shall have the ground evaluated for stability. Clearance distances for the
machine must then be determined, and the operators informed.
In particular, it should be noted that:
o the ground near a slope, pit, etc. could collapse
o Care must be taken on earth ramps so that the machine remains on the compacted travel path.
Failure to observe the above could result in a crawler sinking, and/or the machine tipping over.
 When working in the vicinity of an edge of a slope, bank, pit, etc., the machine must be secured against
shifting, sliding or rolling down.
6.3. Travel Routes

 The travel routes for the machine must be laid out in such a manner that safe and efficient operation can
be maintained at all times. In other words, the routes should be sufficiently wide, have the least possible
slope and be on firm ground.
 If the route is laid on bridges, on top of basements, vaults, etc., the bearing capacity thereof must have
been tested for safety.
 If the route is laid out through underpasses, under bridges, tunnels, etc. the clear widths and heights
thereof must have been checked for safety.
7. Signalmen and Hand Signals for Controlling Operations

 Whenever the operator's view of the travel and/or work area of the machine is obstructed, he must be
assisted by hand signals from a signalman, or the travel and work area must be blocked off with rigid
barricades.
 Only employees who are dependable, trained and qualified may be used as signalmen. They must be
instructed in their tasks prior to the beginning of the operations.
 The signals to be used in the communication between operator and signalman must be established before
operations begin.
 Signalmen must be clearly identified by the special colors of hardhats, armbands and other distinguishing
marking.
 Signalmen may not be engaged in any other activity which could divert their attention from assisting the
operator. They must remain within the operator's sight during the operations.
 Should a signalman disappear from the operator's sight, the operator must stop immediately.
 If it is necessary to give the operator instructions other than those provided by the established hand
signals, the machine must be stopped.
Hand Signals for Controlling Crane Operations

NOTICE: The signalman shown in the following is facing the operator
CAUTION EMERGENCY STOP!

Arm extended upward, hand open With arms stretched, wave repeatedly in and out
DISTANCE STILL TO MOVE

START MOVING
With hands held open in front of body, indicate the
With arm extended upward, hand open,
horizontal distance
wave in and out
Remaining up to “stop”
DISTANCE STILL TO MOVE

STOP MOVING With hands held open in front of body,
Arms extended horizontally indicate the vertical distance remaining
up to “stop”
TRAVEL SLOWLY FORWARD TRAVEL SLOWLY REVERSE

With forearms vertical, hands open; With forearms vertical; hands open,
make pulling motions in direction of travel make pushing motions in direction of travel
TRAVEL TO RIGHT TRAVEL TO LEFT

With right hand on waist, With left hand on waist, point with right thumb in
point with left thumb in direction of travel direction of travel
SWING TO RIGHT SWING TO LEFT

With left thumb pointing in direction of swing, move With right thumb pointing in direction of swing, move
right forefinger in small circle left forefinger in small circle
HOIST LOAD/WORK EQUIPMENT LOWER LOAD/WORK EQUIPMENT

With right forefinger pointing upward, move left hand With right forefinger pointing downward, move left
up and down in front of body hand up and down in front of body.
DECREASE OPERATING RANGE

INCREASE OPERATING RANGE
Fists in front of body, thumbs pointing toward each
Fists slightly raised, thumbs pointing outward
other
OPEN GRAB CLOSE GRAB

With left hand on waist, stretch out right arm with With left hand on waist, stretch out right arm with
hand open downward hand closed
8. Operation in Vicinity of Underground Lines

 Prior to beginning work in the ground, the contractor is to ascertain whether there are underground lines
(electric power, gas, oil, water) in the designated work area.
 The contractor or the persons responsible for the job, such as supervisors or foremen, should get
information from any possible owners or users about the existence of lines on the site. Owners or users
would be e. g. states, cities, districts, communities, utility companies, industrial plants, transport
companies.
 In case there are underground lines, necessary arrangements must be made with the owner or operator
of the lines to determine the location and courses thereof, to decide upon the safety measures to be taken
and to provide the proper protection of the lines and the employees.
 Detailed plans on the location and courses of the lines must be provided by the contractor or his
representatives. The plans must be kept at the construction site and be readily accessible to the
employees.
 Supervisors, machine operators and attendants are to be reviewed on the location of the lines and the
required safety measures. Such reviews should be given by authorized representatives of the owner or
operator of the lines as required.
 The courses of the lines in the work area are to be clearly identified, under supervision, before the start
of earth-moving operations.
 If the courses of the lines are not clear, they have to be traced by means of careful ditching.
 Excavation with a machine must not be permitted closer than 50 cm to an underground line!
 If other companies are at work simultaneously near the lines, the respective contractors or their
representatives must agree in advance on the coordination of work procedures and safety measures to
be taken. It may be useful to have such agreements put down in writing and kept available at the
construction site.
 If a line, or a protection thereof, is encountered unexpectedly, or damaged by accident, the operator must
promptly stop operating and inform his supervisor.
 The owner or operator of the line must be notified. It may be required that excavation work be stopped
until a representative of the owner or operator of the line arrives.
 Exposed lines are to be fastened, supported or restrained in such a manner that they may not sway, slide
or shift.
9. Operation in Vicinity of Overhead Power lines

To operate with the equipment in the vicinity of an overhead power line or live wire, no part of the machine, work
tools or suspended load may be capable of coming within the following minimum distances, to prevent an
accidental contact.
Table 7 : Minimum distances from live lines and components
Nominal system voltage of the line: Minimum clearance distance to be kept:

Up to 1000 V 1.00 m
1 kV through 110 kV 3.00 m
If voltage is unknown 5.00 m
 To prevent equipment encroaching the above minimum distances, the operator must also take the
following factors into consideration:
 Machine conditions such as the position of the boom, rope sway caused by the machine in motion,
dimensions of suspended load or tool, etc.
 Ground conditions; uneven ground can cause the machine to tilt so that the distance to the line will be
reduced.
 Wind conditions; wind gusts can cause both the line and the suspended load or tool to sway so that the
distance will be reduced.
 In case the above clearances cannot be maintained, the contractor must take other measures, in
agreement with the owner or operator of the line, to protect the equipment and persons from electrical
current.
The adequate measures can be, for example:
o To de-energies the line.
o To string the particular sections of the line safely out of way.
o To place stop-logs or barriers limiting the equipment operating range.
 If an electrical charge is induced in the equipment, the operator must raise, lower or swing the respective
part of the equipment out of the energized area, or travel out of the area. If that is not possible, he must
keep the following rules:
o Not leave his position in the cab.
o Warn people around not to touch the equipment.
o Give orders to shut off the power.
10. Accidents with Electricity -First Aid

If a person gets an electric shock, start emergency measures at once!
 Cut off the power at once!
o With low voltage (e. g. 220/380 V): Cut off the power at once! Switch off, unplug, and remove
fuses. If that cannot be done immediately, do the following: Isolate the person from the electric
source or electrified substance by placing a non-conductive material (e. g. a wooden board) in
between, or take hold of the person's clothing and pull him away. Take care to be sufficiently
insulated (e. g. with a dry board, dry clothing, a thick newspaper under your feet) and not to come
into contact with other objects (e. g. a wall, a scaffold, other persons).
o With high voltage (more than 1000 V): DANGER! The power must be cut off, but only by a
qualified electrician! Do not touch (neither physically nor with an object – not even if insulated)
the electrified person, or get close to him, until the circuit has been broken.
 Secure the person from falling, or catch him!
 Check the person's breathing: If it has ceased, begin with mouth to mouth resuscitation at once.
 Examine his blood circulation: If there is cardiac arrest (no pulse to be felt at the main artery in the neck,
dilation of the pupils), immediately give cardiac massage on his chest together with the respiration. The
cardiac massage may be given only by a trained person.
 If he is burnt or his clothes are burning: Quickly put out the fire with water or (wet) blankets, cloths, etc.
or by rolling the person over the ground. Remove any clothes from burns, but only where they are not
sticking. In case of burns from steaming water (scalds), remove all clothing at once. Apply burn dressings
onto injured parts. If such dressings are not available, use clean linen.
o Do NOT apply ointments, powders etc. to burns!
11. Leaving the Equipment Unattended

When leaving the equipment for a work break or after termination of operations, the equipment must be shut down
and secured against accidents and abuse. Therefore, the following steps must be carried out:
 Before leaving the cab, the operator must
o park the machine on firm and level ground, safely out of way of traffic -the equipment must not
be an obstacle to traffic on the jobsite or a public road
o put any tool or suspended load on the ground
o apply all brakes
o set each control to off
o switch off the engine and all hydraulic motors
o Remove the ignition key and close cab windows.
 Before leaving the equipment, the operator must then
o lock the cab door
o place wheel chocks under crawlers, if the ground is uneven
o Place guards around the equipment -such as warning triangles, cones, barrier tapes, flashing or
glowing lights -to identify the location of the equipment where necessary.
12. Load Handling

"Load handling" means here any lifting, moving and lowering of load suspended by wire rope, chains, slings etc.
to the load line or hook, and for which the operator needs assisting people to engage and disengage the load.
 The load must not exceed the machine's capacities.
 Lifting-eyes, shackles and suspension slings used must have sufficient capacity and be in good working
order.
 all lifting gears and Lifting machines should be undergone to Third Party Inspection test according to the
Sri Lankan factory ordinance
 The load must be fastened and distributed in such a manner that it cannot slide, shift or tip.
 Persons assisting the operator must stay in his view at all times during the operation.
 The operator must move the load very slowly, to avoid its swinging, and must not move it above other
people.
 The load must be kept as low as possible and must not drag over the ground or objects.
 Travel with load suspended to the machine is permitted only where the travel path is firm and level.
 Hoisting equipment must never be used to lift persons.
13. Assembly, Maintenance and Repair

13.1. General
Assembly, installation, setting, adjusting, inspection, maintenance and timely replacement of parts on the
equipment must be performed in accordance with the instructions given in the manual.
Personnel:
 Personnel must comply with the safety regulations set forth for the type of job in question. It is the
responsibility of the contractor using the equipment to inform personnel accordingly of accident prevention
and environment protection and to see to that the applicable national safety codes are followed.
 Personnel must wear the appropriate personal protection required for the job, such as protective clothing,
safety glasses, gloves, protective shoes etc. Hard hat (protective helmet) is a must with any kind of
assembly, maintenance, inspection and repair! Clothing must fit tightly enough not to catch on protruding
or rotating parts. Long hair must not be worn loose, and rings, bracelets and necklaces must be removed.
 The persons carrying out the job must be qualified, familiar with the equipment and have been assigned
by the contractor.
 The assigned persons must be briefed on the job and their tasks before they begin, and one person shall
be designated to supervise the job
Work area and tools:

 The area required for the job must be closed-off to unauthorized people where necessary; the closed-off
area must be of adequate size.
 Tools and auxiliary devices used must fit the action and be in good working order.
Equipment control:
The equipment must be shut down while repairs or adjustments are being made unless operation of the equipment
is required in making the repairs or adjustments.
 The prescribed maintenance jobs must not be carried out on equipment in operation or machine in travel
unless the manual gives other instructions.
 The equipment controls must be applied, set to On, Off or Neutral in compliance with the instructions
given in the manual for the job in question.
 Once the equipment has been shut down for maintenance or repair, accidental restarting must be
prevented by
o locking all main controls, such as the engine ignition, and removing the keys
o And/or placing warning tags on main switches.
 If operation of the equipment is required in making repairs or adjustments, the following rules must be
adhered to:
o The servicing person shall not be allowed to perform on his own: he must be assisted by the
equipment operator at all times during the job!
o Both the servicing person and the operator must be fully aware of all the hazards involved and
take the proper safety precautions.
o A reliable system of communication between the servicing person and the operator must have
been established before the job is begun.
o The work area must be sufficiently illuminated.
o The operator must keep his position at the equipment controls, watch over the servicing person
and have direct access to the emergency stop button at all times.
 Only when the equipment is completely shut down and safely secured against accidental restarting and
movement may a servicing person work on the equipment without the assistance of an operator
positioned at the equipment controls.
Lifting
 If parts or assemblies are to be lifted, the hoisting equipment used must fit the action, have sufficient
capacity and be in safe working order.
 Heavy parts or assemblies to be mounted or removed must be safely restrained by hoisting equipment.
 Only skilled persons may engage load to hoisting equipment and give hand signals or audible assistance
to control load-handling operations; the assisting person(s) must stay within the operator's sight or
hearing.
 Load must be safely secured and shall not be moved over persons; persons must keep out of the load-
handling area. No personnel shall be allowed to work under a suspended load.
Access ways
 Where permanent stairways, steps and work platforms are provided on the equipment they must be used;
climbing or standing on equipment parts is forbidden. Where permanent access ways are not provided,
adequate ladders, ramps or platforms meeting the safety requirements must be used to provide safe
access to the elevation required.
 Personnel working on an unprotected and high elevation must wear a body belt attached to a lifeline.
 Stairways, treads, handrails, ladders, platforms etc. must be maintained free of mud, grease, snow and
ice to permit personnel safe access.
 If a hammer or a wire brush is used to chip or scratch office or mud, the person carrying out the job should
wear safety glasses to protect his eyes.
Cleaning and inspection

 The respective parts of the equipment, couplings and screwed connections in particular, must be
thoroughly cleaned free of oil, fuel and treating agents before maintenance or repair is begun.
 Detergents used must not be harmful to the equipment material. Rags or cloths used for cleaning must
be lint-free.
 To clean with compressed air, the person carrying out the job must wear eye protection and protective
clothing. The air pressure must not exceed 2 bar.
 Before using water, steam jet or other methods to clean the equipment, all openings where introduction
of water/steam/detergent/etc. could affect operating safety or functions of the equipment must be
thoroughly covered up/masked -electric motors and control cabinets in particular.
 The equipment must be rendered totally free of all the applied covering/masking after it has been cleaned.
 After having cleaned the equipment, it is necessary that all fuel, engine oil and hydraulic lines be inspected
for leaks, loose connections, scrubbed parts and damage. Any defects found must be repaired without
delay.
Reinstalling
 If screwed connections are loosened or opened up during assembly, maintenance or repair, they must
be properly reconnected and retightened after completion of the job.
 If guards or safety devices are removed during assembly, maintenance or repair, they must be promptly
reinstalled and rendered in proper working order as soon as the job is completed.
Waste materials
 It must be ensured that all discarded parts and waste material are properly disposed of, in an environment
protecting way.
 waste material must be segregated and need to hand over to authorized person or institute in the area
13.2. Supervision
Assembly, modification or disassembly on this type of equipment may be carried out only under direct supervision
by a person who has been designated by the contractor.
13.3. Stability
 Stability of the equipment must be guaranteed at all times of an assembly, maintenance or repair job.
 To mount or remove components which could cause changes in the weight distribution on the equipment,
additional adequate support of the equipment must be provided.
 Counterweights may be lifted only at the places prescribed by the counterweight manufacturer.
 To jack up the equipment, the jacks used must be placed in such a manner that they cannot slide away.
Jacks must stand upright and be applied square to the body of the equipment.
 Jacked-up equipment must be underpinned with square timbers laid crosswise, or with steel trestles.
 It is prohibited to work underneath hydraulic equipment which is supported by its hydraulics only. After
having lifted such equipment, it must be safely underpinned before assembly, maintenance or repair is
begun; otherwise, the equipment can fall violently in case a lever is touched by accident or if a hydraulic
hose or line disengages.
13.4. Drive Engine

 The engine must be shut off before maintenance or repair is begun and during refueling.
 With equipment using a combustion engine, the battery must be disconnected from the electrical system
before service is carried out on an unprotected part thereof, to avoid accidental reconnection and starting.
 Only services which require that the drive or electrical charge is on may be carried out with the engine
running and the battery connected.
13.5. Work Equipment

 The equipped appliances used for working with the machine must be placed safely on the ground or be
safely secured by clamps, trestles, bracings etc., so they cannot move or shift during assembly,
maintenance or repair. The upper carriage should be swing-locked and secured to prevent rotation as
required.
 Such measures can be necessary where a boom or mast is to be assembled / disassembled or lifting or
hoisting equipment is to be serviced. Hydraulic-driven work equipment can be secured by limiting the
stroke of the respective piston (using a clamp, stop-pin etc.).
 Mast sections and boom inserts must be supported during assembly / disassembly; it is prohibited to carry
out any job underneath them unless they are safely supported.
13.6. Protective Parts

 Protective parts such as guards for moving components of the equipment (like engine shields, doors,
gratings, covers. etc.) may be removed only when the equipment has been shut down and secured
against accidental restarting.
 Protective caps and covers must remain installed as long as possible and be removed only just before
assembly, maintenance or repair is begun.
 All removed protective parts must be reinstalled immediately after the job is finished.
 If the equipment is to be maintained / repaired outside the operator's cab while the engine is running, the
operators left control console (or the pilot-oil control stick) must be raised to shut off the hydraulic functions
of the machine.
13.7. Hydraulics and Pneumatics

 Only persons trained in hydraulics may carry out maintenance or repair on a hydraulic installation of the
equipment.
 All lines, hoses, fittings and connections must be regularly inspected for damage. Any damage recognized
must be repaired immediately.
 Oil spraying from a leak can cause injury and fire.
 Hydraulic systems as well as lines with compressed air must be depressurized before they are opened
up for maintenance or repair. Any equipped containers or cylinders which are under pressure require
extremely careful handling.
 Hydraulic and pneumatic lines require absolutely correct assembly and mounting by skilled persons.
Couplings or screwed connections must not be mixed up. Hose fittings, lengths, tube size and quality
must meet the operating requirements.
 Safety or pressure relief valves in hydraulic or pneumatic systems may be set/ readjusted only with the
manufacturer's permission.
 Incorrectly adjusted safety valves can cause excessively high working pressures which will result in
damage to hoses, fittings, lines and connections.
 The hoses used must comply with the equipment manufacturer's recommendations.
13.8. Welding, Cutting and Grinding

 General requirement: Only qualified and experienced welders shall be permitted to weld on the
equipment.
 Welding on load bearing members of the equipment may be carried out only by the manufacturer or by
an authorized workshop.
 Welding, cutting or grinding on the equipment may be initiated only with special work permit and where
there is no danger of fire or explosion.
 Before welding, cutting or grinding is begun, the equipment and the surrounding area must be made free
of dust and combustible materials. Adequate ventilation must be provided to prevent risk of explosion.
 Welding machine should have a body earth and it should be powered trough safe DB . And Gas cutter
should have non return valve to its touch and cylinder. And grinding wheel should be guarded adequate
and safely.
13.9. Electrics
 Only genuine fuses of the prescribed amperage should be used. If there is a fault in the electric power
supply, the machine must be shut down immediately.
 Electrical equipment and wiring must be protected against moisture. Cables must be protected against
mechanical damage (vehicular traffic e. g.).
 Work on electrical equipment may be carried out by experienced electricians only, or under direct
supervision by an experienced electrician, and in compliance with electrical safety rules.
 Machines and equipment to be inspected, maintained or repaired must be switched off where prescribed.
The suspect part must be tested so that it is free of electrical charge and the remaining circuit be bonded
to a "short" and be grounded. Surrounding components for which the power cannot be switched off must
be isolated.
 When a cable is unplugged, dust cap must be placed on both the plug and the socket.
 All electrical apparatus on the equipment must be regularly inspected/tested. Any defects found such as
loose connections or scorched cables must be corrected without delay.
 If it is required to make a repair, adjustment etc. on a component with the power switched on, the servicing
person must be assisted by a second person who may cut off the power at once in case of an emergency.
The work area must be closed off with white and red barrier chain and a warning sign. Tools used must
be insulated.
 If it is required to carry out a job on a high-voltage assembly, the power supplying cable must be removed
from the power source and be grounded with a rod. The assembly components (such as capacitates)
must also grounded.
13.10. Noise
 All equipped sound insulating covers must remain on the equipment while it is in operation.
 Personnel must wear the prescribed hearing protection.
13.11. Oils, Greases and Chemicals

 Oils, greases and chemicals used shall be handled in compliance with their producer's specifications and
recommendations.
 Bottles containing oxygen, acetylene or fuel gases shall not be stored or taken into the vicinity of oils and
greases (danger of explosion!) and must not be exposed to extremes of temperature (sunshine).
 Extreme caution must be exercised in the handling of hot liquids, to prevent scalds and burns.
 Oil and grease cans used must be clean and have a closing lid.
 Filler openings and lube nipples on the equipment must be thoroughly cleaned free of dirt and old grease
before they are refilled.
 Filler openings must be closed immediately after refilling, to prevent introduction of dust and dirt.
 Oil collecting containers of sufficient size must be provided before an oil change is begun, and the waste
oil must be properly disposed of.
 Only prescribed oils and greases may be used; see the lubricant guide in the manual.
 Lubricants used must be fresh, uncontaminated and not previously used.
 Should maintain a chemical log and MSDS for each and every chemical
 Before changing to an oil or grease of another brand, the compatibility of the two products must be
assured.
13.12. Replacement Parts

 Hydraulic installations are to be checked in accordance with the instructions given in the manual. When
it is necessary to replace a hydraulic hose or component, make sure that it is replaced by a genuine
BAUER spare part only!
 The use of genuine spare parts is mandatory for safety and shall apply also to all electrical and electronic
components as well as any load bearing members of the equipment, such as
o Bolts
o pins
o springs
o wire ropes
o boom or mast components
o Winches
 Apart from the regular service and maintenance jobs which are to be carried out in the prescribed
intervals, trained and experienced maintenance personnel may make repairs and replace worn parts
whenever necessary.
14. Travelling
14.1. Towing
The machine must NEVER be towed.
14.2. Transporting
 The vehicle (low loader or other suitable vehicle) used to transport the machine and accessories shall not
be loaded beyond rated capacity.
 Hoisting equipment used for loading/unloading must have sufficient capacity.
 Lifting slings used must be in good order and may be attached only by skilled persons and only to the
lifting-eyes provided for this purpose (see the manual).
 Surfaces on which a load will be placed must be free of mud, grease, snow and ice and support the load
safely.
 Warning signs must be posted where required.
 The operator must be assisted by a skilled signalman who helps control the operations.
 Any auxiliary devices used (like ramps, planks, blockings) must be secured against movement.
 Equipped (metal) ramp on low loader must be covered with wooden planking before the machine may
travel up or down it.
 Machine crawler tracks must be cleaned free of mud, snow and ice to prevent them skidding.
 All recommended/supplied devices for securing the machine and work equipment against unintended
movement must be applied during loading/unloading and transportation respectively, so that
o The upper carriage may not rotate
o The machine may not shift or slide

o The work equipment may not move.
 All tie-downs and blocking devices applied to secure the machine during transportation must be removed
before the machine is started.
 Any components which have been removed from the machine before transportation must be reinstalled
and put into in proper working order before the machine is used again.
14.3. Transport Route

The intended route should be inspected before transportation of the machine and accessories is begun, to
ascertain that the roads chosen are in a condition to safely support and accommodate the transport. Any bridges,
tunnels, overpasses and underpasses along the route must have sufficient bearing capacity, width and clear
height.
15. Routine Inspections

 The equipment is to be walk-around inspected for loose or missing bolts, pins and retainers, oil and fuel
spills, damage and recognizable changes at the start of each new shift.
 The operator must test all operating controls, indicators and displays for proper functioning at the start of
a new shift, and must observe the equipment performance for recognizable deficiencies during operation.
 Before applying hoisting equipment, the operator must test all relating safety devices (such as automatic
holding brake, warning and shut-off devices) for proper working order.
 If a deficiency is detected, the operator must promptly inform his supervisor thereof and also the next
operator when changing shifts.
 If deficiencies are found which affect operating safety, the equipment must be promptly shut down for
repair.
 Wire rope which is excessively worn damaged or on which wires are broken must be replaced with new
rope.
 Hydraulic hose on which a damage or soaked section is detected must be replaced with new hose.
 A new rope/hose must comply with the size and quality prescribed by the equipment manufacturer.
16. Test Inspections

 Equipment of this kind shall be thoroughly inspected and performance tested in the following intervals:
o Prior to initial onsite operation.
o Whenever the equipment has been modified, altered or has undergone extensive repair, including
reigning.
o At least once each 12-month period where the operating conditions are normal.
o At least twice each 12-month period where the operating conditions are extreme.
 The person conducting the inspection and performance tests shall be a licensed professional engineer
competent in the field, who has experience with this type of equipment and who is familiar will all the
relating safety standards and regulations, to be able to determine whether the equipment is in satisfactory
working order and in compliance with all requirements.
17. Personal Protective Equipment

All persons involved in work with this equipment must wear the following protective items:
 At all times on a jobsite:
Protective helmet ("hard hat")
Protective shoes or boots (Ankle Support Safety Shoes) or Gumboots
Hearing protection where the noise is > 85 dB (A)

 Additionally depending on the job
Work gloves when handling contaminated, hot, sharp or heavy materials
Protective glasses when welding or grinding, or cleaning with air jet
Respirator where dusts are created or the soil or air is contaminated
Reflective Jackets
18. Environment Protections

Note-Environmental control is cost-saving and helps saving our future and quality of life. Offences against
environmental regulations must be reported to the authorities!
18.1. Storage of Equipment / Plants

In water protection areas the regulations may be stricter
 Oil clinging to components must be removed (by water jet) prior to putting the equipment into storage.
Waste water containing oil must be cleaned by suitable separating appliances.
 Hydraulic couplings and hose ends must be thoroughly closed with blind plugs.
 The surface on which equipment / plants and hydraulic components are stored must be reinforced
(concrete or road construction style).
 Stored equipment must be regularly checked (weekly) for tightness, during the storage. Where storage
on a reinforced surface is not possible, no oil or fuel may escape into the ground.
18.2. Transporting
 Prior to transporting power packs, thoroughly close hydraulic couplings and hose ends.
 Oil collecting receptacles on power packs must be emptied before transporting.
 Lubricated stored material should be protected from rain, as oil can be mixed in to the environment with
the rain water.
18.3. Assembly / Disassembly, Service, Maintenance

 When mounting or removing hydraulic components, during oil changes and repairs, take care not to spill
oil into the ground.
 Place suitable receptacles of sufficient size underneath to collect oils / fuels.
 Keep refilling or draining of oil reservoirs / hydraulic lines under consistent observation.
 Recover oil spills with an absorbent.
 Store oil cans and drums in receptacles.
18.4. Biodegradable Oils and Greases

The use of biodegradable oils and greases is often prescribed for jobs in water protection areas and nature
reserves.
 Never mix fully synthetic liquids free of minerals or greases based on vegetable oils with greases based
on mineral oil. A thorough rinse-down is required before changing.
 Before changing over to biodegradable greases procure and observe the respective producers’
specifications of the grease products in question as to their compatibility with seals, hoses, filter systems
and paints on surfaces in tanks and reservoirs.
 A conversion of the above components, if so required, may be performed only after consultation with the
BAUER after Sales Service and upon the receipt of a written approval from the same.
18.5. Disposal of Waste Oil, Filters and Auxiliaries

 Dispose of waste oil in the manner prescribed by the local authorities. For proper disposal, mineral oil
must not be mixed with:
o Fuel (petrol, diesel, fuel oil)
o coolant antifreeze
o brake fluid
o vegetable oils (rape oil)
o oils based on glycol
o cleaners, chemicals, emulsions, forming oil
o products containing halogen, CKW, PCB
Upon consultation with the disposal agency in question, synthetic hydraulic oils based on ester (bio-oil) may in
general be disposed of together with mineral waste oil.
 Store drums or containers holding waste oil in an additional receptacle, or store the waste oil in reservoirs
that have a double wall.
 Leave waste oil to an authorized disposal agency only.
 Never dispose waste oil into the environment (ground, water, and sewer) and never mix it with other
wastes or have it incinerated in a plant that is not authorized.
 Leave coolant antifreeze, brake fluids, oil filters and hydraulic hoses to the appropriate agencies for
recycling or disposal.
18.6. How to Response to an Accident with Water Hazardous Materials

Should oil (or any other water hazardous material like fuel etc.) escape in spite of all the preventive measures,
immediately proceed as follows:
 Collect the oil, seal the leak.
 Immediately pick up oil spills with absorbent materials or oil absorbing rags.
 Block or cover up inlets to sewers (make barriers of soil or absorbents) where they are endangered.
 When a considerable amount of oil has escaped into a sewer system, immediately report it to the
respective clarification plant.
 Excavate the polluted soil as soon as possible and collect it in tight containers that have a closing top.
 Have the collected soil disposed of by an authorized agency, in compliance with the local regulations.
 Depending on the size of the accident, notify the authority in charge (environmental offences are notified).
18.7. Fuel / Refueling

 When transporting fuel, observe the regulations set forth for the transport of hazardous goods.
 When storing fuels in drums or cans keep them additionally in a receptacle, or store fuel in containers
that have a double wall.
Refueling
Refueling from a mobile station or from a tank truck is permissible only when the fuel is dispensed through an
automatic self-closing valve.
 Prior to refueling, check how much fuel the tank can accept.
 Do not fill up to more than 95 %, to prevent fuel flowing over when there is a temperature rise or when
the equipment is sloping.
 The engine and any auxiliary heater fitted to the equipment must be shut down during the refueling.
 Have absorbent materials ready!
 Keep the refueling procedure under consistent observation.
 Recover liquid spills with absorbents.
 In water protection areas the regulations may be stricter.
18.8. Fuel Consumption, Emissions

 Shut down the engine during lengthy work breaks, to avoid unnecessary emission of noise and exhaust
fumes and to reduce the fuel consumption
 To diminish the emission of S02 and to reduce the amount of soot particles, operate the equipment with
sulfur-free diesel.
18.9. Contaminated Areas

 For maintenance and repair on equipment that is or has been in use in contaminated areas, do by all
means tell the maintenance personnel / BAUER mechanics with what kind of materials and to what extent
the equipment is polluted.
19. Specific Requirements for Safe Operation

In addition to the foregoing, each type of earthmoving equipment has its own specific safety requirements which
must also be met. The different types of equipment and their specific requirements are given in the following.
19.1. Rotary Drill Rigs

Start-Up: On crawler-mounted rigs, the crawlers must be extended to the maximum track gauge
o before counterweights are mounted
o before the mast is raised
o before drilling operation is begun
o Before the rig's auxiliary winch is applied.
 Counterweights must be completely assembled to specified weight and be properly mounted to the rig's
carrier machine before the machine is put to use.
 All rig functions must be tested for proper working order before start of operations.
Rigging, Maintenance and Repair:

 Load handling, such as lifting of drilling equipment during rigging and derigging or lifting of reinforcement
cages during drilling, may be carried out with the auxiliary winch only. The load must not exceed the rig's
capacities (see load capacity charts in the manual) and may be lifted in the vertical only; sideways
dragging of load is prohibited.
 Equipped crowd winch with sledge must never be used for load handling as this could endanger the
stability of the rig.
 When mounting a drilling tool to the rotary drive, all bolts, pins and retainers provided for the purpose
must be fitted -with no exemptions and at all times.
 The rig must never be serviced, maintained or repaired while it is at an open borehole! Before making
any service, adjustment or repair on the rig it must be travelled away, be parked at a safe distance from
the borehole and be shut down and secured against accidental restarting. Any additional installations and
power suppliers used must also be shut off and secured.
 None of the equipped winches or the rotary drive may be used as a personal hoist or lift, not even for
assembly work on the mast.
Danger Zone
 Persons must keep out of the danger zone of the rig.
o Rig danger zone during drilling
o Rig danger zone during travel
 At all times, make absolutely sure that the above danger zone (travel path, swing area) is free of persons
before moving the rig.
Only when the rig has been brought to a stop on the site of operations, has been aligned and is stationary (i. e.
when no more travel or swing motions will be carried out), may personnel enter the work area.
Operation:
 Adequate outdoor lighting must be provided at all times in all areas where the rig is used.
o Minimum illumination intensities for construction operations can be found in the national or
international safety standards, under "work area lighting intensities" or similar wording. In
addition, consideration must be given to type and proper placement of the lights so that glare,
dark shadows etc. are eliminated and safe operation is provided.
 The operator is the only person authorized to stay at the rig while it is in operation.
 The mast of the rig must be set to the required angle of inclination before drilling is begun. Once drilling
is in progress, the mast must not be repositioned unless it has been displaced by hard rock, boulders etc.
 With a drill string bored into the ground, or with a casing oscillator in operation, the carrier machine must
be kept absolutely stationary (i. e. no travel, no swing).
 Any hoses (mud and hydraulic) and cables must be safely out of way before travel is started; they must
not be driven over.
 Completed, open boreholes which are not under direct and consistent supervision must be protected by
a cover of sufficient bearing capacity.
o To be safe for personnel to tread on, the cover should have at least 100 kp/sq.m bearing capacity
and be secured against movement. Its surface must be slip free and stumble free to permit
personnel safe passage.
o No vehicular traffic whatsoever shall be permitted on a borehole cover.
 Wherever a safely supporting cover is not practicable, barricades must be erected around the borehole,
at a safe clearance distance there from.
 Heavy material must not be stored or taken into the vicinity of a borehole, to prevent the ground and the
bore hole collapsing.
Work Breaks, Termination of Work:

 The rig operator must never leave his control position (operator's cab) while the rig is in operation. Before
an intended break, the operator must shut down the rig and secure it against movement, accidental
restarting and abuse. Abuse can be prevented by removing the engine ignition key, shutting off any
additionally used power suppliers and locking the windows and door of the cab.
Rigging, Maintenance and Repair:

 Load handling, such as lifting of pile driving and pulling equipment during rigging and de-rigging, may be
carried out with the auxiliary winch only. The load must not exceed the rig's capacities (see load capacity
charts in the manual) and may be lifted in the vertical only; sideways dragging of load is prohibited.
 Equipped crowd winch with sledge must never be used for load handling as this could endanger the
stability of the rig.
 When mounting pile driving and pulling equipment to the rig, all bolts, pins and retainers provided for the
purpose must be fitted -with no exemptions and at all times.
 At all times, make absolutely sure that the above danger zone (travel path, swing area) is free of persons
before making a move with the rig
 Only when the rig has been brought to a stop on the site of the operations, has been aligned and is
stationary (i. e. when no more travel or swing motions will be carried out), may personnel enter the work
area.
Operation:
 Adequate outdoor lighting must be provided at all times in all areas where the rig is used.
 Minimum illumination intensities for construction operations can be found in the national or international
safety standards, under "work area lighting intensities" or similar wording. In addition, consideration must
be given to type and proper placement of the lights so that glare, dark shadows etc. are eliminated and
safe operation is provided.
 Pile driver and vibrator operations require that the work area be illuminated with at least 100 Lux.
 Personnel must wear the appropriate protective equipment. Adequate hearing protection is of great
importance during work with a pile driver or vibrator.
 The operator is the only person authorized to stay at the rig while it is in operation.
 The mast of the rig must be set to the required angle of inclination before operation is begun. Once
operation is in progress, the mast must not be repositioned unless it has been displaced by hard rock,
boulders etc.
 With a pile element suspended to the pile driver/vibrator and driven into the ground, the carrier machine
must be kept absolutely stationary (i. e. no travel, no swing).
 A vibrator and its clamps must never be used for load handling.
 The rated maximum permissible line pull must never be exceeded; see the specifications given in the
manual.
 With dynamic pulling equipment which operates with hydraulic or mechanical-driven holding clamp(s), the
suspended pile element (unless it is cast in situ) must be engaged to the pulling equipment with an
additional tagline, sling or similar device of the same capacity as the clamp(s) holding the load.
 Any hoses (mud and hydraulic ones) and cables must be safely out of way before travel is started; they
must not be driven over.

 The rig operator must never leave his control position (operator's cab) while the rig is in operation. Before
an intended break, the operator must shut down the rig and secure it against movement, accidental
restarting and abuse. Abuse can be prevented by removing the engine ignition key, shutting off any
additionally used power suppliers and locking the windows and door of the cab.
 The rig must never be left behind with a pile element freely suspended to the mast or to a vibrator.
 It is prohibited to leave vibrator or pile driving and pulling equipment clamped to a pile element which is
in the ground unless the equipment is held suspended by a lift-crane. Exemption is permitted only when
the pile element is supported in a profile locking and has been driven so far into the ground that stable
and safe support of the equipment is provided.
Operation:
 Adequate outdoor lighting must be provided in all areas where the equipment is used, at all times:
o Minimum illumination intensities for construction operations can be found in the national or
international safety standards, under "work area lighting intensities" or similar wording. In
addition, consideration must be given to type and proper placement of the lights so that glare,
dark shadows etc. are eliminated and safe operation is provided.
 The operator is the only person authorized to stay at the machine while it is in operation.

 The equipment operator must never leave his control position (operator's cab) while the equipment is in
operation. Before an intended break, the operator must shut down the equipment and secure it against
movement, accidental restarting and abuse. Abuse can be prevented by removing the engine ignition
key, shutting off any additionally used power suppliers and locking the windows and door of the cab.
 Wheel chocks must be placed under machine crawlers where the ground is sloping, to prevent motion, in
addition to the hydraulic parking brakes being applied.
20. References
 Safety Information Bauer Doc No SIC0030E
 Health and Safety control Plan, Access Engineering PLC, January 2008.
 Safety, Health and welfare on Construction sites, International labor office, Geneva.
 Construction Safety and Environmental management Program by The office of Health and Safety by
Brown University.
 Construction Safety Manual by Metropolitan Washington Airports Authority.
ANNEX – D: SEQUENCE OF PILING PROCESS

TYPICAL PILING PROCESS
Setting out of pile location.

Make 03 offsets of drilling location.
Pre Drilling with soil auger up to 3~4 m.
Tool used - Soil Auger of required diameter
Installation of temporary Steel

Casing with the rotary drive.
Casing attached to casing driving adaptor in rotary

head by two pin connections. Then Casing pushes
and drives up to the required depth.
Temporary casing thickness= 12/16 mm

After Installation of Temporary casing, Casing

position and verticality shall bechecked.
Maximum Permitted deviation of the pile

center = 75 mm in any direction
Verticality
Maximum permitted deviation of the pile from the
vertical is 1 in 75.
Note- As per the ICTAD / DEV/16
Excavation of the soil with drilling bucket

Stabilized the borehole with bentonite slurry.
Too used - Boring Bucket with appropriate diameter
Bentonite properties shall be checked as per the

Specifications
Coring of rock with bullet teeth Core Barrel

Once reach the hard rock, Samples and depth
should check with the engineer.
With the confirmation of engineer, hard rock socketing

starts with core barrel.
Tool used - required diameter Core Barrel with round
shank chisel.
This will be used to core the rock of which Uni-axial
compressive strength < 80 MPa
Coring of rock with roller bit Core Barrel

Tool used - required diameter Core Barrel with round
shank chisel.
Cutting ring with staggered arrangement of roller bits

Screw-on type roller bit system. strong rock (more
than 100 MPa)
Vertical Transport of Soil/ Excavated Rock
Tool is mounted on telescopic Kelly bar; It is used as

drilling tool and as transport medium.
Cleanliness of Pile Base

Tool Used - Cleaning Bucket
Drilling Bucket With Cleaning Edge
Once drilling is finished, drilling bucket with cleaning

edge is used to clean the pile base.
Rebar Cage Installation
After cleaning the pile base, rebar cage for the design
depth is lowered in to the bored hole.
Rebar cages are joined by welding method.
Rebar beyond pile cutoff level are covered with PVC

pipes for protection.
Pile concreting method using tremie pipes
Narrative : BORED PILING WORKS

1 Construction of Working Platform
2 Positioning of Casing and Soil Boring
3 Rock Excavation for socketing of Pile
4 Rebar Cage Installation
5 Concreting using Tremie pipes
6 Temporary Backfilling
7 Pile Head Treatment
ANNEX – E: OTHER DOCUMENT FORMATS

ANNEX – F: MSDS OF BENTONITE

ANNEX – G: CROSS HOLE SONIC LOGGING

TEST FOR BORED PILES
ANNEX – H: LOW STRAIN PILE INTEGRITY

TEST (PIT)
ANNEX – I: HIGH STRAIN DYNAMIC LOAD

TEST (PDA)
ANNEX – J: COMPANY PROFILE OF TESTING

AGENCY

MWPP Accss Civ PRD 0004 RG Eddited

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Page No: Page 1 of 235

Method Statement for Construction MWPP-ACCSS-CIV-

METHOD STATEMENT FOR CONSTRUCTION

CONSTRUCTION OF 100MW SEMI DISPATCHABLE WIND

Client: Main Contractor: BoP Sub Contractor (Civil):

Revision Date Changes Overview Remarks

A 10/01/2019 Initial issue

B 18/01/2019 ITP included.

E 06/05/2019 Addressed Vestas comments

F 02/06/2019 Addressed CEB comments in DTS 33

G 01/08/2019 Addressed Vestas comments

Dinidu Priyankara QA/QC Manager

4.3. Pile Boring ....................................................................................................................................................... 22

6.3. Travel Routes ............................................................................................................................................... 104

20. References .............................................................................................................................................125

Comments Reply Sheet

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DTS 068 COMMENTS AND REPLY

Document Comments (by CEB) Access Reply

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5. Static load test shall be done as per

8. Deformations are required to develop

Document Comments (by CEB) Access Reply

In any requirement where necessary

16. On site calculation shall be submitted for 16. Noted.

Document Comments (by CEB) Access Reply

23. Acceptance criteria shall be based on site 23. Not clear

Document Comments (by CEB) Access Reply

30. Above items shall include fulfilling the 30. Noted.

34. Calibration reports for the testing

35. The initial test reports and raw data

37. Final reports of the CSL test shall be

Item Description Unit Quantity

2.1.1 Test pile

Item No. Description Unit Quantity

3.2. Manpower list per team

4.1. Drilling Sequence of Single WTG Foundation

Figure 1: Sequence of pile foundation construction of single WTG location

4.2. Preliminary Survey &Driving temporary steel casing

Figure 2: Working Platform Preparation for piling work

4.2.2 Pre-Drilling and Driving Temporary Casing

4.2.3 Maximum Permitted Deviation

4.3. Pile Boring

4.3.2 Drilling Fluid

4.3.3 Boring Near Recently Cast Pile

Characteristics for Bentonite Suspensions

Figure 3: Bentonite Slurry Sampler and Working Principle

4.3.5 Drilling Termination

Figure 4: Cover Block Details – Plan View

Figure 5: Cover Block Details – Section Y-Y

4.4.3 Placement Rebar cage

4.5. Cleaning and Concreting Bored Pile

4.5.2 Working sequence of pile base cleaning in flushing stage

Figure 6: Bauer De-Sander BE 170 and Bentonite Mixer BM 10