PIPELINE REROUTING WORKS

FOR VISHAKHA NEW WHITE OIL

TERMINAL,VIZAG,AP

Project No. Unit Doc.Type Mat Code Serial No. Rev. Page
W-343 ON CP 0000 001 01 1 0f 19

PROCEDURE FOR PILING WORKS

Hindustan Petroleum Corporation Ltd.

PIPELINE REROUTING WORKS FOR VISHAKHA NEW WHITE OIL TERMINAL, VIZAG, AP

Procedure for Piling Works

For

PIPELINE REROUTING WORKS FOR VISHAKHA NEW WHITE OIL TERMINAL, VIZAG, AP

0 11.12.2017 Issued for review BB BB GV GV

REV. DATE DESCRIPTION PREPARED CHECKED APPROVED PROJ.
BY BY BY MANAGER
(Initials) (Initials) (Initials) (Initials)
DOCUMENT REVISIONS
Sections changed in last revision are identified by a line in the right margin
 PIPELINE REROUTING WORKS
FOR VISHAKHA NEW WHITE OIL
TERMINAL,VIZAG,AP

Project No. Unit Doc.Type Mat Code Serial No. Rev. Page
W-343 ON CP 0000 001 01 2 0f 19

PROCEDURE FOR PILING WORKS

TABLE OF CONTENTS

1. INTRODUCTION .............................................................................................................................. 3
2. SCOPE OF WORK ...................................................................................................................... 4
2.1 Purpose of this document ................................................................................................................ 5
2.2 Definitions ..................................................................................................................................... 5
2.3 Abbreviation .................................................................................................................................. 5
2.4 References ..................................................................................................................................... 5
3. QHSES ........................................................................................................................................... 6
3.1 QHSE considerations ....................................................................................................................... 6
3.2 QA / QC considerations ................................................................................................................... 6
3.3 Document Responsibilities ............................................................................................................... 6
4. EQUIPMENT SPREAD ...................................................................................................................... 6
5. TECHNICAL INFO ............................................................................................................................ 7
6. GENERAL ....................................................................................................................................... 7
6.1 Soil and Site Conditions ................................................................................................................... 7
6.2 Codes and Standards ....................................................................................................................... 7
7. OBJECT .......................................................................................................................................... 8
8. PILING WORK ................................................................................................................................. 9
8.1 General.......................................................................................................................................... 9
8.2 Materials ....................................................................................................................................... 9
8.3 Concrete Mix ................................................................................................................................ 10
8.4 Mixing ......................................................................................................................................... 10
8.5 Concrete ...................................................................................................................................... 10
8.6 Workmanship ............................................................................................................................... 10
8.7 Construction of Pile ....................................................................................................................... 11
8.8 Replacement of Defective Bored Piles ............................................................................................. 14
8.9 Basic Properties of Drilling Mud (Bentonite)..................................................................................... 14
8.10 Testing of Concrete ....................................................................................................................... 15
9. INTRODUCTION OF DMC PILING METHOD ...................................................................................... 15
10. TASK PLAN ................................................................................................................................... 17
 PIPELINE REROUTING WORKS
FOR VISHAKHA NEW WHITE OIL
TERMINAL,VIZAG,AP

Project No. Unit Doc.Type Mat Code Serial No. Rev. Page
W-343 ON CP 0000 001 01 3 0f 19

PROCEDURE FOR PILING WORKS

1. INTRODUCTION

Hindustan Petroleum Corporation Limited, a Government of India Enterprise, is a Global Fortune

500 Energy Company involved in the business of Refining and Marketing of Petroleum Products.

Hindustan Petroleum Corporation Limited proposes to carry out the pipe line laying and
associated jobs for Re-Routing of 2 no’s 24” Pipelines and 1 no 4” pipeline for approximate portion of
400 to 500 meters within HPCL Refinery Premises out of existing pipelines from OR Jetty and SS Jetty
and from Refinery, to White Oil Terminal, in Malkapuram, Visakhapatnam, Andhra Pradesh. This tender
envisages Fabrication, erection, welding, testing, and commissioning of pipeline along with allied
civil/mechanical jobs including Hook up with existing Pipelines.
 PIPELINE REROUTING WORKS
FOR VISHAKHA NEW WHITE OIL
TERMINAL,VIZAG,AP

Project No. Unit Doc.Type Mat Code Serial No. Rev. Page
W-343 ON CP 0000 001 01 4 0f 19

PROCEDURE FOR PILING WORKS

2. SCOPE OF WORK
Scope of the job involves but not limited to the following:
1. Construction of pile/open foundations for elevated pipe Bridge and Pipe pedestals
2. Supply and fabrication of elevated structural pipe bridge.
3. Construction of pipe pedestals.
4. Laying of 24” pipeline of piggable service and 4” pipeline.
5. Hooking up of the newly laid pipelines with existing pipelines above ground as well as with
underground portion.
6. Fabrication of long radius bends for 24” pipelines
7. Supply of various fittings, as mentioned in the schedule of quantities.
8. Flushing of approximately 15000 meters of 24” pipelines. The entire work will be inside refinery
premises.
9. Third Party Inspection (TPI) for all stages of fabrication for Pipe Line and fabrication of structures at
contractor’s workshop as per approved QAP is deemed to be included in the Quoted BOQ Rates and no
extra payment will be made for the same. The Third party representative should be present at site on
continuous basis for the duration of entire fabrication of structure on daily basis. For pipe line
inspection, presence of third party representative at every stage/hold point will be acceptable.
 PIPELINE REROUTING WORKS
FOR VISHAKHA NEW WHITE OIL
TERMINAL,VIZAG,AP

Project No. Unit Doc.Type Mat Code Serial No. Rev. Page
W-343 ON CP 0000 001 01 5 0f 19

PROCEDURE FOR PILING WORKS

2.1 Purpose of this document

The purpose of this document is to describe in detail the procedure of piling works

The works required will be presented in the format of step by step task plans and drawings which shall
be used by construction personnel to perform the work.

2.2 Definitions

Name Description
COMPANY/HPCL Hindustan Petroleum Corporation Ltd.
CONTRACTOR Narmada Offshore Constructions Pvt Ltd

“WORK” shall mean all activities necessary or

incidental to be carried out, including all services
WORK
to be rendered by the CONTRACTOR in accordance
with the CONTRACT.

2.3 Abbreviation

NAME DESCRIPTION
COMPANY Hindustan Petroleum Corporation Limited (HPCL)
CONTRACTOR Narmada Offshore Constructions Pvt Ltd
GP General Purpose
HSEQS Health, Safety, Environment Quality Surveyor
MT Metric Ton
N/A Not Applicable
SWL Safe working Load
TBA To be advised
2.4 References

 3524/E/001 PROPOSED PIPE PEDASTAL-FOUNDATION LAYOUT WITH DETAILS

 PIPELINE REROUTING WORKS
FOR VISHAKHA NEW WHITE OIL
TERMINAL,VIZAG,AP

Project No. Unit Doc.Type Mat Code Serial No. Rev. Page
W-343 ON CP 0000 001 01 6 0f 19

PROCEDURE FOR PILING WORKS

3. QHSES

3.1 QHSE considerations

All activities / operations described in this document will be executed in accordance with the
CONTRACTOR’s HSE Plan and in accordance with the COMPANY’s HSE requirements for CONTRACTORs.

Prior to commencing the works, Task Risk Assessment (TRA) will be performed on individual tasks. The
purpose of the TRA is to identify possible hazards for a specific activity and to identify any mitigating
actions required to perform the task safely. The TRA result will also be presented on worksheets collated
in the Risk Assessment Register. TRA will be performed as part of procedure review or also conducted
prior to commencement of work. A TRA toolbox talk shall be conducted with the workforce prior to
undertaking any work activities.

3.2 QA / QC considerations

All activities and operations shall be performed and completed in accordance with approved
procedures, Drawings, and specifications.

The Field Engineer and the work site supervisors are responsible for monitoring the progress of the work
and recording pertinent information as dictated in the task plan.

3.3 Document Responsibilities

Field Engineer is responsible for preparing and updating this document.

Construction manager is responsible for checking this document and ensuring it complies with the
overall project requirements.

Project Manager is responsible for approving this document.

4. EQUIPMENT SPREAD

ITEM NUMBERS
CONVENTIONAL PILING RIGS 5
HYDRALUIC CRANE 1
DIESEL GENERATOR 1
ELECTRICAL MOTOR FOR BENTONITE MIXING 1
 PIPELINE REROUTING WORKS
FOR VISHAKHA NEW WHITE OIL
TERMINAL,VIZAG,AP

Project No. Unit Doc.Type Mat Code Serial No. Rev. Page
W-343 ON CP 0000 001 01 7 0f 19

PROCEDURE FOR PILING WORKS

5. TECHNICAL INFO

ITEM # ITEM DESCRIPTION DETAIL

1 Number of piles to be done with 500MM Dia 88 No’s
2 Number of piles to be done with 900MM Dia 18 NO’s
3 Distance between each 500mm Dia Piles 6M C/C
4 Total Pedestals to be installed 44 No’s

6. GENERAL
6.1 Soil and Site Conditions

The tenderer, before submission of his tender, shall visit the site and ascertain nature of subsoil,
local, site and traffic conditions, the accommodation he may require for his staff and labour etc., all
obstructions in the area and allow for any extras likely to be incurred due to any such conditions in his
quoted rates. No future claim on this account shall be admissible under any circumstances.

6.2 Codes and Standards

Unless specifically mentioned otherwise, all latest applicable codes and standards published by the
Bureau of Indian Standards shall govern design, workmanship, quality and properties of materials,
methods of construction, testing and measurement for different items of work. Some of the relevant
codes are listed below:

IS:456 … Code of Practice for

Plain and Reinforced
Concrete
IS:2911 … Part-I/Section 2 –
Code of Practice for
Design and
Construction of Pile
Foundations – Bored
Cast-in-Situ Concrete
Piles
IS:2911 … Part IV – Code of
Practice for Design and
Construction of Pile
Foundation – Load test
on Piles
 PIPELINE REROUTING WORKS
FOR VISHAKHA NEW WHITE OIL
TERMINAL,VIZAG,AP

Project No. Unit Doc.Type Mat Code Serial No. Rev. Page
W-343 ON CP 0000 001 01 8 0f 19

PROCEDURE FOR PILING WORKS

7. OBJECT
 The work covered under this specification includes provision and installation of bored cast-in-
situ reinforced cement concrete piles of different diameters to competent rock strata, routine
load test on piles, pile integrity testing and submission of records of boring, concreting and
testing as specified.
 The work shall consist of marking locations of piles on ground, sinking holes of specified
diameters to required depth by approved method and equipment, collection of soil samples of
various strata and founding rock layer, measurements of final depth and bore diameter etc.
complete as specified.
 The piles shall be cast with grade of concrete and reinforcement as specified and by suitable
method approved by the Consultant/HPCL and samples of concrete shall be taken for testing in
an approved laboratory and submission of test results to the Consultant/HPCL.
 The scope of pile testing shall include excavation to required depth and size, placement of Kent
ledge, reaction loading, reaction blocks/frames for vertical compression, pull-out and lateral
load tests, preparation of pile heads by breaking and chipping up to specified test level and
making good the same for load testing and conducting routine load test of working piles
complete in all respects as specified.
 Integrity testing shall be carried out on a number of selected piles to detect any defects like
cracks, intrusion and diameter changes, etc. if any on pile shaft.
 All information and test results shall be collected, analyzed and presented with necessary
approved drawings, curves, charts and detailed test data/report to be submitted

8. PILING WORK

8.1 General

Piles shall be bored cast-in-situ reinforced cement concrete type with safe load bearing capacities as
stated below:

Pile Diameter Capacity

(mm) Ton
400 55
600 120
1000 300
 PIPELINE REROUTING WORKS
FOR VISHAKHA NEW WHITE OIL
TERMINAL,VIZAG,AP

Project No. Unit Doc.Type Mat Code Serial No. Rev. Page
W-343 ON CP 0000 001 01 9 0f 19

PROCEDURE FOR PILING WORKS

8.2 Materials

8.2.1 Cement: 43/53 grade Ordinary Portland Cement shall conform to IS: 8112 and IS: 12269 and
Portland Blast Furnace Slag Cement shall conform to IS: 455. The Contractor shall carry out the
required tests at his own cost in an approved testing laboratory, at the direction of the
Consultant/HPCL /HPCL, for all cement procured by them and submit test report for approval of
the Consultant/HPCL /HPCL, before using the cement in works. If there is any doubt in the quality
of Cement, Consultant/HPCL /HPCL may ask the Contractor for supplying of cement sample for
testing of the same in employer testing laboratory. Cement shall be stored on raised platforms
inside stores covered on all sides and roof with provision for ample ventilation. Different types of
cement shall be stored separately and more than ten bags (10) of cement shall not be stacked
one above the other in the stack. Sufficient space shall be left around the stacks for approach.
Stacking shall be so arranged that bags from the oldest consignment in the stack can
conveniently be removed first for use on first in first out (F1F0) basis. Cement which has
hardened cladded or deteriorated due to over stacking or long storage shall not be used in works
and shall be removed from site immediately.

8.2.2 Aggregates: All aggregates shall conform to IS: 383. Coarse aggregates shall be approved crushed
stone or gravel washed clean. Fine aggregates shall be river or pit sand. Coarse and fine
aggregates shall be stored at site separately on clean and hard base or in separate
compartments/hoppers. Samples of aggregates to be used shall be submitted to the
Consultant/HPCL /HPCL for approval before commencement of work. No aggregate shall be used
without prior approval of the Consultant/HPCL /HPCL. The Contractor shall ensure that over
entire period of construction all consignments of coarse and fine aggregates brought to the site
conforms to the quality and grading as approved in mix design by the Consultant/HPCL /HPCL
before commencement of work. If necessary, grading of aggregates shall be maintained by
blending different sizes of aggregates that shall be brought to site and stacked in separate stock
piles. Whenever directed by the Consultant/HPCL /HPCL, the Contractor shall perform tests at his
own cost to satisfy the Consultant/HPCL /HPCL that grading and quality approved for coarse and
fine aggregates are being maintained. Sampling of aggregates shall conform to IS: 2430 and tests
shall conform to IS: 2386. The percentage to flaky and elongated pieces should not exceed 15%.

8.2.3 Reinforcement: MS rounds shall conform to IS: 432, mild steel and medium tensile steel
deformed bars and cold twisted steel bars to IS:1786. All reinforcements shall be free from oil,
paint, loose rust, mill scale or other matter likely to weaken or destroy their bond with concrete.

8.2.4 Binding Wire: Binding wire shall be approved 20 SWG annealed iron wire.

8.2.5 Water: Water shall be clean and of potable quality of PH value ranging between 6-8.

8.2.6 Bentonite: Bentonite shall conform to Appendix-A of IS: 2911 (Part-I/Section 2).
 PIPELINE REROUTING WORKS
FOR VISHAKHA NEW WHITE OIL
TERMINAL,VIZAG,AP

Project No. Unit Doc.Type Mat Code Serial No. Rev. Page
W-343 ON CP 0000 001 01 10 0f 19

PROCEDURE FOR PILING WORKS

8.3 Concrete Mix

The concrete shall be controlled concrete as defined by IS: 456 and IS: 2911 (Part-1/Section-2). The
grades of concrete shall be as specified and the strength requirements shall be in accordance with IS:
456.
Aggregates in each mix of concrete shall be graded and the water cement ratio controlled in
accordance with IS: 456 and frequent tests conducted to ensure usage of correct grade of concrete. The
Contractor shall furnish to the Consultant/HPCL /HPCL mix design calculations and test results for
approval before start of the piling work.

8.4 Mixing

All components of concrete shall be proportioned by weight for each grade. Mixing shall be done
in a concrete batching plant.

8.4.1 Consistency: Consistency will be controlled as per IS: 456 and checked by slump tests in
accordance with IS: 1199 and IS:2911 (Part I/Section-2).

8.4.2 Tests: Sampling, making up, curing and testing of concrete specimens shall comply with IS: 456,
516 and 1199. The cost of all work/laboratory tests shall be included in Contractor's rates.

8.5 Concrete

Materials and methods of manufacture for cement concrete shall in general be in accordance with
the method of concreting under conditions of pile installation.
Normally, the minimum cement content should be 400 Kg/m3 of concrete. For design purposes, the
strength of concrete mix using quantity of cement mentioned above may be taken equivalent to M25.
Slump of concrete shall range between 150 to 180 mm where concrete is to be placed under drilling
mud, by tremmie. Plasticizers and/or retarders of approved make as may be necessary for ease of
concreting shall be provided by the Contractor at no additional cost to the Employer.

8.6 Workmanship

8.6.1 Control of Piling Installation

8.6.1.1 The piles shall be bored cast-in-situ reinforced cement concrete piles capable of being tested
for load carrying capacity after 28 days of casting. Bored cast-in-situ piles shall be constructed
by suitable choice of installation techniques; e.g. using casing and/or drilling mud; manner of
 PIPELINE REROUTING WORKS
FOR VISHAKHA NEW WHITE OIL
TERMINAL,VIZAG,AP

Project No. Unit Doc.Type Mat Code Serial No. Rev. Page
W-343 ON CP 0000 001 01 11 0f 19

PROCEDURE FOR PILING WORKS

concreting and choice of boring tools in order to achieve satisfactory performance of the piles
at site.
8.6.1.2 Control of Alignment: Piles shall be installed accurately at site. Tolerance limits for completed
vertical piles at the working level of piling rig shall be as given below:
8.6.1.3 Displacement – Shall not exceed 75 mm in any direction from its true position shown on
approved drawing.
8.6.1.4 Verticality – Shall not deviate more than 1.5 per cent.
8.6.1.5 Any pile deviating beyond these limits and to such an extent that the resulting eccentricity
cannot be taken care of by redesign of the pile cap, the piles shall either be replaced or
supplemented by one or more additional piles as may be required. The additional cost of
construction of the redesigned pile caps or the supplementary piles including the cost of free
issue items shall be borne by the Contractor.
8.6.1.6 Any deviation from the designed location, alignment or load capacity of any pile shall be noted
and adequate measures taken by the Contractor well before the concreting of the pile cap and
plinth beam is done.

8.7 Construction of Pile

8.7.1 Rotary Piling Rigs : The pile boring rigs shall be crawler mounted, hydraulically/mechanically
operated rotary rig with capability for accessories/attachments e.g. compressed air pulverizer,
oscillating type liner, different cutting tools etc. or equivalent capable of boring / drilling through hard
compact slag, soft/weathered as well as sound hard rock with necessary mud circulation technique.
These rigs shall preferably be light, easy to transport and fully self-erecting so that they can be set up
quickly without aid of auxiliary cranes. The rigs shall consist of telescopic leaders/Kelly bars, expandable
tracks and a low center of gravity. The engines and winches of such rigs shall be of adequate capacity to
generate enough torque (15 – 25 t-m) to bore through hard, compacted slag and sound hard rock at
high speed.
Adequate hydraulic system adaptable to different equipment like hammers, rotary heads, augers,
vibrators etc. shall be an essential feature of such rigs. The Contractor shall select his equipment based
on one or more methods of working as above in such a way that the time schedule can be strictly
maintained.
Tripod Rigs: Conventional tripod rigs with bailer-chisel arrangement with provision of installing casing
up to depths as necessary based on site condition and equipped with Direct Mud Circulation (DMC)
arrangement shall be deployed. The Contractor shall select his equipment based on one or more
methods of working as above in such a way that the time schedule can be strictly maintained.

8.7.2 Boring: In general, pile bore shall be kept cased with a lead-in-tube to prevent ingress of soil
followed by temporary casing to required depth. Minimum length of temporary casing during boring, if
required, using conventional tripod rig, shall be 1.5 metre. However, actual length of casing in all cases
will depend upon requirements based on site condition. In soils, which are liable to flow, bottom of
 PIPELINE REROUTING WORKS
FOR VISHAKHA NEW WHITE OIL
TERMINAL,VIZAG,AP

Project No. Unit Doc.Type Mat Code Serial No. Rev. Page
W-343 ON CP 0000 001 01 12 0f 19

PROCEDURE FOR PILING WORKS

casing shall be kept sufficiently below boring tool to prevent entry of soil into pile bore, thus preventing
formation of cavities and settlement/ subsidence in adjoining ground. Alternatively, inflow of ground
water and soil shall be controlled and sides of boreholes stabilized by using sufficient head of drilling
mud such as bentonite suspension. The head of bentonite slurry shall be kept at least one metre (1 m)
above the standing water level.
Soil and rock cuttings removed from pile bore shall be collected for inspection during progress of boring
and compared with descriptions given in soil investigation borehole records and samples of soil and rock
cores collected during soil investigation for the purpose of strata identification. Decision of the
Consultant/HPCL /HPCL regarding identification of various strata shall be final and binding on the
Contractor. Piles shall be terminated into competent hard rock for minimum socket length given as
under:

Pile Diameter Minimum Depth of Socket Length

(mm) into Compact Hard Rock (mm)
400 800
600 1200
1000 2000

Final depth of boring shall be determined by sounding and in case of uncased bores, diameter of bore at
different depths shall be determined by a pentograph or other suitable means, to the satisfaction of the
Consultant/HPCL /HPCL. After completion of boring, the borehole shall be cleaned by controlled air-lift
method of flushing with fresh drilling fluid.
Lowering Reinforcement Cage : On satisfactory completion of boring, the reinforcement cage shall be
lowered inside the borehole with sufficient numbers of round cement concrete cover blocks attached to
the lateral links. The lap length and the spiral links shall be tack welded to the main reinforcement. The
reinforcement cage should go down into the borehole and shall be kept hung by suitable arrangement
from the top of borehole and in no case the cage shall be allowed to stand on its own from bottom of
bore to avoid buckling. Precaution shall be taken to ensure that the cover blocks do not get damaged
during cage lowering.
8.7.3 Concreting : In case pile boring using drilling mud, specific gravity of the mud suspension near
about bottom of hole shall, whenever directed, be determined by suitable slurry sampler in the first few
piles and at suitable intervals of piles and recorded. Consistency of drilling mud suspension shall be
controlled throughout the boring as well as concreting operations in order to keep the hole stabilized
and avoid concrete getting mixed up with thicker suspension.
Concreting operations shall not be taken up when specific gravity of bottom slurry is more than 1.2.
Concreting shall be done by tremmie method in all such cases. The slurry shall be maintained at least 1.5
m above the ground water level if casing is not used.
Concreting of piles shall commence immediately after completion of final cleaning. Should a borehole,
which is not cased, be left unconcreted for more than two hours, it shall be cleaned thoroughly before
placing concrete to the satisfaction of the Consultant/HPCL /HPCL.
 PIPELINE REROUTING WORKS
FOR VISHAKHA NEW WHITE OIL
TERMINAL,VIZAG,AP

Project No. Unit Doc.Type Mat Code Serial No. Rev. Page
W-343 ON CP 0000 001 01 13 0f 19

PROCEDURE FOR PILING WORKS

Bottom of the borehole shall be cleaned of all accumulated sand, muck and loose materials by
controlled air-lift flushing with fresh drilling fluid. The tremmie pipes shall extend to the bottom of
borehole at start and shall be joined in sections and fitted with the hopper for receiving concrete pour at
top of borehole. The first charge of concrete shall be poured in hopper with bottom opening temporarily
closed by a steel plate placed at top of the opening. The hopper shall have adequate capacity to receive
volume of concrete sufficient enough to displace drilling mud within tremmie pipe and from bottom of
borehole. After the hopper is filled up the steel plate shall be quickly removed to allow concrete to rush
into pile bore and fill it up from the bottom by displacing the drilling fluid from tremmie pipe and the
bottom of the borehole. As the concreting progresses, the tremmie pipes shall be removed in sections
ensuring every time that bottom of tremmie pipe remains embedded for at least one (1) metre into
concrete. Placing of concrete shall be done in one continuous operation and the tremmie pipes shall be
held concentric with the bore. Level of concrete shall be checked at frequent intervals to maintain a
sufficient head of concrete above the discharge end of tremmie pipes. It shall be ensured that sufficient
numbers of mixes are poured to expel the first mix of concrete contaminated with bentonite such that
good concrete is obtained at least up to 150 mm above the cut-off level. At all stages of concreting, care
shall be taken to prevent voids and segregation in concrete.
The top of concrete in a pile shall be brought above the cut-off level to permit removal of all laitance
and weak concrete before capping and to ensure good concrete at the cut-off level for proper
embedment into pile cap. Where cut-off level is less than 1.5 m below the working level, concrete shall
be cast to a minimum of 300 mm above cut-off level. For each additional 300 mm increase in cut-off
level below the working level additional coverage of 50 mm minimum shall be allowed. Higher
allowance may be accepted depending on pile length. When concrete is placed by tremmie method
concrete shall be cast to a minimum of one metre above cut-off level. In the circumstances where cut-
off level is below ground water level, the need to maintain a pressure on the unset concrete equal to or
greater than water pressure, should be observed and accordingly length of extra concrete above cut-off
level shall be determined.
8.7.4 Withdrawal of Casings: Extraction of casing pipes shall be done in such a way that no necking or
shearing of concrete in shaft takes place.
8.7.5 Sequence of Piling: Sequence of piling shall be such that there is no damage caused to concrete
recently laid in adjacent pile. Construction of piles shall be done in accordance with the priority of
construction of various pile groups. Sequence of piling shall be decided by the Consultant/HPCL /HPCL.
8.7.6 Finishing of Pile Heads: Top level of concrete in the pile shall be brought up sufficiently above cut-
off level to allow for slumping or withdrawal of casing tube, and also to have a minimum allowance
above cut-off level for removal of all laitance and weak concrete at top level. Any defective concrete at
the head of completed pile shall be chipped off and made good with new concrete bonded to old
concrete. Manual chipping of pile heads may be permitted after three (3) days of pile concreting.
Pneumatic tools for chipping shall not be used before seven (7) days of concreting.
8.7.7 Consumption of Concrete in Piling: After completion, actual quantity of concrete shall be
compared with the average obtained from observations actually made in the case of a few piles initially
cast. The actual quantity of concrete may also be worked out based on actual consumption of cement
duly certified by the Consultant/HPCL /HPCL. If the actual quantity is found to be considerably less,
special investigations shall be conducted and appropriate measures taken.
 PIPELINE REROUTING WORKS
FOR VISHAKHA NEW WHITE OIL
TERMINAL,VIZAG,AP

Project No. Unit Doc.Type Mat Code Serial No. Rev. Page
W-343 ON CP 0000 001 01 14 0f 19

PROCEDURE FOR PILING WORKS

8.8 Replacement of Defective Bored Piles

Defective piles shall be removed or left in place without affecting the performance of adjacent piles or
capping above and additional piles shall be provided to replace them, as directed by the
Consultant/HPCL /HPCL or his representatives. The cost of replacement and/or provision of additional
piles, and additional cost of providing larger size pile caps and plinth beams shall be borne by the
Contractor at no extra cost to the Employer.

8.9 Basic Properties of Drilling Mud (Bentonite)

8.9.1 Properties: Drilling mud shall be used to keep the sides of boreholes stabilized. The drilling mud
shall have `Thixotropic' properties, i.e. gel forming properties. The drilling mud shall have such
properties as to permit formation of filter cake on the inside surface of boreholes, thickness of which
depend on nature of sub-soil deposits. Sodium based bentonites have ideal properties suitable for use
as drilling mud.
8.9.2 Specification: The bentonite suspension used for piling work shall satisfy the following
requirements:
a) Liquid limit of bentonite when tested in accordance with IS: 2720 (Part V) shall be more than 300 %
and less than 450 %. b) Sand content of bentonite powder shall not be greater than 7 %.
c) Bentonite solution shall be made by mixing it with fresh water using pump for recirculation. Density of
bentonite solution shall be about 1.12 maximum.
d) The Marsh Cone viscosity value when tested by a Marsh Cone shall be about 37 seconds.
e) Swelling index measured by swelled volume after 12 hours in abundant quantity of water shall be at
least 2 times its dry volume.
f) The pH value of bentonite suspension shall be less than 11.5.
The Contractor shall carry out all tests required as above in an approved laboratory /at site/at
Employer’s Laboratory.
8.9.3 Loss of Bentonite: In the event of sudden loss of bentonite suspension during boring, the borehole
shall be backfilled without delay and instructions of the Consultant/HPCL /HPCL shall be obtained.
8.9.4 Removal of Bored Muck: All reasonable steps shall be taken to prevent spillage of bentonite
suspension on the site and dispose off away from the immediate vicinity. Discarded bentonite
suspension that has been pumped from boring shall be removed from site by the Contractor at no extra
cost to the Employer.
 PIPELINE REROUTING WORKS
FOR VISHAKHA NEW WHITE OIL
TERMINAL,VIZAG,AP

Project No. Unit Doc.Type Mat Code Serial No. Rev. Page
W-343 ON CP 0000 001 01 15 0f 19

PROCEDURE FOR PILING WORKS

8.10 Testing of Concrete

Concrete shall be tested, to ascertain its cube strength at 7 days and 28 days. The number of piles for
which test cubes are to be taken would be as follows:

Pile Group No. of Piles

2 to 4 1
5 to 8 2
Above 8 Every 4th Pile

8.10.1 Six (6) cubes shall be taken in accordance with IS:1199 for testing a set of three (3) cubes
after 7 days and the second set of three (3) cubes after 28 days.
8.10.2 The method of testing concrete cubes shall be in accordance with IS: 516 and the strength
requirements of concrete shall be as specified in IS: 456.

9. INTRODUCTION OF DMC PILING METHOD

Direct Mud Circulation method of pile foundation installation is used for bored cast in-situ piles.
Direct Mud Circulation method is best suited when working-space is a huge constraint.

In Industries and power plants where there is a labyrinth of pipelines snaking all around, DMC
comes to the rescue. While the other methods are comparatively expensive, DMC is a fairly cheaper
method to install piles.

The apparatus basically comprises a Tripod with pulley, winch machine, wire-rope, Chisel, drill
pipes, tremie pipes, a vertical pump and a pit where bentonite powder is mixed with fresh water.

A tripod as the name suggests is a three-legged structure which is mounted with a pulley at the
apex to maneuver the chisel that bores the earth, which is further appended to drill pipes in tandem
with a wire rope that is ultimately knotted to the winch machine. To make it sound simple, the chisel is
the primary boring tool and the drill pipes are mere appendages that provide the depth, and also,
suffuse the bore with bentonite suspension.
 PIPELINE REROUTING WORKS
FOR VISHAKHA NEW WHITE OIL
TERMINAL,VIZAG,AP

Project No. Unit Doc.Type Mat Code Serial No. Rev. Page
W-343 ON CP 0000 001 01 16 0f 19

PROCEDURE FOR PILING WORKS

The number of drill pipes required varies depending on the depth of the bore required. Besides
this, a vertical pump is installed in the bentonite pit so as to pump the bentonite solution into the bore
hole through drill pipes and chisel.

The method is termed as Direct Mud Circulation because it involves the circulation of mud from
the pile bore directly to the bentonite pit where the pump reuses the bentonite slurry leaving alone the
settled mud.
 PIPELINE REROUTING WORKS
FOR VISHAKHA NEW WHITE OIL
TERMINAL,VIZAG,AP

Project No. Unit Doc.Type Mat Code Serial No. Rev. Page
W-343 ON CP 0000 001 01 17 0f 19

PROCEDURE FOR PILING WORKS

10. TASK PLAN

RESPONSIBLE
REFERENCE
STEP TASK DESCRIPTION PARTY /
DWG
EQUIPMENT
Installation of Pile
Conduct Tool Box talk and TRA with all the parties in the
1 Site HSE / FE
job.
Position the sand bags and / or carry out the necessary
works near piling point to facilitate piling works
2 FE/HSE
All the necessary work required for installing the pile
shall be performed.

3 Prior to start of work, Work permits to be at site FE/HSE

Make sure that surroundings of piling activity to be

4 HSE/FE
cleared/ covered
Make sure that all equipment’s using in piling activity to 3524/E/001
5 be checked prior to work start and all electrical HSE/FE PROPOSED
insulations and connections to be cross checked. PIPE
After checking all the spread/equipment then proceed PEDASTAL-
6 HSE/FE
to work FOUNDATION
LAYOUT WITH
The Tripod is made to stand around the target pile (two
DETAILS
legs around the pile and one into the slot provided in
winch machine) and a plumb bob is then hung down the
7 pulley (mounted on the tripod) aiming the center of the DMC RIG/FE/HSE
target pile so as to obtain the center for the chisel. The
maximum tolerance permissible for piles with diameter
600mm or more is 75mm or D/2, whichever is more.
Once the position of winch machine and the tripod is
fixed, casing is installed into the earth keeping the
center point intact. A wall made up of sacks filled with
rubble or soil is created around the pile-area so as to
8 DMC RIG/FE/HSE
channel an artificial conduit directed towards the
bentonite pit. This channel directs the mixture of mud
and bentonite slurry coming out from the bore to the
bentonite pit.
 PIPELINE REROUTING WORKS
FOR VISHAKHA NEW WHITE OIL
TERMINAL,VIZAG,AP

Project No. Unit Doc.Type Mat Code Serial No. Rev. Page
W-343 ON CP 0000 001 01 18 0f 19

PROCEDURE FOR PILING WORKS

RESPONSIBLE
REFERENCE
STEP TASK DESCRIPTION PARTY /
DWG
EQUIPMENT
The topmost drill pipe is connected with a hose
emerging from the vertical pump (installed in the
bentonite) pit sending fresh bentonite slurry to the
borehole through a fine opening in chisel and when the
9 bore hole is filled to the brink, it flows back to the DMC RIG/FE/HSE
bentonite pit along with the mud through the artificial
conduit. In this way the mud from the bore keeps on
moving up the borehole and is directed to the bentonite
tank.
It is preferred to use fresh and clean water for the
preparation of bentonite suspension as the minutest
impurities may alter the properties of a suspension. In
10 case, clean water is not available at the site, special DMC RIG/FE/HSE
additives such as Ferro some lignosulphate in
combination with soda ash, phosphates and flocculants
are added.
The specific gravity of the bentonite suspension should
be between 1.05 to 1.12 as it is responsible for the
retention of the vertical cut soil surface of pile borehole.
Cohesiveness and surface tension develop among the
soil particles if the specific gravity of the suspension is
overlooked which eventually leads to the collapse of
vertical cut soil surface.

To achieve the requisite specific gravity of the bentonite 3524/E/001

solution, the concentration of bentonite is calculated as PROPOSED
under: PIPE
11 DMC RIG/FE/HSE PEDASTAL-
Ys=1+0.006 x Cs FOUNDATION
LAYOUT WITH
Where “ys” is the density of the bentonite suspension DETAILS
and “Cs” is the concentration of bentonite by weight.

“Concentration of bentonite” means percentage of

bentonite (by weight), to be mixed with water.

So, Cs=1/6 x (1.05-1) x1000 =8.33% by weight.

i.e In 1m3 of water 83.3kg bentonite shall be mixed to

 PIPELINE REROUTING WORKS
FOR VISHAKHA NEW WHITE OIL
TERMINAL,VIZAG,AP

Project No. Unit Doc.Type Mat Code Serial No. Rev. Page
W-343 ON CP 0000 001 01 19 0f 19

PROCEDURE FOR PILING WORKS

RESPONSIBLE
REFERENCE
STEP TASK DESCRIPTION PARTY /
DWG
EQUIPMENT
get 1.05 specific gravity of the bentonite solution.

There are two stages of use of bentonite suspension

First flushing: When earth is being bored, bentonite
suspension of specific gravity between 1.05 to 1.12 is to
12 DMC RIG/FE/HSE
be maintained.
Second flushing: When the bore has to be cleaned after
the completion
Chisel is then driven inside the casing and the earth is
bored until the chisel has fully gone down inside the
earth. Drill pipes are attached to the chisel in tandem
and the boring progresses by maneuvering the winch
13 machine until the requisite depth is bored. Flushing is DMC RIG/FE/HSE
done all the while during the pile boring. After the
completion of bore, chisel is brought outside and the
second flushing of the bore hole is done to remove all
the mud and impurities.
Cage Insertion should be done immediately after the
completion of second flushing. It is recommended to
14 provide temporary hooks to the cages so as to keep the DMC RIG/FE/HSE
verticality of the cage in view while inserting it down
the bore hole.
Tremie are finally inserted into the bore hole attached
to a hopper at the top hung by the wire rope. The joint 3524/E/001
between the hopper and tremie pipe is closed with a PROPOSED
steel plug before the first charge of concrete. The PIPE
15 DMC RIG/FE/HSE PEDASTAL-
hopper is then filled with concrete to its full capacity.
Once filled, the steel plug is removed to allow the FOUNDATION
concrete to flow down the tremie pipes thereby LAYOUT WITH
replacing the bentonite solution. DETAILS
Concreting is done up to at least 1m above the cut-off
16 levels to ensure good concrete for proper embedment DMC RIG/FE/HSE
into pile cap.
Repeat the steps 01-16 for installation of piles in
17 DMC RIG/FE/HSE
adequate location