CLIENT:

Ashuganj Power Station Company Ltd. (APSCL)

REPORT ON:
INTEGRITY TEST ON 08 NOS CAST-IN-SITU PILES FOR THE CONSTRUCTION
OF ASHUGANJ 400 MW COMBINED CYCLE POWER PLANT (EAST) PROJECT
AT ASHUGANJ, BRAHMANBARIA, BANGLADESH.

NAME OF THE CONTRACTOR:

China National Technical Import & Export Corporation and China
Corporation for Overseas Economic Cooperation Consortium.

December 2018

TEST PERFORMED BY:

SYNERGY DESIGN AND DEVELOPMENT
House # 4/4 (Ground Floor), Gate # 10, Block # F
Lalmatia, Mohammadpur, Dhaka-1207
Email id: sk.harunur.rashid@gmail.com, Cell: 01712153814
 SDD/GEO/PIT/2018-157

CONTENTS

Page

1. INTRODUCTION 1
2. SCOPE OF THE WORK 1
3. PILE HEAD PREPARATION 1
4. THE PILE INTEGRITY TEST 1
5. DEVICE USED FOR INTEGRITY TESTING 4
5.1 Characteristics of the Device 4
5.2 Testing 5
5.3 Interpretation 5

6. LOCATION OF THE PILES TESTED 5

7. COMMENTS FROM OBSERVATIONS OF PILE INTEGRITY TEST 5
8. REFERENCES 6

APPENDIX-A: PILE IDENTIFICATION DRAWING

APPENDIX-B: SITE PHOTOGRAPH
APPENDIX-C: Reflectograms from Pile Integrity Tests
1. INTRODUCTION
M/S SYNERGY DESIGN & DEVELOPMENT was entrusted with the pile integrity test
for construction of ASHUGANJ 400 MW COMBINED CYCLE POWER PLANT
(EAST) PROJECT AT ASHUGANJ, BRAHMANBARIA, BANGLADESH.
2. SCOPE OF THE WORK
The scope of the work consisted of the following:
(i) To carry out the pile integrity tests
(ii) To comment on the length and quality of pile shaft i.e. quality of concrete, cross
section of pile shaft etc.
3. PILE HEAD PREPARATION
For the best results the pile head is required to be clear, accessible, sound and free from
standing water. Cast in situ piles should be cured at least 28 days before testing. Pile head
was accessible.
4. THE PILE INTEGRITY TEST
Low strain integrity testing of piles is a tool for quality control of long structural elements
that function in a manner similar to foundation piles, regardless of their method of
installation, provided that they are receptive to low strain impact testing. The test provides
velocity (and optionally force) data which assists evaluation of pile integrity and pile
physical dimensions (i.e. cross-sectional area, length), continuity and consistency of pile
material. The test does not give any information regarding the pile bearing capacity or
about pile reinforcement. Integrity test principles have been well documented in literature
(ASTM D5882-96; Klingmuller, O., 1993). A brief outline on integrity test is presented
here.
There exist two methods of integrity testing (i) Pulse Echo Method (PEM): The pile head
motion is measured as a function of time. The time domain record is then evaluated for
pile integrity, (ii) Transient Response Method (TRM): The pile head motion and force
(measured with an instrumented hammer) are measured as a function of time. The data are
evaluated usually in the frequency domain.
For testing the piles in the present case, the Pulse Echo Method was followed and a Sonic
Integrity Tester (SIT) made by Profound B. V., Netherlands was used. In this method a
small accelerometer is placed on the pile top and the pile head is struck with a small
hammer. The stress wave thus generated travels down the pile shaft, reflects at the toe of
the pile and is registered by the accelerometer. The accelerations are then integrated to

1
obtain the pile head velocity. Apparent reflections occurring prior to the toe response that
are of the same sign as the input are due to a relative decrease of impedance. Reflections
of the opposite sign are due to a relative increase of impedance. The pile impedance z is
defined by the following equation:

z = EA/c (1)

Where, E is the elastic modulus (Young’s modulus) of pile material

A is the cross-sectional area
and c is the stress-wave velocity.
According to one-dimensional stress-wave theory, the stress-wave velocity (c) is given by
the following equation:

c  E/ (2)

Where,  is the mass density of pile material.

Combining the above equations (1) and (2), the following expression for pile impedance
(z) is obtained:

z  A E (3)
Thus an impedance reduction can be caused by a decrease in area A, modulus E or
density . Since both E and  are related to concrete strength, it can be concluded that a
change in impedance is related to a change in cross-sectional area or concrete quality.

The pile length is calculated from the time of toe reflection (T), if apparent, and the
velocity of wave propagation through concrete (c) using the following equation:
c.T
L (4)
2
The magnitude of stress-wave velocity usually ranges from 3000 m/sec to 4500 m/sec.
Integrity evaluation from low strain tests is to be made with due consideration to other
information such as construction details (length of temporary casing, concreting methods,
concrete consumption etc.), soil profile, unusual occurrences during construction (e.g.
delays during concreting, premature withdrawal of tremie tubes, water conditions etc.).
The shaft friction between the pile and soil plays an important role in pile integrity test, as
shaft friction dampens the magnitude of the signal. The reduction in magnitude of the
signal is a function of pile length, pile type, soil type and consistency and the length to
diameter ratio of the pile. If reflectograms are obtained from a reference pile of known

2
length and good quality (such as a driven pile) at the same site then the effect of soil
resistance can be judged and an improved interpretation can be made.

Certain limitations are inherent in low-strain integrity testing. Integrity evaluation of a pile
section below a crack that crosses the entire pile cross-sectional area or below a section
filled with soil is not normally possible since the impact wave is likely to reflect
completely at the discontinuity. Piles with highly variable cross-sections or multiple
discontinuities are difficult to evaluate.
Integrity testing may not identify all imperfections, but it can be used in identifying major
defects within the effective length. In literature, there are many examples that highlight the
success of low strain integrity testing (Klingmuller. O, 1993).
With regards to the implication of pile integrity test, one should consider the following
factors:
 This sonic echo pile integrity testing or dynamic response method is based on
measuring (or observing on an oscilloscope) the time it takes for a reflected
compression stress wave to return to the top of the pile. Some waves will be
reflected by a discontinuity in the pile shaft when the compressive strength is
known for the pile material involved, the depth to the discontinuity and the pile
length can be determined.
 On the other hand, area of pile shaft and hence its diameter, is determined from
impedance of wave response, while impedance in any section is a function of
elastic modulus of pile material, shaft area and wave velocity propagating through
that section. If the concrete material is uniform throughout the pile length, elastic
modulus and the wave velocity (provided disturbance from other source of
vibration nearby is insignificant) are constant for that pile. In that case, changes in
impedance usually indicate changes of pile cross-sectional area.
 While evaluating pile integrity (i.e., pile length and shaft diameter), the wave
velocity is usually assumed to be constant throughout pile length. Therefore, the
reliability of integrity evaluation entirely depends on the pile material and its
uniformity throughout shaft length while casting was done. Thus the length and
diameter obtained from pile integrity test is merely an indication of the actual
length and diameter of the tested piles.

3
  Besides, this test can only assess shaft integrity and gives no information for pile
bearing capacity determination. However, if a large number of piles are tested, it is
generally easy to focus the piles having unusual responses. Therefore, whenever an
integrity testing is contemplated, consideration must be given to the limitations of
the various methods/process of pile driving (and casting) and the possible need for
further investigation to check the results of such testing.

Fig. 1 Basic principle of low strain integrity testing (after Klingmuller, 1993)

5. DEVICE USED FOR INTEGRITY TESTING

SIT (Sonic Integrity Testing) program, ver.7.4 and a device made by TNO Profound of
Netherlands was used for the integrity tests of the piles at the site.
5.1 CHARACTERISTICS OF THE DEVICE
The SIT-system is a dedicated instrument for carrying out sonic integrity testing on piles
and is especially designed to resist rough handling and adverse site conditions. It is
operated by one man only and requires no preparation time on the building site. With the
SIT-system, the integrity of foundation piles after installation can be accurately and
efficiently verify. The SIT-system enables to check the pile length and to detect

4
irregularities and/or cracks in the pile shaft. The system is robust, light, easily portable and
operates fully digital.
5.2 TESTING
The test is carried out by pressing a transducer onto a pile top while striking the pile head
with a hand held hammer. The SIT-system registers the impact of the hammer followed by
the response of the pile and shows both on the Note Book Computer display. If so
instructed by the operator, the signal will be stored in the memory of the SIT-system
together with other information, such as pile number, date, time, site, amplification factor,
filter length, etc.
5.3 INTERPRETATION
The reflectograms are horizontally scaled and vertically amplified to compensate external
soil friction, which facilitate the interpretation. Consequently the reflection of the pile toe
matches the length of the pile, which will be confirmed by the SIT-system. In case of any
defects, the exact location can be determined from the graph on the display. Little
experience is generally needed to read a reflectogram.
6. LOCATION OF PILES TESTED
The foundation of the proposed ASHUGANJ 400 MW COMBINED CYCLE POWER
PLANT (EAST) PROJECT AT ASHUGANJ, BRAHMANBARIA, BANGLADESH cast
in situ piles out of which 08 nos piles were tested. All the piles were cast in place by wash
boring method.
7. COMMENTS FROM OBSERVATIONS OF PILE INTEGRITY TEST
For matured concrete the stress-wave velocity ranges between 9800ft/sec to 14800 ft/sec
(3000 m/sec to 4500 m/sec). During the test a stress wave velocity of 11811 ft/sec (≈3600
m/sec) were employed. The recorded reflectograms for each pile are presented in
Appendix-C. Although several set of recordings were made for each pile, only the most
suitable set of recording is presented the Appendix. The reflectograms records were later
analyzed using various stress wave velocity, amplification and data correction scheme to
assess the length of the piles, integrity of the shaft and quality of concrete.
Interpretation of the reflectograms regarding length, cross-sections, concrete quality
and defects of each pile are provided in Table 1-2. It should be noticed that the
lengths mentioned in Table 1-2 are estimated lengths using an average compression
wave velocity of 11811 ft/sec (≈3600m/sec) through the pile concrete and do not
necessarily represent the actual length. If a greater compression wave velocity (of

5
course within the reasonable upper limit) is assumed, then the estimated lengths of
these piles will be increased. This indicates that the quality of concrete in these piles
may be relatively good compared to that of a concrete with 11811 ft/sec wave
velocity. On the other hand, if for any pile the mentioned length is higher than the
expected length then it would indicate relatively poor concrete.

Out of the total 08 piles tested, all piles were found to have uniform or nearly
uniform cross-section and concrete strength along the pile shaft. These piles are
assessed to be sound piles and are termed as “Satisfactory”

The pile length is used to determine the signal length. The pile length should be
estimated between 90% and 110% of the real pile length.

It should be noted that pile integrity test is an indicative test about the length, cross-section
and quality of concrete in the pile shaft. This test does not give any data about the actual
load capacity of a pile.

8. REFERENCES
ASTM D5882. “Standard Test Method for Low Strain Integrity Testing of Piles”
Klingmuller, O., “Sonic Echo Pile Integrity Testing and Quality Control”,
Ground Engineering, December 1993, pp 25-30.
Tchepak, S., “Experiences with Low Strain Integrity Testing of Cast-In-Situ Piles”.

6
APPENDIX-A
o

I
APPENDIX-B
SITE PHOTOGRAPH_ Ashuganj Power Station Company Ltd. (APSCL)
SITE PHOTOGRAPH_ Ashuganj Power Station Company Ltd. (APSCL)
SITE PHOTOGRAPH_ Ashuganj Power Station Company Ltd. (APSCL)
SITE PHOTOGRAPH_ Ashuganj Power Station Company Ltd. (APSCL)
APPENDIX-C
 Table 1: Interpretations and Comments on recorded Reflectograms from integrity tests

Expected Length Estimated length

Sl No. Pile ID Interpretation of Reflectogram Comments
(m) (m)

Minor variation in cross-section and/or concrete strength along

1 TP6-01 25 25.9 Satisfactory
the pile shaft

Nearly uniform cross-section and/or concrete strength along

2 TP6-02 25 25.4 Satisfactory
the pile shaft

Minor variation in cross-section and/or concrete strength along

3 TP6-03 25 25.5 Satisfactory
the pile shaft

Nearly uniform cross-section and/or concrete strength along

4 TP6-04 25 26 Satisfactory
the pile shaft

TEST PERFORMED BY
SYNERGY DESIGN AND DEVELOPMENT
SYNERGY DESIGN AND DEVELOPMENT

17.7 25.9

[mm/s] [m]

19.1 25.9

20.9 25.9

4/3 0 2.5 5 7.5 10 12.5 15 17.5 20 22.5 25 27.5 30 [m]

SITE APSCL_600 D. 3600[m/s] f:8 exp:1 sr
PILE TP6-01.. Tue Dec 11, 2018 V7.4

20.8 25.4

[mm/s] [m]

23.8 25.4

21.3 25.4

4/3 0 2.5 5 7.5 10 12.5 15 17.5 20 22.5 25 27.5 30 [m]

SITE APSCL_600 D. 3600[m/s] f:8 exp:1 sr
PILE TP6-02. Tue Dec 11, 2018 V7.4

ASHUGANJ 400 MW COMBINED CYCLE POWER PLANT (EAST) PROJECT AT ASHUGANJ, BRAHMANBARIA.
SYNERGY DESIGN AND DEVELOPMENT

8.2 25.5

[mm/s] [m]

10.1 25.5

10.9 25.5

4/3 0 2.5 5 7.5 10 12.5 15 17.5 20 22.5 25 27.5 30 [m]

SITE APSCL_600 D. 3600[m/s] f:8 exp:1 sr
PILE TP6-03. Tue Dec 11, 2018 V7.4

14.9 26.0

[mm/s] [m]

15.0 26.0

14.1 26.0

4/3 0 2.5 5 7.5 10 12.5 15 17.5 20 22.5 25 27.5 30 [m]

SITE APSCL_600 D. 3600[m/s] f:8 exp:1 sr
PILE TP6-04. Tue Dec 11, 2018 V7.4

ASHUGANJ 400 MW COMBINED CYCLE POWER PLANT (EAST) PROJECT AT ASHUGANJ, BRAHMANBARIA.
 Table 2: Interpretations and Comments on recorded Reflectograms from integrity tests

Expected Length Estimated length

Sl No. Pile ID Interpretation of Reflectogram Comments
(m) (m)

Nearly uniform cross-section and/or concrete strength along

5 TP8-01 30 29.6 Satisfactory
the pile shaft

Minor variation in cross-section and/or concrete strength along

6 TP8-02 30 30.2 Satisfactory
the pile shaft

Nearly uniform cross-section and/or concrete strength along

7 TP8-03 30 30.4 Satisfactory
the pile shaft

Nearly uniform cross-section and/or concrete strength along

8 TP8-04 30 30.8 Satisfactory
the pile shaft

TEST PERFORMED BY
SYNERGY DESIGN AND DEVELOPMENT
SYNERGY DESIGN AND DEVELOPMENT

13.7 29.6

[mm/s] [m]

12.5 29.6

13.7 29.6

4/3 0 4 8 12 16 20 24 28 32 36 [m]
SITE APSCL_800 D. 3600[m/s] f:8 exp:1 sr
PILE TP8-01 Tue Dec 11, 2018 V7.4

15.3 30.2

[mm/s] [m]

14.6 30.2

14.6 30.2

4/3 0 4 8 12 16 20 24 28 32 36 [m]
SITE APSCL_800 D. 3600[m/s] f:8 exp:1 sr
PILE TP8-02.. Tue Dec 11, 2018 V7.4

ASHUGANJ 400 MW COMBINED CYCLE POWER PLANT (EAST) PROJECT AT ASHUGANJ, BRAHMANBARIA.
SYNERGY DESIGN AND DEVELOPMENT

12.9 30.4

[mm/s] [m]

12.4 30.4

14.5 30.4

4/3 0 4 8 12 16 20 24 28 32 36 [m]
SITE APSCL_800 D. 3600[m/s] f:8 exp:1 sr
PILE TP8-03. Tue Dec 11, 2018 V7.4

10.0 30.8

[mm/s] [m]

10.4 30.8

8.5 30.8

4/3 0 4 8 12 16 20 24 28 32 36 [m]
SITE APSCL_800 D. 3600[m/s] f:8 exp:1 sr
PILE TP8-04.. Tue Dec 11, 2018 V7.4

ASHUGANJ 400 MW COMBINED CYCLE POWER PLANT (EAST) PROJECT AT ASHUGANJ, BRAHMANBARIA.