METHOD STATEMENT FOR CONSTRUCTION OF

BORED CAST IN-SITU PILES USING MECHANICAL

ROTARY RIG
Rev. No 0 Method Statement No. Page No. 1

1.1 Scope
 To document a suitable methodology for construction of bored cast in-situ piles using
mechanical rotary rig in accordance with the requirements of the specifications and
drawings.

1.2 References
 Contract Agreement
 Indian Railway Bridge Manual

1.3 Responsibility and Authority

 Construction Manager & Site Engineer shall be responsible for executing the work as
per approved methodology.
 QC In-charge shall be responsible for controlling the testing activities.
 Chief SHE Manager shall be responsible for safety during construction.

1.4 Equipment
 Total Station / Leveling Instrument
 Measuring Tape
 Winch with engine
 Pile driving tools & accessories (bailer, chiseler, tremmie pipe etc.).
 Tripod & monkey
 Mechanical Rotary Rig
 Generator
 Welding machine
 Bar Cutting/Bar Bending Machine
 Batching Plant
 Transit Mixer
 Concrete Pump

1.5 Methodology
1.5.1 Setting Out
 The location of the pile shall be set out with respect to the control points (co-
ordinates) and shall be got checked by Employer’s Representative.
 Guide points / reference points (minimum 3 points) shall be fixed at the
suitable location outside the casing for future reference while executing the pile

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 METHOD STATEMENT FOR CONSTRUCTION OF
BORED CAST IN-SITU PILES USING MECHANICAL
ROTARY RIG
Rev. No 0 Method Statement No. Page No. 2

and these reference points shall be guarded and ensured that these reference
points are not disturbed during piling.
 Truck shall be positioned on the pile in such a manner that the center of the rig is in
line with the center of the pile.
 Each pile shall be identified with a reference number. The convenience of
installation may be taken into account while scheduling the sequence of piling in a
group.
 Piles shall be installed as accurately vertical as possible. The permissible limits for
deviation with respect to position and (inclination) alignment shall confirm to
specifications.

1.5.2 Boring
1.5.2.1 Installation of Permanent MS liners
 Permanent MS Liners of specified thickness painted from outside with coal tar epoxy
shall be provided for piles up to point of refusal or scour depth as applicable.
 The diameter of liners shall be such as to give the necessary finished diameter of
the concrete pile.
 Pilot hole of approximately 1 to 2m deep shall be made at the pile location. First liner
of 1.5m length shall be installed in this pilot hole and shall be checked for verticality
and position with reference to reference points. This liner shall be driven up to
working platform level using monkey/chisel/bailer.
 Second piece of the liner shall be placed on the first liner and the horizontal joint
shall be fully welded and the driving shall be done using monkey/chisel/bailer. It
shall be ensured that 1m boring is available below the liner tip of second liner. For
the purpose of installation of liners boring shall be done using chisel and bailer.
 In the same manner third piece of liner shall be driven ensuring that more than 1m
bore is available below it. Now boring shall be advanced up to the bottom of already
driven liners.
 During liner driving the verticality of the bore shall be constantly checked .
 This liner driving process shall be continued till the refusal.

1.5.2.2 Boring with Mechanical Rotary Rig

 Boring operations shall be done with mechanical rotary rig. The cutting tool shall
have suitable ports for the Bentonite slurry circulation.
 Working platform level shall be above the cut of level.

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 METHOD STATEMENT FOR CONSTRUCTION OF
BORED CAST IN-SITU PILES USING MECHANICAL
ROTARY RIG
Rev. No 0 Method Statement No. Page No. 3

 After installation of the permanent MS liners Pilot bore of 600/850 mm diameter

shall be done with mechanical rotary rig up to the tip level specified in the drawing.
During the boring the verticality of the bore shall be constantly checked. After pilot
bore final bore of 1200mm diameter shall be done with mechanical rotary rig up to
the tip level specified in the drawing.
 Bentonite slurry shall be maintained at 1.5m above ground water level during boring
operations and till the pile is concreted. Bentonite solution shall be made by mixing it
with fresh water using pump for circulation. The density of the freshly prepared
Bentonite suspension shall be between 1.034g/ml to 1.10g/ml. The density of
Bentonite suspension after mixing with deleterious materials in the pile bore shall be
up to 1.25g/ml.
 The depth of the bore shall be checked / measured with the sounding chain.
 The details of pile boring like depth and type of strata shall be recorded.

1.5.3 Cleaning of Pile bore

 After completion of the pile bore upto the required depth, the pile bore shall be
cleaned by three stages flushing of slurry using airlift technique. The bottom of the
pile bore shall be thoroughly cleaned by airlift technique. Cleaning shall ensure the
the pile bore is completely free from sludge / bored material, debris of rock /
boulder etc. Necessary checks shall be made so as to confirm the through cleaning
of the pile bore.
 Pile bore shall be cleaned by fresh drilling mud through tremie pipe before and after
placing the reinforcement and just before the start of concreting.
 Concreting operations shall not proceed if the contaminated drilling mud at the
bottom of the pile bore possesses a density of more than 1.25 t/ cu.m. The drilling
mud sample shall be collected from the bottom of pile bore. For this a solid cone
shall be lowered by a string to the bottom of pile boring. A sampler tube closed at
top with a central hole (hollow cylinder) is lowered over the cone, then a top cover
shall be lowered over the cylinder. Care shall be taken for proper fittings of
assembly to minimize the leakage, while lifting the cone assembly to the ground
surface. The slurry collected in the sampler tube shall be tested for density and
sand content.
 Consistency of the drilling mud suspension shall be controlled throughout concreting
operations in order to keep the bore stabilized as well as to prevent concrete
getting mixed up with the thicker suspensions of the mud.

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 METHOD STATEMENT FOR CONSTRUCTION OF
BORED CAST IN-SITU PILES USING MECHANICAL
ROTARY RIG
Rev. No 0 Method Statement No. Page No. 4

1.5.4 Reinforcement Cutting/Bending/Fixing

 CPCC treated reinforcement bars shall be cut and bent to the required length/size
and shape at rebar yard as per the approved bar bending schedule.
 1mm GI wire shall be used as binding wire.
 The reinforcement bars shall be arranged and fixed as per approved drawing.
 Cover to reinforcement shall be achieved by placing concrete cover blocks of
suitable thickness as specified in the drawings.
 Testing of CPCC treated reinforcement bars shall be done as per approved QAP.

1.5.5 Concreting
 Permit for pouring concrete shall be obtained from the Employer’s Representative.
 The reinforcement cage shall be lowered in to the pile bore with the help of tripod
and winch or tower crane.
 Immediately after the lowering of reinforcement cage, tremmie pipes of 250 mm
with funnel at top shall be lowered into pile.
 Flushing shall be carried out by flushing fresh drilling mud through tremmie pipe to
clean the pile bore.
 Provide a gap/clearance of minimum 300 mm between the tremmie pipe bottom and
the pile tip level.
 The volume of first pour of concrete shall be calculated such that the concrete
flows in single go and seals the bottom of the tremmie pipe so that the subsequent
pour shall be in dry (capacity of funnel shall also be selected based on the same) and
a minimum of 600 mm depth of concrete is to be built up inside the pile bottom.
 Initially a lid shall be provided at the funnel bottom and the concrete of first batch
(calculated volume) shall be poured, the lid shall be removed so that the concrete
shall flow into the tremmie pipe and shall reach the pile bottom.
 During concreting it shall be ensured that the bottom of the tremmie pipe is always
embedded in the concrete of minimum 600 mm.
 During the course of concreting, if tremmie is with drawn out of concrete either
accidentally or to remove a choke in the tremmie, the method given in the following
manner as per sub para 10 of para 415 of IRS Bridge Manual which is reproduced as
under –
“In case of withdrawal of tremie out of the concrete either accidentally or
to remove a choke in the tremie, the tremie may be reintroduced in the following
manner to prevent impregnation of laitance or scum lying on top of the concrete
deposited in the bore. The tremie shall be gently lowered on to the old concrete with
very little penetration initially. A vermuculite plug should be introduce in the tremie.
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 METHOD STATEMENT FOR CONSTRUCTION OF
BORED CAST IN-SITU PILES USING MECHANICAL
ROTARY RIG
Rev. No 0 Method Statement No. Page No. 5

Fresh concrete of slump between 150 mm and 175 mm should be filled in the tremie
which will push the plug forward and will emerge out of the tremie displacing the
laitance/scum. The tremie will be pushed further in steps making fresh concrete
sweep away the laitance/scum in its way. When tremie is buried by about 60 to 100
cm,concreting may be resumed.”
 Initially a vermiculate ball plug shall be introduced in the tremmie, fresh concrete of
slump between 150 mm to 180 mm is filled in the tremmie which shall go on pushing
the plug forward and emerge out of the tremmie. After this the tremmie is pushed
further in steps making fresh concrete displace the lean concrete.
 When the tremmie is buried about 0.6 m to 1.0 m in the concrete then the
concreting is resumed/continued.
 Concreting by tremmie shall continue to allow the initial pours of concrete mixed
with Bentonite slurry, sludge and cut spoils from the bore over flows and the
consistency and quality of the over flowing concrete is comparable to that of
designed mix.
 It shall be ensured that the volume of concrete poured is at least equal to the
theoretically computed volume of the pile being cast.
 The top of concrete in pile as cast shall be above the cut-off-level as shown in
drawings (maximum) to remove all laitance and week concrete and ensure good
concrete at cut-off-level, for proper embedment into the pile cap.
 Concrete shall be built up to the cut off level and shall be confirmed by sounding
chain.
 Measurements shall be recorded.
1.6 Quality Control
 Quality control of all the materials shall be done as per the frequency specified in
the approved Quality Assurance Plan.

1.7Safety
 Work site shall be barricaded.
 All the personnel in the module shall be wearing the personal safety gear like safety
gloves, safety hats and shoes during the operations.
 Minimum number of persons shall be present during the works and unauthorized
persons shall not be allowed.
 The work site shall be cleaned from loose material, cut rebar from the site at regular
intervals.

 
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