K.K. ASSOCIATES SHEET NO.

1
9505- CONSTRUCTION OF PARTIALLY ACCESS CONTROLLED FOUR
LANE ELEVATED HIGHWAY BETWEEN SAMRALA CHOWK ( DESIGN
CHAINAGE KM 0+00) TO LUDHIANA MUNICIPAL LIMIT (DESIGH
CHAINAGE KM12+951) OF NH-95 (SECTION PASSING THROUGH LUDHIANA
CITY) IN THE STATE OF PUNJAB ON EPC MODE UNDER NHDP IV

CLIENT

NHAI

DOCUMENT NAME:- Revision 3 General Method Statement &Anchor Pile Design for Initial Vertical Load
Test by Anchor Pile at Flyover, Near P87 for NH-95,
DATE :- 03-03-2018

CONSULTANT

_______________________

EPC CONTRACTOR

GAMMON ENGINEERS AND CONTRACTORS PRIVATE LIMITED

SUBMITTED BY :-
TESTING AGENCY

M/S K.K. ASSOCIATES

M-521, FIRST FLOOR, GURUHARKISHAN NAGAR,
NEW DELHI-110087, PH.:-011-25276993, 09311141919
E-MAIL:- bee_gupta@yahoo.co.in, sg_iitd@yahoo.com
Testing Agency (K.K. Associates) Contractor
Designed by Checked by

Kautilliya Kumar Saurabh Kr. Gupta

K.K. ASSOCIATES SHEET NO. 2
METHOD STATEMENT FOR INITIAL VERTICAL LOAD TEST ON TP-01 AT
NH-95 IN THE STATE OF PUNJAB ON EPC MODE UNDER NHDP IV

1. Purpose

Purpose of Initial Vertical Load Test is to Find-out the Safe Load carrying capacity on single piles of

uniform diameter computed by Static formula.

2. Relevant Code

Initial pile load test shall be conducted on Test Pile as per I.S. 2911 (PART 4)-2013 CODE OF

PRACTICE FOR DESIGN AND CONSTRUCTION OF PILE FOUNDATION PART 4

LOAD TEST ON PILES.

3. Scope

Pile shall be constructed by DMC Mechanical Winch Rig or by Crawler Mounted Hydraulic Rig as

per I.S. 2911 Part 1 Section-2.

Scope of work includes conducting the Initial Vertical Load Test.

Type of Test - Initial Load Test in Compression on single Pile

a. Test Pile ID - TP-01

b. Design Load - As per Table on Next Page

c. Test Load - As per Table on Next Page

d. Pressure Gauge - (Range 0 to 1000 Kg/cm2) OR (Range 0 to 700 Kg/cm2)

e. Dial Gauges - 4 Nos. having least count 0.01mm

K.K. ASSOCIATES SHEET NO. 3
4. Details of Test Piles

Test Pile ID Diameter Length Safe /Design Test Test

(mm) (Meter) Load (Ton) Load Arrangement
(Ton)
TP-01 1200 AS Per 550 1375 1375 x 1.25
Test Pile = 1720.00
Drawing
K.K. ASSOCIATES 4
SHEET NO.
5. Test Set-up for Initial Pile Load Test in Compression (Vertical)

a. Pile shall be chipped of till the sound concrete level and pile head shall be built up with
M-35 grade of concrete.
(Note:- If the test is being conducted at higher level instead-off cut-off level due to
some site conditions like water table & other reasons then chipping the concrete and
making the pile head up to required level, earth shall be removed below the test level to
cut-off level and casing pipe shall be lowered of higher dia than the dia of pile so that
surrounding soil may not fallen to ensure to eliminate the surrounding friction of any
type. If soil is firmed/ dense then no need to lower the casing pile/ liner.)
b. Over the constructed Pile head a layer of POP/Cement Plaster shall be applied for
precise leveling of head and over the layer of POP/ Cement Plaster bearing plate shall
be placed.
c. Over the bearing plate jack shall be placed and over the jack ram 2nd bearing plate shall
be placed to support the girders.
d. Main girder MG-1 (combination of 2 Girders) shall be placed over the suitable support.
e. At suitable distance from the centre of main girder MG-1, two cross girder named CG-1
and CG-2 (Combination of 2 girders) shall simply rest at the top flange of Main girder
on both the sides.
f. U shape steel reinforcement shall be used to take the Anchorage from 4 Nos. anchor
Piles (design enclosed) which shall pass over the top flange of CG-1 and CG-2 and
shall be welded to the reinforcement of Anchor Piles. U shaped anchors shall be
tightened with the Top flange of CG-1 and CG-2 by small chisels (cheni).
g. All the Jacks shall be operated by single pump and a common manifold.
h. To record the settlements, four Dial Gauges of 0.01 mm sensitivity shall be positioned
at equal distances around the Pile.
i. The dial gauges shall be held by magnetic holders attached to Datum bar which shall be
resting on immovable support.
K.K. ASSOCIATES SHEET NO. 5

Figure No. 2 :-Typical Layout of Anchor Pile with respect to Test Pile (TP-01 of 1200mm dia.)
Note :- (All Dimensions in Mtr.) Dia of Anchor Pile = 1000 mm Nos. of Anchor Piles = 4 Nos. Grade of Concrete: - M-25, Grade of Steel FE 500D.
K.K. ASSOCIATES SHEET NO. 6
Details of Anchor Piles

Test Pile ID Safe /Design Load Test Pile Test Load Anchor Pile Anchor Pile Reinf. Length
(Ton) Dia. (Ton) Dia. (Meter) Length from COL
(Meter.) from COL (Meter)
(Meter) Length
L1
TP-01 550.00 1.20 1375.00 1.00 20.00 20.00
K.K. ASSOCIATES SHEET NO. 7

Photograph 1:- Photograph of Pile Load Test with 4 Anchor Pile conducted by us.

Details of Project :-
Name of work :- C/o Bridge at Hindon River, Ghaziabad.
Client :- Ghaziabad Development Authority and CRRI
Contractor :- M/s Vijay Nirman Company Private Limited
(Girder used in the preset project may not be the same girder as shown in the Photograph)
K.K. ASSOCIATES SHEET NO. 8

E L E V A T IO N A R R A N G E M E N T O F P IL E
LO AD TEST SETU P

Figure 1 :-Typical Elevation of Girders for Initial Vertical Load Test

K.K. ASSOCIATES SHEET NO. 9

6. Application of Load:-

Load shall be applied by Hydraulic Jack as below:-

• 4 Jack of Ram Diameter 30 cm

Loading computation:-

Jack Area = 4 x pi/4 x (302) = 2827.43 cm2

Load = Jack Area x Pressure (700 kg/cm2) = 2827.43 x 700

= 1483.65 Ton

OR

• 1 Jack of Ram Diameter 48 cm

Loading computation:-

Jack Area = pi/4 x (482) = 1808.64 cm2

Load = Jack Area x Pressure (700 kg/cm2) = 1808.64 x 700

= 1266.00Ton
K.K. ASSOCIATES SHEET NO. 10

7. Calibration of equipment used in the test:-

• Pressure Gauge :-

Pressure Gauge shall be got Calibrated by from NABL Accredited Laboratory from Delhi.

• Dial Gauge :-

Dial Gauge shall be got Calibrated by from NABL Accredited Laboratory from Delhi.
K.K. ASSOCIATES SHEET NO. 11
8. Measurement of Load :-

Load shall be measured by the taking the observation of pressure from the calibrated pressure gauge.

For example for 20 Kg/cm2 pressure Load for the computation shall be as below:-

• 3 jack of Ram Diameter 30 cm

Loading computation:-

Jack Area = 4 x pi/4 x (302) = 2827.43 cm2

Load = Jack Area x Pressure (20 kg/cm2) = 2827.43 x 20

= 56.55 Ton

• 1 jack of Ram Diameter 48 cm

Loading computation:-

Jack Area = pi/4 x (482) = 1808.64 cm2

Load = Jack Area x Pressure (20 kg/cm2) = 1808.64 x 20

= 36.17 Ton

9. Measurement of Settlement :-

Settlement of Pile head shall be measured by four nos. dial gauge having least count of 0.01 mm

sensitivity resting on the Datum Bar with the help of Magnetic Base. Plunger of Dial Gauge shall rest

on the Glass Strip.

Load measured by pressure gauge and settlement measured by the dial gauge as above shall be used

for plotting the load v/s settlement graph and arrive at the Safe Load Capacity of Pile.

10. Attachment of Anchors of Anchor Piles to the Girders for Reaction:-

Main Longitudinal reinforcement from the Anchor Piles shall be welded to the U- Shaped

Reinforcement Anchors. At the top of flange wedge shaped packing (Cheni) as shown shall also be

used.
K.K. ASSOCIATES SHEET NO. 12
11.Precautions

Precaution shall be taken during conducting the test that Datum bar is not disturbed by human

movement.

12.Safety Arrangements

• Safety tape shall be installed all around the test location and safety helmet shall be used while

conducting the test.

• During the application and release of Load only Testing agency representative are allowed in the

Pit area.

• Earth of Welding Machine shall be disconnected.

• Sitting arrangement if any shall be at least 20-30 meters away from Test Pit.

• Calibration certificate of Dial gauges and Pressure Gauge shall be available at Site.
K.K. ASSOCIATES SHEET NO. 13

13.Terminology

a. Datum Bar - A rigid bar placed on immovable supports.

b. Net Displacement - Net movement of the pile top from the original position after

the pile has been subjected to a test load and subsequently released.

c. Test Pile - A pile which is meant for Initial test and will not be a working

pile in any case.

d. Total Displacement - The total movement of the pile top under a given load.

e. Safe Load - It is a load on a pile derived by applying a factor of safety on

ultimate load capacity of pile as Calculated by Static Formula.

f. Working Load - The load assigned to a pile according to design.

g. Working Pile - A pile forming part of foundation of a structural system which

may be used for routine load test.

K.K. ASSOCIATES SHEET NO. 14

14.Test Procedure for Initial Pile Load Test in Compression

a. The test shall run in general as per procedures laid down in I.S. 2911 (PART-IV)-2013.
b. The pressure gauge of Jack and Dial Gauges shall be set to zero before application of any load.
c. The load shall be applied in increment of about 1/5 of the Safe Load and shall be maintained as
given under:-
Period of maintaining the Displacement of Pile top

Load

60 minutes If displacement of Pile top is less than 0.2

mm in first 60 minutes.

120 minutes If displacement of Pile top is more than

0.2 mm in first 60 minutes. After 120

minutes i.e. 2 hrs, next increment shall be

applied whatever may be the

displacement.

d. load increment shall be applied once the settlements under the applied load has been settled for
which I.S. code has mentioned threshold rate of settlement 0.02 mm per hour. Relevant clause is
pasted below :-

e. Further next increment shall be applied and shall be maintained as stated above. Increment shall be
given till the Final Test Load is achieved and same shall be maintained for 24 hrs.
f. Final Test load shall be unloaded in the same decrement and rebound shall be recorded at the
intervals of 15 minutes.
K.K. ASSOCIATES SHEET NO. 15
15. Procedure for resetting of dial gauges

4 Nos. of dial gauges of least count 0.01 mm with travel 0-25 mm shall be used to measure the pile

settlement. Once the settlement of Pile is observed around 20 mm all the dial gauges shall be reset one

by one and settlement shall be recorded cumulatively as explained below :-

Dial gauge A is showing 20.01 mm settlement, it shall be reset to 0.00 mm and settlement shall be

recorded cumulatively in the test record. So on for dial gauges B, C and D.

K.K. ASSOCIATES SHEET NO. 16
16.Acceptance Criterion

As per clause 7.1.5 of I.S. 2911 (PART-IV)-2013 LOAD TEST ON PILES, the Safe Load will be the
Least of the following (a and b):
a) For piles up to and including 600 mm diameter:
1) Two-thirds of the final load at which the total displacement attains a value of 12 mm unless
otherwise required in a given case on the basis of nature and type of structure in which case, the safe
load should be corresponding to the stated total displacement permissible; and
2) Fifty percent of the final load at which the total displacement equal to 10 percent of the pile
diameter in case of uniform diameter piles and 7.5 percent of bulb diameter in case of under-reamed
piles.
b. For piles more than 600 mm diameter:
1) Two-thirds of the load at which the total displacement attains a value of 18 mm or maximum of 2
percent pile diameter whichever is less unless otherwise required in a given case on the basis of
nature and type of structure in which case, the safe load should be corresponding to the stated total
displacement permissible.
2) 50 percent of the final load at which the total displacement equal to 10 percent of the pile diameter
in case of uniform diameter piles and 7.5 percent of bulb diameter in case of under-reamed piles.
K.K. ASSOCIATES SHEET NO. 17

DESIGN OF ANCHOR PILES FOR C/O

MAIN BRIDGE NEAR P87

AS PER IRC 78:2014

K.K. ASSOCIATES SHEET NO. 18

Design of Anchor Piles

Name of structure Anchor Pile Length from GL 20.00 Meter
Project Cut off level 245.24 AS per Test Pile Drawing No.
Anchor Pile dia
(Mtr.) 1
Type of Test Initial Test
Test Pile No. TP-1 Depth of Water Table Considered for Anchor Pile Design 30 Meter
Factor for Pile
Load Test 2.5 irc NO Meter AS per Soil Report No.
As per Appendix-5, Page 76 IRC 78:2014 States (Effective overburden
pressure at pile tip limited to 20 times diameter of
Length Considered for Over Burden Pressure (20 x D) 20 Meter pile for piles having length equal to more than 20 times diameter)
Design Load as Per Drawing 550.00 Ton AS per Test Pile Drawing No.
Test Load 1375 Ton AS per Test Pile Drawing No.
Nos. of Anchor Piles to be used for reaction 4 As Shown in the Anchor Pile Drawing
Uplift Load on each Anchor Pile 343.75 Ton Total Test Load/ Nos. of Anchor Piles
Reduction Factor for Ultimate Uplift Capacity of Pile 0.7 As per Clause 709.3.6.2 of IRC 78:2014
FOS for Computation of Allowable Uplift Load on Pile 2 (As per IRC : 78 :2014 FOS on Uplift Capacity is 2.5 However same has been adopted as
2.0 and has been rationalized as the Piles shall
be used as Temporary Anchor Piles and not the
part of permanent structure.)
K.K. ASSOCIATES SHEET NO. 19

Design of Anchor Pile by Static Formula As per IRC 78:2014

Effective
Effective
Depth over
Depth Depth over
of Soil burden
of Soil of Pile Thickness Density burden Shaft
layer D Asi Cu ø pressure
layer Rem. below of Layer ά Ki (γ ) tanø pressure resistance
From (m) (m2) Ton/m2 (Degrees) at
To COL Li (m) Ton/m3 at Tip of Qs (Ton)
EGL Centre
(Meter) (Meter) Layer
(Meter) of Layer
(Ton/m2)
(Ton/m2)
247.54 245.24 COL -242.94 2.30 0.00 1.00 7.22 1.50 0.00 0.00 0.00 0.00 0.00 0.00 0.00
245.24 244.54 -242.24 0.70 0.00 1.00 2.20 1.50 1.70 0.00 25.00 0.47 1.19 0.60 0.91
244.54 241.54 -239.24 3.00 0.00 1.00 9.42 1.50 1.70 0.00 28.00 0.53 6.29 3.74 28.10
241.54 239.04 -236.74 2.50 0.00 1.00 7.85 1.50 1.70 0.00 31.00 0.60 10.54 8.42 59.54
239.04 236.04 -233.74 3.00 0.00 1.00 9.42 1.50 1.70 0.00 31.00 0.60 15.64 13.09 111.14
236.04 232.54 -230.24 3.50 0.00 1.00 10.99 1.50 1.70 0.00 31.00 0.60 21.59 18.62 184.39
232.54 227.24 -224.94 5.30 0.00 1.00 16.64 1.50 1.00 0.00 31.00 0.60 26.89 24.24 363.58
20 x
227.24 224.24 D
-221.94 2.00 0.00 1.00 6.28 1.50 1.00 0.00 31.00 0.60 28.89 27.89 157.86
Length of Pile below COL 20.00 Meter 905.52
Ultimate Uplift Frictional resistance of Pile
after applying reduction factor of 0.7 as per
IRC 78:2014 633.86 Ton
Self Weight of Pile added to Uplift Capacity 39.25 Ton
Total Ultimate Uplift Capacity of Anchor Pile 673.11 Ton
Qsafe uplift (T) 356.18 Ton
Uplift Load on each Anchor Pile 343.75 Ton
Hence Safe
Total Ultimate Uplift Capacity of All Anchor Piles 2692.442 Ton
Ultimate Compressive Capacity of Test Pile 1375 Ton
Arrangment Load 1718.75
Reaction Required/ Reaction Available 1.57
Since Both the Test Pile and Anchor Pile are adopted in the same Soil Strata if Test Pile is able to sustain the Test Load of 1375 Ton which inturn is
equivalent to the ultimate compression capacity of Test Pile hence Anchor Piles will certainly be able to resist the Ultimate Uplift Load of 2692 Ton
Hence Anchor Piles are Much Safer and Reaction Available is 1.95 Times the reaction required.
Hence Safe
K.K. ASSOCIATES SHEET NO. 20

Design of Reinforcement of Anchor Piles

Top Portion Reinforcement
Load on Each Anchor Pile 343.75 Ton
Factored Load on Each Anchor Pile 429.69 Ton Factored Load = Load on Anchor Pile X 1.25
Dia of Reinforcement (mm) 32.00 mm
Wight of Steel per Meter 6.31 Kg/meter
Yield Stress of Reinforcement 500.00 N/mm2
Permissible Stress of Reinforcement 435.00 N/mm2
Load carrying Capacity of Each Bar 34.97 Ton
Nos. of Longitudinal Bars to be provided 12.29 Say 14.00 Nos.
Provide 8 mm dia Rings @ 250 c/c
Length of Bar from COL 20.00 Say 20.00 Mtr.
K.K. ASSOCIATES SHEET NO. 21

Design of Welding Length for conducting Pile Load Test

Package
Name of structure
Type of Test Initial Vertical Load Test
Factor For Load Test 2.5
Safe/Working/Design Load 550.00 Ton
Test Load 1375.0 Ton
Arrangement required (25 % Extra) as per I.S. 2911 Part-4 1719
Nos. of Anchor Piles to be used to take reaction 4 Nos.
Uplift Load on each Anchor Pile 429.6875 Ton
Load on Each Anchor Pile 429.69 Ton
Dia of Reinforcement (mm) 32.00 mm
Nos. of Longitudinal Bars provided 14.00
Load on each Bar 30.69 Ton
Permissible Stress in the field fillet weld 86.40 N/mm2 (Clause 7.1.2 & 7.2 of I.S. 816)
Size of Weld 12.80 mm
Strength of Weld per mm length = K (0.7) x Size of Weld x
Strength of Weld per mm length of weld 774.14 N/mm permissible stress
Length of Weld Required 396.46 mm
Provide Weld length of 400 mm one side
K.K. ASSOCIATES SHEET NO. 22

S C H E D U L E O F A N C H O R P ILE S (T A B LE -1)

T H IS D R A W IN G IS V A L ID O N L Y C O N D U C T IN G IN ITIA L L O A D T E S T F O R T P -0 1 , P 8 7 , N H -9 5 A N D S H A LL
N O T B E U S E D A T A N Y O T H ER L O C A T IO N .

T Y P IC A L L A Y O U T A R R A N G E M E N T
O F A N C H O R P ILE S

T Y P IC A L P L A N

T Y P IC A L R E IN F O R C E M E N T D E T A ILS O F A N C H O R P IL E

T Y P IC A L R E IN F O R C E M E N T D E T A IL S O F A N C H O R P ILE E L E V A T IO N A R R A N G E M E N T O F P IL E
LOAD TEST SETUP

S C H E M E F O R IN IT I A L P IL E L O A D
K .K . A S S O C IA T E S T P -1 (1 2 00 M M D IA T E S T P IL E S )

Note :-Kindly replace the sheet refer drawing no.:- KKA/GAD/NH95/TP-01/P87/R3

K.K. ASSOCIATES SHEET NO. 23

TYPICAL REINFORCEMENT DETAILS OF ANCHOR PILE

TYPICAL REINFORCEMENT DETAILS OF ANCHOR PILE

Figure 5 :- Typical Details of Anchor Piles for Test Pile TP-1
Note :- Reinforcement in the Anchor Piles shall be placed as shown in “details A” below so that Main
Girders CG-1 & CG-2 can easily pass through the Anchor Pile and U Shaped Anchors can easily be
welded with Bars of Anchor Piles.
Grade of Concrete in Anchor Piles shall be M-25.
Note:- If Print is not clear please refer Drawing no:- KKA/GAD/NH95/TP-01/P87/R3
K.K. ASSOCIATES SHEET NO. 24

Form No. 2:- Loading Increment for Initial Vertical Load Test

Project
Location Test Pile No. TP-01
Safe Load 550.00 Ton FOS 2.5
Test Load 1375.00 Ton Increment 110.00 Ton
Ram Dia 30 cm Ram Area of 1 Jack 706.86 Sqcm
Nos. of jacks 4 Ram Area of 4 Jack 2827.43
Sr. No. Theoretical Theoretical Actual Pressure Actual Remarks
Load Pressure Load

(M.T.) (kg/cm2) (Kg/cm2) (M.T.)

0 0.00 0.00 0 0.00 Initial Test
Setup
1 110.00 38.90 40 113.10
2 220.00 77.81 80 226.19
3 330.00 116.71 120 339.29
4 440.00 155.62 160 452.39
5 550.00 194.52 190 537.21
6 660.00 233.43 230 650.31
7 770.00 272.33 270 763.41
8 880.00 311.24 310 876.50
9 990.00 350.14 350 989.60
10 1100.00 389.05 390 1102.70
11 1210.00 427.95 430 1215.80
12 1320.00 466.85 470 1328.89
12.5 1375.00 486.31 490 1385.44
Load
Maintained
for 24 Hours
Rebound Started
12 1320.00 466.85 470 1328.89
11 1210.00 427.95 430 1215.80
10 1100.00 389.05 390 1102.70
9 990.00 350.14 350 989.60
8 880.00 311.24 310 876.50
7 770.00 272.33 270 763.41
6 660.00 233.43 230 650.31
5 550.00 194.52 190 537.21
4 440.00 155.62 160 452.39
3 330.00 116.71 120 339.29
2 220.00 77.81 80 226.19
1 110.00 38.90 40 113.10
0 0.00 0.00 0 0.00
K.K. ASSOCIATES SHEET NO. 25

Form 1:- Test Details for Initial Vertical Load Test No. ___
Abstract of Initial Vertical Load Test conducted of Pile No. TP-___, at Chainage __________

Client = NHAI

Contractor =
1. Pile identification no. TP-1
2. Date of casting of pile
3. Date of load test
4. Type of test Initial Vertical Load Test
5. Loading method Maintained Load
Method
6. Dia of Test Pile (mm) mm
7. Length of pile below COL (Meter)
8. Grade of concrete M-35
9. Reinforcement in pile As per Drawing
10. Working load/ Safe Load Ton
11. Test load Ton
12. Test load applied
13. Nos. of Jack
14. Ram dia. of Jack
15. Ram Area (cm2)
16. Pressure gauge 0-700 Kg/cm2
17. Nos. of Dial Gauges of sensitivity 0.01mm 4
18. Total settlement
19. Net settlement
20. Rebound settlement
K.K. ASSOCIATES SHEET NO. 26
Form 2- Settlement Record

Name of Work Sheet No.

Client Dia of Pile
Contractor Length below COL
Sub-Contractor Grade of Concrete
Ram Dia. cm Safe Load
Ram Area Sqcm Test Load
Pile No.
Test No

Settlement (mm) Average Signature

Sr. Time Pressure Load Rem-
Settlement
No (Hrs) (kg/cm2) (Ton) arks
DG-A DG-B DG-C DG-D (mm) Client Cont
K.K. ASSOCIATES SHEET NO. 27
Sheet No.

Settlement (mm) Average Signature

Sr. Time Pressure Load Rem-
Settlement
No (Hrs) (kg/cm2) (Ton) arks
DG-A DG-B DG-C DG-D (mm) Client Cont
K.K. ASSOCIATES SHEET NO. 28
Sheet No.

Settlement (mm) Average Signature

Sr. Time Pressure Load Rem-
Settlement
No (Hr) (kg/cm2) (Ton) arks
DG-A DG-B DG-C DG-D (mm) Client Cont
K.K. ASSOCIATES SHEET NO. 29

CALIBRATION
CERTIFICATE
K.K. ASSOCIATES SHEET NO. 30
K.K. ASSOCIATES SHEET NO. 31
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K.K. ASSOCIATES SHEET NO. 33
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K.K. ASSOCIATES SHEET NO. 38