METHOD STATEMENT FOR CAST IN SITU BORED PILE ( DMC METHOD)

MASTERS Page No 1
“SUNSHINE” IN SHRIRAM GRAND CITY, UTTARPARA, HOOGHLY of 12

METHOD STATEMENT
FOR
CAST IN SITU BORED PILE
USING
DIRECT MUD CIRCULATION METHOD
BY
POLYMER

CLIENT : SPL ESTATES PVT. LTD

PMC : MASTERS DEVELOPEMENT MANAGEMENT (I) PVT. LTD

CONTRACTOR: SHAPOORJI PALLONJI AND COMPANY PRIVATE LIMITED (SPCPL)

Rev Date Description Prepared By Checked By Approved By

no
00 METHOD
STATEMENT FOR
BORE PILING
WORK

1. Purpose:
 METHOD STATEMENT FOR CAST IN SITU BORED PILE ( DMC METHOD)

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The purpose of the procedure is to provide details of safe operating system of piling
operation for building work foundation, Bore Piling work by DMC method, construction
plant & manpower to ensured that piling operation are carried out safe manner .This
procedure will help to ensured piling standard & a safe & healthy work environment at site
at all time.

2. Scope:
This method statement details the procedure for Bore Piling Work by DMC Method. Before
commencing this activity the site execution team is recommended to evaluate risk by
conducting risk assessment.

3. Role & Responsibility:

The Project Leader, Construction Manager and , the Execution Engineer & QA/ QC In
charge of Shapoorji Pallonji and Company Private Limited shall be responsible for the
Overall implementation of this method statement.

4. Reference Code:
1. Contract Document.
2. Good for Construction Drawings for Piles.
3. Product Technical Sheet of Polymer.
4. Material Safety Data Sheet (MSDS) of Polymer.
5. IS 14593 – Latest edition with all amendments.
6. IS: 2911 (Part 1, Section 2) – Latest edition with all amendments.
7. IS 2911 (Part 4) – Latest edition with all amendments.
8. IS 456 – Latest edition with all amendments.
9. IS 1786 – Latest edition with all amendments.
10. BOQ

5. Machineries Used:
 Tripod with Winch
 Kelly
 Chisel
 Bailer
 Wire Rope with D-Shackle
 Guide Casing (Minimum Length of 3 meter)
 DMC Rod.
 Tremie Pipe with Hopper
 Boring Pump (Minimum 20HP) etc.
 Polymer Vat (MS,3 partition recommended)
 3 Phase Welding Machine.

Manufacturers Test Certificate of the Polymer shall be produced. Calibration

certificate of the above equipment’s shall be produced / submitted.
 METHOD STATEMENT FOR CAST IN SITU BORED PILE ( DMC METHOD)

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6. Materials to be used:
 Polymer- Poly-Fluid By Eco Drilling Fluids Pvt Ltd
 Reinforcement Steel
 Concrete
 Construction Water
 Binding Wire (18 Gauge)
 Welding electrode (E-6013)

7. Manpower Deployed for Piling Work. :

A. Supervisor
B. Rig Operator
C. Welder-
D. Unskilled Worker
E. Steel Fitter

8. Construction Procedure:
a) Survey Work
1. Surveyor to give all Pile point with Total Station as per latest approved drawing.
2. Reference points shall be marked or fixed at a suitable distance from Pile points to
cross checked the center of the Pile the boring operation.
3. The Setting out of Pile positions shall be carried out by qualified Surveyor for every
location.
4. Pile Points to be checked by Developer /PMC before start of boring.

b) Rig Fixing & Alignment.

1. After Pile point is cleared by Developer / PMC Rig is to be placed maintaining all
safety requirement. (See detail in Risk Assessment).
2. Pile Location shall be checked by Bailer in case of Tripod Rig.
3. Verticality of Rig to be checked as per the given point.

c) Handling Polymer.
1. Polymer shall be delivered to site in Bag and stored in a dedicated, dry storage hut.
2. The pH of Water should be adjusted before adding Polymer. For bringing the water pH
to the requirement, add Sodium Hydroxide in a concentration of 48% @ 1 liter/ Cum of
Water.
3. The Polymer powder shall be mixed together with water at a minimum rate initially, us-
ing hand stirring and pump and pumped into the storage silos or tanks. Polymer when
mixed in tanks shall be added to water that is passed through tube or hopper, across a
stationery panel or surface, stirred or agitated, in a manner which avoids the formation
of lumps and results in a homogeneous mixture of polymer in water. The polymer
slurry may be agitated until required viscosity is developed and particles of partially dis -
solved polymer do not settle in the bottom. Agitation is normally done by blowpipes,
motorized stirrers or other suitable and effective means. The mixing tank should be
 METHOD STATEMENT FOR CAST IN SITU BORED PILE ( DMC METHOD)

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constantly in agitation. The Properties of freshly prepared Polymer solutions are as fol -
lows.
a. Viscosity: 40-45 Sec.
b. Density < 1-1.04 g/ ml.
c. pH: 09-12

4. The Polymer storage, circulation and treatment system will be developed to suit experi-
enced site conditions including production, site layout, soil conditions and disposal re-
quirements. It will however consist of separate storage for fresh (flushing) Polymer, ex -
cavation Polymer and contaminated (disposal) Polymer. The size and relative type and
location of each storage unit will vary as dictated by the above. Polymer while in stor-
age will be agitated consistently by the system of pumps and/or compressors to pre -
vent settlement of the Polymer from the solution and properties will be checked and
recorded at least once a day.
5. Polymer will be delivered to and from the trench by a system of pumps, valves and
100mm diameter pipes.
6. Upon completion of excavation the used Polymer will be replaced completely.
7. Disposal of redundant Polymer shall be performed in bulk form. In order to undertake
this, the Polymer must be discharged into the designated storage tank / VAT on site
and mixed with dry spoil and /or lime before disposal in bulk form.

d) Bailer & Chisel for Tripod Rig placing

1. Guide casing is then gradually hammered down in the bore formed by Bailer & Chisel
up to the required depth.
2. During placing & hammering of casing position of the same is to be checked
continuously.

e) Points to be checked by Developer/PMC in presence of SPCPL

representatives

1. Length & Dia of Casing before starting Casing fixing.

2. Verticality, Length & Dia of Chisel before starting Casing fixing.
3. Verticality & length of DMC Rod before starting Casing fixing.
4. Dia & Length of Tremie Pipes before starting Casing fixing.
5. Chisel to be fixed with DMC Rod. The DMC Rod shall be connected with Wire Rope
of Winch.
6. During boring verticality of DMC Rod is to be checked at frequent interval
throughout the entire boring period.
.
f) Cage Making:
1. Cage is to be fabricated with approved Steel only. (TMT Fe 500)
2. Cage is to be fabricated as per latest approved drawing.
3. All welding is to be checked at reinforcement yard before sending to pile location.
4. During lowering into the bore, no part of the cage should be damaged.
 METHOD STATEMENT FOR CAST IN SITU BORED PILE ( DMC METHOD)

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5. Welding at the lap joint shall be done as per drawing and checked thoroughly
before lowering.
6. Grade of Cover block shall be same as Grade of Concrete for piling/PVC cover block.
7. Cover blocks shall be tied to the reinforcement properly by annealed 18 gauge
binding wire and by welding with 3.15 mm or 2.5 mm dia welding rods adequately.

g) Detail Procedure:
1. In case of Tripod Rig, Bailer brought to the exact location of a particular pile to be
installed with the help of a Wire Rope & Winch of suitable capacity.
2. Bailer in case of Tripod Rig is raised and lowered freely in the pile location a number of
times so that a bore of suitable size as necessary for placing a mild steel Guide Casing.
3. This guide casing is then gradually hammered down in the bore formed ( Bailer in case
of Tripod Rig) up to the required depth the top being kept at a suitable level and the
boring with the help of the Bailer continued till the casing is 300 mm above Existing
Ground Level.
4. Thereafter Bailer to be removed & Chisel fitted below the required length of connecting
pipe (DMC rod) to be placed in the bore hole.
5. The Polymer suspension shall be made by mixing it with fresh water by circulation and
the density of freshly prepared Polymer suspension shall be 1- 1.04 g/cc , pH shall be
09-12 & Viscosity before discharge to Bore Hole shall be 40-45 Sec (for stabilizing the
sides of the bores). The suspension is pumped under pressure through the DMC rod
such that the same is discharged from the chisel below and comes upwards through the
annular space between the bored hole and the DMC rod.
6. During such circulation, Chisel with DMC Set is moved up and down facilitating cutting
of the soil strata below and conveying the excavated soil upwards thus increasing the
depth of the bore.
7. The slurry level should be maintained at least 2 m above the water table to balance
hydrostatic pressure and to prevent collapse of unstable formation. If the slurry drop
below this level, the operation should be paused and the proper slurry level re-
established by adding fresh water and polymer directly to the hole or by transferring
premixed slurry from holding tank to the hole.
8. Boring is thus continued till the specified depth is reached extending the DMC rod from
time to time.
9. The cutter assembly is then taken out and the bore is cleaned by flushing with Polymer
slurry circulation to ensure that the bottom is free from bored materials.
10. The reinforcement cage is then gradually lowered (with in-situ tack welding for laps)
into the bore till the same has reached up to the bottom of the bore.
11. An open-ended Tremie pipe of suitable diameter is then lowered into the bore till it
reaches almost the bottom of the bore. The top end of the pipe is kept at a suitable
level. A funnel is fitted at the top of the Tremie pipe.
12. After cleaning Polymer Vat, the bore shall be flushed with fresh Polymer slurry. Flushing
should be continued till coarse materials cease to come out with the overflowing fluid.
The finer materials will normally remain suspended in the fluid but they do not pose
any problem.
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13. The first batch of sufficient quantity of Ready Mixed Concrete is then poured by chute
cart or any other suitable means into the funnel / Tremie Hopper so that the water in
the Tremie pipe is pushed out and the concrete is discharged through bottom end of
the pipe filling 300 mm to 500 mm height of the bore and also retaining some Concrete
inside the Tremie pipe.
14. A steel plate or a ball is placed at the bottom of the hopper and the hopper is filled with
concrete. The first charge of concrete is sent down the tremie by removal of this plate
or ball. Additional concrete is then added into the hopper and by surging action is
pushed down the tremie and into the pile bore to the bottom of the pile.
15. A few such batches having been poured the Tremie pipe is gradually raised up to 1 m
maintaining the tip of the Tremie pipe always inside the concrete filled in the bore
already and thus avoiding concrete coming in contact with the Polymer or other
impurities.
16. The Tremie is moved up and down also up to 1 m for compacting the concrete
discharged into the bore.
17. The process of pouring concrete and gradually lifting the Tremie pipe is thus repeated
till the bore is filled up to the required finish level to complete the process.
18. The guide casing is then withdrawn and the rig moved to the position of the next pile
19. Empty Bore shall be filled with Silver Sand or Excavated Earth, suitable for filling.

9. Quality Control:
Following Measures are taken to Control of Quality of Piling Work:

1. Adequate supply of water of good quality should be available for slurry making and
water shall always be available to take care of scheduled operations and unknown
contingencies. A tank for storage of water shall be used to ensure sufficient and
undisturbed slurry mixing.
2. All ingredients for concreting shall be tested as per approved Inspection Test Plan and
get approved by Client or their representative.
3. All Steel & Cement shall be tested as per approved Inspection Test Plan and get
approved by Client or their representative.
4. Density of Polymer shall be checked before boring & after washing of bore.
5. The pH of Reused suspension shall be 09-12 & Viscosity shall 40-45 Sec. and density
≤1.06.
6. Prior to commencement of concreting, the density of the Polymer suspension shall be
≤1.06 g/cc , pH shall be 8-12 & Viscosity shall 45-55 Sec.
7. During concreting, Slump is to be checked to ensure the proper workability of the
concrete. Slump should be in the range of 150-180mm.
8. Where cut-off level is less than 2.5 m below the ground level, concrete shall be cast to
a minimum of 600 mm above cut-off level. For each additional 0.3 m increase in cut-off
level below the working level, additional coverage of minimum 50 mm shall be allowed.
9. Cubes shall be taken for 7 days & 28 days Compressive Strength test. No. of Set shall
be as per Project Specification.
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10. A sliding plug of polystyrene or similar material lighter than water and approved by the
Client / PMC shall be placed in the Tremie pipe to prevent direct contact between the
first charge of concrete in the Tremie and the Polymer slurry.
11. Two numbers of alignment bar to be used to hold the reinforcement cage vertically
during concreting.
12. The Lap of Reinforcement Cage should be maintained in staggered fashion as per
provision of IS Code of Specification.
13. The numbering of DMC Rod shall be ensured by welding / panting prior to
commencement of Boring.
14. In case of any discrepancies, the order of precedence shall be as follows.
1. The Technical Specification & Bill of Quantities (BOQ) of the Contract
Agreement.
2. IS Code of Specification & Relevant Code of Practice.
3. Approved Work Method Statement.

10. Records:
1. Formats for Bore Detail
2. Pour Cards
3. Bar Bending Schedule.
4. Survey Report

11. Health Safety & Environment:

A. General Guideline:
a) Underground utilities like gas pipe line & electrical cable line to be checked before
start of work. Area clearance should be taken from the concerned authority.
b) Proper planning & precaution to be taken to prevent & control the accident the
engaged workman.
c) All surface obstacle to be removed at the work site.
d) Providing proper levelled ground for piling rig & ensures that Piling Rig m/c with
stand properly on its three legs & all legs must be locked with the ground / base by
fixing rod/pin to its foot rest.
e) Third party inspection of piling rig & other lifting tools tackles to be conducted
before use.
f) Piling rig driven equipment, rig m/c should be inspected before starting the activities
& also checked the condition of pulley & hoist rope for the smooth movement. P&M
dept. shall inspect all the tools & tackles in schedule time.
g) Bore should be barricaded or covered by mesh/ gratings before concreting.
h) Only competent & experience person shall be permitted to operate the Piling , rig
m/c.
i) Proper PPEs (Safety Helmet, Gum Boot, Safety Shoes, Full body harnesses, fall
arrester, hand gloves, etc) to be ensured to the workers.
j) Proper illumination (Minimum. 50 Lux) to be ensured for night work & all electrical
connection to be provided through 30ma ELCB,s RCCB,s & MCB,s.
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k) All rotating parts of rigs, Pumps, etc to be well guarded.

l) Site supervisor to be ensured from standing or working near to the rotating part of
the m/c.
m) Concreting should be carried out with proper supervision & care must be taken at
the time of reversing of transit mixer by deploying signalman/banks-man.
n) Concrete Pouring chute should be properly supported and guide rope shall be used
to Control the Movement of funnel hopper.
o) Handle the polymer suspension with care, use & mix it as per the manufacturer
recommendation. It should be removed from site as per requirement.
p) Regular checking for the stability of rig m/c to be ensured.
q) All pile-driving equipment should be of good design and of sound construction,
taking into account as far as possible ergonomic principles and to be maintained
properly.
r) Pile work to be carried out only under the supervision of a competent person.
s) Pile-drivers should be firmly supported on heavy timber still, concrete beds or other
secure foundation.
t) Pile-drivers to be adequately guyed.
u) Erect pile-drivers in dangerous proximity to electrical conductors to ensure they are
first made disconnected or dead.
v) Two pile-drivers are erected at one place they should be separated by a distance at
least equal to twice the length of the longest pile from the pile-driver.
w) Adequate precautions should be taken, by providing stirrups or by other effective
means, to prevent the rope from coming out of the top pulley or wheel.
x) A responsible person for inspecting pile driving equipment inspects such equipment
before taking it into use and takes all appropriate measure as required for the safety of
building workers before commencing piling work by such equipment.
Y) Area Barricades to keep non- essential Personnel out of exclusion zone.
Z) Proper training should be conducted on Material handling.
1) Fire extinguisher should be provided near to the piling area.
2) Materials should be stacked orderly.
3) Suitable access & proper housekeeping should be maintained.

B. Pile operation:-
Before commencing the pile operation it is important to consider the following.
1. Stability of Adjacent Structure
2. Protection of Operator
3. Instruction to and Supervision of Building Workers working on a pile driving
Equipment.
4. Entry of Unauthorized Person.
5. Inspection and Maintenance of pile driving Equipment.
6. Operation of Pile -Driving Equipment.
7. Use of Polymer.
8. Pile Testing.
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B.1. Stability of adjacent structure:-

The Site engineer/supervisor shall ensure that there is any question of stability of structure
for its adjoining areas to be piled, such structure is supported, where necessary, by
underpinning, sheet piling, bracing or by other means to ensure safety and stability of such
structure and to prevent injury to any Person .

B.2. Protection of operator:-

Operator of every pile driving equipment is protected from falling objects, stem, cinders or
water.

B.3. Instruction to and Supervision of Building Workers working on pile driving equipment:-
The Site engineer/supervisor shall ensure that every building worker working on pile driving
equipment is given instruction regarding SOP to be followed in piling operation & is
supervised by a responsible person throughout such work.

B.4. Entry of unauthorized person:

Ensure that all piling area where pile driving equipment is in use is effectively cordoned off
to prevent entry of unauthorised person.

B.5. Inspection & maintenance of pile driving equipment:

a) Pile driving equipment is not taken into use until it has been inspected by a responsible
person & found to be safe for such use.
b) Pile driving equipment in use is inspected by a responsible person for such inspection at
suitable intervals to ensure safety to the worker working on such equipment.
c) All pile lines & pulley blocks are inspected by responsible person before the beginning.

B.6. Operation of Pile-Rig:

1. Only experienced and trained person should operate pile -drivers, so as to avoid any
probable danger from such operation.
2. Pile operations should be governed by generally prevalent and accepted signals so to
prevent any probable danger from such operations.
3. Every building worker employed in pile – driving operation or in the vicinity such pile -
driving operation wears ear practicable and safety helmet or hard and safety shoes, safety
harness.

B.7. Use of Polymer:

1. Polymer should be stacked as per the manufacturer recommendation (MSDS) & away
from the working place.
2. Polymer mixing vats should be hard barricaded with display of signboard.
3. Use proper PPEs like nose musk, goggles, gum boots, hand gloves for mixing & handling
the betonies
4. Dispose Polymer waste as per manufacturer recommendation or concern with local
authorities for disposal.
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5. Don’t live the betonies vats open & don’t fill it with normal soil/ sand as regular
backfilling.

B.8. Pile Testing:

1. The testing of pile is conducted under the supervision of a responsible person for such
testing.
2. All practicable measure like displaying of warning notice, barricading the area & other
similar measure are taken to protect the area where the pile testing is carried out.
3. Entry to a pile testing area is prohibited to general public to ensure safety.

C. Concreting work:
1) Concreting should be carried out with proper supervision & care must be taken at the
time of reversing of transit mixer by deploying signalman/banks-man.
2) Concrete Pouring chute should be properly supported and guide rope shall be used to
Control the Movement of funnel hopper.

D. Hot Work (Welding & Gas cutting):

1. Gas cutting and welding area to be cleaned properly.
2. Flash back arrester to be used.
3. Gas cutters should use proper PPE.
4. Before use of gas cutting set should be checked properly & proper trolley /stand should
be provided. Flash back arrester should be provided.
5. Earthling should be ensured for welding & grinding machine. Power should be used
through 30mA ELCB/RCCB.
6. All combustible materials should be removed under & around the hot work area.
7. Fire extinguisher should be provided.
8. Tool box talk should be conducted.
9. Engaged trained workmen.
10. PTW should be ensured.

E. Shifting of Piling Rig:

1. Trained worker should be deployed.
2. Shifting work should be carried out in safe manner & with proper supervision.
3. Guy ropes should be provided & it to be shifted with hydra crane.
4. Winch should be fixed properly. All guards of rotating parts will be ensured.
5. Base of the Piling Rig should be placed & fixed properly.

F: Hazard involved During Bore Pile

1. Fall from Height
2. Fall of materials
3. Improper fixing of sling
4. Electrocution
5. Struck by Falling/ Moving Object
6. Failure of lifting tools, derrick & machinery
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7. Caught In Between
8. Slip/Trips
9. Poor access control
10. Poor housekeeping
11. Improper illumination
12. Fire /explosion
13. Improper guarding arrangement of rotating parts
14. Underground cable/ service line
15. Improper ground/ soil condition,
16. Improper manual handling.
17. Radiation &Toxic fumes
18. Improper use of chemicals (Polymer)
19. Run over
20. Toppling of Piling Rig

G: Safety Requirement:
Equipment’s & List of Indicate
Tools Equipment’s, Tools & Tackles Fitness Test & Certification
[Submit Test Needed/TPT
Certificate
before start Winch m/c, Lifting Gear & Equipments Checked By P & M Dept. Authorised
of work Appropriate tools. 3rd Party Agency
wherever
applicable]
Piling Rig, Water Pump, SPT testing m/c, Checked By safety and P & M Dept.
Tremie pipe, DMC rod, Cutter/Chisel, Gas Of SIL
Cutting & Wielding machine.

Non- acceptable Control Measures to be ensured against Hazards/Risks

Hazards/Risks
Engineering Administrative PPE
[Attach HIRA]
Controls Controls
1. Fall from Height 1. Erection & shifting of Piling Rig as 1. Put sign board and Full body
2. Fall of materials per planned & safe system of alert worker. harness, Safety
3. Improper fixing of erection must be followed. Proper Training Helmet, fall
sling 2. Stability of soil to be checked (Potential Hazard arrester, Safety
before erection. during Plastering Work) goggles, Hand
4. Electrocution
2. Valid PTW must be Gloves, safety
5. Struck by Falling/ 3. All materials should be inspected
before use. required. shoes/gum
Moving Object
3.Take rest for avoid boot and
6. Failure of lifting 4. Underground cable or service lines fatigue & sunstroke reflective
tools, derrick & should be checked before start of 4. Heights pass to be jacket.
machinery work.
ensured to all workers.
5. Maintained Safe procedure for
7. Caught In 5. Work should be
materials handling.
Between carried out with proper
6. Barricade & Fencing to be ensured
8. Slip/Trips supervision.
at working area.
7. Trained worker &
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9. Poor access 7. Base of Piling Rig should be rested operator should be

control properly. deployed.
10. Poor 8. Capacity and condition of sling to 8. TPI of all lifting tools
housekeeping be checked. & machinery to
11. Improper 9. 'D' Shackle and clamping of sling ensured. Inspection of
illumination to be made proper. Lifting Equipment to be
done prior to use for
12. Fire /explosion 10. Clutch, locking device and
defects and proper
13. Improper machine guards will be ensured.
capacity.
guarding 11. Condition of wire rope & wire
9. MSDS of Polymer
arrangement of drum should be checked & end of
should be displayed.
rotating parts wire rope should be fixed securely.
10. Dispose of Polymer
14. underground 12. Gas cutting and welding area to waste from site will be
cable/ service line be cleaned properly. ensured as per
15. Improper 13. Flash back arrester to be requirement.
ground/ soil provided. 11. Care must be taken
condition, 14. Proper trolley /stand should be at the time of reversing
16. Improper provided. of transit mixer by
manual handling. 15. Earthling should be ensured for deploying
17. Radiation &Toxic welding & grinding machine. Power signalman/banks-man.
fumes should be used through 30mA
18. Improper use of ELCB/RCCB.
chemicals (Polymer) 16. Fire extinguisher should be
19. Run over provided.
20. Toppling of Piling 17. Proper illumination should be
Rig. provided.
18. Proper housekeeping & suitable
approach/access should be ensured.