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Name of the work :

Construction of 4 Lane Access Road CLIENT: ADCL , VIJAYAWADA Rev No.0


from Western Boundary(Near
Dondapadu) of A.P Capital City to CONTRACTOR: M/S. NCC LIMITED.
Undavalli Village in Guntur Dist, Date:25.05.2
Package-I 017

Construction of 4 Lane Access Road from Western


PROJECT Boundary(Near Dondapadu) of A.P Capital City to
Undavalli Village in Guntur Dist, Package-I

DOCUMENT METHOD STATEMENT INITIAL VERTICAL LOAD TEST AND


INITIAL LATERAL LOAD TEST ON TEST PILES

TABLE OF CONTENTS

Page 1 of 16
Name of the work :
Construction of 4 Lane Access Road CLIENT: ADCL , VIJAYAWADA Rev No.0
from Western Boundary(Near
Dondapadu) of A.P Capital City to CONTRACTOR: M/S. NCC LIMITED.
Undavalli Village in Guntur Dist, Date:25.05.2
Package-I 017

1. GENERAL....................................................................................................................................................3

2. INTRODUCTION......................................................................................................................................3

3. PLANT & MACHINERY........................................................................................................................4

4. PILE DETAILS...........................................................................................................................................4

5. TEST METHOD.........................................................................................................................................4

6. REFERENCE DOCUMENTS..............................................................................................................12

7. CONCLUSION.........................................................................................................................................12

LATERAL PILE LOAD TEST METHODOLOGY...................................................................................13

8. TEST ARRANGMENT..........................................................................................................................13

9. MAINTAINED LOAD TEST METHOD:..........................................................................................13

1. GENERAL

Page 2 of 16
Name of the work :
Construction of 4 Lane Access Road CLIENT: ADCL , VIJAYAWADA Rev No.0
from Western Boundary(Near
Dondapadu) of A.P Capital City to CONTRACTOR: M/S. NCC LIMITED.
Undavalli Village in Guntur Dist, Date:25.05.2
Package-I 017

The Capital Region Development Authority (CRDA) has under taken


construction of 4 lane access road to seed capital, Amaravathi. NCC Limited has
been awarded contract for the road works between km0+000 to km 18+270.

As part of the road construction, two major bridges are to be constructed


at km 3+979 and at km 8+740. The bridges are to be founded on pile foundations
due to weak soil strata at top layers. Design consultant M/s. Aaarvee associates
has done the pile design and drawings are issued to NCCL.

It shall be established that the design parameters, considered in pile


design, matches at site by testing the piles by Initial load test. The methodology
to conduct the initial load test is described in this document.

2. INTRODUCTION

This Method Statement is prepared for conducting the Initial Pile Load Tests to be
carried out on 1200mm diameter piles installed for Bridges to be constructed for
seed capital access road.
As per design it is proposed to have 1200mm dia of length 30 m bored piles with
bore depth of 34 to 41 m due to cut-off level variation.

Pile No. Bridge Dia Of Design Load Design Load


Chainage Pile mm Vertical (MT) Horizontal (MT)
Km
TP01 8+740 1200 350 25
TP02 8+740 1200 350 25
TP03 3+979 1200 400 25
TP04 3+979 1200 400 25

Total 4 nos of test piles are installed, 2 on each bridge location. These piles shall be
tested for 2.5 times the designed pile capacity.

3. PLANT & MACHINERY


DTH drilling machine

Page 3 of 16
Name of the work :
Construction of 4 Lane Access Road CLIENT: ADCL , VIJAYAWADA Rev No.0
from Western Boundary(Near
Dondapadu) of A.P Capital City to CONTRACTOR: M/S. NCC LIMITED.
Undavalli Village in Guntur Dist, Date:25.05.2
Package-I 017

Grouting Pump
Hydra 14 Ton
Dewatering pump
Hydraulic Jacks 1000T total capacity
Dial gauges 0.01mm accuracy , 0-50 mm

4. PILE DETAILS

Bridge
Pile Dia Of FOUNDING DATE OF
Chainage EGL COL
No. Pile mm LEVEL CASTING
Km

TP01 8+740 1200 19.86 -20.30 19.86 31.03.2017

TP02 8+740 1200 20.20 -20.30 20.20 05.04.2017


TP03 3+979 1200 21.949 -2.657 21.949 09.04.2017
TP04 3+979 1200 21.949 -2.75 21.949 11.04.2017
5. TEST METHOD

a) Pile head Preparation :-

The area around the pile shall be excavated using the JCB / Excavator to expose the
pile head. Excavation will continue till the test level is reached. All the reusable
excavated earth will be kept near to the site for backfilling; sloped excavation shall
be carried out to avoid the edge collapse.

Top of the Pile- pile head - chipping shall be done in order to remove the
contaminated concrete till the good concrete is observed. After exposing the pile
concrete, the pile chipping personnel with jack hammers will be taken to the pit.
Using jack hammer the pile chipping will be done by piercing the hammer in to the
concrete. This will be repeatedly done such that concrete breaks and falls down. All
such broken concrete pieces will be collected and disposed at designated location.
Chipping shall continue till the good concrete is observed. The grade of concrete if
used to built up the pile shall be higher than pile concrete grade. Preferably the
same shall be avoided.

Exposed reinforcement of 1200mm Dia Pile shall be cut and the top surface of the
pile shall be made to a horizontal level using cement sand mortar, Mortaring shall
be done at least 36 hours prior to the testing. If the testing time is within 24 hours,

Page 4 of 16
Name of the work :
Construction of 4 Lane Access Road CLIENT: ADCL , VIJAYAWADA Rev No.0
from Western Boundary(Near
Dondapadu) of A.P Capital City to CONTRACTOR: M/S. NCC LIMITED.
Undavalli Village in Guntur Dist, Date:25.05.2
Package-I 017

then levelling of pile top surface shall be done with GP2 material so that the
hardening will be achieved within 24 hours. Levelling layer thickness shall be kept
minimum most possible by chipping carefully at the final test level.

b) Platform :-
The platform which offers resistance to the jack when load is applied on the pile is
called kentledge. This kentledge system (type-1) is erected such that the centre of
the platform coincides with the centre of the pile. The platform will be loaded with
sand or precast concrete blocks to offer resistance against load applied on the pile.
In the alternate method, instead of steel platform, steel anchor beam (type 2) will
be placed and connected to rock anchors to offer resistance against load applied by
jack on the pile. It is required to install anchors for resisting the load applied on the
pile.

Kentledge method is proposed to be used for testing the pile TP1& TP2 installed at
the ch. 8+740 km where rock is not available at shallow depths and anchor test
method is proposed to be used in the test pile TP3 & TP4 at ch 3+979 where the
piles are terminated in rock.

b.1) Type-1 Kentledge system:-

Five Girders of ISMB600 will be placed on top of the pile such that their centre of
gravity falls exactly in centre of the test pile. A platform will be made of beams,
ISMB300 30 nos , placed over the main girders in transverse directions to form a
grid. On this grid, steel plates of 3.15mm thick will be placed to cover the entire
platform to support the sand. Sand bags are placed on top of this platform on all
four sides except central portion. In central portion, loose sand will be placed using
the excavator to form a solid platform. The weight of this total kentledge including
steel girders shall be 20% higher than final test load so that safety of the platform
is ensured.

b.2) Type-2 Rock anchors system :-

Pile Testing by Rock anchor system is proposed in Ch 3+979 piles due to the
availability of rock at founding depth in this area. Total set up is given in the below

Page 5 of 16
Name of the work :
Construction of 4 Lane Access Road CLIENT: ADCL , VIJAYAWADA Rev No.0
from Western Boundary(Near
Dondapadu) of A.P Capital City to CONTRACTOR: M/S. NCC LIMITED.
Undavalli Village in Guntur Dist, Date:25.05.2
Package-I 017

mentioned drawing. 6 Nos Rock Anchors of 1500 mm diameter will be installed all
around the test pile.

A DTH Drilling Rig and a compressor will be mobilised to test pile location. From
centre of test pile circle will be formed with a diameter of 2.4 m. For six anchors,
position will be marked at a distance of 1256 mm centre to centre along the circle.

Using the DTH Rig and compressor, drilling of 150mm borehole inclining away from
pile centre will be done up to a depth of 30m from EGL. PVC Casing of 150mm dia
6 m length shall be installed to avoid top soil collapse. 14 numbers of 12.7mm High
Tensile strands will be cut for a length of 35m (30 m below GL plus 5 m above GL)
and bundled with spacers and a grout tube will be inserted in the centre to form
anchor cable. Tensile laod Capacity of each bundle will be 200 MT. Six sets of such
cables will be kept ready on the ground before the drilling is complete. The total
load allowed on the 6 anchors would be 6 x 210 T, 1260 MT load against test load
of 1000 T.

The strands bundle will be gently lowered in to the drilled hole. Cement grout with
water cement ration of 0.45 will be pumped in to the boreholes using grout pump
operated by DG power. Admixture CB100 will be used for non shrinking of grout.
Grouting will be done from bottom till the bond length is achieved. Grouted cables
shall not be disturbed for 72 hours after completion of grouting. All the 6 anchors
installation will be completed in the similar manner.

c) Drawings:-

Anchor C/C Distance 1175mm

600mm

1200mm

LOADING FRAME

Page 6 of 16
Name of the work :
Construction of 4 Lane Access Road CLIENT: ADCL , VIJAYAWADA Rev No.0
from Western Boundary(Near
Dondapadu) of A.P Capital City to CONTRACTOR: M/S. NCC LIMITED.
Undavalli Village in Guntur Dist, Date:25.05.2
Package-I 017

d) Testing Apparatus :-
i) Kentledge Method :
A bearing plate made of mild steel of thickness 40 mm or 2 nos of 20 mm thick
plates shall be placed on top of the pile, the pile shall have levelled surface to
receive these plates.

Hydraulic jacks 2 Nos of 500T capacity shall be placed on the steel plates such
that the centre of jacks shall match with the centre of plate and pile. When all the
centres are matched the load transformed to the pile uniformly/centrally. The gap
between jacks top and beams will be filled with steel plates.

ii) Rock Anchor Method :


Hydraulic Jacks will be placed on the prepared pile head in the same way as done
for kentledge method. Loading frame as shown in the sketch shall be lowered on
top of the jacks and aligned. The Loading frame is carefully aligned and levelled
such that all anchor holes are matching with the axis of the anchors on the ground.

The HT strands shall be then carefully threaded through the loading frame and each
strand is inserted through the anchor hole. The bearing plate is inserted on each of
the anchor and wedges are inserted on to each strand. Each strand shall be loaded

Page 7 of 16
Name of the work :
Construction of 4 Lane Access Road CLIENT: ADCL , VIJAYAWADA Rev No.0
from Western Boundary(Near
Dondapadu) of A.P Capital City to CONTRACTOR: M/S. NCC LIMITED.
Undavalli Village in Guntur Dist, Date:25.05.2
Package-I 017

to 10% of UTS of the strand in such sequence as to maintain the even distribution
of load across loading frame.
iii) Dial gauges fixing :
Datum bars, 2 nos, shall be fixed with independent supports on both sides of the
pile with 1.8m support from edge of the pile. These supports shall be by fixed
placing concrete on the ground.
Dial gauges 4 nos shall be placed on periphery of the plate to measure the
settlement on four corners of the pile.

Jacks shall be connected to hydraulic pump with a pressure gauge to measure the
pressure of oil supplied to the jacks. All the joints shall be rechecked and sealed
using mseal, if required, to avoid leakages of hydraulic oil during the test.
Calibration certificates of the pressure gauge and dial gauges shall be submitted to
the clients at the time of test.
Record the initial readings of all the dial gauges before starting load test.

e) Maintained Load Method:


The Maintained Load Test Method shall be carried on the test piles selected for
conducting the Initial vertical load test to find out whether the design assumptions
does match with the site practices on 1200 mm diameter pile.

The following is the procedure for the Maintained Static Load Test where the load is
applied in increment of 20% of the design load up to 2.5 times the design load.

Incremental loading shall be carried out at each stage by applying a series of vertical
incremental load and each increment being of about 20 percent of design load on the
pile. Each loading shall be maintained as per the criterion given below:

Dial gauge reading taken at regular interval of 4, 6, 10, 15 and 30 minutes.


Load shall be maintained for 30/60/120 minutes during loading based on the
criteria and 15 minutes for each unloading.
Change of load should be carried out only if the settlement of the pile is not
more than 0.1 mm (difference between 2 minutes reading and 30 minutes
reading) in half an hour or 0.2mm in an hour or till 2 hours.
2.5 times design load shall be maintained for 24 hours if the pile is carrying
final test load without continuous settlement.

Page 8 of 16
Name of the work :
Construction of 4 Lane Access Road CLIENT: ADCL , VIJAYAWADA Rev No.0
from Western Boundary(Near
Dondapadu) of A.P Capital City to CONTRACTOR: M/S. NCC LIMITED.
Undavalli Village in Guntur Dist, Date:25.05.2
Package-I 017

After full load is maintained, load shall be lowered at 20T intervals and readings
shall be recorded.
Readings shall be recorded before and after applying increment/decrement of
load.
Loading and unloading stages:-
Ch 8+740 km
Desig
n Increment Total Load (T)
load
350 T 1st increment 70

2nd increment 140

3rd increment 210

4th increment 280

5th increment 350

6th increment 420

7th increment 490

8th increment 560

9th increment 630

10th increment 490

11th increment 350

12th increment 210


875
Maintain the design load for 24
13th increment
hours by observing the settlement
at hourly interval
1st decrement
630
unloading
2nd decrement 742

3rd decrement 424

4th decrement 210

Total unloading 0
Loading and unloading stages:-
Ch 3+979 km
Design
Increment Total Load (T)
load
400 T 1st increment 80

Page 9 of 16
Name of the work :
Construction of 4 Lane Access Road CLIENT: ADCL , VIJAYAWADA Rev No.0
from Western Boundary(Near
Dondapadu) of A.P Capital City to CONTRACTOR: M/S. NCC LIMITED.
Undavalli Village in Guntur Dist, Date:25.05.2
Package-I 017

2nd increment 160

3rd increment 240

4th increment 320

5th increment 400

6th increment 480

7th increment 560

8th increment 640

9th increment 720

10th increment 800

11th increment 880

12th increment 960


1000
Maintain the design load for
13th increment 24 hours by observing the
settlement at hourly
interval
1st decrement
800
unloading
2nd decrement 640

3rd decrement 400

4th decrement 160

Total unloading 0

Final load shall be maintained for 24 hrs and readings shall be recorded hourly.
Reading shall be tabulated and to be enclosed with the report.

f) Pile Load Testing period:

Sl.No Description Time Period

1 Pile Layout & 6 nos of Anchors boring by DTH 2 Day

Page 10 of 16
Name of the work :
Construction of 4 Lane Access Road CLIENT: ADCL , VIJAYAWADA Rev No.0
from Western Boundary(Near
Dondapadu) of A.P Capital City to CONTRACTOR: M/S. NCC LIMITED.
Undavalli Village in Guntur Dist, Date:25.05.2
Package-I 017

1 Day
6 nos of Anchors cement grouting (Anchor Depth
2
as per causations)

3 Anchors strength achievement 21 days


1 day
Testing Tress/Bream Arrangement and LRPS
4
strands Trussing

5 Initial pile load testing 2 days

Total period for testing 28 days

By kentledge system 18 days are required to complete one test.

g) Load Test Record:

Load Vs Settlement Curve Graph shall be prepared and to be enclosed based on


the load and final settlement observed before the next increment of load is given.

Load will be drawn on x- axis starting from 0 to the maximum load will be marked
and divided equally to the specified scale.

Settlement will be marked on y axis starting from 0 to the maximum settlement


will be marked and divided equally to the specified scale.

All the points of load and settlement corresponding to the load will be marked in
the graph and connected by best possible curve.

From the load settlement curve, the load at which 18mm settlement will be noted
and kept for the final conclusion .

Similarly if any failure or excessive settlement is observed in the graph, the same
will be noted,

6. REFERENCE DOCUMENTS

Sr.
Document Title Document Details
No.
1. a) Drawing for details of test
AA/1881/FDPR/STR/8740/TP/001 pile for proposed major

Page 11 of 16
Name of the work :
Construction of 4 Lane Access Road CLIENT: ADCL , VIJAYAWADA Rev No.0
from Western Boundary(Near
Dondapadu) of A.P Capital City to CONTRACTOR: M/S. NCC LIMITED.
Undavalli Village in Guntur Dist, Date:25.05.2
Package-I 017

b) AA/1881/FDPR/STR/3979/
bridges
TP/001
Code of Practice for design and
2. IS 2911 (Part 4) construction of pile foundations
Load test on piles
3 Cube test results To be Attached

7. CONCLUSION

Based on the load settlement curve conclusion will be derived and submitted as per IS-
2911 Part 4,

The design load is considered as safe load when

1. the settlement at 1.5 times design load is not more than 18 mm and
2. at 2 times design load the pile settlement is less than 120mm

LATERAL PILE LOAD TEST METHODOLOGY

8. TEST ARRANGMENT

Page 12 of 16
Name of the work :
Construction of 4 Lane Access Road CLIENT: ADCL , VIJAYAWADA Rev No.0
from Western Boundary(Near
Dondapadu) of A.P Capital City to CONTRACTOR: M/S. NCC LIMITED.
Undavalli Village in Guntur Dist, Date:25.05.2
Package-I 017

After conducting the vertical load test on test pile, same test pile will be used for
conducting the initial lateral load test pile.
The pile shall be further exposed on sides by excavating 0.5 m all round the pile.
Clean the pile surface and make it to level.
Steel liners 1200 mm dia 6 m depth 2nos will be driven inside ground at a center
to center distance of 3 m from test pile. Sand shall be filled inside casing and ISMB
300 beam 4 nos shall be driven on test pile side of these liners to get additional
support- this system is called as reaction block. Alternatively additional pile may be
installed to act as reaction block.

A bearing plate made of steel to be placed on side surface of the pile and hydraulic
jack set up in between the casing and test pile such that the test pile center, jack
axis and reaction block center are in one axis. This will make sure that the load is
transformed to the pile uniformly/centrally. Jack ram will be placed touching the
steel plate. The gap between the bottom of the jack and driven casing shall be filled
with another beam and steel plates.

Datum bar was fixed with independent supports on both sides of the pile and the 2
dial gauges were placed on opposite side to measure the displacement. One dial
gauge shall be fixed exactly on the axis of the jack and test pile.
Test arrangements are given in enclosed sketch.

Note the initial readings of the dial gauges.

9. MAINTAINED LOAD TEST METHOD:

The Maintained Load Test Method shall be carried on the Initial test piles for lateral load
test.
The following is the procedure for the Maintained Static Load Test where the load is
applied in increment of 20% of the design load up to the failure or 2.5 times the design
load, whichever is later.

Incremental loading shall be carried out at each stage by applying a series of vertical
incremental load and each increment being of about 20 percent of design load on the
pile.
Loading and unloading stages:-

Page 13 of 16
Name of the work :
Construction of 4 Lane Access Road CLIENT: ADCL , VIJAYAWADA Rev No.0
from Western Boundary(Near
Dondapadu) of A.P Capital City to CONTRACTOR: M/S. NCC LIMITED.
Undavalli Village in Guntur Dist, Date:25.05.2
Package-I 017

Design
Increment Total Load (T)
load
25 T 1st increment 5

2nd increment 10

3rd increment 15

4th increment 20

5th increment 25

6th increment 30

7th increment 35

8th increment 40

9th increment 45

10th increment 50

11th increment 55

12th increment 60
63
Maintain the design load for 24 hours
13th increment
by observing the settlement at hourly
interval
1st decrement
50
unloading
2nd decrement 40

3rd decrement 30

4th decrement 20

5th decrement 10

Total unloading 0

The load test shall be carried out as per the provision of Clause 8.0 of IS 2911 (Part-4) :
2013. The loading shall be applied in increments of about 20% of the safe load. The next
increment shall be applied after rate of displacement is nearer to 0.1mm per 30 minutes.

Displacement shall be read by using a dial gauge of 0.01mm sensitivity placed


diametrically opposite to the jack, which shall directly measure the displacement. The
arrangement is depicted in the enclosed sketch.

Page 14 of 16
Name of the work :
Construction of 4 Lane Access Road CLIENT: ADCL , VIJAYAWADA Rev No.0
from Western Boundary(Near
Dondapadu) of A.P Capital City to CONTRACTOR: M/S. NCC LIMITED.
Undavalli Village in Guntur Dist, Date:25.05.2
Package-I 017

Displacement shall be read by using at least two dial gauges of 0.01mm sensitivity
suitably spaced one above the other on the test pile and the displacement in dial gauge
opposite to jack in actual displacement
Second dial gauge shall be used by interpolating from similar triangles.

LOAD TEST RECORD.

Record the load test readings and draw a graph by Load on x axis and settlement on Y-
axis. Arrive the load at which 5 mm and 120mm displacement is reached.

The safe lateral load on the pile shall be taken as the least of the following:

(a) Fifty percent of the final load at which the total displacement increases to
120mm.

(b) Final load at which the total displacement corresponds to 5mm.

Page 15 of 16
Name of the work :
Construction of 4 Lane Access Road CLIENT: ADCL , VIJAYAWADA Rev No.0
from Western Boundary(Near
Dondapadu) of A.P Capital City to CONTRACTOR: M/S. NCC LIMITED.
Undavalli Village in Guntur Dist, Date:25.05.2
Package-I 017

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