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Method Statement for construction of new elevated track

along existing Rohtak -Gohana-Panipat branch line from km


0/800-km 5/650

1.General description of site

The site of proposed new elevated track is along existing rohtak - gohana - panipat branch line and
starts from km 0/800 - km 5/650. New track will be laid along right side of existing track at around
6.36m c/c from existing track, there is also a provision of future track along new track which will be
laid at 5.3 m c/c of new track. The track structure will start raising from km 1/300 and will run on
embankment supported by retaining walls from km 1/500 to 2/480 (rohtak side) and from km 5/250
to km4/607 (gohana side) . The intermediate portion will be on viaduct from km 2/480 to km 4/607
. Site is well connected by roads and is intersected by 5 level crossings (starting from rohtak to-
wards gohana side viz 1b, 3a, 4a,4b,6c ) [Photos attached ]

2. Scope of Work

The scope of work consists of construction of new track along existing track with approaches on
earth retaining walls of various heights (upto 1.5m (on L type open foundation ),1.5m-2.5m (curved
portion on pile foundation ),2.5m -3.5m (curved and straight alignment retaining wall on pile foun-
dation), 3.5m -4.2m retaining wall on pile foundation). Viaduct portion will be constructed as per
approved RDSO bridge span of 18.3m (composite girder welded type upto 4 degree curve with
RCC deck slab) and 12.2 m () .
The following work involves design and construction of open foundation , pile foundation for re-
taining wall , pier on pile foundation , pier cap and abutment , fabrication and launching of compo-
site welded girders , RCC deck slab , laying of new track and linking , construction of camp offices
, RMC plant , weighing bridge, fabrication yard for steel girders and other activities in connection
with it.

Chainage type of retaining wall


1500-1930 upto 1.5m high with open foundation
1950-2000
5250-5140
1930-1950 1.5m-2.5m high(curved portion) on 450mm dia
2000-2240 pile foundation
2240-2480 2.5m-3.5m curved portion
4875-4689 straight portion on 450mm dia pile foundation

4689-4607 3.5m-4.2m high on450 mm dia pile foundation

• km 2/240 -km 4/607 is on viaduct portion of span 18.3m and 12.2m of approved RDSO drawing.

3. Materials and Testing

a. Cement : Cement shall be of OPC 43/53 grade of approved make like ACC, Ultratech,
Shree,Ambuja, J.K. Super and birla cement or any other make as approved by Engineer in
charge and should confirm to IS : 8112 & IS:12269 ; Cement should be properly stacked on a
platform and not on ground to avoid ingress of moisture. It should be so procured so that it gets
consumed in reasonable amount of time and not more than 3 months; If cement more than 3
months old is used it shall get tested according to relevant IS code before being used in con-
struction work.

b. Admixture : To improve the workability of concrete and cement grout, admixture(plasti-


cizer/super plasticiser ) confirming to IS : 6925 and IS: 9103 in accordance with clause 5.5 and
clause 10.3.3 of IS 456:2000 may be permitted as directed and approved by Engineer in charge
subject to satisfactory proven use, manufacturer’s certificate and laboratory tests as applicable.
The decision of engineer in charge shall be final in this regard. Approved admixtures like
BASF, MYK, SIKAMENT, CICO,PROTECT, FOSROC, MBT or any other similar brand or as
approved by engineer in charge

c. Reinforcement Steel : Reinforcement steel should be of Fe500 grade and should be of ap-
proved make like TISCO, SAIL, JINDAL, ESSAR ispat industries etc . It should confirm to IS
: 1786 :2000 code . Steel should be procured from approved primary producers of steel having
Integrated Rolling plant using iron ore as the basic raw material and should have in house roll-
ing facilities followed by production of liquid steel and crude steel as per ministry of steel
guidelines.

d. Structural Steel : Structural steel shall be of E250 grade B0 quality(killed/fully normalised)


according to IS: 2062:2011. All finished steel shall be free from any defect and well and cleanly
rolled to the dimensions, sections and masses specified. It should be free from surface flaws;
laminations ; rough/jagged and imperfect edges and all other harmful defects .All tests should
confirm according to IS code :2062:2011. Engineer at site should see visually that structural
steel members are free from any visual defects and that all tests are in place. Structural steel
shall be properly stacked .

e. HT Strands : Tata, Usha Martin or as approved by engineer in charge

f. Electrodes/Wires/Flux : Advani-Oerlikon, D&H, Manglam, Ador, Welding Electrodes (India)


Ltd and Esab India or as approved by engineer in charge.

g. Bolts, Nuts and Washers : Unbraco , Precision Fasteners Ltd. , Deepak Fasteners, GKW,
Laxmi Precision Screw, Pooja Forge Ltd. or as approved by engineer in charge.

h. Paints for steel works : Paint and other accessories including those for metallising work will
be supplied by the contractor. Paints manufactured only by the following firms may be used
subject to their being in approved list of RDSO and final approved by the engineer like M/S
Jenson Nicholson paints, british burger paints , shalimar paints, I.C.I. paints , nerolac paints .
Final approval of paint shall be given when inspected for quality is done at site. Contractor shall
furnish all relevant details of paints like date of manufacture certified by manufacture with nec-
essary container marking and test certificate for paint confirming to relevant IS code. In addi-
tion of above weight per litre, consistency ,scratch test and flexibility and adhesive test should
be carried out at site.

i. Concrete : Concrete used in construction work shall be designed mix of approved strength
(M35) governed by IS:456:2000 . Design mix shall got approved by engineer in charge well be-
fore used in construction work. The mix shall be designed to produce the grade of concrete
having required workability and characteristic strength. The target mean strength of concrete
mix should be equal to characteristic strength + 1.65 times standard deviation. Standard devia-
tion shall be calculated according to IS 456:2000.

i) Batching : Weigh batching of constituents like cement , fine and coarse aggregate
should be done . Water should be weighed or measured in volume in a calibrated
tank. Supply of properly graded aggregate of uniform quality should be maintained
over a period of work. The grading of coarse and fine aggregate should be checked
as frequently as possible or as determined by engineer in charge to maintain
specified grading.

ii) Mixing : Concrete shall be mixed in a mechanical mixer. The mixer shall comply with
IS 1791 and IS 12119 .

iii) Formwork : Formwork should be cleaned and uniform with no leakage before
concrete is placed .The tolerances on the shapes, lines and dimensions shown in
the drawing shall be according to clause 11.1 of IS 456:2000 .

iv) Transportation , placing , compaction and curing : After mixing, concrete shall be trans-
ported to the formwork as rapidly as possible by methods which will prevent the segregation or loss
of any of the ingredients or ingress of foreign matter or water and maintaining required workability.
The concrete shall be deposited as nearly as practicable in its final position to avoid rehandling. The
concrete shalll be placed and compacted before initial setting of concrete commences and should
not be subsequently disturbed. Concrete shall be compacted using mechanical vibrators complying
with IS 2505 , IS 2506, IS 2514 and IS 4656.
v) Curing : Exposed surfaces of concrete shall be kept continuously in a damp or wet condition
by ponding or by covering with a layer of sacking , canvas, hessian or similar materials and kept
constantly wet for at least 7 days from the date of placing of concrete in case of OPC and 10 days
where mineral admixtures are used. The period of concreting shall not be less than 10 days for dry
and hot conditions to avoid loss of moisture from concrete.

vi) Frequency of Sampling and Acceptance Criteria : shall be governed by clause 15.2 and 16.1
of IS 456:2000 . ( table attached )

Quantity of concrete in the work, m3 Number of Samples

1-5 1
6-15 2

16-30 3

31-50 4

51 and above 4 plus one additional sample for each additional 50 m3 or


part thereof

Acceptance criteria for compressive strength : Concrete shall be deemed to comply with the clause
16.1 of IS 456:2000.

4. Method of Construction

a. Prerequisite of Construction
i) All surveys including Preliminary survey, soil survey, OGL survey , alignment survey etc and
fixing of centre line pegs for new alignment accurately at site .
ii) Removal of encroachment (all types like trees, cables, poles, buildings, signalling gears, temple,
pipeline, level crossing gate lodge, quarters etc.) by writing to concerned authorities before on-
set of work.
iii) Preparation of all necessary drawings and got them approved before commencement of work
iv) Barricading the site of work from existing running track adequately for safe movement of men
and material.
v) Building of camp offices, RMC plant, steel fabrication shed, labour rooms etc
vi) Approval of mix design before concreting work
vii) Maintenance of all relevant registers as mentioned in GCC and SCC or as directed by site engi-
neer.
viii) Approval of material(s) before construction work.
ix) Following all relevant conditions of GCC and SCC required to be fulfilled before starting of
construction work.
x) All inspections required beforehand and approval required
xi) Ensuring safety at site

b. Commencement of Construction Work


i) Approaches on retaining walls ( open / pile foundation)
ii) Extension of minor bridges falling in the proposed alignment
iii) Piling Work

TECHNICAL SPECIFICATIONS FOR PILING


IN-SITU BORED RCC FRICTION PILES FOR FOUNDATION ( approaches and on viaduct
portion )
General
The design of plies has been prepared for 450 mm diameter bored cast-in-situ reinforced concrete
piles for retaining wall portion on approaches 2.5m-4.2m height and 1200mm diameter bored cast in
situ piles for viaduct portion . The accompanying drawings has been prepared by SM consultant and
checked by kashmiri gate design office and handed over to the contractor. The contractor is advised
to go through the subsoil investigation report enclosed. The information provided in the subsoil in-
vestigation report is for the guidance and is only indicative. The contractor shall assess all other nec-
essary information at his own cost. The diameter of finished concrete inside the temporary casing
shall be equal to the specified diameter of the piles.
For bored cast-in-situ piles various operations such as boring, lowering of reinforcement cage and
concreting of pile for full height shall be completed in one continuous operation without any stoppage.

Length
The number and lengths of piles are shown in enclosed drawings for each section (drawings en-
closed). It will be the responsibility of the contractor to ensure by subsequent routine load tests that
the installed length of piles shall be able to carry the specific safe load and the resulting deflections
shall be within permissible limits as specified in IS 2911: Part IV. In case of failure of any pile in
routine load test, the additional cost on account of remedial measures including the consultant fees
for suggesting remedial measures shall be borne by the contractor and no claim shall be entertained
on this account.
The pile length shall be measured for payment from the cut off level to the tip of the pile.

Boring
Boring equipment and accessories shall generally confirm to IS 2911 and MORTH specifications.
Boring shall be done by high capacity hydraulically operated power rotary boring rig (with hydraulic
feed). The sides of the borehole shall be stabilized by the use of the bentonite slurry (drilling mud)
throughout its length and a temporary liner at the top having a minimum length of 2m. Temporary
liner shall have adequate strength to withstand soil pressures and hydrostatic pressure of concrete at
all stages of work and shall have wall thickness of not less than 6mm plate.

Drilling Mud( Bentonite Slurry)


The drilling mud shall be used at least 1.5m above from the level of subsoil water depending upon
site conditions and the hole shall then be always kept almost full with the fluid which shall preferably
be kept in motion during boring operation. The density and composition of the fluid shall be such as
to suit the requirements of the ground conditions and maintain the fine materials from the boring in
suspension. Bentonite suspension shall meet the following specifications:- ( according to IS Code
2911; part 1 section 2) :2010
(i) density = 1.05 g/cc.
(ii) Marsh Cone Viscosity between 30 to 60 stokes
(iii) The pH value between 9 and 11.5
(iv) The liquid limit of bentonite not less than 400%
(v) The silt content<1%
The bentonite suspension shall be made by mixing it with fresh water using a pump for calculation.
The density of freshly prepared bentonite suspension shall be between 1.03 and 1.10 gm/ml depend-
ing upon the pile dimensions and the type of soil in which the pile is to be bored. the density of ben-
tonite after contamination with deleterious material in the bore hole may rise upto 1.25 gm/ml by
flushing before concreting.
The level of drilling mud shall be maintained at least 1.5m above the contemporary water level. The
bentonite slurry shall not be allowed to discharged into any nallah/drain of on the ground. The waste
slurry shall be removed by tanked/vehicles as directed by the Engineer-in-Charge and discharged at
locations arranged by the contractor. In order to avoid collapse of upper soft soil into the borehole,
temporary liner of thickness not less than 6mm shall be provided upto at least 2m from the existing
ground level for 450mm dia and 10m length pile . The liner shall be provided by hydraulically oper-
ated mechanism. After concreting of pile the liner shall be extracted by vibrator or jacking.

Cleaning of Borehole Bottom


The bottom of the hole shall be cleaned very carefully prior to the commencing of concreting. The
cleaning of the hole shall be ensured by careful operation by reverse circulation. Alternative method
shall be employed only with the prior permission of the Engineer-in-Charge in writing. To lift the
soil at founding level before concreting, borehole shall be agitated by jetting with fresh drilling mud
at a relatively higher pressure than that used during boring, or by air jetting through a pipe attached
to the tremie pipe and flushing with bentonite slurry simultaneously. The specific gravity of the mud
suspension in the vicinity of the bottom of the bore hole shall be determined by using a suitable
direction of the Engineer-in-charge and recorded. Consistency of the drilling mud should be such that
keep the sides of the hole stabilized as well as to avoid concrete mixed up with the thicker suspension
of the mud.
The bore must be washed by fresh bentonite solution flushing to ensure clean bottom at two stages
viz. after completion of boring and prior to concreting after placing the reinforcement cage. Flushing
of bentonite shall be done continuously with fresh bentonite slurry till the consistency of in-flowing
and out-flowing slurry is similar.

Concreting
The concrete used for the piles shall confirm to the provisions, contained in Document and as men-
tioned in conditions of contract . Concreting of borehole shall start as soon as possible after boring
has been completed. If the borehole is left unconcreted for more than 2 hrs., it shall be cleaned thor-
oughly as directed by the Engineer-in-Charge before placing concrete. Concreting shall be done by
tremie pipe according to clause 8.4 of IS code 2911: part 1 section 2 :2010. It shall, however, be
ensured that concrete entering the tremie pipe does not get mixed up with the bentonite slurry/water.
Concreting should not be taken up when the specific gravity of bottom slurry is more than 1.2. when
the specific gravity of the bottom slurry is more than 1.2 the same shall be replaced by the fresh
bentonite slurry.

Tremie method
The tremie pieces and funnel shall be filled with concrete and lifted 15cm. above the bottom of the
hole before releasing the concrete column in order to facilitate flushing it out. The concrete levels in
the tremie shall be checked for every few feet in order to note the difference, if any, between the
theoretical quantity that should have been placed and actual quantity that has gone in. this serves
when fixing the position of over cut during pouring.
In case the actual quantity of concrete poured in the borehole is less than 90% of the theoretical
quantity of concrete for the pile, the pile shall be subjected to rejection.
The diameter of the pipe shall be 200mm . minimum and the funnel should be capable of holding
0.4cum. of concrete.
Following rules shall strictly be observed prior to and during the tremie method, cited above.
(i) The concrete of a pile must be completed in one continuous operation.
(ii) The concrete shall be coherently rich in cement and having slump in the range of
150mm to 180mm.
(iii) A temporary liner should be installed for at least top 5m. depth of soil as mentioned
elsewhere in the tender documents, which would ensure that fragments of compara-
tively loose soil cannot drop from the sides into the concrete. Arrangement for low-
ering and withdrawal of temporary liner should be independent of those for the tremie
pipe, etc.
(iv) The tremie shall be large enough in order to cater for the size of aggregates thereby
allowing a smooth uninterrupted flow of concrete. For instance, a tremie of 200mm
diameter shall suffice the requirements with 20mm aggregate. The tremie should be
of robust construction confirming to the approved standards.
(v) The first charge of concrete shall be placed with a sliding plug pushed down the tube
ahead of it to prevent mixing of concrete and water/bentonite slurry. However, the
plug shall not be left in the concrete as a lump.
(vi) The tremie pipe shall always penetrate deep enough (at least 1m) into the concrete
with an adequate margin of safety against accidental withdrawal.
(vii) The pile shall be concreted wholly by tremie and the method of deposition shall not
be changed part way up the pile in order to prevent the latency from being entrapped
within the pile.
(viii) The tremie shall essentially be watertight in order to avoid mixing of bore fluid with
the concrete.
(ix) All tremie tube shall be scrupulously cleaned after every use.
(x) To ensure compaction of concrete by hydraulic static head, rate of placing of concrete
in the pile shaft shall not be less than 6m. length of pile placing per hour.
Normally the concreting of the piles shall be uninterrupted. In case, under the unavoidable circum-
stances, the operation has to suspend for a period of 2hrs. maximum the tremie shall not be taken out
of concrete. Instead it shall be raised and lowered slowly from time to time which would prevent the
concrete around the tremie from setting. Concreting should be resumed by introducing a little richer
concrete (5% additional cement) with a higher slump for easy displacement of the partly set concrete.
If the concreting cannot be resumed before final set of the concrete already placed, the pile so cast
may be liable for rejection. Acceptance with modifications shall be at the sole discretion of the Engi-
neer-in-Charge provided contractor is able to prove to the satisfaction of the Engineer-in-Charge that
the modifications suggested by him are acceptable. Nothing extra shall be paid on this account. Sim-
ilarly, contractor shall be liable to carry out all remedial measures at no extra cost to the employer.
In case of withdraw of tremie out of the concrete the pile shall be subjected to rejection.

Cut-off Level
The top of concrete in the piles shall be brought above the cut-off level (as approved by the Engineer-
in-Charge) in order to remove all latency and weak concrete before capping and ensure the design
concrete at the cut-off level for the proper embedment into the pile cap. This work shall be done by
the main bridge contractor and therefore not included in the scope of this contract. However for all
the test piles, chipping of the top concrete shall be done by the contractor of this contract at no extra
cost to the Employer.
No separate payment shall be made for empty boring above the cut off/concreting level when the
piling is done from ground level.
The concrete shall be cast to the piling platform level to permit overflow of concrete for visual in-
spection or to a minimum of one meter above cut-off level. In the circumstances where cut-off level
is below ground water level the need to maintain a pressure on the unset concrete equal to or greater
than water pressure shall be observed and accordingly length of extra concrete above cut-off level
shall be determined and provided without any extra cost to the Employer.
pile cut off level is decides as follows at site :
At particular chainage and rail level ( established using DGPS and control points survey done earlier
) and proposed formation level , we arrived at height of retaining wall to be adopted ;
height of retaining wall = proposed formation level - ground level (calculated as explained previ-
ously);
pile cap level = ground level - 300mm (pile cap top level is 300mm below ground level as per
drawing);
pile cap bottom level = pile cap level - 675mm ( thickness of pile cap );
pile cut off level = pile cap bottom level + 50 mm ( into pile cap);
pile tip level = pile cut off level - 10.0 m (length of pile);

ground level

pile cap top level

pile cut off level


pile cap bottom level

Sequence of Piling
During installation of piles, the sequence of construction shall be followed as directed by the Engi-
neer-in-Charge.

Defective Pile
In case of defective piles are formed, they shall be removed or left in place whichever is convenient
without affecting performance of the adjacent piles or the cap as a whole. Additional piles shall be
provided at contractor’s cost to replace them as directed by the Engineer-in-Charge and in his regard
the decision of the Engineer-in-Charge shall be binding on the contractor.
Any deviation from the designed location, alignment or load capacity of any pile shall be noted and
adequate measures shall be taken well before limit. All such alterations shall be done at contractor’s
cost and to the satisfaction of the Engineer-in-Charge. The contractor shall have to submit requisite
design calculations for the changes arising out of the above situation for approval by the Employer.
The contractor shall have to bear the cost of such redesigning and its checking by the consultant
appointed by the employer.
Eventualities of reinforcement cage getting lifted up and bucket getting stuck during any stage of
installation of pile shall render the pile defective.

Control of Alignment
Piles shall be accurately installed as per design and drawings. Vertical piles shall be bored straight
without any kink in the profile. During installation of vertical piles, the following limits shall not be
exceeded.
(i) Verticality:
The tilt of piles shall not exceed 1 in 150. For this purpose, the alignment of boring shall be
checked during boring operation for every 5m. depth of bore or at closer intervals as desired by the
Engineer-in-Charge. Suitable corrective measures shall be taken to rectify any tendency of the bore
to go beyond this limit at no extra cost. Contractor shall have to maintain the record of profile of
boring as a part of pile to be submitted by him.
(ii) Shift:
The resultant shift in any direction from the designed position at cut off level shall
not exceed 75mm. This shall be measured at pile top at cut-off level. This data shall
also be submitted by the contractor along with standard record of pile boring.
In case during installation, above limits are violated, the contractor shall be liable for action in the
following manner:
Submit revised calculation for the pile groups and pile caps and bear all costs related to such designs
and its checking by the consultant of the employer. In addition, he shall not be entitled to any addi-
tional extension of time relating to such design and approval by the employer. All additional work
arising out of such redesigning of pile and pile caps shall be executed by the contractor at no extra
cost to the employer.
In case deviations are exceeded beyond above limits to the extent that the resulting eccentricity cannot
be taken care of by redesigning of the pile group and pile caps, the pile shall be replaced or supple-
mented by one or more additional piles by the contractor at his own cost. The decision taken in this
regard by the Engineer-in-Charge shall be final and binding the contractor.

Chipping of Pile Top


Manual chipping shall be permitted after three days of pile casting. Pneumatic chipping if permitted
by the Engineer-in-Charge shall not be started before 7 days or as directed by the Engineer-in-Charge.
Full care should be taken to prevent any damage/distortion of pile reinforcement.

Adjacent Structure
When working near the existing structures care shall be taken to avoid any damage to such structures.
In case of bored piles, care shall be taken to avoid the effect due to loss of ground.
In case of deep excavations carried out adjacent to piles, proper shoring or other suitable arrangement
shall be done to guard against the lateral movement of soil stratum of releasing the stresses confining
the soil.

Reinforcement
Main longitudinal reinforcement, preferably in one length, in the length of the piles as well as links
or spirals shall be provided as shown in the drawing. Reinforcement cage shall be handled and in-
stalled carefully without damaging its shape. Quality, workmanship and all other requirements of
reinforcement bars shall satisfy the corresponding specifications referred in the contract. In case the
cage is fabricated in more than one stage, it shall be ensured that the entire length is absolutely in a
straight line with due regard to the prescribed tolerances.
The clear cover to the reinforcement in pile shall be 75mm. not withstanding any other provision
mentioned in the codes and specifications mentioned elsewhere.

Recording of Data
During installation of pile the following data shall be recorded along with any other relevant data
directed by the Engineer-in-Charge. These data shall be submitted to the Engineer-in-Charge in trip-
licate after installation of each pile.
(i) Sequence of installation of piles in group.
(ii) Dimension of the pile, including reinforcement details and mark of the pile.
(iii) Details of mild steel liner where provided along with stiffner.
(iv) Depth bored and founding level along with a bore log indicating nature of statum.
(v) Time taken in penetration of every 15cm. for last 2m. depth above founding level.
(vi) Method of cleaning bottom of hole at founding level before commencing the concret-
ing.
(vii) Time taken in concreting.
(viii) Cut-off level/working level/RL of top of concrete.
(ix) Number of cement bags consumed, slump of concrete.
(x) Any other relevant observations suggested by the Engineer-in-Charge and which may
eventually affect the overall performance of piles.

LOAD TEST ON PILE


General
The load test on a concrete pile shall not be carried out unless the concrete has achieved its specified
28 days strength. Also the age of concrete at the time of testing shall not be less than 14 days.
There shall be two categories of static tests on piles, namely, initial load tests and routine load tests.
Initial tests should be carried out on test piles, which are not to be incorporated in the work. Routine
tests shall be carried out as a check on working piles. The number of initial and routine tests on piles
shall be as determined by the engineer-in-charge depending upon the number of foundations, span
length, type of superstructure and uncertainties of founding strata. Number and locations of initial
and routine load tests shall be decided by the engineer-in-charge. These tests shall be carried out at a
cut-off level wherever practicable. Otherwise, allowance shall be made in the interpretation of test
results if the test is not made at cut-off level.
Reaction may be applied using kentledge, anchor piles or ground anchors with the prior approval of
the scheme by the engineer-in-charge. Reaction to be made available shall be 25% more than the test
load. A loading equal to 2.5 times the design capacity for initial test and 1.5 times the design capacity
for routine test shall be applied both for vertical and lateral load test. The working piles shall not be
used as reaction piles for deriving the reactions for test pile.
The methodology of carrying out load tests and of arriving at safe load on piles shall confirm to
is:2911 (part iv). A detailed method statement of pile testing (vertical and lateral) including method-
ology, sketches, expected results, etc. Shall be submitted to the contractor or review by the consultant
at least 2 weeks in advance at no extra cost to the employer.
All piles tests shall be duly recorded and analyzed with calculations in format approved by the engi-
neer-in-charge.

Method
The test load shall be applied by jacking against kentledge and ground anchors or reaction piles. The
reaction piles shall not be selected amongst the working piles. Any kentledge loading truss if used
shall be adequately supported in order to enhance its stability particularly in the event of a sudden
change in the load reaction from the pile. The reaction from kentledge to be made available for the
test shall be 25% more than the final test load proposed to be applied.
The load test shall be carried out preferably at cut-off level, if not feasible then at a maximum 1.5 m
below G.L as directed by the engineer-in-charge. Details regarding the test set up and the loading
scheme shall be submitted to the engineer-in-charge well in advance for approval. Any excavations
required for testing including filling them back and reinstating of the ground shall be deemed to be
included in the rates quoted for testing.
Load
The hydraulic jack shall be powered by an electric pump whose discharge can be adjusted in order to
suit the required rate of loading. The load applied to the pile shall be recorded either by a gauge in
the hydraulic system or a proving ring with fresh calibration from an approved laboratory. The sen-
sitivity of the recording device shall not exceed 1.2% of the full load. However, in any event the
accuracy and sensitivity of the system shall be checked against an approved instrument.
A test certificate and fresh calibration chart from an approved laboratory for jack and pump is to be
produced well in advance before their application in any load testing on piles.
Deflection Measurements
The settlement of the pile shall be recorded by a minimum three dial gauges recording to 0.02 mm
and placed at angles round the test pile. The dial gauges shall be fixed to datum bars whose ends rest
upon non-movable supports. The supports for datum bars with reference to which the settlement of
the pile would be measured, shall be at a distance of at least 3d from the edge of the test pile, where
d is the test pile stem diameter

INITIAL TEST
The test shall generally confirm to IS 2911 (PART IV)-1985. Pile head shall be prepared for load test
by suitably sitting/bending the projecting pile reinforcement. A bearing plate with a hole at center
shall be placed over the pile head for placing the jacks. Approximately 25 mm gap (as per manufac-
turer’s recommendations) between the bearing plate and pile head shall be kept which will be filled
with prepacked free-flowing, high strength, non-shrink grout such as fosroc’s conbextra-hf or ap-
proved equivalent. Nothing extra shall be paid on this account.
Interpretation of pile load capacity shall be done as per clause6.1.5 of IS 2911 (PART IV)-1985

ROUTINE TEST
The test shall generally confirm to is 2911 (part iv). Preparation of pile head and placement of bearing
plate including non-shrink mortar shall be as explained in the above clause.

Test load shall be equal to 1.5 times the estimated capacity of pile determined as per above clause.
Interpretation of results shall be done as per clause 6.1.5 of IS 2911 (PART IV)-1985.
Selection of the piles for routine load test, which is often the most inferior set of piles, shall be made
by the Engineer-In-Charge, determined by Integrity Test.

INTEGRITY TEST/LOW STRAIN DYNAMIC TESTING


This low strain dynamic test using pile driving analyzer or approved equivalent for pile integrity shall
be performed on about 25% of the piles as directed by the Engineer-In-Charge. The top of the pile
shall be made accessible, chipped off up to hard concrete, leveled by trimming it back as far as prac-
ticable. The reinforcing bars of the piles to be tested shall be bent sideways with smooth curvature.
No sharp bending of reinforcing bars shall be allowed.
The test shall be performed after removal of bad/weak concrete at top so that the wave propagation
is steady through hard concrete. The test shall not be carried out unless the concrete has achieved its
28 days strength. Also the age of concrete at the time of testing shall not be less than 14 days after
concreting the piles. A specialist approved agency shall be employed for the test and the tests shall
BARRICADING OF HT. 2M AND SITE CLEARANCE
generally be as par recommendations of the agency, unless directed otherwise by the Engineer-In-
Charge.
SURVEY AND LINEOUT TO MARK THE COORDINATES
AND THE CENTRE OF PILE ACCURATELY

HIGH STRAIN DYNAMIC TESTING


CENTRING
At any stage of construction the AND ALIGNMENT OF HYDRAULIC
Engineer-In-Charge may orderRIGto
AND
conduct high strain dynamic tests
ITS ATTACHMENT OVER THE PILE POINTS
on the selected piles by an approved agency. The testing charges of any such test shall be born by the
BORING BY TILL ABOUT 500MM. BY ROCK AUGER
employer. However the contractor shall provide necessary facilities for testing as required by the
Engineer-In-Charge. No claim for delay or otherwise due to this reason shall be entertained on this
PLACING OF CASING IN THE BOREHOLE ALONG THE CENTERLINE OF THE PILE
account. AND CHECKING OF ITS ALIGNMENT W.R.T. REFERENCE POINTS

BORING TILL SUGGESTED DEPTH AND ASCERTAINED AT SITE

SEQUENCE OF PILING
USE OF BENTONITE SLURRY TO STABILISE BORE HOLE AC-
CORDING TO THE SPECIFICATIONS

Following sequence of piling activities at site should be followed step by step .


CHECKING OF DEPTH BY SOUNDING CHAIN AT SUITABLE IN-
TERVALS UPTO DESIRED BORE DEPTH

CLEANING AND LEVELING OF BOTTOM OF THE


BORE HOLE

LOWERING OF REINFORCEMENT CAGE USING CRANE AND


WELDING THE CAGES IF MORE THAN ONE

LOWERING OF TREMIE PIPE WITH HEAD ATTACHED

FLUSHING WITH BENTONITE SLURRY TILL ITS OUT COMING SPECIFIC GRAVITY IS
LESS THAN OR EQUAL TO INPUT SPECIFIC GRAVITY OF BENTONITE SLURRY

CONCRETING (M35) IN SINGLE CONTINUOUS POUR WITH


SLUMP OF 150 -180MM.

COLLECTION OF TEST CUBES OF CONCRETE

COLLECTION OF BENTONITE SLURRY IN THE RETURN PIT


AND THAN TO THE SEDIMENTATION TANK

REMOVAL OF CASING ON COMPLETION OF


CONCRETING
Methodology of Fabrication of steel members at site

FABRICATION SCHEME

1. Stage 1 (Approval)

• preparation and approval of detail drawing in fabrication of girder based on RDSO standard draw-
ings ( drawing no enclosed)
• Approval of QAP and WPSS (attached) to execute the fabrication work at site
2. Stage 2 (Structural steel procurement , stacking and cutting )

• preparation of cutting plan from approved drawings as per required size of steel plates, sections
etc.
• procurement of RAW materials as per IS:2062-2011 of Gr E250 quality B0 (killed/fully normal-
ised) steel plates members, sections from railway approved vendor i.e. SAIL/JINDAL ( Ref. doc-
uments like manufacturer’s test certificates, challan recieved from manufacturers and material re-
ceiving register shall be maintained as mentioned in GCC and SCC)
• Identification and co relation of material with manufacturer’s invoice, dimensions verification,
chemical composition and mechanical properties, charpy impact test details, USFD details from
manufacturers test certificates
• Stacking the materials in proper level bed with proper drainage and easy access.
• Raw material sampling carried out for one sample per heat per thickness of controlled steel plates,
sections for conducting chemical, mechanical and charpy V notch impact test for plates 12mm
thick and above at 0 deg C tests from reputed labs ( NABL approved)
• Inspection and passing of camber layout, jigs and master’s (jig register shall be maintained)
• Marking for cutting plates done accordingly to cutting plan and cutting of plates by cutting ma-
chine(i.e. PUG M/C). Less distortion ensured after cutting tolerances +3mm to +5mm depending
upon thickness of plates.
• Straightening of plates done with proper arrangement.
• Required dimensions are marked by Punch line on each member.
• Finishing of ends of plates done.

3. Stage 3 (Approval of Welder and Fit up)

• Inspection and approval of welder for welder qualification from RDSO, Lucknow
• fit up of each part of plates to make a member in fit-up fixtures by Tack welding
• different fixtures are maintained in different section of member.
• Fit up assembly maintained at proper level.
• Tack weld not less than throat thickness/leg length/root run.
• Approved tack welder was engaged in every stages of welding.
• Squareness of corrections are ensured.
• Proper tolerances followed as per IS and RS Specification.
4. Stage 4 ( Welding)

• Welding carried out in accordance with approved welding procedure specifications Sheet (WPSS
attached ) , approved welder and approved welding consumables for SAW, MIG correlated with
grade of steel. Electrodes should be of approved make as explained in part 3 point f of this docu-
ment.
• Approved drawings, relevant IS and IRS specifications followed.
• Welding consumables procured from RDSO’s list of approved manufacturers.
• Run on and run off tabs fixed with every member for maintaining continuity in welding process.
• Proper welding sequences, arrester, clamping arrangement, fixtures used for preventing distortion
after welding.
• Fusion faces and adjacent faces are to be cleaned and made free from rust, cracks, notches, mill
scales , grease, paint, etc. which may affect the weld quality.
• Proper preheating and proper level of fixtures ensured before welding.
• In SAW welding, proper wire and flux combination and in case of MIG welding, proper class of
wire with respect to steel grade to be followed.
SAW: Wire W1 and flux F1 as per IRSM39, GMAW: Class I Mig Wire as per IRSM 4 ,
MMAW: A2 class of electrode as per IRSM 28, IRS B1-2001 and WBC-2001
• Proper leg length , throat thickness and penetration maintained in every stages of welding
• Current control the rate of melting the wire ,voltage and travel speed control the penetration.
Higher voltage cause less penetration so proper supervision is ensured here.
• After welding , inspection of weld like visual , dye penetration test, macro etching test done in
weld surface for checking of leg length, throat thickness and penetration of weld.
• Rectification of weld defect i.e. pin hole, under cut done as per relevant IS and IRS specification.
• Welding procedure data register, dye penetrant register and macro thing register maintained.

5. Stage 5 ( Distortion Correction, Marking and drilling)


• After welding, distortion correction done in proper sequence.
• Diagonal cross check measurement done in every member.
• Right angle check can also be done to ensure Verticality.
• After welding, inspection of welding i.e. M&C inspection like dye penetrant test, macro etching
test and welding surface check should be carried out to ensure quality of welding
• After that, marking holes to each member by punch mark. The baby jig/part jig fixed with the
member with proper fixture.
• After that job placed in level position before drilling. level checked by Spirit level.
• Drill bit of respective hole diameter of good quality fixed and the tip sharpened on daily basis.
• At first marking holes drilled by fixing body jig/part jig and then with the help of marking hole,
group of holes drilled by fixing body jig/part jig.
• After drilling, the finishing work done and ready for inspection, painting and further stages of
work.

6. Stage 6 ( Final Finishing of Fabrication Work )


• Final finishing i.e. member final length , notch cut with proper profile gauge done by End grind-
ing, End milling machine as per IRS B1-2001

Fabrication Scheme

7. Stage 7 ( Final inspection of fabricated components )

• After final finishing , final inspection with respects to dimensions of fabricated components i.e.
B&S Inspection for one span in assembled condition and rest spans in loose condition done.

8. Stage 8 ( Sand blasting, Metallising and Painting )

• After receiving of inspection clearance certificate , the fabricated components sent for sand blast-
ing , metallising and painting.
• The surface preparation of each member done before blasting as follows:
1. The surface should be clean, dry and free from contaminants and it should be rough enough to
ensure adhesion of the paint film, however it should not be so rough that paint film cannot cover
surface peaks.
2. The cleaning of the surface shall be done initially with the use of emery paper , wire brushes,
scrappers, etc. for spot cleaning to remove rust, scale etc. Subsequently sand blasting of the sur-
face shall be done to remove rust, mill scale along with some of the base metal. This will be
achieved by high velocity impact of abrasive material against the surface in accordance with the
provisions of IS : 6586, which will also create a base for good adhesion. the abrasive material
once used for cleaning heavily contaminated surface should not be reused even through re-
screened. Washed salt free from angular silica sand of mesh size 12 - 30 with a minimum 40%
retained on a 20 mesh screen shall be used for blasting. the material specifications and other re-
quirements shall be as provided in Indian Railways Bridge Manual, 1998.
3. All site rivets, bolts, nuts and washers shall be thoroughly cleaned and dipped in boiled linseed
oil. All machined surface are to be well coated with a mixture of white lead conforming to IS 887
as per specifications before dispatch to site. Nothing extra shall be payable to contractor on this
account.
• The sand blasting is to be carried out in proper sequence as per IRS B1-2001.
• During blasting the surface checked by standard comparator
• Metalizing and painting system of girder :
1. After blasting metal spraying should be carried out soon as possible but in any case within such
period that the surface is still comparatively clean , dry and without visible oxidation . Any oil ,
grease or contaminant removed from the surface before painting
2. The wire method shall be used for the purpose of metallising the diameter of the wire being 3mm
or 5mm as approved by engineer , specified thickness of coating shall be applied in multiple lay-
ers and in no case less than 2 passes of the metal spraying unit shall be made over every part or
the surface after spraying shall be free from uncoated parts of lumps of loosely pattered metal.
3. The composition of the aluminium to be sprayed shall be in accordance with BS: 1475, material
1-B (99.53) aluminium otherwise as per IS:739 & IS:2590.
4. At least one coating must be applied within four hours of blasting and the surface must be com-
pletely coated within 8 hours of blasting with minimum coating applied of 115 microns and aver-
age thickness should be more than 150 microns. It should be checked by approved magnetic
thickness measuring gauge. At least one reading per sqm area shall be taken.Dry film thickness
is to be measured in accordance with appendix VII of IRS B1:2001.
5. The coating is applied with spray ,pressure type spray gun should be used.
6. One coat of wash primer as per IS : 5666 first applied.
7. After application of wash primer one coat of zinc chrome primer to IS:104 with the additional
provision that zinc chrome to be used in the manufacture of primer shall confirm to type 2 of IS
51 applied or two coats of ready mixed paint red lead priming to IS 102. After hard drying of
zinc chrome primer, two coats of aluminium paint IS : 2339 is applied.After the steel work is
erected at site the second coat shall be applied after touching up the primer and the finishing coat
if damaged in transit.
8. Calibrated coating thickness meter is used for measuring thickness of each coating.
9. Final dry film thickness (DFT) after finishing of all coating of paints which is about 200- 210 mi-
crons. Sprayed metal coating shall be subjected to an adhesion test using the method described in
IRS B1 :2001.
iv) Construction of viaduct portion : with all activities explained earlier like pile foundation and
concreting work as per methodology explained earlier .
v) Launching of prefabricated steel girders from one end after construction :
transporting from workshop and stacking at site should be as per clause 31.47.5 of SCC or as di-
rected by engineer in charge. Assembly at site , marking of joints, assembly and launching should
be as per clause 31.47.6, 31.47.7 of SCC or as directed by engineer in charge. Scheme of erection
and launching should be as per clause 31.55 or as suitable at site as decided by engineer in charge.
vi) Closing of level crossings falling in between and construction of LHS in lieu of level cross-
ing by cut and cover method ;
vii) connection to existing line

c. List of Approved Drawings to be followed

d. List of relevant Codes to be followed

e. Inspection and Acceptance criteria for materials and work; ( list attached )

f. Inspection forms ( attached here )