METHOD STATEMENT FOR CONSTRUCTION OF PILE CAPDATE : 24-OCT-15

REV : 01

METHOD OF STATEMENT

CONSTRUCTION OF PILING WORKS

ISSUE DETAILS REVISIONDETAILSPAGESDATE

00FIRST ISSUE1104 July 2015

01RE-ISSUE 108 24 October 2015

JOE P SPROJECT ENGINEERJAYA KUMAR RAMANHSE ENGINEERSR. PROJECT MANAGER

PREPARED BYHSE REVIEWREVIEWED BY

TABLE OF CONTENTS

1. Purpose2. Scope of Work3. References:4. Preparation5. Resources 6. Equipment7. Roles & Responsibility8. Safety Precautions 9. Control Measures10. Work Methodology 11. Inspection and Testing12. Related Forms13. Attachments

1.0 ObjectiveTo provide a detailed description for Pilling works methods to ensure that the works are performed in a safe, professional and controlled manner.

2.0Scope of WorksThis procedure covers Mobilization, Installation of piles, Inserting of Pre-Fabricated reinforcement steel cages and Concreting of 600 mm Diameter piles.

3.0 References:3.1 Contract Specification3.2 All relevant applicable BS, ACI & ASTM codes for various civil works3.3 Approved drawings

4.0 PreparationSimplex will produce a programme of works such that client is aware of proposed area of works can advise on logistical constraints imposed by other departments

5.0 Resources All the materials used in permanent works shall be got approved before using at site. Subcontractor approval shall be sought, if any subcontracting jobs involved in this scope. Before starting of the work, it will be ensure that all the shop drawings are approved.

6.0 Equipment Hydraulic drilling Rig Skid steer loader Crawler crane Vibro Hammer with power pack Rock Auger & Bucket Casing pipes Survey Equipments with necessary accessories Welding Generator Other Tools & Tackles Hand Tools (If any)

7.0 Roles & Responsibilities:Project Managerbear overall responsibility for timely and quality execution of works and ensures the effective use of resources and manpower

Project EngineerTo ensure all operations are in accordance with the relevant Project contract specifications and this method statement and check the accuracy of the works done by the site engineers

Site EngineerTo ensure that all earth works are carried out as per the approved shop drawings. Coordinate with surveyors for accuracy of the work

QQA/QC EngineerTo ensure that the works are carried out as per the specifications. Necessary tests are to be carried out for conformity and results are to be provided to the Engineer.

HSE OfficerTo ensure that the works are carried out in a safe manner. Give necessary guidelines to the workforce and facilitate safe working condition

ForemanTo ensure to carry out the work with proper control over labors and equipments. Coordinate with surveyor for accuracy of the work

SurveyorTo ensure that the work is being carried out accurately as per the approved shop drawings in coordination with Site Engineers and Foreman

8.0 Safety Precautions:

8.1ObjectiveTo ensure that all safe practices are adhered to, as per standard operating procedures, Safety Management Plan and contractual obligations while carrying out installation of Piles.

8.2H.S.E Requirements:The following are the H.S.E. requirements for Piling Works: Proper barricades shall be provided for the working area to prevent unauthorized access. Warning signs shall be fixed near the excavation. A signalman shall be deployed where the vision of the heavy equipments is hindering. All employees shall be provided with safety induction before entering to site. All vehicles entering the site shall be fit and adhere with safety requirements and pre-approved TPC All operators/ drivers should have current valid TPC. All personnel shall wear PPEs i.e. safety jacket, safety shoes, helmet etc.

9.0 Control Measures Ensure all permissions and consents have been obtained Ensure approval status of QAP Ensure approval status of this method statement has been received Ensure approval status of ITP Ensure maintain a system of records that permit verification of any issued report before and after work Ensure all plants are escorted to work site by qualified banksman Ensure work area is cordoned off Site briefings will be undertaken to induct all operatives in the detail of his method statement. All personal attending will sign on the briefing sheet acknowledging they understand the briefing given.10.0 Work MethodologySequence of Piling Work Prior to work Pre-Mobilization Activities Preliminary Survey Mobilization and Erection of Plant, Equipments Installation of Temporary Casing Drilling/Boring Installation of Reinforcement Cage with accessories Pouring of Concrete Demobilization of Plant & Equipments and Man powers.

10.1 Prior to work A certificate or permit shall be obtained from the concerned authority, in accordance with all the requirements of the Client. Where applicable, temporary or permanent rerouting shall be provided for above ground and underground services. For this purpose exploration pit shall be made for known underground services Internal traffic arrangements will be made in the work site area with the assistance of safety personnel. Remove all surface obstructions and unsuitable materials such as debris, rubble, shrubs, hedges, trees, stumps, and roots and surface shall be levelled Area shall be verified & cleared from underground services. Survey the area & spot level readings of OGL recorded. Care shall be taken so that the site clearance does not affect the foundation of existing adjacent structures (if present). Suitable temporary accesses shall be provided for all construction activities.

10.2 Pre-Mobilization Activities The piling shall be carried out from the working platform level or dry levelled excavated platform level as per suitability of execution. Pile setting out drawings shall be provided by M/s EMAL and the survey for pile point shall be done by M/s EMAL. Foundation layout drawing shall indicate working platform level, cut-off level, top of reinforcement, reinforcement detailing and shall be duly approved by the Engineer / Client. Approved Drawings shall be used for execution purpose. Pile length and rock socketing shall also be indicated in the approved pile design. Access to the work areas shall be kept unobstructed and clear at all the times so that the work can be inspected by the Engineer/Client as and when required.

10.3 Survey Pile points shall be established by main Contractor and marked using steel pins as per a pre-approved setting-out drawing. Pile points locations and elevations shall be checked as deemed necessary by the Engineer/Client. Pile shall not deviate 1 % in vertical direction and shall not deviate more than 75mm in any direction on plan. Existing underground services location shall be marked on the ground and reference points shall be established and to be visible

10.4 Mobilization and Erection of Plant, Equipments Crawler and Rig machine shall be mobilized to the location and erected st site. Third party inspection will carried out prior to starting the activities The rig will be positioned at pile point with required boring tool attached to the Kelly. Three nos of offset pins will be positioned at a 2.0 to 3.0m distance, and at right angles to the pile positions pin. (This is to ensure that position is not lost when casings are being placed.) They will be used as reference points. Verticality of mast shall be checked using controls in the operators cabin before commencement of drilling operation and as and when deemed fit during drilling operation.

10.5 Installation of Temporary Casing Depending upon the ground conditions, an initial pre-bore of suitable depth if required shall be made before installation of temporary casing. Temporary casing of adequate length shall be available at site. The Temporary Casing length may vary based on the subsurface conditions. The casing shall be installed by Vibro hammer or by rotary rig using casing adopter attached to its rotary with reference to offset pins and spirit level to ensure that the pile shall not deviate 1 % in vertical direction. Once the casing has achieved the required depth, final checking will be made on this position. The casing top will generally be kept about 600 mm above the ground level.

10.6 Drilling by Rig Machine Installation/drilling of pile will be carried out only after the installation of temporary casing pipes as described in the previous point no. 10.5 For boring through soil strata soil auger/ bucket will be used. As rock is encountered rock auger/ rock bucket replaces the soil auger/ soil bucket and boring continues till termination depth. As soon as rock strata for socketing of piles are met with, the depth will be measured and the boring through such rock will be continued up to a depth as per the pile design and approved shop drawings. At the termination level the pile bottom will be cleaned using cleaning bucket and the final depth measurement and will be jointly recorded.

Tolerance: No piles shall not deviate more than 1 in 75 in vertical direction and shall not deviate more than 75mm in plan in any direction.Disposal of Excavated Material: Disposal of Excavated/Boring materials shall be disposed off as per the project HSE Plan.

10.7 Reinforcement Epoxy coated high yield strength deformed bars cages as per drawings shall be prepared in accordance with a pre-approved shop drawing & BBS. Reinforcements shall be made up into stiff cages using stiffener rings at suitable intervals, main reinforcement sufficiently well wired at suitable points to withstand handling without any distortion or damage. They would be placed in position and be supported away from the sides of the pile shaft by means of spacer blocks. The steel reinforcement cages of required grade shall be provided by the main contractor along with concrete cover blocks and PVC sleeves. Steel above cut off level shall be protected from the concrete/weather by wrapping polythene sheet under the PVC sleeves. Normal lap between reinforcement cages will be as per specifications. The main reinforcing steel would project for a length sufficient to develop bond above the cut off level of the pile as shown in the approved shop drawings. The clear concrete cover to helical reinforcement will be as per project specification and suitable approved spacer blocks will be provided at intervals not exceeding 2m and wired to the helical / rings. For ultrasonic integrity test on pile purpose, MS ducts will be jointed using welding and tied together with reinforcement cage

10.8 Pouring of Concrete Ready mix Concrete of C40 grade will be used for concreting of piles. Concrete of required grade will be brought to the site by transit mixers. Concreting shall be poured in a single continuous operation so there will not be any construction/cold joints.

The Record/Data Sheet of Concrete from RMC wherein the details such as name of RMC supplier, transit mixer number, quantity of concrete received, batching time, concrete arrival time shall be provided (one copy) to the Consultant/Client. The concrete will be placed in the pile bore by tremmie method. Casing position shall be checked and recorded before starting of concrete. The tremmie pipe should clean and watertight throughout the length and shall not be less than 150mm dia. for concrete work. The tremmie pipe shall be attached directly to the concrete pump and is held by crane for lowering and lifting. The tremmie pipe, attached to the concrete pump, will be lowered to the pile bore till toe of the pile and raised approximately 200mm off the bottom (to allow concrete to flow). Once sufficient concrete is pumped in, tremmie pipe will be gradually raised ensuring that the tremmie pipe is always at a minimum of 3.0m into the concrete and a maximum of 6.0m as per the provisions of ICE Specifications for Piling and Embedded Retaining Walls. The lifting operation / movement of the tremmie pipe shall be in tandem with the lifting of boom of the concrete pump. Pumping of concrete will continue until sound concrete is observed. The casing shall be withdrawn initially for 1.0 - 2.0m then the hose of the concrete pump shall be inserted into the casing to complete the balance concreting. Then, the crane with Vibro Hammer shall move to the pile location and the casing shall be fully withdrawn. The crane with casing shall be moved to next pile bore location where an initial pre bore was done. The casing shall be placed in the pre bore and the above point 11 (Installation of Temporary Casing) and point no. 15 (Formation of pile) shall be repeated. DeviationThe permissible Deviation Level/ Tolerances for finished concrete works shall be as per site requirements/ Specification/ drawings

12.0 Inspection and Testing: All sampling and testing of concrete will be carried out as per the technical specification and approved QA/QC Plan in accordance with relevant code provisions. Before placing the concrete in the pile bore workability of concrete for each batch will be checked using slump cone. All pile testing shall be conducted at the frequency specified in Project Specifications. Test piles will be selected by the Engineer at random and nominated immediately prior to casting. Low strain Integrity Test shall be carried for 100% of installed piles in compliance with specifications after 7 days of concreting Ultrasonic Integrity Test on piles shall be carried out on 10% of Piles. ASTM codes shall be followed. Pile Static load test shall be carried on preliminary pile.

13.0 Related Forms:1. Approved shop drawings.2. Inspection request.

14.0 Attachments: Risk AssessmentAPPENDIX-A

METHOD STATEMENT- BRIEFING REGISTER

Project: EMIRATES ALUMINIUM SMELTER PROJECT Sheet No:

Date: Time: Delivery by:

Induction Type: Task Specific (Detail): Construction of Anode Storage Building

# I have been briefed of the contents of the above method statement, site safety and piling work requirements. I fully understand all that has been said to me. I have also had the opportunity to raise any queries relating to the work that is to be carried out.

NO.NAME (PRINT) EMPLOYER (PRINT)SIGNATURE #PAYROLL NO

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