STUDY ON PILING( SUMMER INTERNSHIP - 2010 AS A PART OF COURSE CURRICULUM )

MOHAN PRADEEP YADLAPALLINATIONAL INSTITUTE OF CONSTRUCTION MANAGEMENT & RESEARCH

CONTENTS

• PROJECT BACKGROUND• FOUNDATION• AREA OF STUDY – PILE FOUNDATION• SALIENT FEATURES OF THE PILES IN THE SITE• BORING OF PILE SHAFT BY DMC METHOD• CONCRETING• PILE TESTS• RATE ANALYSIS• PILE STATUS IN BALLING BUILDING (P.P - 2)

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PROJECT BACKGROUND

Essar Steel Orissa Limited (ESOL) is establishing Steel Pellet Plant in

Paradeep, Orissa to produce 12 MTPA Steel Pellets.

Primary Objective:- Essar is planning to cater the captive demand of pellets

in Essar Plant at Hazira (ESHL) using the pellets produced from the Paradeep

plant using beneficiated slurry of 58-59 %Fe. Stage 1

Beneficiation plant of 2 x 4 MTPA

Slurry Pipeline of 12 MTPA

Pellet Plant 1 x 6 MTPA

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FOUNDATION

• Foundation is the lowest part of a structure which provides a base for the superstructure.

• This term includes the portion of the structure below the ground level as well as the arrangement of concrete block, piles, raft, grillage, etc. that are provided to transmit the loads on the structure including self weight of the footing itself to the soil below.

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• Foundation – Purpose• It is used to transmit the load of the structure to

the soil below.• To distribute the weight of the structure over

large area so as to avoid over-loading of the soil beneath.

• To load the substratum evenly & thus prevent unequal settlement.

• To take the structure deep into the ground & thus increase its stability, preventing overturning.

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AREA OF STUDY – PILE FOUNDATION

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Pile Foundations – Classification

PILES

Based on Materials

Based on method of Installation

Based on

Use

Based on mode

of Transferof load

Steel Piles Concrete Piles

Composite Piles Driven piles

Driven Cast In

Situ piles

Bored Cast- In –

Situ Piles

FrictionPiles

End BearingPiles

Tension Piles Sheet Piles Compaction

piles

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• Salient Features of piles in the site• Composition of pile : Concrete pile – M35 Grade• Method of installation : Bored cast in situ• Based on function : Friction Bearing pile• Method of Boring : Direct Mud Circulation (DMC)• Length of the pile : 23m below cut off level• Diameter of piles : 450mm, 500mm, 600mm• Total no. of piles : 539• Sub contractor – Bhagaban Mohapatra Constructions

& Engineers Pvt. Ltd, Bhubaneshwar

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• Boring of Pile by DMC method• Main accessories are 1. Tripod 2. Winch Machine 3. Bailor 4. Chisel 5. DMC rods 6. Tremie pipes

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Winch operator operating winch machine Tremie pipes

Bailor Chisel

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DMC rods DMC rods/Tremie pipe stopper

Bentonite mixing tank Concrete hopper

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Process of boring a pile shaft

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• Steps to be taken care while boring a pile• Ensure that the rigs are placed exactly on the

pile point.• While lowering the reinforcement care should be

taken to ensure the lap length to be 50D• Before washing, the density of bentonite to be

checked by using hydrometer• The density of bentonite slurry should be in

between 1.03 gm/ml to 1.10 gm/ml

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• USE OF BENTONITE IN PILING• In order to keep the sides of the bore intact bentonite is used for drilling by

suspending it in water to form a viscous material. • Bentonite suspensions begin to take on the characteristics of a gel • For these reasons it is a common component of drilling mud used to curtail

drilling fluid invasion and stabilise the bore. • All bentonites have a capacity to exchange cations.

• Suggestions• Mixing of bentonite should be done by Agitator rather than manual mixing.

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• Bentonite PropertiesS.no

Type of Test Method of Test Permissible limits (at 20C)

1 Density Mud balance or Hydrometer 1.03 g/ml to 1.1 g/ml2 Viscosity Marsh cone 30 sec to 90 sec

3 pH Value pH paper strips 9.5 to 12

4 10minute Strength Gel Shearometer or vane shear apparatus

1.4 to 10 N/m2

5 Liquid Limit Casagrande’s Apparatus Less than 300% & not more than 450%

6 Free Swell Consolidation Apparatus Shall be more than 540%

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• Concreting

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• The volume of the concrete hopper is 0.86Cum.• For 450mm diameter pile • Volume of concrete for 1m = 0.159m3

• For 500mm diameter pile• Volume of concrete for 1m = 0.196m3

• For 600mm diameter pile• Volume of concrete for 1m = 0.283m3

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• The length of one tremie pipe is 1.6m• For 600mm diameter volume for 1m = 0.283m3

• Therefore for 1.6m volume of concrete = 0.453m3

• But the volume of concrete in the hopper is 0.86m3

• So at time one tremie pipe can be removed from the pile shaft of 600mm diameter.

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• For 500mm diameter pile• Volume of concrete for 1m = 0.196m3

• Therefore for 1.6m volume of concrete = 0.3136m3

• Volume of concrete hopper = 0.86m3

• So at a time two tremie pipes can be removed from the pile shaft.

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Pile Load Test

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Types of Pile Load Test

LOADTEST

DESTRUCTIVE TEST

NON DESTRUCTIVE

(NDT)

VERTICAL LOAD TEST

LATERALLOAD TEST

PULL OUTLOAD TEST LOW STRAIN HIGH STRAIN

SONIC LOGGINGPILE INTEGRITY

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• Vertical Load Test

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• Pull out Test

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• Table for Pull out TestS.no

Date Time Increment load in tons

Cumulative Dial gauge readings

Average

A B

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• Pile Integrity Test• Concept

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Typical PIT plot – For good pile

Typical PIT record for a doubtful pile

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Rate analysis for piles

• Rate analysis for 500mm diameter pile• Assumptions considered are

Concrete Grade M – 35Bore diameter 500mmBore depth 23mEPIL’s Scope Concrete &

Reinforcement are provided free of cost

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Sub contractors cost – A

S.No Items Units Total Qty Rate per unit (Given in WO)

Total cost

1 Shifting of rigs and Boring cost (below cut off level) Metre 23m 800/m 18400

2 Reinforcement cost (Cutting, bending and placing in bore)

MT 0.4951 7000 3466

3 Pouring Concretie – M35 M 23m 260 5980

4 Static compressive No 1 1160 1160

5 Routine static compressive No 1 1080 1080

6 Lateral load test No 1 350 350

Total Cost 30436

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Material cost - BS.No

Description Quantity Cost Total Cost

1 Concrete – M35 Grade

4.665 Cum Rs 4250/Cum

Rs 19826/-

2 Reinforcement 495.094 Kg Rs 30000/ton

Rs 14852/-

Total Material Cost Rs 34678/-

Total Cost (A+B) Rs 65114/-Over heads (10% T.C)

Rs 6511/-

Profit (10% T.C) Rs 6511/-Grand Total Rs 78136/-

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PILE STATUS

S. NO. PERIOD TOTALNO. OF PILES COMPLETED

NO. OF PILES REMAINING

1 FEB 539 60 479

2 MAR 479 162 317

3 APR 317 115 202

4 MAY 202 87 115

5 JUNE 115 66 49

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ESSARParadeep!

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