Indian Oil Corporation Limited NRP Projects Private Limited

PROJECT Combined Station Works including Civil, Mechanical, Electrical, Telecom &
Instrumentation works at IOCL Terminal in Vallur (Chennai) and CPCL
TITLE OF Job Procedure for Vertical load test on initial and routine Pile
DOCUMENT

NRP Projects Private Limited

CONTRACTOR

CLIENT Indian Oil Corporation Limited

IOCL/NRP/RLNG/24”-EPPL/CIV/012 REV 00
CONTRATOR
DOCUMENTNO.
WORK ORDER NO & 29133926 & 22.08.2023
DATE

PREPARED REVIEWED APPROVED

REV.
DATE DESCRIPTION
NO. Init. Sign Init. Sign Init. Sign
02-12-2023 ISSUED FOR
00
APPROVAL

NRP IOCL IOCL

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 Indian Oil Corporation Limited NRP Projects Private Limited

TEST METHOD STATEMENT VERTICAL

INITIAL AND ROUTINE VERTICAL PILE LOAD TEST TO BE CONDUCTED

INDIAN OIL CORPORATION LIMITED - Vallur – Chennai-103

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Table of Content

1. Purpose
The object of this method statement is to lay down a procedure for carrying out vertical pile load test
(Initial & routine) in bored cat in-situ pile as per relevant technical specifications. This document outlines
the procedure for pile load test by ken ledge method.

Abbreviations:

Following abbreviations are used in the document

RSS Receiving Sub Station

PPE Personal Protective Equipment
FGL Finished Ground Level
RL Reduced level
PLT Plate Load Test
SBC Safe Bearing Capacity
ER Engineer
ISMB Indian Standard Medium Weight Beam

2. Scope of work

 Initial vertical load test on 450 mm dia, bored cast-in-situ pile is performed on a completed single
bore cast in situ pile to access its performance relative to the load bearing / settlement criteria using
static/cyclic method of testing.

 The 450 mm diameter bored cast in situ pile as per design has to be tested for vertical initial load test
for 2.5 times the estimated pile capacity as determined in test pile design.

 Routine vertical load test on 450 mm dia, bored cast-in-situ pile is performed on a completed
single bore cast in situ pile to access its performance relative to the load bearing / settlement criteria
using static/cyclic method of testing.

 The 450 mm diameter bored cast in situ pile as per design has to be tested for vertical initial load test
for 1.5 times the estimated pile capacity as determined in test pile design.

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3. Material, Plant &Equipment, Tools & Tackles.

SI. No Description Of Materials And Tools Qty

1 Pneumatic breaker

2 Hydraulic crane 01 no
3 Excavator (JCB) 01 no
4 Hydraulic Jacks 01 no
5 Pressure Gauge 01 no
6 Hydraulic Pump 01 no
7 ISMB / ISMC 100 as datum bar 02 nos
8 Dial Gauges 04 nos
9 White Glass Plate 04 nos
10 Magnetic stand 04 no
11 Base plate 01 no
12 Welding Set 01 no
13 Cutting Set 01 no
14 Loading platform including loads 01 no
15 Hand tools 01 Set

Kent ledge Details For Intial Vertical Load Test

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A loading platform of 6 m x 6 m is formed using 2Nos Girders of ISMB 450mm x 150mm joists as the Main
beams placed centrally above the pile. 2Nos. of ISMB 300mm joists are on placed either side as support
beams and 10No’s of ISMB 300mm joists are used as cross/distribution girders.

Required quantity of 2.5MT Concrete Blocks are loaded on top of this platform. Total weight of the
Safe Load of the pile is given at 15MT. The test load required is 2.5 times the safe load which works out to
37.5 MT + 25% (9.375MT) Kent ledge load – Total Load 46.875MT.

25 mm thick bearing plate is placed centrally over the pile. The 1 no of 100MT capacity hydraulic jacks is
placed centrally over the pile in such a way that the centre of gravity of the pile, pile cap and the Kent ledge
are in one vertical line. The gap between the jack and the main beams are filled using steel packing material.
Dial gauges were attached to the datum bars using magnetic bases.

Initially the pump is operated such that jack just touches the loading platform and the pressure shows zero,
The initial readings of the dial gauges are noted.
The loads will be applied in increments of 3MT (20% OF Design load). Each percentage increase will be
maintained for 1hr or till the rate of settlement of the pile top is less than 0.1mm in 1hr or 0.2mm in 2hrs. The
maximum load of 37.5MT will be maintained for 24 hrs and hourly reading will be noted. At the end of 24 hrs
unloading will be done gradually (15 min) till the load is release

Kent ledge Details For Routine Vertical Load Test

A loading platform of 6 m x 6 m is formed using 2Nos Girders of ISMB 450mm x 150mm joists as the Main
beams placed centrally above the pile. 2Nos. of ISMB 300mm joists are on placed either side as support
beams and 10No’s of ISMB 300mm joists are used as cross/distribution girders.
Required quantity of 2.5MT Concrete Blocks are loaded on top of this platform. Total weight of the
Safe Load of the pile is given at 15MT. The test load required is 1.5 times the safe load which works out to
22.5 MT + 25% (9.375MT) Kent ledge load – Total Load 31.875MT.

25 mm thick bearing plate is placed centrally over the pile. The 1 no of 100MT capacity hydraulic
jacks is placed centrally over the pile in such a way that the centre of gravity of the pile, pile cap and the Kent
ledge are in one vertical line. The gap between the jack and the main beams are filled using steel packing
material. Dial gauges were attached to the datum bars using magnetic bases.

Initially the pump is operated such that jack just touches the loading platform and the pressure shows zero,
The initial readings of the dial gauges are noted.

The loads will be applied in increments of 3MT (20% OF Design load). Each percentage increase will be
maintained for 1hr or till the rate of settlement of the pile top is less than 0.1mm in 1hr or 0.2mm in 2hrs. The
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maximum load of 22.5 MT will be maintained for 24 hrs and hourly reading will be noted. At the end of 24
hrs unloading will be done gradually (15 min) till the load is released

4. Work Methodology

1.1 Preparation of Pile Head

 After attaining the compressive strength at 7 days, excavation around the test pile already cast shall
be done suitably to accommodate the loading arrangement.

 The pile chipping personnel with jack hammer / breaker will be taken to the test pile location pit.

 Using jack hammer the pile chipping will be done by placing the hammer into the concrete. This will
be repeatedly done till the concrete breaks easily and fall down. All such broken concrete pieces will
be collected and disposed off to designated location.

 The pile head will be chip off to natural horizontal plane till sound concrete is met in order to remove
the contaminated concrete till the good concrete is observed

 The projecting reinforcement will be cut off or bent suitably and the top finished smooth and level
with plaster of Paris or similar synthetic material where required.

 A bearing plate with a hole at the centre should be placed on the head of the pile for the jacks to rest.

 The top of the cast pile will be chipped off carefully to remove the overflowed concrete and dried
bentonite slurry.

 The earth surrounding the pile will be removed.

1.2 Fixing of Platform

 The platform which offers resistance to the jack when is applied on the pile is called ken ledge.

 Required quantity of concrete blocks are loaded on top of this platform.

THE SAFE LOAD ON SINGLE PILE FOR THE INITIAL TEST SHOULD BE LEAST OF THE
FOLLOWING:

 The safe load and displacement values recorded during the test are plated on graph with load on X-
axis and displacement on Y-axis and analysed as per IS 2911 (part 4): 2013 A)

 A) Two-thirds of the final load at which the total displacement attains a value of 12 mm or the safe
load shall b taken of the least of the finally.

 B) 50 percent of the final load at which the total displacement equal 10 percent of the pile diameter in
case of uniform diameter piles

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1.3 TESTING EQUIPMENT PLACING

 Place the required number of hydraulic jacks with adequate capacity in position

 Place a standard MS stool on jack

 Place main girders on Concrete blocks/MS steel stool with its centre concentric with the pile to be
tested.

 Place thick wooden planks /MS girder spanning across secondary girders as the platform.

 Place empty cement bags filled with local sand as the case may be.

 Kentledge arrangement load shall be 25% higher than the test load.

 Pile load test is commenced when it is confirmed that pile head concrete has achieved stipulated
strength at 28 days curing period.

 For each location of load test pile jack calibration and dial gauge shall be submitted separately.

 The pile load test shall be earned out in accordance with as per approved drawing and where no linear
is proposed and bentonite stabilization is considered.

1.4 PILE LOAD TEST PROCEDURE KENTLEDGE METHOD

 Apply a minimum seating load and release it before starting the actual load test. Th is will ensure the
proper functioning of hydraulic jack and load test ken ledge/girder arrangement.

 Kent ledge placed on a platform supported clear of the test pile.

 In case of load test below under-pinned structure, the existing structure if having adequate weight and
suitable construction may serve as kent ledge. The centre of gravity of the kent ledge should generally
be on the axis of the pile and the load applied by the jack should also be coaxial with this pile.

 Initially the pump is operated such that jack just touched the loading platform and the pressure shows
zero, the setting load applied and released. The initial readings of the dial gauges will be noted.

 The load shall be applied in increments of 3MT (20% of Design load of MT). Each percentage
increase will be maintained for 1 hr. or till the rate of settlement of the pile top was less than 0.1mm
in 1hr. or 0.2mm in 1 hr.

 The maximum load of will be maintained for 24 hrs. and hourly reading will be noted. At the end of
24hrs. Unloading will be done gradually till the load is released.

 After completing the pile load test remove the dial gauges, hydraulic jacks with the power pack and
connection to datum bars from the top of the test pile. Remove the load test arrangements like kent
ledge load MS girder, datum bars pillars.

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Fig. 2

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Fig. 3

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Fig. 4

1.5 PRECAUTIONS

 Precautions will be taken to prevent surface water draining at test location.

 The entire test setup will be shielded by tarpaulin from direct sun and adverse weather
condition.

 Warning Signboards & safety barricade will be provided.

 Before applying the initial load, all the packing plates will be concentric with the piston of the jack
and in turn concentric with the main bearing plate.

 The fixed datum support will be free from any interference.

 The datum bar will be adequately stiffened and placed on supports in a manner such that any
effect due to ambient temperature variations are minimized.

2. Quality

 The quality control will be ensured as per enclosed TPI.

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3. Safety, Health &Environment

1.6 General

 Work area shall be barricaded.

 All staff and workers shall be provided with PPE like helmets, safety shoes, reflective jackets, and
other job specific PPE’s

 NO unauthorised person shall be allowed in the vicinity of the working area.

 All the employees will be given Induction Training & then Identity cards (ID) will be issued.

 Second Generation Hydra Crane shall be used at site.

 Third party inspection of equipment and tools & tackles shall be carried out through CMRL approved
agency. The equipment and tools & tackles which are validated and fit for use only will be used in the
work.

 Approved Lifting plan will be followed for all lifting / lowering operation

 Work permit system will be followed

 Work will be carried out in the presence of Site Engineer or Site Supervisor, Safety officeror Safety
Supervisor.

 Site in charge and Safety Staff must be available during entire work period and they will ensurethat
there is no workmen at site before leaving at site.

 Site area & equipment’s will be equipped with fire extinguisher.

 Access & egress arrangement by proper safe method.

 Storage area to be barricaded and sign posters displayed.

 All moving / rotating equipment’s will be guarded and free from damage.

 Equipment’s to be monitored by close supervising.

 Ensure NO stacked materials near excavated edge & proper hard barricading for the deep excavation

 Ensure providing Ear plug for people working nearby noise vehicle

 Welfare facilities like shaded rest place, drinking water, Fan, Toilets etc shall be provide near to site.

 Emergency vehicle shall be provided at site

 Male nurse and first aid facilities will be arranged at site

 Conducting Toolbox meeting at every day before commencing the work

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 Work related awareness and permit system must be carried out

 Proper safety induction shall be done all visitors and workers new to the site
 No unauthorized person shall be allowed in the vicinity of the working area

1.7 Equipment’s & Lifting Tools & Tackles

 The site activity equipment’s and materials shall be arranged proper area to store within RSS
premises

 Vehicle movement shall be control by proper trained banks men

 Crane operation shall be carried out by approved riggers

 Proper hard barricading and warning sign posters shall be provided

 Sufficient access and egress shall be provided

1.8 Communication & Liaison

 All the contract employees will be given Induction Training & then Identity cards (ID) will be
issued.

 Proper coordination and follow up nearby contractor’s activities with safety plan procedure

 All works shall be carried out with the presence of site safety steward and reporting to the concern
person
1.9 Environmental

 All works shall be carried out as per the Environment plan.

 Noise: Safety Ear plug shall be provided

 Dust: Water spraying shall be arranged on regular basis if applicable

 Smoke: Pollution certificate shall be providing all Earthing moving vehicle

 Disposal of waste: All unwanted waste shall be disposed on regularly. Waste bins shall be kept at
site.

 Dewatering: Dewatering system shall be arranged if applicable

 Storage of chemicals / oils: All chemical shall be followed as per MIHC rule 1989 like Separate
shed, avoid direct contact Sun lights, spill kits, Drip tray, Fire points ,Housekeeping and Chemical
inventory control and Suitable Personal Protective Equipment’s Chemical hand gloves, Mask /
respirator, Eye wash station / welfare facilities and frequently periodically medical camp shall be
implemented at site.

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Annexures
a. Annexure 1 - Pile Load Decrement Record
b. Annexure 2 - Testing Agency checklist

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Annexure 2

`Sr. Points to be checked Observations

No.
1 Hazards don't exist around elevating lifting equipment and it
is safe to carryout inspection and load test?
2 Load test procedures for the specified equipment are
reviewed?
3 Check lifting tools and tackles colour coding done?
4 Check capacity of tools and tackles is marked?
5 All safety devices are provided as per applicable standard and
design?
6 All locking devices are as per applicable standard and
design?
7 All limit devices are as per applicable standard and design?

8 Manufacturer load test certificate for equipment is provided?

9 Initial inspection is performed for load test?

1 Rated load test are as per applicable standards or design?

1 Tools and tackles conditions are checked?

1 Witness load test as per pile load test Method
statement procedure?
1 Check excavation area hard barricading done?
1 Check illumination and lighting arrangement to perform the
load test?

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