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TECHNICAL SPECIFICATION & SCOPE OF WORK FOR PILING JOB

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1.0 PURPOSE This document defines the scope of works for RCC bored cast-in- situ piles and its specific requirements including pile foundation system for the proposed Petroleum Product storage Tanks at Paradeep Terminal, Orissa. 2.0 CODES, STANDARDS & SPECIFICATION a. IS: 2911 (All Parts) b. Specification for materials for Reinforcement concrete piles c. Specification for construction and installation for bored cast in situ piles d. Specification for testing of concrete piles 3.0 SCOPE 3.1 General Providing RC bored cast in situ piles and R.C. pile caps as per design carried out by the bidder, vetted by reputed engineering institute like IIT, Kharagpur or any other reputed Engineering Institutes/ Consultant duly approved by HPCL and submitting to HPCL for review before commencement of piling work. All jobs to be completed within the specified time period mentioned in the tender. Supply of all materials is also included in contractor's scope. The scope in general consists of designing the RCC pile foundation basis the soil investigation report/ recommendation, which shall be provided to the successful bidder. The party has to carry out the design of the pile foundation basis the soil report after the award of the contract and get the design vetted by reputed engineering institute like IIT, Kharagpur or any other reputed Engineering Institutes/ Consultant duly approved by HPCL within the quoted rates. For the purpose facilitating the bidders to provide their techno commercial offer the diameter of piles have been assumed ranging from 500 mm dia to 800 mm dia and depth of termination approximately 15 meters The quantities mentioned in the schedule of rates are approximate and actual payment shall be made basis the actual executed quantities based on the approved design. The testing of piles shall also be carried out by the contractor in line with IS 2911­ (Part IV) and relevant specifications of this tender document within the quoted rates. No extra payment shall be made to the Bidders on this account. However the contractor is expected to quote for this tender based on the information provided herein and other sections of this tender document including the Schedule of Quantities. The work involves but not limited to the following:

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(i) (ii)

Design & Construction of Pile foundation for construction of Petroleum storage tanks ( 2 nos of 28 mt dia X 10 mt ht (5000 KL capacity) & 2 nos of 30 mt dia X 10 mt height(6700 KL capacity) Conducting Routine Load tests on designated working piles namely Vertical, Lateral & Pullout load tests.

3.2 Minimum Requirement of Piling Equipment Sufficient no of hydraulic self propelled or manual rotary piling rig complete with casing Adaptor and Casing Oscillator to complete the entire job as per the time schedule provided in this tender document.. The Contractor shall mobilize sufficient spares; cutting tools (e.g. flat teeth bits, round shank bits, holders, etc) to avoid any stoppage of work. 3.3 Surveying and Staking It is the express responsibility of the contractor to bring to site all surveying instruments necessary for the marking out, fixation of levels, etc. and conduct these survey operations himself with utmost accuracy. The contractor shall put-up stable bench marks etc. as necessary for the work. HPCL will be present when this work is being carried out and will inspect all these operations with the Contractor's assistance. The contractor shall be entirely responsible for accurate setting out of the work and he shall at his own expense make good any defects arising from errors in line and levels. 3.4. Dewatering Dewatering of accumulated water in all locations on job site from whatever source or cause untill the virtual completion of the entire work shall be done by the contractor at his own expense and shall not be separately paid for. The rates quoted by the contractor shall be deemed to be inclusive of this. 3.5 Tenderer's shall submit the following information as part of their technical bid: i) Numbers of the piling rig proposed to be deployed. ii) Full Technical details of piling rigs and accessories in the form of catalogues, data sheets, etc. iii) Piling procedure, piling programme and accessories to be mobilized by the contractor at no extra cost to the client. 3.6 The contractor shall use only Ready mixed concrete for the proposed piling and pile caps works. Contractor shall indicate the resources available in this regards including number of batching plants to be mobilized considering the time frame and nature of works. As a specific requirement, only Portland puzzolana cement conforming to IS 1489 shall be used for all concrete works. All rebars shall be Corrosion resistant steel (Tiscon CRS/SAIL-HCR- /RINLHSCR) and shall conform to IS 1786 grade Fe 500 for mechanical properties. 3.7 The work involves but not limited to the following: a) Construction of straight shaft RCC bored cast-in-situ piles of approved diameter and depth of termination (basis approved design carried out by the bidder based on soil investigation report to be handed over the bidder after award of work order) and approximate number of piles 4 of 48

b) Carrying out routine load tests as specified on randomly selected job piles selected by Engineer-in-Charge and as per codal provisions. 4.0 AVAILABLE INFORMATION 4.1 The proposed pile top need to be terminated at 600mm above Pile cutoff level..The same will be chipped off at the time of commencement of pile cap job to progress the job further. The soil profile and design requirements shall dictate length of temporary casing pipe required for construction purposes which shall be immediately withdrawn after casting of the pile Free boring, if any will not be considered for measurement & payment. 5.0 REQUIREMENTS All work shall be carried out in accordance with the specifications enclosed herewith and contractor shall ensure minimum requirements as laid down hereunder: 5.1 Termination of Piles Piles shall be terminated with a minimum embedment of 2.40m inside the soft /disintegrated strata having SPTN Value more than 100 or as per soil investigation report or as per design requirements. After encountering the soft /disintegrated medium dense layer, the beginning of the layer shall be established by conducting SPT. In case SPT is observed more than 100, the pile shall be terminated with an embedment of minimum 2.4m inside the strata. For confirmation of the similar strata two more SPT shall be conducted thereafter with an interval of 1.0m, conducting of SPT shall be done at least one in five (1 in 5) pile location. In case medium hard or hard strata encountered before minimum embedment depth in the above specified strata the pile shall be terminated in this layer with a minimum embedment of 500mm in medium hard strata or 200mm in hard strata. Piling in soft / disintegrated strata shall be done preferably with chisel as per discretion of Engineer-in-Charge and in the case of medium hard / hard rock strata pile boring shall be proceed with chisel of weight 2.5t or more. The level of encountering the particular strata and termination depth in all cases shall be certified by Engineer-in-Charge and shall be binding on the tenderer. 5.2 Safe Load Carrying Capacity For Vertical Compression/Lateral/Uplift The tenderer shall guarantee minimum safe load of 1.5 times the design capacity for the piles provided. The safe load may be increased by 25% in the case of wind and seismic. 5.3 MATERIALS Materials shall conform to specifications for materials for Reinforcement concrete pile which is enclosed elsewhere in this tender document and forming a part of the tender. 5.3.1 CONCRETE The concrete shall have a minimum strength of 30 N/sq. mm at 28 days. The cement for concrete shall be Portland puzzolana cement having minimum cement content not to be less than 400 kg/cum and a max water cement ratio of 0.45. The cement content shall be governed by Design mix or soil characteristics, which ever is higher. The allowable slump shall 5 of 48

be as per relevant latest revision of IS codes (IS 2911 Part 1/Sec 2). The Engineer-in-charge may allow marginal adjustment in water/cement ratio to obtain concrete of good workability. The other concrete specifications shall be as per relevant clauses of "Design, Construction & Installation of Bored cast-in-situ piles forming part of this tender. 5.3.2 REINFORCEMENT Reinforcement shall conform to IS: 1786 (latest version) grade Fe-500 for mechanical properties and shall be Corrosion resistant steel and it shall be either "TISCON CRS" from TISCO or HSCR-M from Vizag Steel or HCR-M from SAIL only. The reinforcement in the pile shall consist of the following: a) Longitudinal/Ties/Spacer bar Reinforcement Reinforcement provided shall be as per approved design with respect to diameter, numbers and should run through the entire length of the pile. d) Cover Clear cover to reinforcement shall be as per approved design (min 75mm). 5.4 INSTALLATION 5.4.1 Installation of piles shall be carried out in accordance with the pile lay out drawings as prepared/vetted/approved which are prepared by the contractor at the time of execution of work. 5.4.2 Cut-off level of the piles shall correspond to those given in the working drawings. 5.4.3 To ensure dense and sound concrete upto cut-off level, concreting shall extend minimum 600 mm above cut-off level. However, no extra payment shall be made for this and quoted rates shall be inclusive of this. 5.4.4 In case the reinforcement cage is made up of more than one segment, the same shall be assembled by welding only, before lowering, as per IS: 456-2000 by providing necessary laps. 5.4.5 The vertical reinforcement shall project 50 times its diameter above the cut-off level. 5.4.6 Pile shall be constructed by using temporary casing upto minimum 1.5m to 3.0m inside the stiff to very stiff clay exists below very soft / marine clay as per site conditions or design requirements. Adequate bentonite mud shall be used as full depth temporary casing not been used during the boring below temporary casing. Concrete shall be placed by tremie. All precautions for obtaining clean and sound pile shaft shall be strictly observed. 5.4.7 For Tremie concreted piles, a sample of drilling fluid shall be taken from the base of the borehole by means of an approved sampling device in the first few piles and at suitable interval of piles thereafter. Concreting shall not proceed if density of fluid exceeds 1250 kg/cu.m. The sand content in the fluid shall not exceed 7 percent. 5.5 MEASUREMENT OF PILES 5.5.1 The piles shall be measured and paid for the actual pile length from pile tip to the cut off level, as per the approved working drawings submitted by the contractor based on the approved design or as indicated by the Engineer-in-Charge. No extra payment shall be made for empty boring, if any. 5.5.2 Payment for routine load tests which shows unsatisfactory results shall not be made. 6 of 48

5.5.3 Piles showing unsatisfactory results shall be treated as defective piles. Defective piles shall be removed or left in place and replaced by additional piles as directed by engineer-inCharge at no additional cost to the owner. 5.5.4 Reaction piles, if required for the purpose of conducting load tests on piles shall not be paid extra. Quoted rate for tests shall be inclusive of this. However, for routine lateral and uplift tests, if required, job piles may be used as reaction piles. 5.5.5 The quoted rate for bored cast in situ piles shall be exclusive of reinforcement conforming to IS 1786 ­ Fe 500 corrosion resistant bars of TISCON ­ CRS, HSCR-M from Vizag steel or HCR-M from SAIL. However, measurement/payment for reinforcement used shall be made through a separate item available in the schedule of rates. 5.6 PILE TESTING 5.6.1 Initial Load Test : DELETED 5.6.2 Routine Load Test Routine load tests shall be carried out up to one and half times the design load. The piles for the test shall be randomly selected by the Engineer-in-Charge 5.6.3 Pile Load Test Details i) For pile load tests, the test set up shall be as per IS 2911 Part IV and specifications for testing of concrete piles. ii) All testing shall be done by Direct method of loading in successive increments as per the relevant clauses of IS: 2911 Part IV & Standard Specifications for testing concrete piles forming a part of this tender iii) Each stage of loading shall be maintained till the rate of movement is less than 0.2 mm per hour. Test shall be carried out at the cut-off level. 5.6.4 Maximum test loads shall be as follows: i) Initial pile load tests: Deleted ii) Routine vertical load test: Load corresponding to 12 mm settlement or one and half times the safe load whichever occurs earlier. 5.6.5 Number of Tests Required The number of tests required shall be as per relevant clause of IS 2911 Part IV. 5.6.6 Payment for testing of Piles No additional payment shall be made for testing of piles. The rates quoted in the schedule of rates shall deem to be inclusive of the pile testing required to be carried out under clause 5.6. NOTE: Kentledge load shall be at least 25% higher than the maximum test loads. 5.6.5 Criteria for Assessment of Safe Loads 5.6.5.1 Safe vertical load on single pile shall be the least of the following: i) Two thirds of the final load at which the total settlement attains a value of 12 mm. ii) 50% of the final load at which the total settlement equals to 10% of the piles dia. iii) Safe lateral load on single pile shall be least on the following: iv) 50% of the final load at which the total lateral displacement equals to 12 mm. v) Final load corresponding to the total displacement of 5 mm.

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5.6.5.2 A full record of pile load test results shall be submitted in triplicate to the Engineer-inCharge immediately on completion of each test. The record shall also include the plots of loadsettlement (for various stages of loads) characteristics of pile and also the interpretation of the pile load test curve as per criteria for safe loads mentioned in the specifications for testing concrete piles forming a part of this tender. Any special observations shall be duly explained by the contractor. 5.6.5.3 Replacement of Rejected Piles Piles/boring/casing that are defective or exceed the tolerances specified above shall be left in place or pulled out as directed by Engineer In Charge without adversely affecting the performance of the adjacent piles. In case the piles/casing cannot be removed they shall be cut out as directed by Engineer In Charge. Voids resulting from rejected borings or extraction of the piles or casings shall be filled with gravel or sand unless other piles are installed in such voids at the cost of contractor . 6.0. General Pumping and bailing out of water, shoring, strutting, etc., if found necessary for successful and speedy operation of work shall be carried out by the contractor and cost of such works shall be included in his rates. No extra claims whatsoever on all subsidiary works pertaining to pilling work will be entertained. All the excavated materials including debris, Loose earth, muck etc shall be carted away and disposed off by the contractor out of the premises to any suitable place as per local statutory authorities. The Contractor shall provide all the equipments, tools and plants required for the work and rates shall include the cost of bringing the equipment etc, to site, proper maintenance and removal of the same after completion of work. Control of Piling Installation shall be as per the relevant IS Code (IS 2911 (part 1 section2). Piles that are defective shall be left in places as judged by Engineer In Charge and additional piles shall be driven to replace them at no extra cost. Adequate length of bars to be left over the cut-off level of the pile to develop anchorage in the pile caps and also dowels to be kept of adequate lengths. Sample of the hard strata shall be taken appropriately marked and preserved by the contractor and finally handed over to HPCL. The level on the container should specify the date of piling, pile marked and depth of strata from which the sample has been obtained. Rig register and weekly report as per the format, approved by HPCL shall be submitted to In-charge of the project.

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During the period of establishing mix- design at site, nominal mix 1:1:2 for piling work only can be followed but the cement consumption for entire volume of piling work under reference will be reconciled based on approved design mix. For the purpose of measurements and payments, the length of pile shall be measured from the tip of the pile to the bottom of the pile cap. The 8 cm. length of the pile projecting into the cap shall not be measured for the payment and also shall not be deducted from the quantity of Pile cap concrete. Reinforcement placed in the pile shall be paid for separately for the actual quantity of reinforcement placed in the pile exclusive of couplings, welded joints, spacer bars and binding wire as stipulated in the relevant specifications for reinforcements. All piles shall be concreted to a level 600 mm above the specified pile cut off elevation which shall be 7.5 cm. above the bottom of the Pile cap. For piles cast by tremie method, in bentonite established bore holes, this level of concreting above pile cut of level shall not less than 600mm. Before casting the pile cap, this excess concrete shall be cut off up to pile cut off elevation. In case sound concrete is not met with at such elevation the piles shall be cut to such elevation where sound concrete is met. Piles shall be cut off at level and true to elevation shown or specified on the Drawings. Care shall be taken not to damage the reinforcement or the concrete below cut off elevation during such stripping operations. Where stripping to be done to a level lower than the specified cut off elevation to obtain dense and sound concrete, the Piling Contractor shall built up the pile up to cut off elevation at his own cost. Upon completion of the piling work, all casing equipments, construction tools, protective covering and debris resulting from the piling operations shall be removed from the works site with the permission of the HPCL. A minimum length of 2-3 metres of temporary casing shall be provided for each bored piles unless otherwise specifically desired. Additional length of temporary casing shall be used depending on the condition of the strata, ground water level etc. 7.0 Recording of Data Daily site records shall be maintained by the Contractor for the installation of piles against each Rig and shall contain the number and dimension of the pile, depth bored ( including depth in soft / hard rock ), time taken for boring, concreting and empty boring ( cut-off level) , chiselling and where the pile is wet or dry. Sample bore log in the initial stage or when major variation occur should be shown. When drilling mud is used, amount of bentonite needed for stabilization of bore, specific gravity of the fresh supply and contaminated mud in the bore hole before concreting shall be checked and recorded regularly. Concrete volume actually cast per pile against required volume and actual cement consumption. Detail of any obstruction encountered, its nature, depth and obstruction 9 of 48

time. Any deviation from the designated location alignment or load capacity of any pile shall be noted. Typical data sheet in triplicate for facility of recording piling data to be prepared by the Contractor before starting of actual piling operation at site and information to be recorded against each pile in the data sheet shall be signed by the contractor and countersigned by HPCL. One copy of the data sheet shall be retained by the Contractor and the other two copies to be submitted to HPCL for records & future reference. At least six photographs are to be taken by the party depicting progress of the job in every week and a set of same to be separately submitted for review and record to HPCL.

STANDARD SPECIFICATION FOR MATERIALS FOR

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REINFORCED CONCRETE PILES

CONTENTS 1. GENERAL 2. MATERIALS FOR CONCRETE 3. ADMIXTURES 4. REINFORCEMENT

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1.0 GENERAL 1.1 Scope 1.1.1 This specification establishes the material specification of reinforced cement concrete to be used in pile foundation. Any special requirements as shown or noted on the drawings shall govern over the provisions of these specifications. 1.1.2 For specific work requirements concerning design and construction or otherwise modifying or supplementing the provision of this specification, refer to the specific requirements. In case of conflict between specific requirements and provision of this specification, former shall govern. 1.2 Definitions 1.2.1 Reference to Indian Standard Codes shall always mean reference to the latest issue of the relevant standards including all its amendments up to date. 1.3 Codes All design and construction shall be performed in accordance with the Indian Standard Code of Practice for Plain and Reinforced Concrete I S: 456 & IS: 2911 12 of 48

2.0 MATERIALS FOR CONCRETE All materials which may be used in the Plain or Reinforced Cement Concrete work shall be of Standard quality conforming to IS or equivalent and shall have IS certification mark as far as possible unless otherwise approved by the Engineer-in-Charge. The contractor shall get all materials approved by Engineer-in-Charge prior to its procurement and before actual use. The Engineer-in-Charge shall have the right to determine whether all or any of the materials offered or delivered for use in the works are acceptable. Any material brought to site and not conforming to specification and instruction of Engineer-in-Charge shall be rejected and the contractor shall have to remove the same immediately from site at his own expense. 2.1 Cement 2.1.1 General The cement used shall be Portland puzzolona cement conforming to IS: 1489 latest version and the make of the same shall be approved by HPCL. 2.1.2 Tests after Delivery Each consignment of cement may, after delivery on the site at the discretion of the Engineerin-Charge, be subjected to any or all of tests and analysis required by the relevant Indian Standard Specifications. Facilities for testing shall be provided by contractor at his own cost. 2.1.3 Storage on the Site The cement shall be stored in a suitable weather-tight building and in such a manner as to permit easy access for proper inspection to prevent deterioration due to moisture and to minimize warehouse deterioration. Cement of different type and brands shall be kept in separate storage. All accepted cement stored on the site shall be arranged in batches, and used in the same order as received from the manufacturer. The contractor shall maintain a cement register, in which all entries shall be completed day to day showing the quantities received, date of receipt, source of dispatch, type of cement, etc. and also the daily cement consumption on site. The register shall be accessible to the Engineer-in- Charge for his verification. 2.1.4 Rejection of Cement The Engineer-in-Charge may reject any cement as a result of any tests thereof, notwithstanding the manufacturer's certificate. He may also reject cement which has deteriorated owing to inadequate protection from moisture or due to intrusion of foreign matter or other causes. Any cement which is considered defective by the Engineer-in-Charge shall not be promptly removed from the site of the work by the contractor at his own expense. 2.2 Aggregates for Concrete 2.2.1 General Coarse and fine aggregates for concrete shall conform in all respect to IS: 383, "Specification for Coarse and Fine Aggregates from Natural Sources for Concrete". Aggregates shall be obtained from a source known to produce those satisfactory for concrete. Aggregates shall consist of naturally occurring sand and granite/basalt trap stone, crushed or uncrushed, or a combination thereof. They shall be chemically inert, hard, strong, dense, durable, clean and free from veins, adherent coatings and shall be of limited porosity. Flaky and elongated pieces 13 of 48

shall not be used. The source of aggregates shall be approved by the Engineer-in-Charge and shall not be changed during the course of the job without his approval. Rejected aggregates shall be removed from the work site by the contractor at his own expense. 2.2.2 Deleterious Materials Aggregates shall not contain any harmful materials such as iron pyrites, coal, mica, shale or similar laminated materials, clay, alkali, soft fragments, sea shells, organic impurities etc. in such quantities as to affect the strength or durability of the concrete. In addition to the above, for reinforced concrete, any material which might cause corrosion of the reinforcement and aggregates which are chemically reactive with the alkalis of cement shall not be used. The maximum quantities of deleterious materials in the aggregates, as determined in accordance with IS: 2386 (Part-II) "Methods of Test for Aggregates for Concrete", shall not exceed the limits given in Table-I of IS: 383. The sum of the percentages of all deleterious materials shall not exceed five. Deleterious materials also include material passing 75 micron IS sieve. 2.2.3 Coarse Aggregates Coarse aggregate is aggregate most of which is retained on 4.75 mm IS sieve. These may be obtained from crushed or uncrushed granite/basalt trap stone as per Cl. 2.3.1 and may be supplied as single sized or graded aggregates given in Table-II of IS: 383. The Engineer-inCharge may allow all-in-Aggregate to be used provided they satisfy the requirements of clause 4.4 and T able-IV of IS 383. 2.2.4 Fine Aggregates Fine aggregate is aggregate most of which passes 4.75 mm IS Sieve but not more than 10% pass through 150 microns IS Sieve. These shall comply with the requirements of grading zones I, II and III and given in Table-III of IS: 383. Fine aggregate conforming to grading zone IV shall not be normally used in reinforced concrete unless tests have been made by the contractor to ascertain the suitability of the proposed mix proportion and approved by the Engineer-in-Charge. Fine aggregate shall consist of natural sand resulting from natural disintegration of rock and which has been deposited by streams or glacial agencies, or crushed stone sand or crushed gravel sand. 2.2.5 Sampling and Testing In case of doubt the Engineer-in-Charge may require the contractor to carry out tests, at the contractor's expense in accordance with ­ IS: 516 ­ Method of Tests for Strengths of Concrete; and IS: 2386- Method of Tests for Aggregates for Concrete. 2.2.6 Storage of Aggregates T he contractor shall at all times maintain at the site of work such quantities of aggregate as are considered by the Engineer-in-Charge to be sufficient to ensure continuity of work. Each type and grade of aggregate shall be stored separately on hard firm ground having sufficient slope to provide adequate drainage to rain water. Any aggregate delivered to site in a wet condition or becoming wet at site due to rain shall be kept in storage for at least 24 hrs. to obtain adequate drainage, before it is used for concreting, or the water content of mix must be suitably adjusted as directed by Engineer-in-Charge. 2.3 Water 14 of 48

Water used for concrete shall be clear and free from injurious amounts of Oil, Acid Alkali, Organic matters or other harmful substances in such amount that may impair the strength or durability of structure. Potable water shall generally be considered satisfactory for mixing and curing concrete. The Engineer-in-Charge may require the contractor to prove at latter's expense, that the concrete mixed with water proposed to be used should not have a compressive strength, lower than 90% of the strength of concrete mixed with distilled water. The Engineer-in-Charge may require the contractor to get the water tested from an approved laboratory at his own expenses and in case the water contains any sugar or an excess of acid, alkali, any injurious salts, etc. the Engineer-in-Charge may refuse to permit its use. 3.0 Admixtures 3.1 Admixtures such as CICO grade I or KIM (KRYTON make) or equivalent may be used in concrete only with the approval of Engineer-in-Charge. 4.0 Reinforcement 4.1 Corrosion resistant Steel reinforcement 4.1.1 The reinforcement shall confirm to IS: 1786, Fe-500 grade. The reinforcement shall be Corrosion resistant steel and it shall be either "TISCON CRS" from TISCO or HSCR-M from Vizag Steel or HCR from SAIL-M normally be mild steel in the form of round bars, conforming to IS: 432-Grade 1 unless specified otherwise. 4.1.2 Hard-Drawn Steel wire Fabric When specified in the drawings, hard drawn steel wire fabric shall be used conforming to IS: 1566, It shall be of approved type and of the weights and dimensions shown in the drawings. 4.2 Welding 4.2.1 Field welding of reinforcing bars will not be permitted without the written consent of the Engineer-in-Charge. Where welding is permitted it must be at staggered locations. Tests shall be made to provide that the joints are of the full strength of bars connected. Welding of reinforcement shall be done in accordance with the recommendation of IS: 2751. 4.3 Storage 4.3.1. The steel reinforcement shall be stored in such a way as to avoid distortion and to prevent deterioration and corrosion. 4.4 Other Specifications 4.4.1 General construction details and workmanship relative to reinforcement including bar bonds, lap splices and installation shall be in accordance with I S:2502- Code of Practice for Bonding and Fixing of Bars for concrete reinforcement, as well as the detailing of reinforcement given in I S:456. 4.4.2 Hot bending of bars shall not be allowed. 4.4.3 The number of sizes, shape and position of all the reinforcement shall, unless otherwise directed or authorized by the Engineer-in-Charge, be strictly in accordance with the drawings. The reinforcement shall be adequately secured and held in position by metal chairs and spacers. Ties of inter-sections shall be made with 16 SWG soft black annealed binding wire.

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4.4.4 The contractor must obtain the approval of the Engineer-in-Charge for the reinforcement placed, before any concrete is placed in the forms. The reinforcement of this time shall be free from loose rust or scale or other coating that will destroy or reduce bond. 4.7.5 Concrete spacer blocks of the same strength as parent concrete shall be used to ensure correct cover to the reinforcement. This clear cover shall be as shown on the drawings or as per instructions of the Engineer-in-Charge. 4.7.6 All the reinforcing bars shall be so tied as to form a rigid cage to prevent displacement before or during concreting.

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STANDARD SPECIFICATION FOR CONSTRUCTION AND INSTALLATION OF RCC BORED CAST-IN-SITU PILES

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CONTENTS 1. SCOPE 2. CODES 3. MATERIALS 4. DESIGN CONSIDERATIONS 5. EQUIPMENTS AND ACCESSORIES 6. PILE INSTALLATION 7. DEFECTIVE PILES 8. RECORDING OF DATA

1.0 SCOPE 1.1 This standard specification covers the construction and installation of load bearing reinforced concrete bored cast-in-situ piles. 18 of 48

1.2 For specific work requirements concerning construction or otherwise modifying or supplementing the provisions of this specification, reference may be made to `Specific Requirements'. In case of any conflict between requirements set forth in `Specific Requirement' and the provisions of this specification, the `Specific Requirements' shall govern. 2 CODES 2.1 IS: 2911 (Part I /Sec.2) ­ Indian Standard Code of Practice for Design and Construction of pile foundations for Bored Cast-in-Situ Piles shall be referred to in conjunction with these specifications during the entire design, construction and installation work. 2.2 Reference to any code shall always mean reference to the latest revised edition of the code including all its amendments up to date, unless otherwise specified. In the event of any conflict between the requirements of this specification and those of the referred codes, the former shall govern. 3 MATERIALS 3.1 All materials, viz. cement, steel, aggregates, water, etc. which are to be used in the construction work, shall conform to Standard Specification for construction and installation of RCC bored cast-in-situ piles. 3.2 Concrete 3.2.1 Methods of the manufacture of cement concrete shall in general, be in accordance with IS: 2911 (Part I /Sec.2) and as per following clauses: 3.2.2 The grade of concrete shall be M-30 with a minimum cement content of 400 kg/cum and a max water cement ratio of 0.45. The cement content shall be governed by Design mix or soil characteristics, which ever is higher. 3.2.3 Slump of Concrete Slump of concrete shall range between 100 to 180 mm depending on the manner of concreting. The table below gives the general guidance. PILI NG A SLUMP (In MM) Min. Max. 100 180 TYPICAL CONDITIONS OF USE Pouring into water-free unlined bore having widely spaced reinforcement. Where reinforcement is not spaced widely enough, cut-off level of pile is within the casting and diameter of pile less than or equal to 600mm, higher order of slump within this range may be used. Where concrete is to be placed under water or drilling mud by tremie or by placer

B

150

180

4 DESIGN CONSIDERATIONS

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4.1 Structural Design: The piles shall have necessary structural strength to transmit the load imposed on it, to soil. Relevant part of IS: 2911 (Part I/ Sec.2) and specific requirements shall be considered to apply for assessing the structural capacity of piles. 4.2 Reinforcement 4.2.1 The minimum longitudinal reinforcement shall be 0.4% of the cross sectional area of the pile. 4.2.2 Clear cover to the main reinforcement shall be 50 mm. This shall be increased to 75 mm in case of aggressive soils and ground water conditions. 4.2.3 The vertical reinforcement shall project 50 times its diameter above the cut-off level. 4.2.4 The minimum clear distance between the two adjacent main reinforcement bars should normally be 100 mm for the full depth of cage. The bars shall be so placed as not to impede the placing of concrete. 4.2.5 The lateral ties in the reinforcing cage shall be preferably spaced not closer than 150 mm centre to centre. 4.2.6 The minimum diameter of the lateral ties shall be 6 mm. 5 EQUIPMENT AND ACCESSORIES 5.1 The equipment and accessories for installation of bored case-in-situ piles shall be selected giving due consideration to the subsoil conditions and the method of installation, etc. These shall of standard type and shall have the approval of the Engineer-in-Charge. 5.2 The capacity of the rig shall be adequate so as to reach the desired depth. 5.3 Provision shall be kept for chiseling within the borehole in case of any underground obstruction/hard strata. However, chiseling shall be carried out only with the approval of Engineer-in-Charge. 5.4 In case pile is required to be socketted in medium or good quality rock strata, the equipment mobilized shall have adequate capability to do so up to the required socket length. For the purpose of classification of rock for the determination of length of socketting, pilot drill holes shall be carried out in the areas to be piled. 5.5 Pilot drill hole shall be of Nx or Bx size as per specific requirements. Rock drilling shall be carried out using double tube core barrel. Drilling and storing of rock cores shall conform to relevant IS codes. Rock quality shall be classified as under depending upon the RQD. RQD (%) <25 25 to 75 >75 ROCK QUALITY Poor Medium Good 20 of 48

6 PILING INSTALLATION 6.1 Control of Alignment 6.1.1 The piles shall be installed as accurately as possible as per the designs and drawings. The permissible positional deviations shall be governed by IS: 2911 (Part I /Sec.2). In case of piles deviating beyond such permissible limits, the piles shall be replaced or supplemented by additional piles, as directed by Engineer-in-Charge. 6.2 Boring 6.2.1 The boring shall be done by one of the following methods: (a) Direct mud circulation (b) Reverse mud circulation (c) Bailer bentonite The actual method of construction to be followed shall be as per specific requirements. 6.2.2 In very soft soil a permanent liner shall be installed to ensure stability of borehole. A liner shall be used to protect the green concrete where a high hydrostatic pressure exists in the subsoil or where an underground flow of water exists and which is likely to damage the concrete on withdrawal of casing. 6.2.3 Use of temporary liner only in lieu of bentonite to stabilize sides of boreholes shall not be permitted. 6.2.4 Properties of bentonite used and quality control shall be as per IS: 2911 (Part I /Sec.2). 6.3 Concreting of Piles 6.3.1 Reinforcement 6.3.1.1 The reinforcements shall be made into cages sufficiently rigid to withstand handling without damage. In case the reinforcement cage is made up more than one segment, the same shall be assembled by providing necessary laps preferably by welding. 6.3.1.2 Stirrups to the main bars shall be tack welded. 6.3.1.3 Care shall be taken to ensure that the reinforcement bars do not come closer while the cage is lowered down the hole. 6.3.1.4 Proper cover and central placement of the reinforcement shall be ensured by use of suitable concrete spacers or rollers, case specifically for the purpose. 6.3.2 Concreting 6.3.2.1 Concreting shall not be commenced until the Engineer-in-Charge satisfies himself that at final borehole depth the soil is not weaker than that taken as the basis for pile design. If necessary, SPT or similar test shall be conducted to ensure the above.

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6.3.2.2 Borehole bottom shall be thoroughly cleaned to make it free from sludge or any foreign matter before lowering the reinforcement cage. The full length of reinforcement cage shall be in position before start of concreting. 6.3.2.3 Concreting shall be done by tremie method. The operation of tremie concreting shall be governed by IS: 2911 (Part I / Sec.2). 6.3.2.4 The concrete placing shall not proceed if specific gravity of fluid near about the bottom of borehole exceeds 1.2. Determination of the specific gravity of the drilling mud from the base of the borehole shall be carried out by taking samples of fluid by suitable slurry sampler approved by the Engineer-in-Charge, in first few piles and at a suitable interval of piles thereafter and the results recorded. Control of consistency of drilling mud shall be carried out throughout boring as well as concreting operations. 6.3.2.5 Care shall be exercised to preserve correct cover and alignment of reinforcement and avoid any damage to it throughout the complete operation of placing the concrete. 6.3.2.6 The top of the pile shall be brought up above the cut off level minimum by 0.75 m so as to permit removal of all laitance and weak concrete before capping and to ensure good and sound concrete at the cut off level for proper embedment into the pile cap. Any defective concrete in the head of the completed piles shall be cut-away and made good with new concrete. 7 DEFECTIVE PILES 7.1 Defective piles shall be removed or left in place, as judged convenient by the Engineer-inCharge, without affecting the performance of adjacent piles of capping above and additional piles shall be provided to replace them. 8 RECORDING OF DATA 8.1 A competent supervisor shall be present to record the necessary information during the installation of piles. The data to be recorded shall include: a) The dimensions of the piles, including the reinforcement detail and the mark of the pile. b) The boring method employed. c) The type of soil in which pile is terminated. d) The depth bored. e) The depth of water table. f) When drilling mud is used, the specific gravity of the fresh supply and contaminated mud in the borehole before concreting is taken up, in case of first few piles and subsequently at suitable interval of piles. g) The time taken for concreting. h) The cut-off level/working level, and i) The consumption of cement. j) Any other important observations. 8.2 Typical data sheets of recording piling data shall be as given in Appendix-D of IS: 2911 (Part I/ Sec.2). 22 of 48

8.3 Any deviation from the designed location, alignment or load carrying capacity of any pile shall be noted and promptly reported to the Engineer-in-Charge.

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STANDARD SPECIFICATION FOR TESTING OF CONCRETE PILES

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CONTENTS 1. GENERAL 2. VERTICAL LOADING TEST 3. LATERAL LOADING TEST 4. PULL OUT CAPACITY OF PILES 5. COMBINED VERTICAL AND LATERAL LOADING TEST 6. SPECIAL TYPE OF LOADING APPENDIX 1 ­ PILE LOAD TEST RECORD

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1.0 GENERAL 1.1 Scope 1.1.1 This Specification covers the requirement and methods of testing of a single pile for evaluating its safe capacity in: a) Vertical Loading (Compression) b) Lateral Loading c) Pull Out d) Combined Vertical and Lateral Loading e) Special type of loading such as vibratory loadings 1.1.2 These specifications shall be applicable for all types of piles in general excepting sheet piles. 1.1.3 For specific work requirements or otherwise modifying or supplementing the provision of this specification, refer to specific requirement. In case of conflict between requirements set forth in the specific requirements and the provisions of this specification, the specific requirements shall govern. 1.2 Definitions 1.2.1 Reference to Indian Standard Codes shall always mean reference to the latest issue of the relevant standards, including all the amendments up to date. 1.3 Codes 1.3.1 All testing shall be performed in accordance with the following codes and the provision of these specifications IS: 2911-(Part IV) ­ Code of Practice for design and construction of pile foundations ­ Load Test on Piles. 1.4 Requirements 1.4.1 The load test shall be required to provide data regarding the load deformation characteristics of the pile up to failure or otherwise specified and the safe design capacity. 1.4.2 Full details of the equipment proposed to be used and the test set up shall be submitted to the Engineer-in-Charge with detailed sketches for approval. Approval of the Engineer-inCharge shall also be obtained after the test set up is complete, prior to commencement of loading. 26 of 48

1.4.3 All measuring devices shall be tested for satisfactory performance and accuracy at an approved institution and a certificate to that effect obtained and submitted to the Engineer-inCharge prior to use. 1.4.4 The test pile shall be constructed using same equipment and technique as for the job piles. 1.4.5 A minimum time period of one week shall be allowed between the time of installation and testing in case of a precast pile and not less than four weeks from the time of casting in case of a cast-in-situ pile.

1.4.6 Records A full record giving all details of the test in the proforma shown in Appendix-I shall be submitted in triplicate to the Engineer-in-Charge immediately on completion of each test. The record shall also include the plot of load time settlement characteristics of piles. 2.0 VERTICAL LOADING TESTS 2.1 Equipment and Test Set -up 2.1.1 Test Pile 2.1.1.1 The test pile shall be decided by the Engineer-in-Charge. It may be one of the working piles or a separate test pile. 2.1.1.2 The head of the test pile shall be brought to the proper level and provided with a pile cap with a level and plane surface and with adequate space for proper seating of a jack and dial gauges. 2.1.1.3 Test pile surface shall be prepared for testing purposes on the expiry of one week after casting the pile. 2.1.2 Loading Systems 2.1.2.1 Loading shall be applied by the reaction method consisting of an hydraulic jack centrally against a loaded platform. Supports of the platforms shall be adequately designed. Special anchor piles or any other suitable type of anchorage systems may be used. However, use of the uplift capacity of neighboring piles for providing the reaction shall normally not be permitted. 2.1.2.2 The loading system shall be adequate to ensure that the test can be carried up to the specified limit. The reaction to be made available for the test shall be at least 25% greater than the maximum jacking force required. 2.1.3 Measuring System 2.1.3.1 Loading on Piles The load applied on the pile shall be recorded on a calibrated pressure gauge mounted on the jack. 2.1.3.2 Settlement of Pile 27 of 48

a) Settlement of the pile shall be recorded by dial gauges suspended from datum bars. Four dial gauges of 0.01 mm sensitivity shall be positioned on four corners around the pile. b) The datum bars shall have rigid supports preferably of concrete pillars or steel sections, embedded well into the ground. The supports shall be located more than three times the pile diameter, subject to a minimum of 1.5 m, clear away from the pile face and also sufficiently away from the supports of the loaded platform to avoid any disturbance on these accounts. Movements near the supports of the datum bar shall be avoided while the test is in progress. 2.2 Method of Conducting Test The test shall be carried out by the direct method of loading in successive increments or by the cyclic loading method as specified and as described by the Engineer-in-Charge. 2.2.1 Direct Method of Loading in Successive Increments The test shall be carried out as per the procedure outlined. a) The load shall be applied to the pile top in increments of about of fifth of the rated capacity of the pile or as specified. Settlement readings shall be taken before and after the application of each new load increment and at 2, 4, 8, 15, 30, 60 minutes and at every two hours until application of the next load increment. b) Each stage of loading shall be maintained till the rate of movement of the pile top is not more than 0.2 mm per hour or until two hours have elapsed, whichever is later. c) Further loading shall then be continued as in (a) above till one of the following occurs: i) Yield of soil-pile system occur causing progressive settlement of the pile exceeding a value of one tenth of the pile diameter. ii) The loading on the pile top equals twice the rated capacity or as specified in the case of a separate test pile and 1.5 times the rated capacity of the pile in case of a working pile. d) Where yielding of the soil does not occur, the full test load shall be maintained on the pile head for 24 hours or more if necessary and settlement readings shall be taken at 6 hours interval during the period. e) Unloading shall be carried out in the same steps as loading. A minimum of half hour shall be allowed to elapse between two successive stages of load decrement. The final rebound shall be recorded 6 hours after the entire test load has been removed. f) If so directed by the Engineer-in-Charge, loading and unloading cycles shall be carried out for all load stages within the assumed working load. g) Assessment of Safe Load The safe capacity of the pile shall be the least of the following values i) Load corresponding to settlement specified in specific requirements which is based on the nature and type of structure. ii) 50 percent of the final load at which the total displacement equals 10 percent of the pile diameter in case of uniform diameter piles and 7.5 percent of bulb diameter in case of under-reamed piles. 2.2.2 Cyclic Loading Test The test shall be carried out as per procedure outlined by IS: 2911-(Part-IV) and as described below: a) The load shall be applied to the pile top in increments of about one fifth the estimated safe capacity of the pile or as specified. Settlement readings shall be taken before and after the 28 of 48

application of each new load increment at 2, 4, 8, 15, 30, 60 minutes and at every two hours until application of the next load increment. b) Alternate loading and unloading shall be carried out at each stage and the total and net settlements recorded as specified. If so directed by the Engineer-in-Charge, more than one cycle of loading and unloading shall be carried out at any or all of the stages. c) Each stage of loading or unloading shall be maintained till the rate of movement of the pile top is not more than 0.2 mm per hour provided that the minimum period if two hours for loading and one hour for unloading. T he following load stages shall however be maintained for longer periods as given below: i) At load of 1.5 time assumed safe capacity (for routine test only) ­ 24 hours. ii) At load of twice assumed safe capacity (for initial test only) ­ 24 hrs. The loading shall be continued till one of the following occurs: i) Yield of the soil pile system occur causing progressive settlement exceeding one tenth of the pile diameter. ii) The loading on the pile top equals twice the estimated safe load in case of a separate test pile and 1.5 times the rated capacity of the pile in case of a working pile. d) Assessment of Safe Load The safe capacity of the pile shall be the least of the following: i) Load corresponding to settlement specified in specific requirements which is based on the nature and type of structure. ii) Half of the final load at which the total settlement equals one tenth of the pile diameter. 3.0 LATERAL LOADING TEST 3.1 Equipment and Test Set -up 3.1.1 Test Pile The test pile shall be decided by the Engineer-in-Charge. It may be one of the working piles or a separate test pile. The test pile shall be cut off at the proper level and provided with a cap with vertical plane sides having an adequate area for proper seating of the jack and dial gauges. 3.1.2 Loading System, 3.1.2.1 Loading shall be applied by an hydraulic jack of adequate capacity, abutting the pile horizontally and reacting against the suitable system. The reaction may be provided by the wall of the excavated pit when the test is being conducted below ground level or by a neighbouring pile in which case thrust pieces shall be inserted on either end of the jack to make up the gap. 3.1.3 Measuring System 3.1.3.1 Lateral load applied on the pile shall be measured by a calibrated pressure gauge mounted on the jack, having a least count of 500 kg. 3.1.3.2 Deflection of the pile head shall be measured by dial gauges, fixed to datum bars and having a least count of 0.01 mm. The datum bars shall be provided with rigid supports as described in Clause 2.1.3.2 (b) above. 3.2 Method of Conducting Tests The test shall be carried out in accordance with the provisions of I S: 2911-(Part-IV) and as detailed below: 29 of 48

3.2.1 Loading shall be applied in increments of 500 kgs or as specified. 3.2.2 Each stage shall be maintained for a period till the rate of movement of the pile head is not more 0.2 mm/hr or 1 hr whichever is greater. 3.2.3 Loading shall be continued till one of the following occurs: a) Deflection of the pile head exceeds 12 mm. b) T he applied load on the pile is twice the assumed lateral load capacity of the pile in case of a separate test pile and 1.5 times the rated capacity in the case of a working pile. 3.2.4 Assessment of Safe Load The safe load shall be the smaller of the following: i) Half of the final load for which the total deflection is 12 mm. ii) Load corresponding to 5 mm total deflection. Note: The deflection is at the cut off level of the pile. 4.0 PULLOUT CAPACITY OF PILES 4.1 Equipment and Test Set up 4.1.1 Test Pile 4.1.1.1 The test pile shall be decided by the Engineer-in-Charge. The test shall be conducted on separate pile installed specifically for this purpose. 4.1.1.2 The test pile shall be built up to the proper length and the head provided with suitable arrangements for anchoring the load applying system. 4.1.2 Loading System 4.1.2.1 Load shall be applied using an approved reaction system. Uplift force on the pile may be applied directly to the test pile or through a level system. T he reaction may be provided by neighboring piles or blocks may be constructed for the purpose. A hydraulic jack shall be used for load application. 4.1.3 Measuring System 4.1.3.1 Load applied by jack shall be measured by a calibrated pressure gauge with a least count of 1000 kgs. 4.1.3.2 Movement of the pile shall be measured by dial gauges, fixed to datum bar and having a least count of 0.01 mm. A minimum of two dial gauges, placed diametrically opposite shall be used. Datum bars shall be provided with rigid supports as described in 2.1.3.2 (b) above. 4.2 Method of Conducting Test T he test shall be conducted as outlined below: 4.2.1 Loading shall be applied to the pile top in increments of one fifth the rated capacity of pile. 4.2.2 Each stage shall be maintained for a period till the rate of movement of the pile head is not more than 0.2 mm/hr or one hour, whichever is greater. 4.2.3 Loading shall be continued till one of the following occurs: 30 of 48

a) Yield of soil pile system occurs causing progressive movement of he pile exceeding 12 mm. b) T he loading on the pile top equals twice the estimated safe load or as specified. 4.3 Assessment of Safe Load The safe capacity of the pile shall be the least of the following: a) Two-thirds of load at which the total displacement is 12 mm or the load corresponding to a specified permissible uplift, and b) Half of the load at which the load displacement curve shows a clear break (downward trend). 5.0 COMBINED VERTICAL AND LATERAL LOADING 5.1 Equipment and Test set -up 5.1.1 The equipment and test set up shall be same as described in Clause 3. In addition, a platform shall be constructed on the pile top, and loaded to 1.0 times the pile capacity in vertical loading. The pile shall be first subjected to the full vertical load. The lateral load shall commence after all settlements due to the vertical load have ceased and while the full vertical load is in position. 5.1.2 The loading system, measuring system and recording of the results shall be the same as described in clause-3. 5.2 Method of Conducting Test and Assessment of Safe Load This shall be in accordance with the provision of clause 3.2 above. 6.0 SPECIAL TYPE OF LOADING This shall include evaluating the pile response to vibratory loads, both horizontal and vertical in nature. The test set up and method of conducting the test shall be covered under specific requirements.

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APPENDIX ­ 1 PILE LOAD TEST RECORD Vertical / Lateral / Pull Out Test Pile No........................ Date of .................. Type........................... Driving.................... Diameter (cm)................ Casting.................... Length below in cms G.L. (M)..................... Location..................... Date Time Total time (hr) Commence of Test .............................. Completion of Test...... Load off (T) Total Load (T) WT of Hammer .......................... AVR. Drop of Hammer................ Total No. of Blows....................... Sum of Temporary Compression .............................................. Ground level .............................. Rebound Remarks (mm)

Load on (T)

Settlement AVR. (Deflection) Settlement Gauge (mm) (Deflection) (mm) I II Total Net

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TECHNICAL SPECIFICATIONS FOR CONCRETE AND REINFORCEMENT WORKS

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1. CONCRETE AND STEEL REINFORCEMENT 1.1 GENERAL: This section describes and specifies work required for plain and reinforced cement concrete including reinforcement and form work. Unless otherwise specified or agreed in writing by the EIC, all materials and methods used in the production, testing and handling of concrete shall comply with the latest editions or amendments of the relevant Indian Standards. MATERIALS: All materials shall be obtained from sources approved by the EIC. The agreed source or quality of any material shall not be changed during the course of the contract except with the approval of the EIC. Whenever requested by the EIC, the Contractor shall provide a certificate from the manufacturer, for each and every delivery of material, showing the source, quantity delivered and confirming that the material has been tested and conforms to the required Indian Standard. 1.3 TESTING OF CONCRETE MATERIALS : Prior to the commencement of concrete work, the contractor shall get all cement aggregates and water tested in the laboratories approved by the EIC and shall keep the approved samples in the site office for inspection at any time of the concreting operation. The test certificates shall be submitted to EIC for review & approval before concreting. During construction also, the materials shall be sampled and tested as often as deemed necessary and also as per the "Periodicity of Testing" by the EIC. Samples shall be taken and tested in accordance with the latest revision of relevant Indian Standard Specifications and the cost thereto shall be borne by the Contractor. CEMENT : The cement used throughout the work shall be to the approval of the EIC. A certificate shall be obtained from the manufacturers and produced to EIC for each delivery of cement and it shall comply with the requirements of as mentioned in the "Technical Specification ­ Materials" . The Contractor shall store the cement in storage sheds to be provided by him for this purpose at site. The cement shall be delivered to the site in bags sealed with the manufacturer' seal and different types of cement shall be stored s separately. The storage sheds with watertight walls and roof, shall be maintained in a perfectly dry and wall ventilated condition, 12" above ground level and the cement shall be stored a per instructions issued by EIC. It shall be turned over from the bottom as and when required by the EIC. Any cement which has been deteriorated caked or which has been damaged due to any reason whatsoever shall not be used. No cement shall be used for the works that has been stored at site for more than three months. Test samples of cement may be drawn from each consignment as delivered and tested by the EIC. Should the results of such test show that any samples does not comply with the specified requirement, the whole consignment from which the sample was taken, 35 of 48

1.2

1.4

shall be rejected and forthwith removed entirely from the site and replaced with cement of satisfactory quality. 1.5 SAND : Sand to be used for concrete shall be well graded mixture from coarse to fine grains, complying with the requirements of IS 383 Latest edition. It shall be clean, hard and free from salt, earth, clay and other impurities. Fine sand confirming to Zone ­ iv shall not be used. It will comply with sieve analysis in accordance with IS 2386 Part I & II. Unless initially clean, all sand shall be thoroughly and carefully cleaned by screening and washing in fresh and clean water. The screened and washed sand shall not contain more than 8% by volume of clay, dust and silt immediately after allowing it to settle for 3 hours in water. Field tests shall be carried out regularly to ensure the suitability of sand. Sample loads shall be available at site for inspection of the EIC and if approved by him all sand in the work shall be of quality at least equal thereto. In case of sand containing moisture the proportions of concrete materials shall be adjusted to give the correct mixture. 1.6 COARSE AGGREGATE : The coarse aggregate for the reinforced concrete work shall consist of crushed black trap, granite/basalt or other stone to the approval of the EIC and shall be free from dust confirming to IS ­ 383 latest edition. If considered necessary by the EIC, the aggregate shall be washed specially until an approved cleanliness is obtained. The use of laminated stone, flat or flaky material will not be permitted. The combined coarse aggregate shall in all respects be so graded as to allow 95% to 100% by weight to pass a 20mm I.S. sieve 25% to 55% by weight to pass a 5mm I.S. sieve and 0% by weight to pass a 5mm I.S. sieve. The aggregates of different sizes shall be stored in separate stacks in clean state and free from all dirt. The coarse aggregate where absorption of water after 24 hours immersion is more than 5% by weight shall not be used. When required by the EIC the tests indicated in I.S. 383 or IS-2386 (all parts) shall be got carried out by the Contractor at his cost to show the acceptability of the materials. Stowage piles of aggregate shall have good drainage, preclude inclusion of foreign matter and preserve the gradation. 1.7 WATER : Water used for all purpose in this contract shall be free from oil, acid, vegetable matter, salts or dirt of any kind which will have adverse effect on cement or steel in the case of reinforced concrete. Whenever called for, the Contractor shall produce test results for water being used on work. The water quality shall confirm to IS-456-2000. ADMIXTURES: 36 of 48

1.8

Admixtures or Cement containing additives (such as accelerators, retarders, water proofing agents etc.) shall not be used unless specified or otherwise directed or approved by the EICs). The Admixtures shall confirm to IS-9103 latest edition. 1.9 FORM WORK : The form work shall be designed and constructed in such a manner that all concrete work shall be true to line, level and size, and free from honeycombing, pinholes, surface irregularities and every other defect whatsoever. All form work shall be adequately propped, braced and framed to prevent deformation under weight and pressure of wet concrete, constructional loads, wind, vibrations and other forces. All joints in shuttering shall be close fitting to prevent the loss of cement paste or mortar from the concrete. All form work shall be carefully cleaned and coated with an approved proprietary mould oil before use, care being taken to keep all reinforcement away from contact with such oil. All moulds shall be free from sawdust, shavings, dirt, mud or other debris by hosing with water or oil free compressed air. The shuttering for beams and slabs shall be erected so that the shuttering on the sides of the beams and of the soffits of the slabs can be removed without disturbing the beam bottoms. For beams having spans greater than 6 meters and for cantilevers, the form work shall be given adequate upward camber as directed by the EIC. Details of all temporary work (timbering, staging etc.) are to be submitted for the approval of the EIC and the form work shall be inspected and approved by the EIC before concrete is placed within it. Notwithstanding such approval, any damage or consequences arising there from shall be the Contractor' entire responsibility. s 1.10 PROPORTIONS FOR CONCRETE: The contractor shall design concrete mixes (by Ready Mix Concrete Plants) to produce concrete of the required strengths. The contractor must submit full designs done from RMC plants of the mixes and shall get it vetted by Reputed Engineering institutesand submit the same for approval of EIC. Site trial mixes will be prepared by the contractor in the presence of the EIC, having workability, strength, minimum cement content and surface finish as criteria. Notwithstanding the acceptance by the EIC of any mix design and series of trial mixes, variations may be made to the proportions when considered necessary by the EIC. Such variations may be made also to normal mixes if used, but variations of this nature will not be allowed to affect the unit price of concrete. For both Nominal as well as Design mix concrete, the quantity of cement shall be determined by weight. Where standard bags of cement are used, their weight shall be checked at frequent intervals and any loss in weight due to leakage etc. shall be made good. In the case of Nominal Mix concrete, aggregates shall be measured by volume, cement by weight and mixing water in graduated cans. In the case of controlled concrete all aggregates and cement shall be measured by weight in approved weigh batching equipment. Mixing water shall be measured in graduated cans. 37 of 48

While calculating the amount of mixing water, the moisture content of the aggregates shall be taken into account.

READY MIX CONCRETE: · The provision in this section shall apply to all concrete grades and is to be considered as a supplementary to general provisions for Plain Cement Concrete & Reinforced Cement Concrete works.

1. Ready mix concrete (RMC) may be manufactured in a central automatic weigh batching plant and transported to the job by agitating Transit mixers. The RMC is to be sourced from reputed & approved batching plants as mentioned in the approved list of manufacturers or suppliers only. The design mix has to be submitted to HPCL before concreting and the same has to be approved by HPCL before concreting is done. Alternatively, a batching plant can also be set up at the site and make design mix as per codal provision including vetting by the reputed Engineering Institutes/ Consultant duly approved by HPCL. Party has to submit vetted design calculations to EIC and obtain approval of the HPCL before commencement of the job. The batching plant need to be certified by third party for robustness of performance and equipments associated with it. · · · · · The design mix is to be carried out as per IS-10262/ as per approved methods by EIC The standard deviation for concrete mix design will be considered as per Table 8 of IS456-2000. The proportion of fine aggregates to coarse aggregates should be adjusted so as to keep them within the specified limits as mentioned in IS-383. The Bidders have to submit the Quality Assurance Plan of theirs as well as the RMC plant for approval and shall strictly adhere to the same. The admixtures used shall confirm to IS-9103.

APPLICABLE CODES AND SPECIFICATIONS; The following specifications, standards and codes are made a part of this specification. All standards, tentative specifications, codes of practice referred to herein shall be the latest editions including all applicable official amendments and revisions. In case of discrepancy between this specification and those referred to herein, this specification shall govern. APPLICABLE IS SPECIFICATIONS AND CODES OF PRACTICE: 38 of 48

IS 269:- Specification for ordinary, rapid hardening and low heat portland cement. IS-10262: Recommended guidelines for concrete mix design. IS 8112:- Specification for high strength ordinary, portland cement. IS 1489 - Specification for portland - pozzolona cement. IS 383:- Specification for coarse and find aggregates from natural source for concrete. IS 455: - Specification for Portland Slag Cement IS 2386:- Methods of test for aggregates for concrete. (Part I to VIII) IS 516:- Method of test for strength of concrete. IS 1199:- Method of sampling and analysis of concrete. IS 3025:- Methods of sampling and test (Physical and chemical) water used in industry. IS 432:- Specification for mild steel and medium tensile steel (parts I & II) bars and hard drawn steel wire for concrete reinforcement. IS 1139:- Specification for hot rolled mild steel and medium tensile steel deformed bars for concrete reinforcement. IS 4926: Ready Mix Concrete ­ Code Of Practice

IS 1566:- Specification for plain hard drawn steel wire fabric (Part I) for concrete reinforcement. IS 1786:- Specification for cold twisted steel bars for concrete reinforcement. IS 2645:- Specification for integral cement waterproofing compound. IS 456:- Code of practice for plain and reinforced concrete. IS 3370:- Code of practice for concrete structures for storage of liquids (Part I to IV) IS 2502:- Code of practice for bending and fixing of bars for concrete reinforcement. IS 2571:- Code of practice for laying in situ cement concrete flooring. IS 3596:- Safety code for scaffolds and ladders. (Part I & II) IS 1200:- Method of measurement of building works. 39 of 48

In the event that state, city or other Government bodies have requirements, more stringent than those set forth in this specification, such requirements shall be considered part of this specification and shall supersede this specification where applicable. The quality of materials , method and control of manufacture and transportation of all concrete works irrespective of the mix , whether reinforced or otherwise, shall conform to the applicable portion of this specification. Engineer shall have the right to inspect the source/s of material/s , the layout of operations of procurement and storage of materials, the concrete batching and mixing equipment and quality control system. Such an inspection shall be arranged and approval of Engineer-In-Charge shall be obtained prior to starting of concrete work. Concrete shall be mixed by mechanical mixer only and no hand mixing shall be allowed for RCC works. GENERAL: The quality of materials and method and control of manufacture and transportation of all concrete work irrespective of mix, whether reinforced or otherwise, shall conform to the applicable portions of this specification. Engineer shall have the right to inspect the source/s of material/s, the layout and operation of procurement and storage of materials, the concrete batching and mixing equipment, and the quality control system. Such an inspection shall be arranged and Engineer's approval obtained, prior to starting of concrete work. MATERIALS FOR STANDARD CONCRETE: The ingredients to be used in the manufacture of standard concrete shall consist solely of a standard type portland cement, clean sand, natural coarse aggregate, clean water and admixtures, if specially called for on drawings or specifications. CONSISTENCY: The consistency of the concrete shall be such that it flows sluggish during pumping of concrete into the forms and around the reinforcement without any segregation coarse aggregate from mortar. The slump tests are mandatory and shall be carried out at regular intervals so that the consistency concrete can be monitored. PLACING OF CONCRETE: Concreting shall commence only after inspection and written approval by EIC. Shuttering shall be clean and free from deposits of foreign materials and proper deshuttering agent shall be applied to the surface. Proper arrangements shall be provided for conveying the concrete the place of deposition without disturbing the reinforcement. COMPACTION: Concrete shall be compacted immediately after placing by means of mechanical vibrators. All RCC works shall be cured for a minimum period of 14 days or more as advised by EIC. 40 of 48

INSPECTION AND RECTIFICATION OF DEFECTS: Immediately on removal of forms, the RCC works shall be examined by the Engg. -in-Charge / Architects before any defects are made good. The work that has sagged or contains honey combing to an extent detrimental to the structural safety or architectural concept shall be rejected. Surface defects on a minor nature may be accepted and the same shall be rectified as follows: a) Bulges due to movement of forms, ridges at forms, ridges at form joints shall be carefully chipped and then rubbed with a grinding stone. b) Honeycombed and other defective areas must be chipped out, the edges being out as straight as possible and perpendicular to the surface. Shallow patches are first treated with a coat of thin grout (1 cement : 1 sand) and then filled with mortar similar to that used in concrete. Large and deep patches shall be filled up with concrete held in place by forms and shall be reinforced. c) Holes left by bolts shall be filled carefully with mortar. Holes extending right through the concrete shall be filled with mortar with a pressure gun. d) The same amount of care to cure the material in patches should be taken as with the whole structure. POST TREATMENT OF SURFACE : The surface which has to receive plaster or where it has to be joined with brick masonry walls shall be properly roughened immediately after the shuttering is removed. ACCEPTANCE CRITERIA OF CONCRETE WORK : will be as per clause 16 of IS-4562000. MEASUREMENT All measurements shall be as per IS 1200 1.11 MIXING OF CONCRETE:

Mixing of concrete shall continue until there is a uniform distribution of material and the concrete is uniform in colour and consistency and for at least two minutes. Mixes and weigh batches shall be maintained in good condition throughout the contract and any mixer or plant which is faulty shall not be used. The drums on all mixers shall revolve at the speed recommended by the maker. A mixer of any type which has been out of use for more than 20 minutes shall be thoroughly cleaned out before any fresh 41 of 48

concrete is mixed. All equipment shall be maintained in a clean serviceable condition and their accuracy periodically checked. 1.12 SLUMP TEST :

The Contractor shall keep at the site of the works for the EIC's use or his representative a standard slump test mould and shall provide facilities throughout the construction for tests to be made as and when the EIC may require. 1.13 COMPRESSIVE STRENGTH : Concrete shall confirm to IS-456-2000. The Contractor shall keep on site minimum 12 nos. standard 15 cm test cube moulds and ancillary equipment for preparing test cubes. Before the Contractor commences any concrete construction they shall make six cubes of mix concrete with the cement sand, aggregate and water which he proposes using on the contract and shall have them tested at a Laboratory approved by the EIC/EIC. Three cubes shall be tested at 7 days and three cubes at 28 days after casting and curing. In all cases the cubes shall give the minimum compressive strength. No concrete construction shall be commenced until Preliminary Tests on the six cubes referred above have been completed and results show the concrete to have the minimum compressive strength. As construction proceeds samples from fresh concrete shall be taken as per IS 1199 - 1959 and cubes shall be made, cured and tested in accordance with IS 516 1959. Three test specimens shall be made from each sample for testing at 28 days. Additional cubes may be required for various purposes as to determine the strength of concrete at 7 days or at the time of striking form work, or to determine the duration of curing, or to check the testing error. The test strength of the sample shall be the average of the strength of three specimens. The individual variation should not be more than 15 percent of the average. Any part of the work from which the cubes fail to give the required minimum compressive strength shall be dealt with by the Contractor as directed by the EIC and at the expenses of the Contractor. The concrete is also liable to be rejected or repaired as per the instructions of the EIC/EIC if it is porous or honeycombed, its placing has been interrupted without providing a construction joint or the reinforcement has been disproportionately displaced. The rejected concrete has to be demolished and redone to the satisfaction of the EIC free of cost. The Contractor shall keep a daily record (Concrete Pour Card) showing the date when each portion of concrete is poured in slab, beam, column etc., curing, removal of form work and test cube results at 7 days and 28 days period. They shall be sent immediately to the EIC/EIC. 1.14 TRANSPORTING, PLACING AND COMPACTING OF CONCRETE : 42 of 48

The concrete shall be transported maintaining required workability in a manner such as to avoid the segregation of the constituent materials, and loss of any of the ingredients. It shall be deposited as nearly as practicable in its final position to avoid re handling. It shall be placed and compacted before setting commences and should not be subsequently disturbed. Methods of pouring should be such as to preclude segregation, and to avoid displacement of reinforcement and movement of form work. Concrete Pumping needs to be arranged for conveying the concrete from transit mixers to work spot. The concrete should be thoroughly compacted and fully worked around the reinforcement, around embedded fixtures and into the corner of the form work without formation of honeycombing, pinholes or surface irregularities and any other defects whatsoever. The use of mechanical vibrators having capacity of producing vibrations at a rate not less than 5000 cycles per minute is recommended. Over vibration or vibration of very wet concrete is harmful. In addition to mechanical vibration, sufficient hand tools must be used to assure full consolidation around reinforcement and at edges and corners. The deposition of concrete shall be carried out as continuously as possible to reduce to minimum joints between new concrete and concrete which has set. Where construction joints are necessary they shall be formed at right angles to the axis of the member concerned by the insertion of rigid stopping off forms, against which concrete can be properly rammed or as per the advise of Structural EIC. No unset concrete shall be brought into contact with unset concrete containing cement of different type. Special permission and instructions shall be obtained when concrete has to be deposited under water. Accumulation of set concrete on the reinforcement shall be avoided. Before fresh concrete is deposited upon or against any concrete which has already hardened, the surface of hardened concrete shall be well roughened if necessary by chipping and laitance remove. The surface shall then be swept clean with wire brushes, thoroughly wetted and covered with a thin layer of cement mortar. 1.15 PROTECTION OF CONCRETE : Newly placed concrete shall be protected by approved means from rain, sun and drying winds. Concrete placed below the ground shall be protected from falling earth during and after placing. Approved means shall be taken to protect immature concrete from damage by debris, excessive loading, vibration, abrasion, deleterious ground-water, mixing with earth or other materials that may impair the strength and durability of concrete. CONSTRUCTION JOINTS : Before construction commences the Contractor shall submit to the EIC, for his approval, sketches showing proposed positions of construction joints.

1.16

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Each section of concrete shall be poured continuously between construction joints. Shuttering to all construction joints should be so made that it produces on the face of joints a suitable grooved or indented surface to act as a sheer key or bond for the subsequent concrete. Inclined joints shall not be permitted. If the concrete has been allowed to harden excessively, the surface shall be chipped over its whole surface to a depth of at least 3/8"and thereafter thoroughly washed. If the concrete has not fully hardened, all laitance shall be removed by scrubbing the wet surface with wire brushes to avoid dislodgement of particles of aggregate. Before fresh concrete is added to the other site of a construction joint the surface of the old concrete will be thoroughly wetted and then covered with a thin layer of cement mortar of the same quality as that in the concrete. No distortion or displacement of reinforcement from the positions shown on the drawings shall be permitted at construction joints. Water stoppers shall be provided to the construction joints of terrace slabs, kitchen and bathroom slabs, and water retaining structures where water leakage poses serious problems. 1.17 STRUCTURAL JOINTS : Expansion joints or other permanent structural joints shall be provided in the positions and of the form described in the drawings or elsewhere. In no case shall the reinforcement, corner protecting angles or other fixed metal items, embedded or bonded into concrete run continuously through as expansion joint. The placing of concrete on either side of the expansion joint shall be done separately after an interval of at least 7 days. 1.18 CUTTING INTO CONCRETE : No concrete shall be cut into, nor shall it be interfered with in any way, without the prior approval in writing of the EIC. Necessary holes shall be provided as required for plumbing work and for electrical pipes etc. at the time of execution. 1.19 CURING OF CONCRETE : Exposed surfaces of concrete shall be kept continuously in a damp or wet condition for at least seven days from the date of placing of concrete. Approved curing compounds may be used in lieu of moist curing with the permission of the EIC. Such compounds shall be applied to all exposed surfaces of the concrete as soon as possible after the concrete has set. 1.20 SUPERVISION : Constant and strict supervision of all the items of the construction is necessary during the progress of the work, including the proportioning and mixing of the concrete. 44 of 48

Supervision is also of extreme importance to check the reinforcement and its placing before being covered. Before any important operation, such as concreting or striking off the form work is started, adequate notice shall be given to the EIC. 1.21 CONTRACTOR' RATES TO INCLUDE : S The rates of contractor for providing and laying cement concrete in various grades or proportions in the Schedule of Quantities shall, apart from any other factors specified elsewhere in the tender documents, include for the following: For all factors and method of work described in these specifications. For all materials, labour, tools and plants, scaffolding, etc. mixing, conveying and placing concrete in position, ramming, vibrating, trawling, curing, providing necessary scaffolding and removing the same after the work is complete. Unless otherwise specified in the Schedule of Quantities the cost for concrete items shall include for providing and fixing form work as described inclusive of erecting, propping to required heights, bracing, providing stays, struts, bolts, nuts and everything necessary to keep the forms rigid, smoothening the surface to receive concrete as per detailed drawing, striking and stripping form work after the concrete is cured, hacking the concrete surface required to receive plaster etc. The reinforcement in case of Reinforced Concrete work will be paid for separately unless otherwise stated in the particular items, but rate shall include for pouring concrete and packing around reinforcement. The measurement of concrete will be as per detailed drawings, shapes and size based on net structural sizes as per drawings i.e. exclusive of plaster. Rates for concrete items shall cover for any shape of structural members like columns, beams, facias, fins, louvers etc. and for cantilevered beams slabs etc. Formation and treatment of contraction and expansion joints (where water bars like copper strips or joint fillers like ' Shalitex'are specified, such materials shall be paid for separately. Design of mixes where so required by specification in an approved Laboratory and on tests of materials and work required in the opinion of the EIC and described in these specifications. Fixing all inserts like pipes, plugs, forming holes etc. as described. Weigh-batching using a Mechanical weigh-batcher or a batching plant or where so specified for volumetric batching. For taking out dowel bars, fan hooks etc. through shuttering. 45 of 48

(a) (b)

(c)

(d)

(e) (f) (g)

(h)

(i) (j) (k)

(l)

In case where at the junctions of beams, columns, slabs, the composition of concrete mix or specified strength be different for columns, beams and slabs, then in such cases only the richer concrete among those specified for in all these members shall be used at the junctions and rate quoted for columns, beams and slabs or any member entering such junctions shall allow for the same. Rate shall also cover for spill over of richer concrete in beams to natural angle of repose of wet concrete required from practical considerations, while concreting the junctions. For forming drip moulds in Chajjas, sills, etc. and where shown in the drawings or as directed. For work at all levels. STEEL REINFORCEMENT : CORROSION RESISTANT STEEL BARS The reinforcement shall confirm to IS: 1786, Fe-500 grade. The reinforcement shall be Corrosion resistant steel and it shall be either "TISCON CRS" from TISCO or HSCR-M from Vizag Steel or HCR from SAIL-M.

(m) (n) 2 2.1

2.2

CLEANING OF REINFORCEMENT : Before steel reinforcement is placed in position, the surface of the reinforcement shall be cleaned of rust, dust, grease and other objectionable substances. CUTTING OF REINFORCEMENT : Before the reinforcement bars are cut, the contractor shall study the lengths of bars required as per drawings and shall carry out cutting only to suit the sizes required as per drawings. PLACING AND SECURING : Reinforcement bars shall be accurately placed and secured in position and firmly supported or wedged by precast concrete blocks of suitable thickness, at sufficiently close intervals, so that they will not sag between the supports or get displaced during the placing of concrete or any other operation of the work. It is most important to maintain reinforcement in its correct position without displacement and to maintain the correct specified cover. Contractor shall be responsible for all costs for rectification required in case the bars are displaced out of their correct position. BINDING WIRE : The reinforcement shall be securely bound wherever bars cross or wherever required with 18 gauge soft annealed steel wire. WELDING : Welding of bars shall not be carried out unless specially authorised in writing by Structural EIC. 46 of 48

2.3

2.4

2.5

2.6

2.7

BENDS ETC : Bends, cranks etc. on steel reinforcement shall be carefully formed, care being taken to keep bends out of winding. Otherwise, all rods shall be truly straight. If any bend shows signs of brittleness or cracking, the rod shall be removed immediately from the site. Minimum radius of 9 times diameter of the bar shall be used unless otherwise specified in the drawings. However, in respect of standard hooks the radius of bend shall be 2 times of diameter of bar. Heating of reinforcement of bar to facilitate bending will not be permitted. The bars shall always be bent cold. In case of mild steel reinforcement bars of larger sizes, where cold bending is not possible, they may be bent by heating with written permission of the Project Engineer. Bars when bent hot shall not be heated beyond cherry red colour and after bending, shall be allowed to cool slowly without quenching. The bars damaged or weakened in any way in bending shall not be used on the work. High strength deformed bars shall in no case be heated to facilitate bending or cranking.

2.8

INSPECTION OF REINFORCEMENT : No concreting shall be commenced until the Structural EIC has inspected the reinforcement in position and until his approval has been obtained. A notice of at least 24 hours shall be given to the Project Engineer by the Contractor for inspection of reinforcement. If in the opinion of the Project Engineer any material is not in accordance with the specification or the reinforcement is incorrectly spaced, bent or otherwise defective, the contractor shall immediately remove such materials from the site and replace the same and rectify any other defects in accordance with the instruction of the Project Engineer to his entire satisfaction.

2.9

NET MEASUREMENTS : Reinforcement shall be placed as shown on the structural drawings and payment will be made on the net measurements from drawings. No laps, dowels, chairs and pins in reinforcement shall be paid for. The Contractor shall allow in his quoted rate for all wastage which will not be paid for. RATES QUOTED FOR REINFORCEMENT SHALL IN ADDITION TO ANY FACTORS MENTIONED ELSEWHERE SHALL ALSO INCLUDE FOR : All cutting to lengths, labour in bending and cranking, forming hooked ends, handling, hoisting and everything necessary to fix reinforcement in work as per drawings. Cost of binding wire required as described. Cost of PVC blocks to maintain cover and holding reinforcement in position. For fabricating and fixing reinforcement in any structural member irrespective of its location, dimensions and level. 47 of 48

2.10 (a) (b) (c) (d)

(e) (f) (g)

Removal of rust and every other undesirable substances, using wire brush etc. as described. Stock piling of reinforcement as described. Work at all levels.

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