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PROJECT TITLE: LNG IMPORT STORAGE & REGAS TERMINAL PROJ
CLIENT NAME: IOCL
SUPPLIER NAME: BLACK & VEATCH PVT. LTD.
REQ NO: 19200-8820A102
SUPPDOCNO: 19200-0102-8310-PR-0258
CLDOCNO:
PROJECT NO: --19200/09 PROJECT LOCATION: ENNORE, TN
PO NO: 19200/102 CLIENT ORDER NO:
SUPPLIER REV: O2
AmecFW Rev: 2
DOC TYPE: PRC
DSN: 629
Status:
Signed:
Dept:
Date:
COMMENT STATUS CODE: 1-Rejected; 2-Comments as Noted;
3-Minor Comments Acceptable; 4-No Comments; 5-Info Only
TAG NOS:
PROJECT TITLE: LNG IMPORT STORAGE & REGAS TERMINAL PROJ
CLIENT NAME: IOCL
SUPPLIER NAME: BLACK & VEATCH CORPORATION
REQ NO: 19200-8820A102
SUPPDOCNO: 19200-0102-8310-PR-0258
CLDOCNO:
PROJECT NO: --19200/09 PROJECT LOCATION: ENNORE, TN
PO NO: 19200/102830 CLIENT ORDER NO:
SUPPLIER REV: O2
AmecFW Rev: 2
DOC TYPE: PRC
DSN: 629
Status: Code 4
Signed: Kumaran Vadivelmurugan (J1981)
Dept: D153 - Engineering
Date: 20/Jan/2016
COMMENT STATUS CODE: 1-Rejected; 2-Comments as Noted;
3-Minor Comments Acceptable; 4-No Comments; 5-Info Only
TAG NOS:
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IOCL LNG LIMITED
LNG IMPORT, STORAGE ANDREGASIFICATION TERMINAL
ENNORE, TAMIL NADU, INDIA
Comment Resolution Sheet Page 1 of 1
Document No: 19200-0102-8310-PR-0258 , Rev: O1 DSN: 629
Title: Job Procedure for Pile Load Test
Sr.
No.Client/PMC Comments Contractor’s Resolution
1 At what level, test to be conducted Incorporated
2 What is test Load Please refer clause no 5.2, 5.4, 5.8, 5.10, 5.14
and mentioned in drawing No: 19200-0102-
8310-42-0201, Rev S1 for Initial test.
3 What is the acceptance criteria For acceptance criteria please refer clause no
5.6, 5.12 & 5.18 and IS 2911, Sec IV.(same as
IOCL Piling Spec- 19000-8310-SP-0018)
4 Kentledge arrangement with load
details to be provided
Design calculation for 600mm dia X
18000mm long pile attached and balance
shall be made available prior to testing.
5 Report formats shall be provided Already approved. Format No :
189150.CIV.QC.006 REV 1
6 Testing record format to be provided Format already approved as above and
record will be submitted in the approved
format after testing.
7 Load vs settlement Load vs settlement curve shall be submitted
after load test only.
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IOCL LNG LIMITED
LNG IMPORT, STORAGE ANDREGASIFICATION TERMINAL
ENNORE, TAMIL NADU, INDIA
JOB PROCEDURE
FORPILE LOAD TEST
DOCUMENT NO. AND REV:
19200-0102-8310-PR-0258Rev O2
BV DOCUMENT NO.
189150_87.1200Rev.1
DSN : 629 Page 2 of 12
Revision History
Rev. Date Details of Revision
O1 18.11.2015 Issued for Approval
O2 29.12.2015 Comments Incorporated
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IOCL LNG LIMITED
LNG IMPORT, STORAGE ANDREGASIFICATION TERMINAL
ENNORE, TAMIL NADU, INDIA
JOB PROCEDURE
FORPILE LOAD TEST
DOCUMENT NO. AND REV:
19200-0102-8310-PR-0258Rev O2
BV DOCUMENT NO.
189150_87.1200Rev.1
DSN : 629 Page 3 of 12
TABLE OF CONTENTS
Sr. No. Description Page no.
1. Purpose 4
2. Scope 4
3. Reference 4
4. Responsibilities 45. Methodology 5
6. Appendix-I
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IOCL LNG LIMITED
LNG IMPORT, STORAGE ANDREGASIFICATION TERMINAL
ENNORE, TAMIL NADU, INDIA
JOB PROCEDURE
FORPILE LOAD TEST
DOCUMENT NO. AND REV:
19200-0102-8310-PR-0258Rev O2
BV DOCUMENT NO.
189150_87.1200Rev.1
DSN : 629 Page 4 of 12
1. PURPOSE
The purpose of this procedure is to describe the system to be followed for load test on pile for
IOCL LNG Regasification Project, Ennore, Tamilnadu, India.
2. SCOPE
To install the piles as per approved drawing issued.
Conducting load test (Pile Load Test to be carried on Test Pile and working Pile as
per the Approved drawing.)
Recording of data, preparation of report and submission to Client for their approval.3. REFERENCES
Project Spec. for Pilling works 19000-8310-SP-0018 Rev. A2
19200-0102-8310-CA-0201; Calculation report for Structural Design of Piling Initial
Load Test.
Approved drawing of pile.
Scheme for load testing arrangement.
Contract documents.
IS: 2911 (Part4) 1985-Code of Practice for Design and Construction of Pile.
IS: 516, 1959- Methods of Tests for Strength of Concrete.
4. RESPONSIBILITESFollowing are the responsibilities and reporting structure of personnel involved in thescope of the procedure:
A. Field Project Manager
Shall report to Project Coordinator. Shall be responsible for providing resources for the
implementation of this procedure.
B. Field Construction Manager
Shall report to the Project Manager. Ensure Compliance to project specifications. Fulfill all required safety measures provide adequate resources for Execution of Work.
C. Surveyor
Shall report to RCM. Shall be responsible for day to day planning of site Construction activities andMaintained Records. Shall Submit the Record for PMC for approval. Shall be responsible forimplementation of Survey activity as per this procedure.Monitored and implement all identifiedcontrol.
D. Field Construction EngineerShall report to RCM, Shall be responsible for day to day planning of site construction activities andpreparation of construction records.
E. Field QC In chargeShall be responsible for implementation of Pile Load Test activity as per this procedure. Monitor andimplement all identified control Responsible to monitor & ensure the quality of work is in accordancewith this procedure. Report non-compliance to the concerned supervisor and ensure rectificationsprior to the next process activity. Shall carry out inspection as per the approved ITP.
F. Field HSE In chargeShall ensure work Permit is in place before commencement of work. Shall ensure that all personals inthe work area wear personnel protective equipment (PPE).The area is cordoned off with tape.
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IOCL LNG LIMITED
LNG IMPORT, STORAGE ANDREGASIFICATION TERMINAL
ENNORE, TAMIL NADU, INDIA
JOB PROCEDURE
FORPILE LOAD TEST
DOCUMENT NO. AND REV:
19200-0102-8310-PR-0258Rev O2
BV DOCUMENT NO.
189150_87.1200Rev.1
DSN : 629 Page 5 of 12
5. TEST PROCEDURE:
I. VERTICAL (COMPRESSION LOAD TEST)
Compression load test on piles will be conducted as per IS: 2911 (Part IV) - 1985
5.1 EQUIPMENT & TOOLS:
Hydraulic jacks of suitable capacity with one pump.
Pre-calibrated pressure gauge with a sensitivity of 20 kg/cm2.
LVDT/Dial Gauges - 4 nos. Four bearing plates.
Two glass plates of size 40 x 40 mm.
Two datum Bar, MS angle of length minimum 8 x diameter of pile.
Additional Reinforcement rods to weld pile reinforcement, if required.
Welding set, electrodes.
Bricks, cement, sand to support the jack, MS pipe and datum bars, if required.
Tools for Excavation.
Record Book and graph sheets.
5.2 TEST PROCEDURE:
Piles to be load tested shall be so designated on the drawings or specified/Selected by
client in the field. (For Initial Test load is 145, 275 & 427.5 Ton and for Routine test
load shall be finalized only after initial load test.)
The kentledge consisting of RSJ or suitable steel section capable of taking reaction
shall be used. The CG of kentledge should be on the axis of pile and the load applied
by the jack should be co-axial with the piles.
Test load shall be applied to the piles by a hydraulic jack with a control pump. Test load
applied shall be such that a constant load is maintained under increasing settlement.
The required reaction shall be derived from adjacent existing pile or vertical cut made
in the ground. Load tests shall in general be carried out after 28 days from the time of
casting the pile. All load tests shall be conducted under the supervision of the client. All
responsibilities for conducting the tests safely and properly rest with contractor.
5.3 INITIAL LOAD TEST:
Initial vertical load tests shall be carried out at Pile COL(Cut off Level). The pile head
shall be cut off at cut off level and capped by an R.C. cap to provide a horizontal plane
bearing surface. Earth around the test pile shall be scooped out so that the pile can
have no soil support. Thereafter, the jacks and other accessories in the pit pertaining to
and necessary for conducting the test shall be set up.
The test load shall be applied by basis of Maintained Load Method. In this method
application of increment of test load and taking of measurement or displacement in
each stage of loading is maintained both Initial and routine load tests.
The displacement of the test pile shall be related to a fixed datum. This may consist ofa reference beam (datum bar) supported by two foundations positioned outside the
zones of influence of the reaction support area. The settlement measuring equipment
must be set up in such a way that any tilting of the pile will not cause errors in the
L A C K V E A T C H
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IOCL LNG LIMITED
LNG IMPORT, STORAGE ANDREGASIFICATION TERMINAL
ENNORE, TAMIL NADU, INDIA
JOB PROCEDURE
FORPILE LOAD TEST
DOCUMENT NO. AND REV:
19200-0102-8310-PR-0258Rev O2
BV DOCUMENT NO.
189150_87.1200Rev.1
DSN : 629 Page 6 of 12
measurement. LVDTs/Dial gauges shall be used for measurement of settlement. The
least count of LVDT/Dial gauge shall be at least 0.01 mm. At least two but preferably
four LVDTs/Dial gauges shall be used and shall be placed at diagonally opposite
corners.
The total test load shall be as per AFC drawings or specified and shall be applied in
equal increments of 20 percent of the estimated safe load. Settlement of pile shall be
measured by at least two LVDTs / Dial gauges each positioned at equal distances
around the pile and held datum bars resting in immovable support at least 3D awayfrom the test pile face. At each load increment, pile settlement shall be observed
accurate to 0.02 mm at an interval of 2, 4, 8, 15, 30 and 60 minutes and thereafter at
half hourly intervals up to a time when the rate of settlement of the pile top reduces to
0.1mm in half hour or 0.2mm in one hour, which will occur first. The test load shall be
maintained for 24 hours. Unloading shall be carried out in same decrements at 30min
interval and rebound for each decrement shall be noted. The final rebound shall be
recorded 3 hours after the entire load is removed.
5.4 ROUTINE LOAD TEST:
Routine load test will be carried out in working piles as designated by
Client/consultant. The pile head shall be cut off at cut off level and capped by an
R.C. cap to provide a horizontal plane bearing surface. Earth around the test pile
shall be scooped out so that the pile can have no soil support. Thereafter, the jacks
and other accessories in the pit pertaining to and necessary for conducting the test
shall be set up.
The total test load shall be 1.5 times the estimated safe load carrying capacity of the
pile or failure, whichever is earlier, and shall be applied in equal increments of 20
percent of the estimated safe load.
The test procedure will be the same as mentioned for initial load test.
5.5 RECORD OF LOAD TEST RESULTS:
Soon after completion of each test, contractor shall furnish a copy of all recorded test data to
the client in the approved format.
5.6 SAFE LOAD :
As per IS: 2911 (Part4)1964, the safe load on single pile shall be least of the following.
Two–third of the final load at which total displacement attains a value of 12 mm.
Or 50 percent of the final load at which total displacement is equal to10% percent of the
pile diameter of uniform diameter pile.
II.LATERAL LOAD TEST:Lateral Load Test on piles will be conducted as per IS: 2911 (Part 4) — 1985,
5.7 EQUIPMENT & TOOLS:
Hydraulic jack of suitable capacity with pump
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IOCL LNG LIMITED
LNG IMPORT, STORAGE ANDREGASIFICATION TERMINAL
ENNORE, TAMIL NADU, INDIA
JOB PROCEDURE
FORPILE LOAD TEST
DOCUMENT NO. AND REV:
19200-0102-8310-PR-0258Rev O2
BV DOCUMENT NO.
189150_87.1200Rev.1
DSN : 629 Page 7 of 12
Pre-calibrated pressure gauge with a sensitivity of 10 kg/cm2
Linear Variable Differential Transducers (LVDT) / Dial Gauges — Minimum 2 nos.
Two bearing plates to suit the perimeter of the pile
Two glass plates of size 40 x 40 mm
Datum Bar, MS angle of length minimum 5 x diameter of pile
MS pipe of suitable diameter & length to fill the gap between jack and pile
Bricks, cement, sand to support the jack, MS pipe and datum bars
Tools for Excavation Record Book and graph sheets
5.8 TEST PROCEDURE:
Piles to be load tested shall be so designated on the drawings or specified /
selected.(For Initial test load is 11 & 16 Ton and for Routine test load not yet
finalized)
Test load shall be applied to the piles by a hydraulic jack with a remote control pump
at Pile COL. Test load applied shall be such that a constant load is maintained under
increasing settlement.
The required reaction shall be derived from adjacent existing pile or vertical cut
made in the ground. Load tests shall in general be carried out after 28 days from the
time of casting the pile. Routine load test on working piles may be performed
concurrently with the pile installation operations if permitted by the client.
All load tests shall be conducted under the supervision of the client.
All responsibilities for conducting the tests safely and properly rest with contractor.
5.9 INITIAL LOAD TEST:
The soil around the pile shall be removed up to the required depth and the pile
surface shall be levelled. Place a steel plate on the pile side surface, jack and other
accessories pertaining to and necessary for conducting the test shall be set up.
The test load shall be applied by basis of Maintained Load Method. In this method
application of increment of test load and taking of measurement or displacement in
each stage of loading is maintained both Initial and routine load tests. Jacks shall be
supported properly.
The displacement of the test pile shall be related to a fixed datum. This may consist
of a reference beam (datum bar) supported by two foundations positioned outside
the zone of influence of the reaction support area. The settlement measuring
equipment must be set up in such a way that any tilting of the test pile will not cause
errors in the measurements. LVDTs/Dial gauges shall be used for measurement of
settlement. The least count of LVDT/Dial gauge shall be at least 0.01 mm.
LVDT/Dial Gauge shall be placed diagonally opposite to jack.
The total test load shall be as per AFC drawing and load shall be applied in equal
increments of 20 percent of the estimated safe load. Unloading may however be in
higher decrements with total number not less than four. At each load increment, pile
L A C K V E A T C H
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IOCL LNG LIMITED
LNG IMPORT, STORAGE ANDREGASIFICATION TERMINAL
ENNORE, TAMIL NADU, INDIA
JOB PROCEDURE
FORPILE LOAD TEST
DOCUMENT NO. AND REV:
19200-0102-8310-PR-0258Rev O2
BV DOCUMENT NO.
189150_87.1200Rev.1
DSN : 629 Page 8 of 12
settlement shall be observed accurate to 0.02 mm at an interval of 2, 4, 8, 15 and 30
minutes and thereafter at half hourly intervals up to a time when the rate of
settlement of the pile top reduces to 0. 1mm in half hour or 0. 2 mm in one hour,
which will occur first.
During the release stage, each load decrement shall be maintained at least for 30
minutes and the readings of settlement noted. When the load is fully released to
zero, measurements of rebound shall be continued till the settlement of the pile top
is not more than 0. 1 mm per half an hour.
5.10 ROUTINE LOAD TEST:
Routine load test will be carried out in working piles as designated in drawing or by
client/consultant. The soil around the pile shall be excavated up to the required
depth and the pile surface shall be levelled. Place a steel plate on the pile side
surface, jack and other accessories pertaining to and necessary for conducting the
test shall be set up.
The total test load shall be 1.5 times the estimated safe load carrying capacity of the
pile or failure, whichever is earlier, and shall be applied in equal increments of 20
percent of the estimated safe load.
The test procedure will be the same as mentioned for initial load test.
5.11 RECORD OF LOAD TEST RESULTS:
Soon after completion of each test, contractor shall furnish a copy of all recorded test data to
the client in the approved format.
5.12 SAFE LOAD:
50% of the final load at which the total displacement increases to 12 mm.
Final load at which the total displacement corresponds to 5 mm
III.PULL OUT LOAD TEST:
PuII out load test on piles will be conducted as per IS: 2911 (part -IV) - 985, “LOAD TEST ON
PILES “. The acceptance criteria for safe load shall be as per clause 8.4 of the above code.
5.13 EQUIPMENT & TOOLS:
The following equipment is required for pile testing:
Hydraulic jack of suitable capacity with pump
Pre-calibrated pressure gauge with a sensitivity of 20 kg/cm2
Linear Variable Differential Transducers (LVDT) / Dial Gauges — Minimum 2 nos.
Four bearing plates to suit the perimeter of the pile
Two glass plates of size 40 x 40 mm
Datum Bar, MS angle of length minimum 5 x diameter of pile
Additional reinforcement to weld to pile reinforcement if required
Welding set with Electrodes
Bricks, cement, sand to support the jack, MS pipe and datum bars
Tools for Excavation
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11/30
IOCL LNG LIMITED
LNG IMPORT, STORAGE ANDREGASIFICATION TERMINAL
ENNORE, TAMIL NADU, INDIA
JOB PROCEDURE
FORPILE LOAD TEST
DOCUMENT NO. AND REV:
19200-0102-8310-PR-0258Rev O2
BV DOCUMENT NO.
189150_87.1200Rev.1
DSN : 629 Page 9 of 12
Record Book and graph sheets
5.14 TEST PROCEDURE:
Piles to be load tested shall be so designated on the drawings or specified. /
selected by client in the field.(For Initial test load is 105.5, 191.3 & 237.9 Ton and for
Routine test load not yet finalized.)
Test load shall be applied to the piles by a hydraulic jack with a remote control pump
at pile COL. Test load applied to the piles shall be such that a constant load ismaintained under increasing settlement.
The required reaction shall be derived from adjacent existing piles or shallow
foundations. Load tests shall in general be carried out not earlier than 28 days from
the time of casting the pile. Routine load test on working piles may be performed
concurrently with the pile installation operations if permitted by the client.
All load tests shall be conducted under the supervision of the client. All
responsibilities for conducting the tests safely and properly rest with the contractor.
5.15 INITIAL LOAD TEST:
Install pile for conduction initial lateral load test. The soil around the pile shall be
removed up to the required depth and the pile surface shall be leveled. Place a steel
plate on pile side surface and jack and other accessories pertaining to and
necessary for conducting the test shall be set up.
The test load shall be so applied that it reaches the pile in a static manner. Reaction
frame shall be supported properly.
The displacement of the test pile shall be related to a fixed datum. This may consist
of a reference beam (datum bar) supported by two foundations positioned outside
the zones of influence of the reaction support area. The settlement measuring
equipment must be set up in such a way that any tilting of the test pile will not cause
errors in the measurements. Dial gauges shall be used for measuring settlement.
The least count of the dial gauges shall be at least 0.02 mm. Dial gauge shall be
placed at diagonally opposite to jack.
The total test load shall be as per design/drawing and shall be applied in equal
increments of 20 percent of the estimated safe load. Unloading may however be in
higher decrements with total number not less than four. At each load increment, pile
settlement shall be observed accurate to 0.02 mm at an interval of 2, 4, 8, 15 and 30
minutes and thereafter at half hourly intervals. Up to a time when the rate of
settlement of the pile top reduces to 0.1 mm in half an hour of 0.2 mm in one hour,
which will occur first. The load increment in general will be as per IS.2911.
During the release stage, each load decrement shall be maintained at least for 30
minutes and readings of settlement noted. When the load is fully released to zero,measurements of rebound shall be continued till the settlement of the pile top is not
more than 0.1 mm per half an hour.
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12/30
IOCL LNG LIMITED
LNG IMPORT, STORAGE ANDREGASIFICATION TERMINAL
ENNORE, TAMIL NADU, INDIA
JOB PROCEDURE
FORPILE LOAD TEST
DOCUMENT NO. AND REV:
19200-0102-8310-PR-0258Rev O2
BV DOCUMENT NO.
189150_87.1200Rev.1
DSN : 629 Page 10 of 12
5.16 ROUTINE LOAD TEST :
The test procedure is same as detailed above. The test load will be 1.5 times of the
pile capacity or specified.
5.17 RECORD OF LOAD TEST RESULTS:
Soon after completion of each test, contractor shall furnish a copy of all recorded
test data to the client in the approved format.
5.18 SAFE LOAD:
The safe tensile load on pile will be least of the following:
Two — thirds of the load at which the total displacement is 12 mm or the load
corresponding to a specified permissible uplift.
Half of the load at which the load — displacement curve shows a clear break (down
— word trend)
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13/30
IOCL LNG LIMITED
LNG IMPORT, STORAGE ANDREGASIFICATION TERMINAL
ENNORE, TAMIL NADU, INDIA
JOB PROCEDURE
FORPILE LOAD TEST
DOCUMENT NO. AND REV:
19200-0102-8310-PR-0258Rev O2
BV DOCUMENT NO.
189150_87.1200Rev.1
DSN : 629 Page 11 of 12
Tentative Sketch for arrangement of Initial Lateral Load Test
Tentative Sketch for arrangement of Routine Lateral Load Test
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14/30
IOCL LNG LIMITED
LNG IMPORT, STORAGE ANDREGASIFICATION TERMINAL
ENNORE, TAMIL NADU, INDIA
JOB PROCEDURE
FORPILE LOAD TEST
DOCUMENT NO. AND REV:
19200-0102-8310-PR-0258Rev O2
BV DOCUMENT NO.
189150_87.1200Rev.1
DSN : 629 Page 12 of 12
PLAN AT B-B
Tentative Arrangement for Routine Pullout Load Test
Tentative Arrangement for Initial Pullout Load Test
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X
D I A L G A U G E
• P L A T E
;
/
x
S T E E L T U B E
O R C O L L A R
- V E L D E B T P L A T E
• P I L E
R E I N F O R C E M E N T V E U J E D
V I T H
C O L L A R
limJ
N t O
- S U I T A B L E
A N G L E I C H A N N E L
DR J O I S T S
at
P I L E
- B R I C K
P I L L A R
O R
B A L L I P O S T
O R O T H E R I M M O V A B L E
S U P P O R T S
DET IL
D
Welded Steel
Steel
Plate
ISMB
v
ydraulic jack nam
Steel
bearing plate
I
I
T D
n
Dial gauge
Concrete Block
Ground level
J1
Test
Pile
Refrence
beam
8/18/2019 Job Procedure for Pile Load Test
15/30
DESIGN
CALCULAT ION
FOR
KENTLEDGE RR NG EM ENT 600 DI
18
Mtrdepth)
3
Nos.
ISMB550
[l 42-M
Mp = BpZp
fy/vmo
Bp
= 1.0 plastic
Zp =
2711.98
CM
3
h
Fy = 250
Mpa
So
•
vmo = 1 10
3-ISMB
550
are
Laterally Supported by
ISMB
350
Mp =
1.0 x
2711.98
x
250/1.10 = 616 KN.M
(1-ISMB
550)
3 Nos. =3x616 = 1848 KN.M
M fcll 8 1848
N
x 6 5
2
/8
W
=349.9
KN/M.
Load = 349.9
x
6.5 = 227.4
MT
Safe
Load
3-ISMB
550
Vd =
Avfy
= 3x550x11 2x250 = 242
MT
Safe
Load
V x 1.10
mo
v* -
In addition stiffener
are
also
provided
which
will
enhance
the
Load
x
S
j
m
SAFE
a
gNQ^
KSS
Petron Private Limited
(Formerly
known as
KazStroyService
Infrastructure India
Private Limited )
Corporate
office:
1
st
Floor,
Vatika
Towers,
A
-
Wing,
Sector
4
Gurgaon
22002,
India
Tel: +91 124
4566800,
4029700, FAX:
+91
124 4566866, Email:
Website: www.kazstroyservice.com
~t
r .
8/18/2019 Job Procedure for Pile Load Test
16/30
DESIGN C L C U L T IO N F O R KENTLEDGE ARRANGEMENT 600 DIA 18Mtr depth
2-ISMB
-50
As per 2007
Code
of
IS:800
5
ISMB-550 Plastic
Mp = Bp x Zp x
fy/
vmo
Bp = 1.0 (Plastic)
Zp = 2711.98 CM
3
6 50
M
h
Fy = 250
Mpa
v o
1 10
ISMB-550
Laterally supported
by ISMB 350
Mp 1 0
x 2711 98 x
1000
x
250/1 10
= 616 KN.m (1-ISMB 550)
For 2 Nos. = 2
x
616 =
1232
KN.m
M Wl
2
/8
1232 Wx6.5
2
/8
W = 233 KN/m
Therefore
: otal Load = 233
x
6.5 = 1514.5
KN
Say
= 150
MT SAFE LOAD
2 Nos. ISMB-550
Vd =
Av fy = 2x550x11.2x250
=
1616.1KN
V3
vmo
ii Jx.
x
1 10
n
;
ay
= 150
MT SAFE SHEAR
LOAD/POINT
LOAD
01
J
r
In additionStiffenerare also
Provided
r
S'
NO
Therefore SO S FE
KSS
Petron Private Limited
(Formerly
known
as KazStroyService Infrastructure India Private
Limited )
Corporate office:
1
st
Floor,
Vatika Towers,
A
-
Wing, Sector
-
4
Gurgaon
-
22002,
India
Tel: +91 124
4566800, 4029700, FAX:
+91 124
4566866, Email:
Website: www.kazstroyservice.com
8/18/2019 Job Procedure for Pile Load Test
17/30
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8/18/2019 Job Procedure for Pile Load Test
20/30
PILING WORK INSPECTION REPORTLoad Test
Project LNG Regasification Terminal-Ennore Project No. 19200
Client IOCL LNG BV Project No. 189150Consultant Amec Foster Wheeler Report No.EPC Contractor Consortium-BV & KSS EPCC-02 Report Date
Ref. Drawing No. Name of the Structure
Form no. 189150.CIV.QC.006 REV 1
Location Pile No
Pile Casting Date Diameter of Pile
Type of Pile Length of Pile Below COL
Type of Test Ground LevelRam Dia Ram Area
Pressure Gauge No. Dial Gauge No.
Date TimeTotal Time
( Mts )Increment
PressureGauge Reading
(Kg/Sq.m)
Total appliedload (MT)
Dial Gauge reading in mm
AverageDisplacement
in mm
Rate ofdisplacementper Hr. ( mm
)
Reboundmm
Remarks A B C D
Description Performed byChecked & Reviewed by
BVPMC OWNER
NAME
SIGN
DATE
LACK
VEATCH
Building worl
of
difference
Ku
8/18/2019 Job Procedure for Pile Load Test
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METHODOLOGY OF CYCLIC VERTICAL LOAD TEST
CONDUCTED ON 600 MM DIA OF TEST PILE
Test Arrangement:
The top of the Test pile was chipped to remove the overflowed concrete and dry Bentonite slurry till to sound
concrete get if required the pile shall be built up to COL. The top of the pile to be finished at cut of level. An
average loading platform of 7.00m x 8.00m was formed using 3Nos ISMB 550 joists as the main beam shall
be placed centrally above the pile top, 15 No’s of ISMB 400 joists will be used as cross / distribution girders.
Required quantities of concrete blocks will be loaded on top of this platform.
The Test load on the pile is 145 MT as mentioned in drawing no: 19200-0102-8310-42-0201, Rev S1. Hence
the total weight of Kent ledge will be 182.00MT (25% extra)
A 30mm steel plate will be placed over the pile top. The 600 MT capacity of hydraulic one jack will be
placed centrally over the pile top in such a way that the centre of gravity of the pile, pile top and the
kentledge shall be co-axial. The gap between the jack and the main beams will be filled using steel
beam/plate as packing material. Datum bars with supports at a distance 4.00 m from the face of the pile will
be placed on either side of pile. Dial gauges will be placed over those datum bars using magnetic bases.
Test Procedure
The cyclic procedure consisted of applying and releasing a large number of unidirectional loads. The time to
complete one load cycle varies from approximately 60 minutes the loading and unloading frequency was
controlled by the capacity of the hydraulic pump and extended length of the ram plunger. After 12”th cycles
from loading frequency was decreased. During 12”th cycle load were applied in every 60 minutes. In
between increment reading will be noted during this cycle using same incremental procedure.
Sustained loads will be applied by incrementally increasing and decreasing the load up to a Final load and
maintaining this load for 24 hours.
Each load increment will be 12.94 MT (approx). Each increment will be maintained for 60 minutes or till the
rate of settlement of the pile top was less than 0.1mm in 30 minutes or 0.2mm in 1hr which will be occurred
first. After every loading and maintain 60 minutes the load shall be released and reading shall be recorded at
15minutes. After that next increment to be applied. This is to be followed for every increment and
decrement. The maximum load of 145.00 MT was maintained for 24hrs and hourly readings shall be noted.
At the end of 24hrs unloading shall be done gradually till the load was released. After releasing the load,
reading observation to be recorded at least for 2 hrs.
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TEST RESULTS
The results of the load test are tabulated in table – 1 & 2 and the load settlement curve presented in Fig – 2
From the curve it may be observed that the maximum settlement at 145 MT was -------mm and net
settlement was ------mm as against a permissible settlement of 12mm as per IS code 2911 – part IV.
CONCLUSION
Since the total maximum settlement …….. at the load ……is within/without limits specified in
IS2911 – part IV – 1985 the pile is safe for a design load of …… MT.
Load vs Settlement Graph: To be furnished after Load test.
TEST DETAILSTypes of test : Cyclic Load Test
Design load : 58 MT.
Test Load : 2.5 Times of the Design Load
2.5 X 58 = 145.00 M.T.
Total Load on Kent ledge : 187.00MT
PILE DETAILS
Type of pile : Board-cast-in-situ-pile
Dia of pile : 600 mm
Pile no : C6
Bore Depth from ground level : 18 m
Bore Depth from COL : 18.50 m
Date of Boring : 05-11-2015
Date of Casting : 05-11-2015
CONCRETE / REINFORCEMENT DETAILS
Design mix : M30
Type / Grade of cement : OPC – 53 Grade
Theoretical Consumption of Cement : 44 bags.
Actual Consumption of Cement : 42.96 bags.
Main Reinforcement : As per drawing.
Stirrups : As per drawing.
Date of Testing (Start) : 30-12-2015
Date of Testing (Completion) :
8/18/2019 Job Procedure for Pile Load Test
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EQUIPMENT
1. Reaction by Concrete blocks Kent ledge.
2. Loading by 1 No. of hydraulic jack of 600 MT Capacity.
3. Type of jack: Single acting spring return.
4. Effective cylindrical area of jack: 1288.77 cm2
5. No. of dial gauged Used: 4 Nos.
Make : Baker
Range : 0 to 25mm
Least Count : 0.01mm
Identification : YFD3568, ULQ617
K2437, YJA1929
Pressure Gauge
Make : MASS
Range : 0 to 420 kg/cm2
Identification : PG-010
Least Count : 10kg/cm2
DETAILS OF KENTLEDGE WEIGHT
Weight of ISMB 550 : 3 Nos X 9.04 mtr X 92.40 kg/m = 2.50 MT
Weight of ISMB 350 : 12 Nos X 7.30 mtr X 56.70 kg/m = 4.97 MT
Weight of Concrete blocks
3rd Layer: 10Nos X 1.60m X 0.80m X 0.80m X 2.35 = 24.06 MT
2 nd Layer: 31Nos X 1.60m X 0.80m X 0.80m X 2.35 = 74.60 MT
1st Layer: 30Nos X 1.20m X 1.20m X 0.80m X 2.35 = 81.22 MT
-------------------
TOTAL WEIGHT = 187.35MT
-------------------
Say - 187.00 M.T.
8/18/2019 Job Procedure for Pile Load Test
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Reqd. Load on Kent ledge:
Design Load : 58.00 M.T.
Test Load : 58 X 2.5times = 145 M.T.
Reaction Load At 25% Extra
Total required Load : 181.25M.T
LOADING CHART
Design Load : 58.00MT
Test Load : 58.00 X2.5 times = 145 M.T.
Ram Dia : 405 mm
Effective Cylindrical area of Jack : 1288.77 cm2
Load increment : 20% of the design Load, .20 x 58 = 11.60M.T.
Pressure : Load / Area
: 11.60X 1000 / 1288.77 Kg/cm2
For 11.60 MT, Pressure required is : 9.00 Kg / cm2
For 10.00 Kg / cm2, Pressure Applied: 12.88 MT
S
N.
DIV
LOAD IN
M.TPRESSURE IN kg / cm
2 REMARKS
ACTUAL APPLIED ACTUAL
APPLIED
1 1.0 11.60 12.88 9.00 10.00
2 2.0 23.20 25.76 18.00 20.00
3 3.0 34.80 38.64 27.00 30.00
4 4.0 46.40 51.52 36.00 40.00
5 5.0 58.00 64.40 45.00 50.00 DESIGN LOAD
6 6.0 69.60 77.28 54.00 60.00
7 7.0 81.20 90.16 63.00 70.00
8 8.0 92.80 103.04 72.00 80.00
9 9.0 104.40 115.92 81.00 90.00
10 10.0 116.00 128.80 90.0 100.00
11 11.0 127.60 141.68 99.00 110.00
12 11.5 145.00 148.10 108.0 115.00 Final LOAD
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8/18/2019 Job Procedure for Pile Load Test
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TEST PROCEDURE
Initially the pump was operated such that jack just touched the loading Pile
and the pressure shows zero, the setting load applied and released. The initial
readings of the dial gauges were noted.
The loads were applied in increments 0.88MT. The maximum load of 11 MT.
Each percentage increase was maintained for ½ hr or till the rate of displacement of
the pile was less than 0.1mm in ½ hr or 0.2mm in 1 hr or 2 hrs after applying the
load. Unloading was done gradually till the load was released.
TEST RESULTS
The results of the load test are tabulated in Table – 1 and the load displacement
curve presented in Fig. 1.
Displacement at 11MT Test load Total Displacement ----mm, Rebound ----
mm, Net Displacement -----mm as against a permissible Displacement of 5mm per
IS2911 – Part IV – 1985.
.
8/18/2019 Job Procedure for Pile Load Test
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LATERAL PIL E LOAD TEST
Design load in MT - 4.4MT
Test load in MT - 11MT
20 MT capacity hydraulic jack - 1No.
Dia of Ram - 75 mm
Effective area of the ram - 44.15cm2
Least count of the gauge - 20.0 kg/cm2
Maximum pressure gauge reading - 11x 1000 / 44.15cm2
249.150 kg / cm
2
Say 250 kg / cm
Pressure = Load/ Area 0.88x1000/44.15 = 19.93Kg/cm2
LOADING INCREMENT STAGES
Sl.
No.Load Increment
Loadrequired
to be
Actual in
MT
Load
required
to be
applied in
MT
Pressurefor load
required
to be
applied in
Kg/cm2
ActualPressure
rounded
off and
applied in
Kg/cm2
Duration
01 0 Increment 0 0 0 0 0
02 1st Increment 0.88 0.883 19.93 20 30 mins
03 2nd
Increment 1.76 1.766 39.85 40 30 mins
04 3
rd
Increment 2.64 2.65 59.78 60 30 mins05 4
th Increment 3.52 3.53 79.71 80 30 mins
06 5th
Increment 4.4 4.416 99.63 100 30 mins
07 6th
Increment 5.28 5.29 119.56 120 30 mins
08 7th
Increment 6.16 6.18 139.49 140 30 mins
09 8th
Increment 7.04 7.065 159.42 160 30 mins
10 9th
Increment 7.92 7.94 179.34 180 30 mins
11 10th
Increment 8.8 8.83 199.27 200 30 mins
12 11th
Increment 9.68 9.72 219.20 220 30 mins
13 12th Increment 11 11.07 249.09 250 30 mins
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EQUIPMENT TO BE
USED I N LATERAL PI LE LOAD TEST
20 capacity of hydraulic jack : 1no
(0-25)mm dial gauges : 2nos
(0-700)kg/cm2 pressure gauge : 1no
Magnetic stand : 2nos
Test Pile Details
TEST DETAILS
Type of test : Lateral load test
Design load : 4.4MT
Test load : 4.4 x 2.5 times = 11MT
PILE DETAILS
Type of Pile : Bored cast – in – situ pile
Dia of pile : 600 mm
Depth of pile : 18.00m
Pile location : L6
Date of concreting the pile : ----------
Date of Testing start : ------------
Date of Testing Completion : --------------
8/18/2019 Job Procedure for Pile Load Test
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GRADE OF CONCRETE : ----
DETAIL OF REINFORCEMENT
Main Reinforcement bars : --------------
Stirrups : ----------------
Resting Block Details
3nos x 1.60 x 0.80 x 0.80 x 2.35 : 7.22 MT
5nos x 1.20 x 1.20 x 0.80 x 2.35 : 13.54 MT
TOTAL : 20.76 MT
Details of Jack
Capacity : 20MT
Ram Diameter : 7.5cm
Maximum pressure : 360 bar
Effective Area of Jack : 44.15 cm2
Details of Dial Gauges
Make : BAKER
Range : 0 to 25mm
Least count : 0.01mm
Identification No : YEC2103, YJA1900, YJA1929
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Details of Pressure Gauge
Make : MASS
Range : 0 -700 kg/cm2
Least Count : 20 Kg / cm2
TABLE
(DIPLACEMENT/REBOUND )
Sl. No.Applied Load
(MT)
Displacement
(mm)
Rebound
Displacement in
(mm)
1. 0 0
2.
3.
4.
5.
6.
7.
8.
9
10
11
12