Initial Load Test Procedure-Test Set Up-Design

Initial Load Test Procedure, Test Set up and desing of Test Pile Cut off level

2.0 Mts. w.r.to FGL

Double under reamed 500 mm dia. pile having working load capacity as uner……… 50 M.T. Compressi Compressive ve Load M.T. Latera Laterall Load Load 5.4 M.T. Diameter and Length of Pile has been proposed as per POWER GRID / Approved Approved soil investigation report

REV

NIL

DATE

REMARK

REV

0

19.04.2016

FOR APPROVAL

PURVANCHAAL PURVANCHAAL VIDYUT VITARAN NIGAM LIMITED POWER GRID CORPORATION OF INDIA LTD.

OWNER EMPLOYER

PACKAGE -A UNDER INTEGRATED POWER DEVELOPMENT SCHEME ( IPDS ) WORKS IN OLD KASHI AREA OF VARANASI TOWN OF UP UNDER DEPOSIT WORK OF PUVVNL.

PROJECT

CC-CS/713-NR1/CBL-3266/3/G7/NOAI/5607,Dated 12-12-2015 CC-CS/713-NR1/CBL-3266/3/G7/NOASERVICE I/5608,Dated 12-12-2015 KEI INDUSTRIES LIMITED CONTRACTOR NOA NO.

SUPPLY

TITLE

Initial Load Test Procedure, Test Set up and desing of Test Pile

Total Sheet Doc.No. 26

KEI/VNS/2016/SS/CIVIL DSN-01

OWNER EMPLOYER PROJECT NOA NO.

SUPPLY SERVICE

CONTRACTOR TITLE

PURVANCHAAL VIDYUT VITARAN NIGAM LIMITED POWER GRID CORPORATION OF INDIA LTD. PACKAGE -A UNDER INTEGRATED POWER DEVELOPMENT SCHEME ( IPDS ) WORKS IN OLD KASHI AREA OF VARANASI TOWN OF UP UNDER DEPOSIT WORK OF PUVVNL. CC-CS/713-NR1/CBL-3266/3/G7/NOA-I/5607,Da CC-CS/713-NR1/CBL3266/3/G7/NOA-I/5607,Dated ted 12-122015 CC-CS/713-NR1/CBL-3266/3/G7/NOA-I/5608,Da CC-CS/713-NR1/CBL3266/3/G7/NOA-I/5608,Dated ted 12-122015 KEI INDUSTRIES LIMITED

Initial Load Test procedure and test pile design for double bulb under reamed piles.

I E K o t i t a t l n a a t T l & u s h n o a h C S n g i s e D

PILE FOUNDATIONS

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Concrete Piles o Under Reamed Piles as per I.S.2911-Part 3. Bored-cast in-situ piles Driven Cast-in-situ Piles o o Pre-cast Piles Steel Piles Pipe piles Rolled steel H-section piles Timber Piles Composite Piles Under reamed concrete piles o

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From above list, most widely adopted piles in firm grounds due to higher load capacity requirement of foundations are under reamed pile concrete piles as per IS 2911 : Part 3.

1. 2. 3. 4.

Strata of soil available at site Load carrying capacity requirements (Horizontal and vertical) Ground water condition Type of structure to be supported

1. Mark the position of pile pile bore at site as per drawing coordinates. 2. Align the drill rig/ bore machine on position. 3. Attach proper diameter tool of drilling as per pile diameter (bore tool is slightly less in dimension if piles are cased/liner is used). Varansi Initial Load Test Procedure and Test Pile Design

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PURVANCHAAL VIDYUT VITARAN NIGAM LIMITED POWER GRID CORPORATION OF INDIA LTD. PACKAGE -A UNDER INTEGRATED POWER DEVELOPMENT SCHEME ( IPDS ) WORKS IN OLD KASHI AREA OF VARANASI TOWN OF UP UNDER DEPOSIT WORK OF PUVVNL. CC-CS/713-NR1/CBL-3266/3/G7/NOA-I/5607,Dated 12-122015 CC-CS/713-NR1/CBL-3266/3/G7/NOA-I/5608,Dated 12-122015 KEI INDUSTRIES LIMITED



4. Drill the bore up to design pile depth. 5. Control the alignment. If pile is design as vertical pile, it should not deviate more than 1.5% (1.5cm per 100cm bore depth). More details as in IS 2911 part 2, cl 7.1.2. 6. If piles are drilled in stabilized soil, bentonite mud, permanent liner (for marine situation) or casing up to required depth is to be provided to protect the sides of bore wall from collapse. 7. During drilling operations, site Engineer has to take care that soil augured / drilled from pile bore is matching with soil investigation bore logs as per visual identification and pile is drilled and terminated in same strata assumed in pile design as per bore logs. 8. After completion of drilling/boring of pile, lower the cage immediately and pour the concrete. 9. To do the concrete in fresh bore as possible as is very good practice of pile foundation. 10. Concrete in pile foundations are done with trimie method suggested in IS 2911 Part 2 cl 7.5. 11. All precaution are to be taken mentioned in cl 7.5 (IS 2911 Part 2). 12. Pour the concrete at least up to 0.6m above cutoff level. 13. Record all the data necessary for pile log and pour card. (formats attached).

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: Minimum grade of concrete for pile: M25 with minimum cement 400 kg/cu m. Slump requirement: 150 – 180 mm for trimie method concrete.

Varansi Initial Load Test Procedure and Test Pile Design

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Initial load test Scope: For determination of ultimate capacity of pile foundation done on separate pile foundation drilled in same strata of project area. Generally load is increased up to 2.5 times of design load or max allowable settlement. Routine load test Scope: For confirmation of working capacity of pile foundations done on working pile foundation of project. Generally load is increased up to 1.5 times of design load. o Static method  Maintained load method  Cyclic method o Dynamic method (high strain integrity test method) Non destructive test o Low strain integrity test method Static test o Kentledge method o Anchor reaction method

Maintained load method: for compression load test (IS 2911 part 4 cl 6.0) 1. Kentledge load method 2. Anchor reaction method. Load application: The test load was applied in a series of vertically down ward incremental loads by means of a set of hydraulic jack connected to hydraulic pump 


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Each increment should not more than 20% of design load. Maintain each increment till pile displacement is less than or equal to 0.1mm for first 30minutes or 0.2mm for first one hour or till 2hour whichever occurs first. Load increments are given up to test load is achieved. Measurement of displacement/settlement: 2 strain gauges were used to record settlements for single pile. Maintain the test load for next 24 hours and take readings of displacement at th every 1 hour interval till end of 24 hour. Unloading: After completion of 24 hrs with test load, load is decreased in equivalent each increment loads after every 15 min. Rebounds reading were taken immediately after unloading and 15 min later for each stage of decrement. Safe load on single pile = least of following (As per IS 2911 Part 4) o 2/3rd load at which the total displacement attains value of 12mm o ½ load at which the total displacement attains equal to 10% pile diameter. o ½ load at which the total displacement attains equal to 7.5% pile bulb diameter for under reamed piles.

Maintained load method: for lateral load test (IS 2911 part 4 Cl. 7.0) Open pit was excavated to expose pile up to cutoff level. The pile overflow concrete was dismantled and dressed with GP2 mortar to smooth and horizontal top surface. Hydraulic jack 1No, datum bar and other test assembly were erected as per sketch attached.  

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Datum bar resting on immovable supports, fixed at a distance of 3.0 times the diameter of pile from the center of pile. 1 No Strain gauge was installed against pile surface as shown in figure 1 with the help of datum bar (Least count = 0.01mm). Load application: The test load was applied in a series of lateral incremental loads by means of a set of hydraulic jack connected to hydraulic pump Each increment should not more than 20% of design load. Maintain each increment till pile displacement is less than or equal to 0.1mm for first 30minutes Displacement: 2 strain gauges fixed on immovable datum bar support to record settlements placed at 30cm spacing on pile stem face. Unloading: After completion of 12 hrs with test load was decreased equivalent each increment loads after every 15 min. Rebounds reading were taken immediately after unloading and 15 min later for each stage of decrement. Safe lateral load on single pile = least of following (As per IS 2911 Part 4) o 50% of final load at which the total displacement attains value of 12mm o Final load at which total displacement corresponds to 5mm o Load corresponding to any other specified displacement as performance requirement.

No of routine test required: 1. 0.5% of total piles to be installed increased up to 2% of total piles to be installed depend on type of structure and variation in soil strata among total no of piles in pile depth zone. (as per IS 2911 part 4 Cl 4.2) 2. 1 test per 200 piles.


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No of Initial pile load test required: 1. one test per 1km stretch

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IS 2911 : Part 1 : Sec 1 : 1979 Driven cast in-situ concrete piles IS 2911 : Part 1 : Sec 2 : 1979 Bored cast-in-situ piles IS 2911 : Part 1 : Sec 3 : 1979 Driven precast concrete piles IS 2911 : Part 1 : Sec 4 : 1984 Bored precast concrete piles IS 2911 : Part 2 : 1980 Timber piles IS 2911 : Part 3 : 1980 Under reamed piles IS IS IS IS IS IS IS IS

2911 : Part 4 : 1985 Load test on piles 5121 : 1969 Safety code for piling and other deep foundations 6426 : 1972 Specification for pile driving hammer 6427 : 1972 Glossary of Terms Relating to Pile Driving Equipment 6428 : 1972 Specification for pile frame 9716 : 1981 Guide for lateral dynamic load test on piles 14362 : 1996 Pile boring equipment - General requirements 14593 : 1998 Bored cast-in-situ piles founded on rocks – Guidelines


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The load test was conducted as per IS 2911 (part 4). The pile shall be tested for initial and routine test as under. Test / method

Initial

Compression

2.5

Routine x

estimated

design 1.5 x design load – max. 75

capacity 125 M.T.

equivalent static.

Pull out

2.5 x design load

1.5 x design load

Lateral

2.5

x

estimated

capacity 13.5 M.T.

design 1.0

x

estimated

design

capacity 5.40 M.T.

Pile foundation is proposed for Building as main unit and there is no pull out force in any of these piles. In view of this, it is proposed to eliminate / not to conduct Initial Load Test for Pullout Load.

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Grade of pile foundation shall be minimum M30 grade with minimum cement content 400kg/cu m.


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The pile top concrete shall be chipped off till sound concrete is met and dressed up to test level/Cut off level.

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The pile top is prepared smooth and in spirit level with GP2/any other non shrink grout/ mortar/concrete (thickness not more than 30mm) and cured for at least 3-5 days such that it attains strength equal to or more than pile concrete.

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Centre to center spacing between test pile and anchor piles shall not be less than 3 times pile shaft diameter or 2m whichever is less.

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For compression load test, anchor piles shall be capable to take pullout load generated during compression load testing. If anchor piles are working piles, care shall be taken that uplift in anchor pile is within permissible limit.

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MS plate of 25 mm thickness shall be placed over the pile top surface.

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Datum bars resting on immovable supports, fixed at-least at a distance of 3.0 times the diameter of pile shaft from the center of pile on either side with minimum 2m from center of test pile.

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Displacement gauges (at least 4 nos. with valid calibration) shall be installed against MS base plate placed on pile top with the help of datum bars (Least count = 0.01mm).


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Hydraulic jack is connected with hydraulic power pack motor operated/manual operated pump.

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Calibrated hydraulic pressure gauge shall be attached to hydraulic pump system for reading the applied load.

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Test set up – reference sketch is given in sketch for setup preparation. However testing agency may adopt their set up.

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Test set up – reference sketch is given in sketch for setup preparation. However testing agency may adopt their set up. Datum bars resting on immovable supports, fixed at-least at a distance of 3.0 times the diameter of pile shaft from the center of pile on either side with minimum 2m from centre of test pile. Displacement gauges (at least 4 nos. with valid calibration) shall be installed against MS base plate placed on pile top with the help of datum bars (Least count = 0.01mm). Hydraulic jack is connected with hydraulic power pack motor operated/manual operated pump. Calibrated hydraulic pressure gauge shall be attached to hydraulic pump system for reading the applied load.

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Reaction pile shall be of ample capacity to resist the lateral thrust.

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Routine lateral load test shall be carried out for a test load equal to the working load; the maximum deflection of test loading in position shall not exceed 5 mm.


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Load application: The test load shall be applied in a series of vertically down ward incremental loads by means of a set of hydraulic jack connected to hydraulic pump.

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Test load: For Initial load test it shall be 2.5 times design ( working ) load. For Routine load test it shall be 1.5 times design ( working ) load.

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Settlement: At least 4 strain gauges were used to record settlements.

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Load increment: each load increment shall equal to 20% of design load. Settlement readings were noted on each displacement gauge immediately after loading and after every 60 minutes for each stage. Next load increment was applied after satisfying following criteria. Of maintained load method. Each stage of loading is maintained till rate of displacement of pile is less than or equal to 0.2mm/hr or 2 hr has elapsed whichever is earlier. Then next increment shall be given. This is repeated till max test load attained or pile exceeds permissible displacement. The test load shall be maintained for 24 hours. If permissible displacement exceeds in test pile, test is discontinued at respective loading and gradual unloading is carried out as under.


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Unloading: After completion of 24 hrs with test load/achieving permissible settlement decrease the load equivalent each increment loads after every 15 minutes. Rebounds reading were taken immediately after unloading and before next decrement up to full decrement (Nil load).

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Safe compression and pull out load on single pile o

least of following (As per IS 2911 (Part 4): 2013)

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2/3rd load at which the total displacement attains value of 12mm for diameter of pile equal to or less than 600mm.

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2/3rd load at which the total displacement attains value of 18mm or 2% or pile diameter which is less for diameter of pile more than 600mm.

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50% of load at which the total displacement attains equal to 10% pile diameter in uniform pile shaft diameter and 7.5% of bulb diameter in case of under reamed piles.

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Safe Lateral load on single pile 

Fifty percent of the final load at which the total displacement increases to 12 mm

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Final load at which the total displacement corresponds to 5 mm

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Load corresponding to any other specified displacement as per performance or design requirements.


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Pile No

:

Type of pile

:

Date of casting

:

Depth of pile from test level

:

Diameter of pile

:

Grade of concrete

:

Date of Testing

:

No of anchors used

:

Type of anchor

:

Capacity of jack

:

No of jack used

:

Ram dia of jack

:

Area of one jack ram

:

Make

:

Least count of pressure gauge : Maximum range

:


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Make Least count Max Range No. of dial gauge used

: : : :

OBSERVATIONS Load increment = 20% of design load = __ x 0.2 = XXX Tonne Pressure req

= LD INCREMENT*1000/RAM AREA = (xxx *1000)/ram area = _____ kg/sq cm

Observation table

DATE /TIME

Load (Tonne)

Pressure Gauge reading

Dial Gauge Readings A

B

C


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Net Average Rdg D

Settlement (mm) Average



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The pile top concrete shall be chipped off till sound concrete is met and dressed up to test level. The pile top is prepared smooth and in spirit level with GP2/any other non-shrink grout/ mortar (thickness not more than 20mm). Kentledge load calculation and setup details are to be approved by client in prior. If test is carried out with anchor piles, Anchor piles shall be capable to take the pullout load generated during compression load testing on test pile. Centre to center spacing between test pile and kentledge supports/anchor piles Grade of concrete and other design requirements shall be as per IS2911 part 1 Section 2. Test shall be conducted after 28 days of casting of anchor piles and test pile and at least 7days of preparation of pile head top.

MS plate of 25 mm thickness shall be placed over the pile top surface. Datum bars resting on immovable supports, fixed at-least at a distance of 3.0 times the diameter of pile shaft from the center of pile on either side. Displacement gauges (at least 4 nos. with valid calibration) shall be installed against MS base plate placed on pile top with the help of datum bars (Least count = 0.01mm). Hydraulic jack is connected with hydraulic motor/manual operated pump. Calibrated hydraulic pressure gauge shall be attached to hydraulic pump system for reading the applied load.


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Centre to center spacing between test pile and anchor piles should not less than 3 times pile shaft diameter. If anchor piles are working piles, care shall be taken that uplift in anchor pile is within limit.

Load application: The test load shall be applied in a series of vertically down ward incremental loads by means of a set of hydraulic jack connected to hydraulic pump. Test load: It should be 2.0 times design load. Settlement: At least 2 strain gauges were used to record settlements. Load increment: each load increment shall equal to 20% of design load. Settlement readings were noted on each displacement gauge immediately after loading and after every 30 minutes for each stage. Next load increment was applied after satisfying following criteria. Maintained load Method: Application of increment of test load and taking of measurement or displacement in each stage of loading is maintained till rate of displacement of pile top is either 0.1mm in first 30 minutes or 0.2 mm in first one hour or till 2 hours which ever occur first. If the limit of permissible displacement is not exceeded, testing of pile is not required to be continued further. The test load shall be maintained for 24 hours. Unloading: After completion of 24 hrs with test load, decrease the load equivalent each increment loads after every 15 minutes. Rebounds reading were taken immediately after unloading and before next decrement up to full decrement (Nil load). Safe load on single pile = least of following (As per IS 2911 Part 4)  2/3rd load at which the total displacement attains value of 12mm


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½ load at which the total displacement attains equal to 10% pile diameter in uniform pile shaft diameter and 7.5% of bulb diameter in case of under reamed piles.

Pile No

:

Type of pile

: Straight Bored cast in situ

Date of casting

:

Depth of pile from test level

: ____m

Diameter of pile

: ____ mm

Grade of concrete

: M ___

Date of Testing

: __________ to ________

No of soil anchors used

: ___Nos.

Type of anchor

: _______________

Or Kentledge

plateform details

: _______________

Capacity of jack

: __ MT

No of jack used

: 1 No

Ram dia of jack

: ___ cm

Area of one jack ram

: _____ sq cm


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Initial Load Test procedure and test pile design for double bulb under reamed piles. :

Make

: _______

Least count of pressure gauge : ____ kg/sq cm Maximum range

: ____ kg/sq cm

Make

: _________

Least count

: 0.01mm

Max Range

: ___mm

No. of dial gauge used

: 2 Nos.

Load increment = 20% of design load Pressure req = (____tonne x 1000)/ram area = _____ kg/sq cm Load increment / decrement

Load

PG RDG

INDI PG RDG

Actual load

Avg Settlement

20% each

tonne

kg/sqcm

kg/sqcm

Tonne

-mm

0 20 40 60 80


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Load increment / decrement

Load

PG RDG

INDI PG RDG

Actual load

Avg Settlement

tonne

kg/sqcm

kg/sqcm

Tonne

-mm

120 140 20% each 160 180 200 180 160 140 120 100 80 60 40 20 0


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Initial Load Test procedure and test pile design for double bulb under reamed piles. Load V/S settlement graph plot


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SUPPLY SERVICE CONTRACTOR TITLE

PURVANCHAAL VIDYUT VITARAN NIGAM LIMITED POWER GRID CORPORATION OF INDIA LTD. PACKAGE -A UNDER INTEGRATED POWER DEVELOPMENT SCHEME ( IPDS ) WORKS IN OLD KASHI AREA OF VARANASI TOWN OF UP UNDER DEPOSIT WORK OF PUVVNL. CC-CS/713-NR1/CBL-3266/3/G7/NOA-I/5607,Dated 12-12-2015 CC-CS/713-NR1/CBL-3266/3/G7/NOA-I/5608,Dated 12-12-2015 KEI INDUSTRIES LIMITED

DESIGN CALCULATION FOR REINFORCEMENT EVALUATION OF ( TEST PILES ) - DOUBLE UNDER REAMED PILE for Initial Load Test

Grade of Pile concrete PILE DETAILS Under Reamed Pile Reinforcing Steel Pile Diameter 500 mm Cut off level w.r.to FGL 2.0 Mts. Min. length of pile shall be as per Soil Investigation Agency's ( POWER GRID Approved ) length for below mentioned working Length of pile load capacity.

I E K o i t t a t l n a a T t l & u s h n o a h C S n g i s e D

M-25 Fe-500

Safe working Test load load per per pile ile Compression 50 125 M.T. Pull out 31.5 78.75 M.T. Lateral 5.4 13.50 M.T. As per IS:2911 (Part-I section-2) - Clause-5.11.1 Ast min. 0.4 % of pile area i.e. 785 mm^2

Design Calculations for Free Head Piles Compression load Test pile

Free Head Pile

Test load for Initial load test for compression = 125 M.T. For a partial safety factor equal to = 1.1 137500 mm^2 Acmin = Pu / 0.4 x Fck = Pu = 0.4 fck * Ac + 0.67 fy * Asc Pu = 1375000 = 1963500 + 0.67*500*Asc Asc min = 785 mm^2 Asc min. for direct compression = 5280 Sq.mm.i.e. 52.8 cm^2 Mom.for min.eccentricity = 20 mm 2.750 T-Mt. i.e. 2750 Kg-Mt. Lim 2 250000 ) = 1375000 / (25x 0.220 Pu/fck.D = 3 125000000 ) = (25x 0.009 Mu/fck*D = 27500000 / Refer Chart 60 of SP16 p/fck = 0 Ast =

0 Sq.mm Thus Ast =

785 mm^2 i.e.

Provide 20 mm Dia + 4 No. of 25 mm Dia + 4.91 8 No. of Actual % of vertical reinf. Provided = Ties 8 mm Tor Reinf. @ 250 mm c/c

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7.85 cm^2 nos i.e. nos i.e. 2.69 %

12.57 cm^2 40.23 cm^2 52.80 cm^2


SUPPLY SERVICE CONTRACTOR



TITLE

Pullout load Test pile

Free Head Pile

Test load for Initial load test for Pullout load For a partial safety factor equal to Direct tensile stress in concrete = 866250/ Ast vertical = Thus Ast =


866250/ / 3150 mm^2

= = 196350

i.e.

Provide 20 mm Dia + 4 No. of 20 mm Dia + 4 No. of Actual % of vertical reinf. Provided = Ties 8 mm Tor Reinf. @ 250 mm c/c

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78.75 M.T. 1.1 = 4.41

N/mm^2

275 31.50 cm^2 nos i.e. nos i.e. 1.28 %

12.57 cm^2 12.57 cm^2 25.13 cm^2

OWNER EMPLOYER


PROJECT NOA NO.

SUPPLY SERVICE CONTRACTOR


TITLE

Lateral load Test pile

Free Head Pile

Test load for Initial load test for Lateral load For a partial safety factor equal to

= =

Lever arm for pile Design (Free head) =

8.60 M.T. 1.1 3.8 Mts.

Lim. Design Moment for Compression with bending = Reduction factor m Lim. Design Moment = 3 143792000 / Mu/fck*D = Refer Chart 61 of SP16 p/fck = Ast =

= = (25x

9.5 x 3.80 = 0.4 0.400 x 35.9 = 125000000 ) =

Vertical Reinforcement Ties

14.379 T-Mt. 0.046

18.65 cm^2 nos i.e. nos i.e. 1.05 %

Actual % of vertical reinf. Provided = Ties 8 mm Tor Reinf. @ 250 mm c/c

Test load

35.948 T-Mt.

0.038

1865 Sq.mm Thus Ast = 1865 mm^2 i.e. Provide 20 mm Dia + 4 No. of 16 mm Dia + 4 No. of

Test Pile


Reinforcement in Test Pile - 500 mm dia. piles Compression load Test Pullout loadTest

12.57 cm^2 8.04 cm^2 20.61 cm^2

Lateral load Test

125 MT

79 MT

20 mm 4 nos.

20 mm 4 nos.

20 mm 4 nos.

25 mm 8 nos.

20 mm 4 nos.

16 mm 4 nos.

8 mm 250 mm c/c

13.50 MT

8 mm -250 mm c/c 8 mm -250 mm c/c

H:\2016\1619-GIS at Varansi for KEI-PGCIL\DESIGN\Pile test related\[TEST PILE DESIGN -Varansi.xls]Varansi-Initial Test Pile

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Initial Load Test Procedure-Test Set Up-Design

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