HCC Management System

Quality Plan: Pile Load Test

HCC N 40 17 10

Quality Plan: PILE LOAD TEST

HCC N 40 17 10
Revision No.: 00
Date of Revision: 28 August 2006

DOCUMENT RELEASE AUTHORIZATION

Prepared by Project Chief Engineer : ________________________

(Priyaranjan)

Approved by Project Manager : ________________________

(R.Madhavan)

Reviewed by Project Representative : ________________________

(N.D.Talukder)

Issued by Document Controller : ________________________

(Hemal)

Issued as: CONTROLLED COPY / UNCONTROLLED COPY for information purpose

(Appropriate status to be highlighted)

This document is the property of HCC and is copyright protected. Unauthorized photocopy either
partly or fully is prohibited. Authorized controlled copy of this document can be had from

HINDUSTAN CONSTRUCTION CO. LTD

LMNHP-WB-4, Madan Lal Camp, Po- Darshan Nagar, Ayodhya Road, Faizabad

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HCC Management System
Quality Plan: Pile Load Test
HCC N 40 17 10

TABLE OF CONTENT

Clauses Description Page

1.0 PURPOSE 4
2.0 SCOPE 4
3.0 DEFINITION 4
4.0 CROSS REFERENCE 4
5.0 RESPONSIBILITIES 5
6.0 CONSTRUCTION METHODOLOGY 6-15
7.0 OHS & ENVIRONMENTAL MANAGEMENT SYSTEM 15
8.0 ATTACHMENT 15
9.0 DISTRIBUTION 15

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HCC Management System
Quality Plan: Pile Load Test
HCC N 40 17 10

History of Revisions

Revision Chapter/clause
Revision date Reason for revision
No. no.& text affected

0 28 April -06 First Issue

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HCC Management System
Quality Plan: Pile Load Test
HCC N 40 17 10

1.0 PURPOSE:
The purpose of this Segment Quality Plan for Pile load test of cast in situ
bored piles is to verify the design carrying capacity of piles as per IS-2911
(Part-4)-1985 to provide details of the Construction Methodology,
Resources deployment, Quality Assurance & Control System/Procedures
adopted by H.C.C.

2.0 SCOPE:
The Scope of this Segmental Quality Plan covers the following activities:

 Survey and Setting out works marking pile points/locations etc.

 Selection, Testing and acceptance of Materials and Mixes for Cast-in-situ
Bored Piles.
 Deployment of Plant/Equipment/Machinery etc.
 Construction Methodology for Initial load test under the guidelines of IS-
2911 (Part-4)-1985.
 Quality Assurance and Quality Control during installation of piling work
and post installation checks, tests etc.

3.0 DEFINITIONS:
The words like contract, Contractor, Engineer (Synonymous to Engineer’s
representative), Drawing, Employer, Government, Works, Worksite used in
this Quality Plan shall be considered to have the meaning as understood
from the definitions of these terms given in the General conditions of the
contract. For other general definitions pertaining to HCC Quality
Management System, refer Project Quality Management Plan, HCC N 39
17 01.

4.0 CROSS REFERENCES:

This Segment Quality Plan shall be read in conjunction with the following
documents:

 M.O.R.T.H – Specifications for Road and Bridge Works (fourth

Revision)
 Contract Supplementary Specifications.
 IS: 2911 (Part-4)-1985 Load test on Piles & IS: 2911 (Part I/Sec – 2) –
1979, Code of Practice for Design and Construction of Pile
Foundations.
 Project Quality Management Plan, HCC N 39 17 01

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HCC Management System
Quality Plan: Pile Load Test
HCC N 40 17 10

5.0 RESPONSIBILITIES:
Responsible personnel for execution and quality control for installation of
bored cast-in-situ piles are as per the following Responsibilities Matrix and
also as per the Project /Segment Organization Chart:

S. Activity Description Performing Checking/ Approving

No. Verifying
01 Preparation of Quality Works Project Chief Engineer
Plans / Construction Mgr./QA Engineer and Project
Methodologies. Manager Mgr.
02 Identification of QA/QC QA/QC
Materials, selection & Mix Engineer/Lab Manager Engineer
design/trials etc. for piling. Technician /Engineer
03 Survey & Setting out Surveyor Works Manager,
works and marking pile QA Engineer Engineer
locations etc. randomly
04 Mobilization of Piling rig, Section-in-
other ancillaries etc. at charge/Site ----- -----
various locations as per Engineer
drawings etc.
05 Pile boring operations. Foreman/Sup
Section-in-
ervisors charge/Site -----
Engineer
06 Fabrication of Steel yard in- Site Engineer/QA
Reinforcement Cage as charge Engineer Engineer
per approved
drawings/BBS
07 Completion of Pile boring Section-in- QA Engineer
up to founding level and charge/Site Engineer
recording pile data as per Engineer
approved format.
08 Pouring of Tremie Section-in- QA & QC
Concrete as per charge / Site Engineer Engineer
specifications and quality Engineer
checks.
09 Casting and Testing of QC QA/QC
Cubes as per ITP and Engineer/Lab Manager Engineer
entering in formats. Technician /Engineer

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Quality Plan: Pile Load Test
HCC N 40 17 10

6.0 CONSTRUCTION METHODOLOGY:

6.1 Materials for Piling:

6.1.1 Cement: Cement conforming to IS: 8112 grade – 43/GRADE 53 shall be

used for piling job with prior approval from Engineer. MTC/lab test
certificate shall be maintained and various laboratory tests to be conducted
for Cement has been described in Inspection and Test Plan for Piling
works, HCC T 39 17 34 attached to this Quality Plan.

6.1.2 Coarse & Fine Aggregate: Coarse & Fine Aggregate conforming to IS:
383 shall be used for Piling. Gradation of combined aggregate shall be in
accordance with IS: 383, Table-5 all-in-aggregate grading for 20mm
nominal size.

Various mechanical properties of coarse aggregates and properties of Fine

aggregate are to be conformed to IS: 383 and tests shall be conducted as
per relevant test codes as described in ITP for Piling works, HCC T 39 17
34 attached to this Quality Plan.

6.1.3 Water: Potable water shall be used for Concreting and should be
conforming to MORTH Specification.

6.1.4 Reinforcement Steel: Reinforcement steel for Piling shall be Fe 415

grade and conforming to IS: 1786, only TMT reinforcement.

6.1.5 Concrete Admixtures: Admixtures to be used in Pile concrete shall be

conforming to IS: 9103 and prior approval from Engineer shall be obtained
for use of Admixture. Dosage of Admixture shall be as per manufacturers
instructions and as per workability requirements, which will be finalized
during, mix design and trials.

6.1.6 Bentonite: Bentonite suspension to be used to maintain the stability of the

borehole shall be tested to check its properties prior to use and all the tests
and their acceptance criteria as per M. O. R. T. & H. shall be carried-out.

6.2 Concrete Mix for Piling:

Concrete Mix design shall be carried out as per IS: 10262 and Grade of
Concrete to be used in cast-in-situ piles shall be M 35 and the minimum
cement content shall not be less than 400 kg per cubic meter of concrete.
The concrete shall be designed to achieve a workability of between 150 to
200 mm to facilitate tremie concrete operation. Trials will be conducted and
cubes shall be cast, tested before acceptance of design mix. Refer to Mix
design report for final proportions of concrete

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Quality Plan: Pile Load Test
HCC N 40 17 10

6.3 Plant and Equipment for Piling Operation:

The following Plant/Equipment shall be used for Installation of Bored cast-

in-situ piles:

1. Piling Rig with Winch: adequate nos. of conventional piling rigs with
driving winches (Electrically motor driven) shall be used for installation
of bored cast-in-situ Piles.
2. DMC Rods: Direct Mud Circulation Pipes of Required diameter shall be
used for drilling of bore hole.
3. Chisel: Chisel of required diameter shall be used for drilling.
4. Miscellaneous Accessories: other miscellaneous piling accessories
i.e., hosepipes, mud pump, channels etc. shall be used in piling
operation.
5. Batching Plant: A batching plant shall be used to produce the
concrete.
6. Transit Mixer: Adequate nos. of transit mixer shall be used for
transporting concrete from batching plant to pile pour location.
7. Slump Cone, Cube Moulds etc.: Cube moulds of adequate nos. shall
be used to cast cubes as per inspection and test plan. Slump cone shall
be kept at plant and site to checks the concrete slump.
8. Hydraulic Jack: with suitable manifolds to a common hydraulic pump
or power pack.
9. Calibrated Dial gauges: for observation during loading & testing of
Initial load test.

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HCC Management System
Quality Plan: Pile Load Test
HCC N 40 17 10

6.4 Construction Methodology: Initial Pile Load Test

Method statement for conducting initial vertical pile load test

Codal Requirements
Pile load test requirements as per IS : 2911 (Part 4) – 1985
Initial pile load test: Requirements as per IS code listed below are taken in to
account.
1 Generally the load application and deflection observation will be made at the
pile top (As per Cl No 5.2).
2 The test shall be carried out as far as possible at cut-off level where-ever
practicable, other-wise suitable allowance shall be made in the interpretation of
the test results/test load if the test not carried out at cut-off level (As per Cl No
5.4).
3 The compression load is applied to the pile top by means of hydraulic jack(s)
against steel joists or suitable load frame capable of providing reaction and the
settlement is recorded by suitably positioned dial gauges. In this case Kent
ledge load is placed
4 Preparation of pile head: The pile head shall be chipped off to natural horizontal
plane till sound concrete is met. The projecting reinforcement shall be cut-off or
bent suitably and the top finished smooth and level with plaster of paris or
similar synthetic material where required. A bearing plate with a hole at the
center shall be placed on the head of the pile for the jacks to rest (As per Cl No
6.1.1).
5 Reaction will be obtained from Kent ledge placed on a platform supported clear
of the test pile (As per Cl No 6.1.3).
6 The reaction to be made available for the test shall be 25% more than the final
test load proposed to be applied (As per Cl No 6.1.3.1).
7 Application of load shall be in increments of about 20% of safe load on the pile
(As per Cl No 6.1.2).
8 The Kent ledge supports shall be away from the pile center which is being
tested by 3 times the test pile diameter subject to a minimum distance of 2 m
from the pile center being tested (As per Cl No 6.1.3.b).
9 The datum bar supports shall be 3 times the test pile diameter subject to a
minimum distance of 1.5 m from the pile center being tested (As per Cl No
6.1.4).
10 The settlement shall be recorded with minimum of 2 dial gauges for single pile
and 4 dial gauges for groups (As per Cl No 6.1.4).
11 The dial gauge least-count shall be 0.01 mm (As per Cl No 6.1.4).
12 The safe load on single pile for the initial test shall be at least 2.5 times the
design load (As per Cl No 6.1.5).
13 The safe load on single pile for the initial test shall be such that the maximum
settlement does not exceed 12 mm (As per Cl No 6.1.5.1).

14 Maintain each incremental load till rate of displacement of the pile top is either

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Quality Plan: Pile Load Test
HCC N 40 17 10
0.1 mm in first 30 minutes or 0.2 mm in first hour or till 2 hours, whichever occur
first.

15 The load on the pile will be released stage by stage by releasing the jacks
steadily. Dial gauge readings will be recorded after release of each stage load
for rebound observations.

Test Data Details of data collected

1 Location Km 5.4 flyover
2 Design load on the pile to be tested (mt) 235.00
3 Factor for testing 2.50
4 Test load (mt) 587.50
5 Kenteledge increased load factor 1.25
6 Kenteledge load including platform etc (mt) 734.38
7 Diameter of pile (meter) 1.20
8 Concrete grade of pile M 35
9 Structure Abutement
10 Pile cut off level 92.478
11 Pile founding level 71.428
12 Reference codes for load test  
  IS: 2911 (Part-4): 1985 and  
  IS: 14593: 1998  
13 Method of nstallation of pile DMC

Preparation for initial pile load test:

1 Concrete cubes taken during concreting of pile be tested for 7 days & 28
days strength.
2 Compile concrete cube test results and ensure that concrete has gained the
desired strength.
3 Excavate around the pile up to bottom of pile head to be built. Concrete above
the pile head bottom level shall be dismantled and the pile head will be
constructed as per GFC drawing.
4 Place 2 Nos of 32 mm thick M. S. plates on top of surface of the pile in a neat
horizontal manner with CM 1:3 if required. Horizontal alignment of this plate
shall be checked with spirit level.
5 Arrangement will be made to support main girders on either side of the pile to
be tested. (Do not excavate the area of length & width of Kent ledge platform)
6 Arrangement will be made to support secondary girders on either side of the
pile to be tested.
7 Place 4 Nos of required capacity hydraulic jacks in position or 2Nos. of 400MT
cap Jacks.

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Quality Plan: Pile Load Test
HCC N 40 17 10

8 Place a common MS stool on jacks or a common plate.

9 Place main girders on MS stool/MS Plate with its center concentric with the pile
to be tested.
10 Place secondary girders on main girder(s) the group center concentric with the
main girder(s) & pile to be tested.
11 Place wooden thick planks spanning across secondary girders as platform.
12 Spread empty cement bags / thick polythene sheet in two layers on
wooden platform.
13 Place required nos of precast concrete blocks & empty cement jumbo bags
filled with local earth/sand as the case may be. The total number of block / bags
& the Kentledge platform weight should be equivalent to the required Kent ledge
load.
14 Place the four supports of datum bars/reference beam firmly in ground and
make suitable arrangements like brick pillars around these supports so that
ends of datum bars do not get disturbed.
15 Fix datum bar/reference beam against supports erected, fabricated out of
suitable MS rolled section(s)
16 Fix angles at suitable places to these reference beams/datum bars to fix dial
gauges. Dial gauges shall be arranged so that settlement can be measured
easily and as far as possible without any resetting of dial gauges.
16 Connect all 4 hydraulic jacks with suitable manifolds to a common hydraulic
pump or power pack. A properly calibrated pressure gauge is connected to the
hydraulic pump or power pack.
17 Load test be commenced when it is confirmed that concrete in pile has
achieved stipulated strength.

Conducting the load test:

1 Apply minimum seating load of at-least 30 Mt and release it before starting the
actual load test. This will ensure proper functioning of hydraulic jacks and of
load test Kent ledge / girder arrangement.
2 Fix 4 Nos of dial/strain gauges at proposed positions.
3 Apply the load to pile in equal increment at an increments of 20% of the design
load. The load increment shall be adjusted to the nearest least count of the
pressure gauge and ram area of hydraulic jacks.
4 Record the settlement with each increment of test load at an interval of 1, 2.25,
4, 6.25, 9, 16, 25, 30 minutes from the time of application of load and thereafter
at an interval of 30 minutes upto a minimum time interval of 2 hour or till the
time when rate of settlement gets reduced to a value of 0.1 mm in sandy soil or
0.02 mm in clayey soils or 2 hours whichever is greater.
Settlement observations in mm from the time of application of load shall be
recorded in a tabular Performa as enclosed.
5 In this manner observations are recorded for individual increment as per
format attached.

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Quality Plan: Pile Load Test
HCC N 40 17 10

6 The applied load is to be hold constant for a period of 24 hours. Total settlement
at end of application of test load is to be calculated and results of load test be
analyzed.
7 The test shall is stopped after reaching the test load or 12 mm settlement
whichever takes place earlier.
8 After completion of load test remove the dial gauges, hydraulic jacks with power
pack, and connections to datum bars etc. from the top of test pile. Remove the
load test arrangement i.e. Kent ledge load, ms girders, datum bars, pillars etc in
a symmetry

Presentation of test results:

1 Observations of applied load, time, and settlement of pile as observed at each

dial gauge shall be symmetrically and sequentially recorded in a proper tabular
form. From these 4 observations, average settlement of pile under each load
shall be calculated. Graph of load v/s settlement shall be prepared on basis of
these observations. From the results of load test, total settlement of pile, elastic
rebound of pile and net settlement of pile shall be calculated. From the results
of load v/s settlement curve, safe load on pile shall be evaluated.
2 The safe load on single pile for the load test shall be evaluated on basis of
following 2 criteria, clause 9.2.2 of IS 14593:1998:(AS per IS –2911 part 1/iv)
1/2 of the final load at which total displacement attains a value of 12 mm unless
otherwise required in a given case on the basis of performance requirement
1/3'rd of the ultimate failure load.

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HCC Management System
Quality Plan: Pile Load Test
HCC N 40 17 10

6.5 Construction Methodology: Routine Pile Load Test

Method statement for conducting routine vertical pile load test

Codal Requirements
Pile load test requirements as per IS : 2911 ( Part 4) - 1985
Routine pile load test: Requirements as per IS code listed below are taken in to
account.
1 Generally the load application and deflection observation will be made at the pile
top (As per Cl No 5.2).
2 The test shall be carried out as far as possible at cutoff level where-ever
practicable, otherwise suitable allowance shall be made in the interpretation of
the test results/test load if the test not carried out at cut-off level (As per Cl No
5.4).
3 The compression load is applied to the pile top by means of hydraulic jack(s)
against steel joists or suitable load frame capable of providing reaction and the
settlement is recorded by suitably positioned dial gauges. In this case Kentledge
load is placed
4 Preparation of pile head: The pile head shall be chipped off to natural horizontal
plane till sound concrete is met. The projecting reinforcement shall be cut-off or
bent suitably and the top finished smooth and leveled with plaster of Paris or
similar synthetic material where required. A bearing plate with a hole at the
center shall be placed on the head of the pile for the jacks to rest (As per
Cl No 6.1.1).
5 Reaction will be obtained from Kent ledge placed on a platform supported clear
of the test pile (As per Cl No 6.1.3).
6 The reaction to be made available for the test shall be 25% more than the final
test load proposed to be applied (As per Cl No 6.1.3.1).
7 Application of load shall be in increments of about 20% of safe load on the pile
(As per Cl No 6.1.2).
8 The Kent ledge supports shall be away from the pile center which is being tested
by 3 times the test pile diameter subject to a minimum distance of 2 m from the
pile center being tested (As per Cl No 6.1.3.b).
9 The datum bar supports shall be 3 times the test pile diameter subject to a
minimum distance of 1.5 m from the pile center being tested (As per Cl No 6.1.4).
10 The settlement shall be recorded with minimum of 2 dial gauges for single pile
and 4 dial gauges for groups (As per Cl No 6.1.4).
11 The dial gauge least-count shall be 0.01 mm (As per Cl No 6.1.4).
12 The safe load on single pile for the initial test shall be at least 1.5 times the
design load (As per Cl No 6.1.5)
13 The safe load on single pile for the routine test shall be such that the maximum
settlement does not exceed 12 mm (As per Cl No 6.1.5.1).
14 Maintain each incremental load till rate of displacement of the pile top is either
0.1 mm in first 30 minutes or 0.2 mm in first hour or till 2 hours, whichever occur
first.
15 The load on the pile will be released stage by stage by releasing the jacks
steadily. Dial gauge readings will be recorded after release of each stage load for
rebound observations.

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HCC Management System
Quality Plan: Pile Load Test
HCC N 40 17 10

Test Data Details of data collected

1 Location
2 Design load on the pile to be tested (mt)
3 Factor for testing 1.50
4 Test load (mt)
5 Kenteledge increased load factor 1.25
6 Kenteledge load including platform etc (mt)
7 Diameter of pile (meter) 1.20
8 Concrete grade of pile
9 Structure
10 Pile cut off level
11 Pile founding level
12 Reference codes for load test  
  IS: 2911 (Part-4): 1985 and  
  IS: 14593: 1998  
13 Method of nstallation of pile DMC

Preparation for routine pile load test:

1 Concrete cubes taken during concreting of pile be tested for 7 days & 28 days
strength.
2 Compile concrete cube test results and ensure that concrete has gained the
desired strength.
3 Excavate around the pile up to bottom of pile head to be built. Concrete above
the pile head bottom level shall be dismantled and the pile head will be
constructed as per GFC drawing.
4 Place 2 Nos of 25 mm thick M. S. plates on top of surface of the pile in a neat
horizontal manner with CM 1:3 if required. Horizontal alignment of this plate shall
be checked with spirit level.
5 Arrangement will be made to support main girders on either side of the pile to be
tested. (Do not excavate the area of length & width of Kent ledge platform).
6 Arrangement will be made to support secondary girders on either side of the pile
to be tested.
7 Place 4 Nos of required capacity of hydraulic jacks in position.
8 Place a common m s stool on jacks.
9 Place main girders on m. s. stool with its center concentric with the pile to be
tested.

10 Place secondary girders on main girder(s) the group center concentric with the
main girder(s) & pile to be tested.

11 Place wooden thick planks spanning across secondary girders as platform.

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Quality Plan: Pile Load Test
HCC N 40 17 10

12 Spread empty cement bags / thick polythene sheet in two layers on wooden
platform.
13 Place required number of precast concrete blocks and empty cement jumbo bags
filled with local earth/sand as the case may be. The total number of blocks/ bags
& the Kent ledge platform weight should be equivalent to the required Kent ledge
load.
14 Place the four supports of datum bars/reference beam firmly in ground and make
suitable arrangements like brick pillars around these supports so that ends of
datum bars do not get disturbed.
15 Fix datum bar/reference beam against supports erected, fabricated out of
suitable MS rolled section(s).
16 Fix angles at suitable places to these reference beams/datum bars to fix
strain/dial gauges. Strain gauges/dial gauges shall be arranged so that
settlement can be measured easily and as far as possible without any resetting of
dial gauges.
16 Connect all 4 hydraulic jacks with suitable manifolds to a common hydraulic
pump or power pack. A properly calibrated pressure gauge is connected to the
hydraulic pump or power pack.
17 Load test be commenced when it is confirmed that concrete in pile has achieved
stipulated strength.

Conducting the load test:

1 Apply minimum seating load of at-least 30 Mt and release it before starting the
actual load test. This will ensure proper functioning of hydraulic jacks and of load
test Kent ledge / girder arrangement.
2 Fix 4 Nos of dial/strain gauges at proposed positions.
3 Apply the load to pile in equal increment at an increments of 20% of the design
load. The load increment shall be adjusted to the nearest least count of the
pressure gauge and ram area of hydraulic jacks.
4 Record the settlement with each increment of test load at an interval of 1, 2.25, 4,
6.25, 9, 16, 25, 30 minutes from the time of application of load and thereafter at
an interval of 30 minutes upto a minimum time interval of 2 hour or till the time
when rate of settlement gets reduced to a value of 0.1 mm in sandy soil or 0.02
mm in clayey soils or 2 hours whichever is greater.
Settlement observations in mm from the time of application of load shall be
recorded in a tabular Performa as enclosed.
5 In this manner observations are recorded for individual increment shall be
recorded as per format attached.
6 The applied test load is to be hold constant for a period of 24 hours. Total
settlement at end of application is calculated and results of load test be analyzed.
7 The test shall be stopped after reaching the test load or 12 mm settlement
whichever takes place earlier.

8 After completion of load test remove the strain/dial gauges, hydraulic jacks with
power pack, and connections to datum bars etc. from the top of test pile. Remove
the load test arrangement i.e. Kent ledge load, ms girders, datum bars, pillars etc
in a symmetrical manner.

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HCC Management System
Quality Plan: Pile Load Test
HCC N 40 17 10

6.6 Inspection & Testing (Quality Control for Piling):

All the Inspection and Testing requirements for various activities in the
Piling shall be carried out as per relevant M.O.R.T.H Specifications &
Contract Technical Specifications/relevant Codes/Standards etc. are
identified and documented in the form of Inspection and Test Plans.

These Inspection and Test Plans shall consists of type of Inspection/ name
of the Test to be conducted for Product Realization, frequency of
inspection/ testing, acceptance criteria and category of Inspection as
mentioned in the legend of ITP.

Inspection and Test Plans shall be revised whenever there is any change
in methodology and specifications etc. Various Field and Laboratory Test
Formats referred in Inspection and Test Plans shall be maintained as per
the frequency mentioned in respective ITP’s for various activities.

Any Non-Conformity observed during Field Inspection and also during

Testing of Materials the same Non-Conformity shall be recorded in the
specified Format and necessary Corrective/Preventive actions shall be
initiated to prevent such things in future.

All Product Non-Conformities shall be observed, recorded,

corrective/preventive actions and closing of NCR’s shall be as per the
established documented procedure described in Project Quality
Management Plan.

Various Document/Records required to be maintained for the present

segment has been presented in the subsequent chapter.

7.0 OHS & ENV. MANAGEMENT PLAN:

The OH & Safety and Environmental Management Plan for the Project has
been prepared to meet the various Safety and Environmental Management
requirements as mentioned in Contract documents and also as per the
established OH & Safety and Environmental Management Systems and
Procedures of HCC.

8.0: ATTACHMENTS:
ITP for Inspection of the Pile Load Test: HCC T 40 17 25

9.0 DISTRIBUTION:
The document shall be distributed to all the concerned users.

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