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SIP- final - LinkedIn
Essar Steel is establishing a steel pellet plant in Paradeep, Orissa requiring pile foundations. The project involves constructing 539 piles of various diameters using the bored cast in situ method with direct mud circulation. Pile tests, including load tests and integrity tests, were conducted. A rate analysis was performed for a sample 500mm diameter pile considering costs of boring, reinforcement, concrete, testing, and contractor overhead and profit to determine the total cost per pile was approximately 78,000 Indian rupees. The status of pile construction was tracked monthly, with over 80% of the piles completed after 4 months.
SIP- final - LinkedIn
- 1. STUDY ON PILING (SUMMER INTERNSHIP - 2010 AS A PART OF COURSE CURRICULUM ) MOHAN PRADEEP YADLAPALLI NATIONAL INSTITUTE OF CONSTRUCTION MANAGEMENT & RESEARCH
- 2. CONTENTS • PROJECT BACKGROUND •FOUNDATION • AREA OF STUDY – PILE FOUNDATION • SALIENT FEATURES OF THE PILES IN THE SITE • BORING OF PILE SHAFT BY DMC METHOD • CONCRETING • PILE TESTS • RATE ANALYSIS • PILE STATUS IN BALLING BUILDING (P.P - 2) NICMAR HYDERABAD
- 3. PROJECT BACKGROUND Essar SteelOrissa Limited (ESOL) is establishing Steel Pellet Plant in Paradeep, Orissa to produce 12 MTPA Steel Pellets. Primary Objective:- Essar is planning to cater the captive demand of pellets in Essar Plant at Hazira (ESHL) using the pellets produced from the Paradeep plant using beneficiated slurry of 58-59 %Fe. Stage 1 Beneficiation plant of 2 x 4 MTPA Slurry Pipeline of 12 MTPA Pellet Plant 1 x 6 MTPA NICMAR HYDERABAD
- 4. FOUNDATION • Foundation isthe lowest part of a structure which provides a base for the superstructure. • This term includes the portion of the structure below the ground level as well as the arrangement of concrete block, piles, raft, grillage, etc. that are provided to transmit the loads on the structure including self weight of the footing itself to the soil below. NICMAR HYDERABAD
- 5. • Foundation –Purpose • It is used to transmit the load of the structure to the soil below. • To distribute the weight of the structure over large area so as to avoid over-loading of the soil beneath. • To load the substratum evenly & thus prevent unequal settlement. • To take the structure deep into the ground & thus increase its stability, preventing overturning. NICMAR HYDERABAD
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- 7. AREA OF STUDY– PILE FOUNDATION NICMAR HYDERABAD
- 8. Pile Foundations –Classification PILES Based on Materials Based on method of Installation Based on Use Based on mode of Transfer of load Steel Piles Concrete Piles Composite Piles Driven piles Driven Cast In Situ piles Bored Cast- In – Situ Piles Friction Piles End Bearing Piles Tension Piles Sheet Piles Compaction piles NICMAR HYDERABAD
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- 10. • Salient Featuresof piles in the site • Composition of pile : Concrete pile – M35 Grade • Method of installation : Bored cast in situ • Based on function : Friction Bearing pile • Method of Boring : Direct Mud Circulation (DMC) • Length of the pile : 23m below cut off level • Diameter of piles : 450mm, 500mm, 600mm • Total no. of piles : 539 • Sub contractor – Bhagaban Mohapatra Constructions & Engineers Pvt. Ltd, Bhubaneshwar NICMAR HYDERABAD
- 11. • Boring ofPile by DMC method • Main accessories are 1. Tripod 2. Winch Machine 3. Bailor 4. Chisel 5. DMC rods 6. Tremie pipes NICMAR HYDERABAD
- 12. Winch operator operatingwinch machine Tremie pipes Bailor Chisel NICMAR HYDERABAD
- 13. DMC rods DMC rods/Tremiepipe stopper Bentonite mixing tank Concrete hopper NICMAR HYDERABAD
- 14. Process of boringa pile shaft NICMAR HYDERABAD
- 15. • Steps tobe taken care while boring a pile • Ensure that the rigs are placed exactly on the pile point. • While lowering the reinforcement care should be taken to ensure the lap length to be 50D • Before washing, the density of bentonite to be checked by using hydrometer • The density of bentonite slurry should be in between 1.03 gm/ml to 1.10 gm/ml NICMAR HYDERABAD
- 16. • USE OFBENTONITE IN PILING • In order to keep the sides of the bore intact bentonite is used for drilling by suspending it in water to form a viscous material. • Bentonite suspensions begin to take on the characteristics of a gel • For these reasons it is a common component of drilling mud used to curtail drilling fluid invasion and stabilise the bore. • All bentonites have a capacity to exchange cations. • Suggestions • Mixing of bentonite should be done by Agitator rather than manual mixing. NICMAR HYDERABAD
- 17. • Bentonite Properties S.n o Typeof Test Method of Test Permissible limits (at 20°C) 1 Density Mud balance or Hydrometer 1.03 g/ml to 1.1 g/ml 2 Viscosity Marsh cone 30 sec to 90 sec 3 pH Value pH paper strips 9.5 to 12 4 10minute Strength Gel Shearometer or vane shear apparatus 1.4 to 10 N/m2 5 Liquid Limit Casagrande’s Apparatus Less than 300% & not more than 450% 6 Free Swell Consolidation Apparatus Shall be more than 540% NICMAR HYDERABAD
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- 19. • The volumeof the concrete hopper is 0.86Cum. • For 450mm diameter pile • Volume of concrete for 1m = 0.159m3 • For 500mm diameter pile • Volume of concrete for 1m = 0.196m3 • For 600mm diameter pile • Volume of concrete for 1m = 0.283m3 NICMAR HYDERABAD
- 20. • The lengthof one tremie pipe is 1.6m • For 600mm diameter volume for 1m = 0.283m3 • Therefore for 1.6m volume of concrete = 0.453m3 • But the volume of concrete in the hopper is 0.86m3 • So at time one tremie pipe can be removed from the pile shaft of 600mm diameter. NICMAR HYDERABAD
- 21. • For 500mmdiameter pile • Volume of concrete for 1m = 0.196m3 • Therefore for 1.6m volume of concrete = 0.3136m3 • Volume of concrete hopper = 0.86m3 • So at a time two tremie pipes can be removed from the pile shaft. NICMAR HYDERABAD
- 22. Pile Load Test NICMARHYDERABAD
- 23. Types of PileLoad Test LOAD TEST DESTRUCTIVE TEST NON DESTRUCTIVE (NDT) VERTICAL LOAD TEST LATERAL LOAD TEST PULL OUT LOAD TEST LOW STRAIN HIGH STRAIN SONIC LOGGINGPILE INTEGRITY NICMAR HYDERABAD
- 24. • Vertical LoadTest NICMAR HYDERABAD
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- 27. • Pull outTest NICMAR HYDERABAD
- 28. • Table forPull out Test S. no Date Time Increment load in tons Cumulative Dial gauge readings Average A B NICMAR HYDERABAD
- 29. • Pile IntegrityTest • Concept NICMAR HYDERABAD
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- 31. Typical PIT plot– For good pile Typical PIT record for a doubtful pile NICMAR HYDERABAD
- 32. Rate analysis forpiles • Rate analysis for 500mm diameter pile • Assumptions considered are Concrete Grade M – 35 Bore diameter 500mm Bore depth 23m EPIL’s Scope Concrete & Reinforcement are provided free of cost NICMAR HYDERABAD
- 33. Sub contractors cost– A S.No Items Units Total Qty Rate per unit (Given in WO) Total cost 1 Shifting of rigs and Boring cost (below cut off level) Metre 23m 800/m 18400 2 Reinforcement cost (Cutting, bending and placing in bore) MT 0.4951 7000 3466 3 Pouring Concretie – M35 M 23m 260 5980 4 Static compressive No 1 1160 1160 5 Routine static compressive No 1 1080 1080 6 Lateral load test No 1 350 350 Total Cost 30436 NICMAR HYDERABAD
- 34. Material cost -B S.N o Description Quantity Cost Total Cost 1 Concrete – M35 Grade 4.665 Cum Rs 4250/Cum Rs 19826/- 2 Reinforcement 495.094 Kg Rs 30000/ton Rs 14852/- Total Material Cost Rs 34678/- Total Cost (A+B) Rs 65114/- Over heads (10% T.C) Rs 6511/- Profit (10% T.C) Rs 6511/- Grand Total Rs 78136/- NICMAR HYDERABAD
- 35. PILE STATUS S. NO.PERIOD TOTAL NO. OF PILES COMPLETED NO. OF PILES REMAINING 1 FEB 539 60 479 2 MAR 479 162 317 3 APR 317 115 202 4 MAY 202 87 115 5 JUNE 115 66 49 NICMAR HYDERABAD
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Editor's Notes
- #2 Anand George Mohammed Sameer Shrikant Kokate