fqp pile

GUJARAT ENERGY TRANSMISSION CORPORATION LTD.

Sardar Patel Vidyut Bhavan, Race Course, Vadodara: 390 007

FQP PILE CONSTRUCTION

GETCO/C/FQP– PILE/R0 DT. 15/03/2008


STANDARD FIELD QUALITY PLAN FOR PILE FOUNDATION WORKS

SECTION : Foundation Materials

Sl. No.

Component/Operation &

Description of Test

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with basis

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& acceptance norm

Testing Agency

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Check

1. CHECKING OF

FOUNDATION MATERIALS

A) CEMENT

i) Fitness One sample IS:456, IS:4031, IS:269, Manufacturer/ Review of B ii) Compressive Strength per lot of IS:8112, IS:12269 / GETCO manufacturers iii) Initial & final setting time 100 MT or part IS:1489 & GETCO approved lab test certificates iv) Soundness thereof from specification. (MTCs) and

v) Heat of Hydration for low each source laboratory test heat cement (Not Applicable for MTC's and results by for OPC & PPC) one sample per GETCO

lot of 200 MT or part thereof from each source for site testing.

vi) Chemical Composition of One sample per IS:456, IS:4031, IS:269 Manufacturer Review of

B Cement lot of 100 MT IS:8112, IS:12269 manufacturers or part thereof IS:1489 & GETCO test certificates from each specification. by GETCO source for MTCs.

B) COARSE AGGREGATES

i) Determination of Particle One sample IS:383, IS:2386 GETCO Each source to be B size (Sieve Analysis) per lot of and GETCO approved lab GETCO.

ii) Flakiness Index 200 cubic meter specification. Review and iii) Crushing Value or part thereof acceptance of iv) Specific Gravity* from each test result by v) Bulk Density* source for each GETCO vi) Absorption Value* size vii) Moisture Content* viii) Soundness of Aggregate** ix) Presence of deleterious

materials

* Applicable to design mix concretes only. ** Applicable to concrete work subject to frost action. PAGE-1



Section : Foundation Materials

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C. FINE AGGREGATE

i) Gradation : Determination One sample IS:383, IS;4031, IS:2386, GETCO Each source to B

of Particle size per lot of 200 IS:236, IS:456 and approved lab be approved by (Sieve Analysis) cubic meter or GETCO specification GETCO.

ii) Specificy Gravity and density* part thereof Review and iii) Moisture content* from each acceptance of iv) Absorption Value* source test result by v) Bulking* GETCO vi) Silt Content Test vii) Presence of deleterious

materials

D) WATER

i) Cleanliness 100% IS:456, IS:3205 and Contractor Each source C (Visual Check) GETCO specification. to be approved

The water used for mixing by GETCO concrete shall be fresh, clean and free from oil, acids and alkalies, organic materials, or other deleterious materials

ii) Suitablity of water for One sample per GETCO specificaiton Contractor Certification

B RCC work source Potable water is generally regarding suitably for concreting. potability of

water by contractor and approval by GETCO

RCC work

iii) P.H Value One sample per IS : 456, IS : 3025 and GETCO Approval by B source GETCO specification approved lab GETCO Min. 6

Contactor Max. 8

* Applicable to design mix concretes only. ** Applicable to concrete work subject to frost action. PAGE-2




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Description of Test

Sampling Plan

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E. REINFORCEMENT STEEL

i) Identication & size Random IS:432, IS:1139, IS:1786 & Contractor Approval by B GETCO specification GETCO

ii) Chemical Analysis Test One sample per IS:432, IS:1139, IS:1786 & Manufacturer Review of B

heat GETCO specification manufacturers test certifcates by GETCO

iii) Tensile Test One sample per IS:432, IS:1139, IS:1786 & Manufacturer Review of B iv) Yield Stress/ proof stress lot of 40 MT GETCO specification manufacturers v) Percentage Elongation or part thereof test certifcates

for each size as well as lab by of steel GETCO confirming to IS:1139 and 5 MT or part thereof for HDS wire for each size of steel as per IS:432. For steel as per IS:1786 under 10 mm 1 sample for each 25 MT or part thereof. 10mm - 16 mm 1 sample for each 35 MT or part thereof. Over 16 mm 1 sample for each 45 MT or prt thereof.

vi) Bend/ Rebend Test One sample per IS:432, IS:1139, IS:1786 Manufacturers Review of B

lot of 20 MT or GETCO specification GETCO manufacturers part thereof for Approved lab test certificates

as well as lab PAGE-3




Sl. No.


Description of Test

Sampling Plan

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Testing Agency

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Check

each size of test result by steel as per GETCO IS:432/ IS:1139. For steel as per IS:1786 under 10mm. 1 sample for each 25 MT or part thereof. 10 mm - 16mm. 1sample for each 35 MT or part thereof. Over 16 mm. 1 sample for each 45 MT or part thereof.

vii) Reverse Bend Test or HDS wire One sample per IS:432 GETCO Manufacturer/ Review of B

lot of 5 MT specification GETCO manufacturers or part thereof approved lab. test certificates for each size. as well as lab

test result by GETCO.

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Section : Foundation


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Description of Test

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2. FOUNDATION

A) EARTHWORK

(EXCAVATION)

i) Initial ground level, depth of Each pipe GETCO approved Joint Approval by B xcavation, final bed level. drawings/ specification Inspection by GETCO

GETCO & Contractor

ii) Dimension of Excavated PIT Each pile GETCO approved Joint Approval by B

drawings/specification Inspection by GETCO GETCO & Contractor

iii) Side slopes during excavation Each pile As per Site working Joint Approval by C

final bed level condition Inspection by GETCO GETCO & Contractor

iv) Nature of soil/rock Each pile GETCO specification -do- -do- B

B. STUB & TEMPLATE

(Applicable only if it is in the scope of pile foundation contractor)

i) Identification & Assembly 100% on GETCO approved Joint Approval/ B

each location drawings/specifications Inspection by clearance GETCO & GETCO contractor

ii) Template level, width & 100% on GETCO approved Joint Approval/ B

diagonal each location drawings/specifications Inspection clearance GETCO

by GETCO and contractor

iii) Tightening of all bolts & 100% on GETCO approved Joint Approval/ C

nuts of template, stub & cleats each location drawings/specifications Inspection by clearance by GETCO & by GETCO contractor

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GUJARAT ENERGY TRANSMISSION CORPORATION LTD. Section : FOUNDATION


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Description of Test

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iv) Stub setting 100% on GETCO approved Joint Approval/ B

each location drawings/specifications Inspection by clearance by GETCO b y GETCO and contractor

C) P.C.C. Padding For all locations IS:456 and GETCO Joint Approval by B

approved foundation Inspection by GETCO drawings & specification GETCO

and contractor D) STAGING FOR RAISED

CHIMNEY

i) Check durability, strength & 100% GETCO Joint Approval by B soundness of staging, joints specification Inspection by GETCO adequacy of its joints & GETCO specific levels and contractor

E) SHUTTERING (Formwork)

i) Check for materials, 100% GETCO Joint Approval by C

breakage or damage specification/approved Inspection by GETCO drawings GETCO

and contractor

ii) Check for plumb alignment, 100% before GETCO Joint Approval by B parallelism, squareness and casting specification/approved Inspection by GETCO equidistance from stub. drawings GETCO

and contractor

iii) Dimensional check 100% before GETCO Joint Approval by B casting specification/approved Inspection by GETCO

drawings GETCO and contractor

iv) Check for level & height 100% before GETCO Joint Approval by B

casting specification/approved Inspection by GETCO drawings GETCO

and contractor v) Check for rigidity of frame/ 100% GETCO Joint Approval by C

tightness specification/approved Inspection by GETCO drawings GETCO

and contractor PAGE-6




Sl. No.

Component/Operation & Description of Test

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Check

vi) Cleaning and oiling 100% GETCO Joint Approval by C

approved specification / Inspection by GETCO drawings GETCO and contractor

vii) Diagonal bracing if required 100% GETCO Joint Approval by C

as per drawings /site approved specification / Inspection by GETCO conditions drawings GETCO

and contractor

viii) Checking of joints to avoid 100% GETCO Joint Approval by C undue loss of cement specification/approved Inspection by GETCO slurry drawings GETCO

and contractor

F. PLACEMENT OF REINFORCEMENT STEEL

i) Check the steel bars for 100% IS:456 and GETCO Joint Approval by C

rust, cracks, surface flaws, Specification/approved Inspection by GETCO laminate etc. (Visual check) drawings GETCO

and contractor

ii) Check as per the bar bending For all IS:456 and GETCO Joint Approval by B schedule before placement locations Specification/approved Inspection by GETCO of concrete drawings GETCO

and contractor

iii) Check cutting tolerance for For all IS:456 and GETCO Joint Approval by B bars as per check list/ locations Specification/approved Inspection by GETCO drawings. drawings GETCO Check whether all the bent and contractor bars and lap lengths are as per approved bar bending schedule

iv) Check whether all joints 100% IS:456 and GETCO Joint Approval by C

& crossing of bars are tied Specification/approved Inspection by GETCO properly with right guage drawings GETCO & annealed wire as per and contractor specification

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Ref. Document

& acceptance norm

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Check

v) Check for proper cover 100% IS:456 and GETCO Joint Approval by C

distance, spacing of bars, Specification/approved Inspection by GETCO spacers & chairs after the drawings GETCO reinforcement cage has been and contractor put inside the formwork.

vi) Check whether lapping of 100% IS:456 and GETCO Joint Approval by B

bars are tied properly with Specification/approved Inspection by GETCO right guage and annealed drawings GETCO wire as per specification. and contractor

G. PILE FOUNDATION

(additional Tests)

i) Checking of centre line of Each pile group IS:2911 & GETCO Joint Checklist to be B pile group approved pile foundation Inspection by prepared and

drawings/specification. GETCO signed jointly and contractor

ii) Check pile location Each pile IS:2911 & GETCO Joint Checklist to be B

approved pile foundation Inspection by prepared and drawings/specification. GETCO signed jointly

and contractor

iii) Temporary casing tube & Each pile IS:2911 & GETCO Joint Verticality of the B permanent liner also check approved pile foundation Inspection by tube to be thickness of liner material drawings/specification. GETCO checked (if applicable) and contractor

iv) Bentonite slurry Each pile IS:2911 & GETCO Joint Records to be B

(if applicable) approved pile foundation Inspection by kept by drawings/specification. GETCO GETCO

and contractor for specific gravity of slurry

v) Pile depth, level, size and Each pile IS:2911 & GETCO Joint Approval by A

alignment approved pile foundation Inspection by GETCO drawings/specification. GETCO

and contractor PAGE-8




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vi) Chipping of pile head Each pile IS:2911 & GETCO Joint Before concreting B approved pile foundation Inspection by pile cap, pile head drawings/specification. GETCO to be chipped off

and contractor for concreting

vii) Standard Penetration Test As per IS:2911 & GETCO Joint Records to be B GETCO approved pile foundation Inspection by kept by BOQ/ drawings/specification. GETCO GETCO. specification and contractor Approval by

GETCO

viii) Pile load testing As per IS:2911 & GETCO Joint Records to be B GETCO approved pile foundation Inspection by kept by BOQ/ drawings/specification. GETCO GETCO. specification and contractor Approval by

GETCO ix) Anchor bolts if applicable

a) Level,, centre to centre 100% on each GETCO Joint Checklist to be B

distance of bolts location approved pile foundation Inspection by prepared and drawings/specification. GETCO signed jointly

and contractor

b) Visual check for galvanising 100% on each GETCO Joint Checklist to be B location approved pile foundation Inspection by prepared and

drawings/specification. GETCO signed jointly and contractor

3) CONCRETING

A) BATCHING, MIXING & 100% IS:456 and GETCO Joint Approval by B PLACING OF CONRETE approved drawings and Inspection by GETCO AND COMPACTING specifications. GETCO

and contractor

B) FIXING OF CHIMNEY 100% IS:456 and GETCO Joint Approval by C COLUMN approved drawings and Inspection by GETCO Check for Width/length, specifications. GETCO squareness, parallelism & and contractor equidistance from stub

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Sl. No.


Description of Test

Sampling Plan

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C) PLACING CONCRETE, 100% IS:456 and GETCO Joint Min. gap between C

POKING AND approved drawings and Inspection by boxes and reinfor- COMPACTING specification. GETCO cement bars

and contractor should be maintained. Approval by GETCO

D) CONCRETE TESTING

i) Slump Test One sample per IS:456, IS:516, IS:1199 Contractor Approval by B

location and GETCO GETCO specification.

ii) Check for quantities for 100% on all IS:456, IS:516, IS:1199 Contractor Checklist to be B

cement, fine aggregate, locations and GETCO prepared and coarse aggregate and water specification. signed jointly while batching

E) CHECK FINISHING, 100% IS:456, IS:516, IS:1199 Contractor Approval by B

DIMENSIONAL and GETCO GETCO CONFORMITY AND specification WORKMANSHIP BEFORE & AFTER BOX REMOVAL

F) BACKFILLING 100% GETCO Contractor Approval by C i) Check for thickness of specification GETCO

layer & watering ii) Check for compaction/

ramming

G) COPING 100% on all GETCO Contractor Approval by B location Specification GETCO

H) CURING 100% on all GETCO Contractor Approval by C

location Specification GETCO

I) EARTHING 100% IS:5613 and GETCO Contractor Approval by B (Pipe or counter poise type) Specification GETCO

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J) CONCRETE CUBE

TESTING

i) Compressive Strength a) One sample IS:1199, IS:456, IS:516 GETCO Approval by A for each and GETCO approved lab GETCO locations (One Specification Cubes must be sample consists tested within a of min. 3 test week after 28 cubes for 28 days curing days strength) period and test b) For pile results should be foundation one approved before sample for tower erection. each pile.

ii) Compressive Strength for One sample for IS:1199, IS:456, IS:516 GETCO - DO - A

concrete of pile cap, beams, every 20 Cum and GETCO approved lab chimney etc. of concrete or Specification

part thereof for each days of concreting

PAGE-11



Section : GENERAL GUIDELINES FOR IMPLEMENTATION

1. Details of categories of check codes A, B & C including accepting and deviation dispositioning authorities are indicated at Annexure-I.

2. GETCO specification shall mean GETCO technical specification, approved drawings/data sheets and A/T provisions applicable for the specific contract.

3. Acceptance criteria and permissible limits for certain tests are indicated at Annexure-II. For balance tests, site to verify the same with respect to GETCO specification, relevant Indian Standards and/or prevalent code of practice.

4. It is clarified that the tests indicated at column 2 of this FQP i.e. against column "Component operation & Description

of Test," are only generally required to be conducted. However, GETCO reserves the right to carry-out any additional tests at any stage if the situation so warrants.

5. GETCO site representative shall witness all the tests conducted by the contractor as mentioned in this FQP.

However, in case of tests conducted in the GETCO approved lab, it is preferred to witness the tests in the lab itself, if possible.

6. Head of Construction Division shall approve testing laboratory before accepting the test results from the lab.

7. Head of Construction Division shall approve the sources for cement, coarse aggregate, fine aggregate & water before actual utilisation.

8. All the testing & measuring equipments used by the contractor for testing are required to be calibrated. A copy

of valid calibration report shall be retained by GETCO as records.

9. Classification of foundations shall be approved by GETCO based on the Joint Inspection Report & soil investigation reports.

10. Curing of concrete work should be continued for a minimum period of 10 days.

11. Zone-IV fine aggregate shall not be used for concreting work. PAGE-12



Section : GENERAL GUIDELINES FOR IMPLEMENTATION

12. CEMENT

12.1 In case supply of cement is in the scope of the contractor, the same shall be procured from sources approved by GETCO site and got tested at site on sample basis for specified acceptance tests as specified in this FQP at a reputed Third Party Lab approved by GETCO site.

12.2 The samples of cement for site testing shall be taken within three weeks of the delivery and all the tests shall be

commenced within one week of sampling.

13. REINFORCEMENT STEEL

13.1 In case supply of reinforcement steel is in the scope of the contractor, the same shall be procured from the main producers i.e. SAIL, TISCO, IISCO or Rashtriya Ispat Nigam or the rerollers approved by main producers. The reinforcement steel shall be got tested at site on sample basis for specified acceptance tests as specified in this FQP at a reputed Third Party Lab approved by GETCO site.

13.2 The results of the testing of cement and reinforcement steel referred to in 13.1 and 14.1 above shall be got approved

from GETCO site before cement and reinforcement steel are put to use. However, in exceptional cases due to exigencies of work., GETCO site may authorise the contractor to use Cement and Reinforcement Steel even before the test results are received. However, in all such cases, if the test results subsequently received are found to be not complying with the specified acceptance criteria, the contractor shall have to dismantle and recast all such foundations cast with such non-conforming materials at his own cost. Confirmation to this effect shall be obtained from the contractor by the Project authorities beforehand in all such cases.

PAGE-13

ANNEXURE - I

ACCEPTING AND DEVIATION DISPOSITIONG AUTHORITIES FOR DIFFERENT CATEGORIES OF

CHECKS AS ENVISAGED IN FIELD QUALITY PLAN

C ATEGORY TYPE OF 100% COUNTER CHECK/ ACCEPTING AUTHORITY, DEVIATION

CHECK CHECKING/ SURVEILLANCE IF TEST RESULTS DISPOSITIONING

WITNESSING BY CHECK BY ARE WITHIN AUTHORITY

PERMISSIBLE LIMITS

A' CRITICAL CONSTRUCTION CONSTRUCTION EE CONST. DN. SE(CIVIL)

S/DN. DN.

B' MAJOR CONSTRUCTION CONSTRUCTION EE CONST. DN. SE(CIVIL)

S/DN. DN.

C' MINOR CONTRACTO R S CONSTRUCTION CONSTRUCTION DN. EE CONST. DN.

RESENTATIVE S/DN.

PAGE-14

ANNEXURE - II

ACCEPTANCE CRITERIA AND PERMISSIBLE LIMITS FOR

FOUNDATION MATERIALS & CONCRETE A) CEMENT : Description of the 33 Grade OPC 43 Grade PPC as per Low Heat tests as per IS:269 cement as IS:1489 Cement

per IS:8112

(i) Fineness (Min.) 225 m2/kg 225 m2/kg 300 m2/kg 225 m2/kg

(i) Compressive Strength (Min.) 72 + 1 hours 160 kgf/cm2 23 MPa 16 MPa 100 kgf/cm2

168 + 2 hours 220 kgf/cm2 33 MPa 22 MPa 160 kgf/cm2

672 + 4 hours - 43 MPa 33 MPa 350 kgf/cm2

(ii) Initial Setting Time (Minimum) 30 Minutes 30 Minutes 30 Minutes 30 Minutes

(iv) Final Setting Time

(Maximum) 600 Minutes 600 Minutes 600 Minutes 600 Minutes

(v) Soundness Maximu m Maximu m Maximu m Maximu m (Le chatelier Method) 10mm 10mm 10mm 10mm

expansion expansion expansion expansion

(vi) Heat of hydration --- - Max. 65 cal/

(Max.) gm for 7 days & max. 75 cal/gm for 28 days

(vi) Chemical Composition As per IS As per IS As per IS As per IS

B) C OARSE AGGREGATE :

(i) Sieve Analysis

PERCENTAGE PASSING FOR GRADED

IS SIEVE DESIGNATION AGGREGATE OF NOMINAL SIZE

40 mm 20 mm

40 mm 95 to 100 100

20 mm 30 to 70 95 to 100

10 mm 10 to 35 25 to 55

4.75 mm 0 to 5 0 to 10

PAGE 1 OF 3 PAGE-15

ANNEXURE - II

(i) Flakiness Index — Not to exceed 25%.

(ii) Crushing Value — Not to exceed 45%.

(iv) Soundness of aggregate — Loss of weight after 5 cycle not to exceed 12% when tested with

applicable for concrete works Sodium sulphate and 18% when tested with magnesium sulphate. subject to froast action

(v) Deleterious material — Not to exceed 5% of the weight of aggregate.

(C) FINE AGGREGATE

(i) Sieve Analysis — Shall confirm to Zone I, Zone II or Zone III. IS Sieve Percentage Passing for

designation Grading Grading Grading Grading Zone-I Zone-II Zone-III Zone-IV

10 mm 100 100 100 100

4.75 mm 90-100 90-100 90-100 90-100

2.36 mm 60-95 75-100 85-100 95-100

1.18 mm 30-70 55-90 75-100 90-100

600 Micron 15-34 35-59 60-79 80-100

300 Micron 5-20 8-30 12-40 15-50

150 Micron 0-10 0-10 0-10 0-15

(i) For guidance of adjusting the quantity in mix of concrete, the following table may be used.

Moisture Content % Bulking % by volume

2 15

3 20

4 25

5 30

(ii) Silt content Test : Shall not exceed 8%.

(iv) Deleterious Materials : Total deleterious material shall not be more than 5% by weight.

(D) REINFORCEMENT STEEL : As per relevant Indian Standards

PAGE 2 OF 3

PAGE-16

ANNEXURE - II

(E) CONCRETE CUBE TEST

For nominal (volumetric) concrete mixes, compressive strength for 1:1½:3 (cement : sand : Coarse aggregate)

concrete shall be 265 kg/cm2 for 28 days and for 1:2:4 nominal mix, it shall be 210kg/cm2.

(F) ACCEPTANCE CRITERIA BASED ON 28 DAYS COMPRESSIVE STRENGTH FOR NOMINAL MIX

CONCRETE

a) The average of the strength of three specimen be accepted as the compressive strength of the concrete,

provided the strength of any individual cube shall neither be less than 70% nor higher than 130%

of the specified strength.

b) If the actual average strength of accepted sample exceeds specified strength by more than 30%,

the Engineer-in-charge, if he so desires, may further investigate the matter. However, if the strength

of any individual cube exceeds more than 30% of specified strength, it will be restricted to 30%

only for computation of strength.

c) If the actual average strength of accepted sample is equal to or higher than specified strength upto

30%, then strength of the concrete shall be considered in order and the concrete shall be accepted

at ful rates.

d) If the actual average strength of accepted sample is less than specified strength but not less than

70% of the specified strength, the concrete may be accepted at reduced rate at the discretion of

Engineer-in-Charge.

e) If the actual average strength of accepted sample is less than 70% of specified strength, the Engineer-

in-Charge shall reject the defective portion of work represented by sample and nothing shall be paid

for the rejected work. Remedial measures necessary to retain the structure shall be taken at the

risk and cost of contractor. If, however, the Engineer-in-Charge so desires, he may order additional

tests to be carried out to ascertain if the structure can be retained. All the charges in connection

with these additional tests shall be borne by the Contractor.

(G) ACCEPTANCE CRITERIA FOR DESIGN MIX CONCRETE SHALL BE AS PER IS:456

PAGE 3 OF 3 PAGE-17

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