MS 01 - Bored Piles

CHINA HARBOUR ENGINEERING COMPANY
REPRESENTATIVE OFFICE IN SRI LANKA

COLOMBO PORT CITY DEVELOPMENT Document No.
PROJECT INFRASTRUCTURE AND CHEC/CPCDP
LANDSCAPE WORKS (PHASE 1) / P-V /MS-01
PACKAGE V - PUMP STATIONS & STORAGE
TANKS
Title: Method Statement for Construction of Pages 17
Board Pile Revision 0
Method Statement
For
Construction of Board Pile
0 14-03-2018 Initial Issue Dinesh

Prepared By Reviewed By
Reviewed By Approved By
Rev. Date Status Technical Technical
DPM Project Manager
Engineer Manager
Colombo Port City Development Project
Package V – Pump Stations & Storage Tanks
Table of Content
1.0 Introduction................................................................................................................................. 3
2.0 Scope of Method Statement ........................................................................................................ 3
3.0 Documents to be referred with This Method Statement ............................................................. 4
4.0 Responsibilities ........................................................................................................................... 4
5.0 Resources .................................................................................................................................... 4
5.1 Manpower:- .................................................................................................................................. 4

5.2 Machinery, Plants and Equipment & Tools:- ............................................................................... 4
5.3 Material ................................................................................................................................... 5
6.0 Installation Procedure ................................................................................................................. 5
6.1 Setting Up At the Pile Location ............................................................................................. 6

6.2 Execution Tolerances of cast-in-situ bored pile .................................................................... 7
6.3 Fabrication and Installation of Steel Casing.......................................................................... 7
6.4 Excavation Procedure ............................................................................................................ 7
6.5 Fabrication and Installation of Reinforcement Cage ........................................................... 11
6.6 Concrete Placing .................................................................................................................. 11
6.7 Piling Records ..................................................................................................................... 13
6.8 Cutting of Pile Heads .......................................................................................................... 13
6.9 Piling Problems and Risks during Execution Works ........................................................... 13
7.0 Quality Assurance and Control Measures................................................................................. 15
8.0 Health Safety and Environmental Monitoring .......................................................................... 16
9.0 Appendix A – Risk Assessment ................................................................................................ 18
10.0 Appendix B – Inspection and Test Plan for Piling work .......................................................... 21
11.0 Appendix C – QA/QC Record Sheets ...................................................................................... 23
12.0 Appendix D – Sequence of Pile Construction .......................................................................... 24
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China Harbour Engineering Company
1.0 Introduction
Port City Colombo is a brand new city development built as an extension of the Central
Business District of Sri Lanka’s vibrant commercial capital, Colombo. Spanning 269
hectares of reclaimed land from the sea, Port City Colombo will be South Asia’s premiere
residential, retail and business destination, offering unmatched planned city living along the
warm waters of the Indian Ocean. The development will comprise of 5 different precincts
including the Financial District, Central Park Living, Island Living, The Marina and the
International Island.
PHASE 1
PHASE 2
Figure 1: Colombo Port City Development Layout
Package V – Pumping Stations & Storage Tanks under Infrastructure and Landscape Works
(Phase 1) Project of Colombo Port City Development Project, is to build Infrastructure and
Utility Buildings.
2.0 Scope of Method Statement

The main purpose of this Method Statement is to outline the procedure for the construction
of Concrete Board Piles at Colombo Port City Development project, Sri Lanka, in
compliance with all the required specifications, standards, and proper construction
procedures.
This method statement covers the details of materials, equipment, procedure and relevant
documents related to the work for the Concrete Board Piles in Buildings Listed in following
Table, including quality control and safety precautions to be implemented at site as follows;
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SUMMARY OF PILE DETAILS

DARWING No. PILE DIA No. OF CUT OFF TOE
ITEM BUILDING
(CPCDP-ATK-) TYPE (mm) PILES LEVEL (m) LEVEL (m)
1 ELECTRICAL BUILDING UPW-GA-DR-S-1008 P1 900 27 -0.05 -21.8
SEWAGE PUMPING STATION - 2
2 UFW-GA-DR-S-1250 P1 600 8 -3.683 -14.183
(SPS - 2) (WET WELL)
P1 900 6 NA -21.05
SEWAGE PUMPING STATION - 1 P2 900 9 NA -21.05
3 UFW-GA-DR-S-1210
(SPS-1) P3 900 20 NA -21.05
P4 900 25 NA -21.05
POTABLE AND FIRE WATER P1 900 24 NA -20.1
4 PUMPING STATION & UPW-GA-DR-S-1000 P2 900 193 NA -20.1
ESERVOIR PH-1 P3 900 3 NA -20.1
IRRIGATION PUMPING STATION P1 900 19 -3.45 -23.00
5 UIWGA-DR-S-1100A
AND RESERVOIR PH - 1 P2 900 36 -2.75 -23.00
220kV SUBSTATION -
6 HEL-SS-DR-C-3039 P1 600 105 NA NA
R1 PHASE 1
Scope could be slightly changed due to unforeseen site conditions.
3.0 Documents to be referred with This Method Statement

The documents to be referenced are appended as followings;
Contract Particular Specification
Relevant Contract Drawings
Project Safety Plan
4.0 Responsibilities
Detailed organizational responsibilities and accountabilities of key personal; Project
Manager, Construction manager, Engineering staff, Supervisory staff, etc…; whose scope
of works defined in ‘Occupational Health & Safety Plan’ shall be responsible for referred
construction activities under this project. Further, details of records in respect of carrying
out the works are outlined in the Inspection and Test Plan for Board Piling Works, which is
enclosed in Appendix A.
5.0 Resources
Whole Work would be categorised to specified sub tasks as follows to assign resources
effectively. The capacity/size of the below tools and equipment shall be judged in
accordance with site conditions, requirements, and availability at the time of execution.
5.1 Manpower:-
 QAQC Manager - 01  Skilled Workers - As required
 Site Engineer - 01  Labours - As required
5.2 Machinery, Plants and Equipment & Tools:-

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 Pile Rig - 02  Generator - 03

 50T Crawler Crane - 01  Water/slurry pump - 06
 Excavator - 01  De-sander - 01
 Dump Trucks - 04  Bentonite mixing plant - 01
 Concrete Mixture Trucks - 04  Metal Tape 50m/5m - 01
 Bar Cutting machine - 01  Survey Instruments - As required
 Bar Bending Machine - 01  Trimi pipes & Funnel - As required
5.3 Material
 Bentonite
 Concrete
 Reinforcement
 Metal casing
6.0 Installation Procedure

Preparation for installation of cast in-situ board piles can be summarise as follows.
a. Technical director is responsible to ask relevant people to jointly review the drawing,
understand the design idea and study corresponding documents.
b. The constructors should be familiar with the geological situation of the project.
c. The technical director formulates and adds the technical schemes and measures of the
construction in accordance with the features of the project.
d. Make technical disclosure and record to all the constructors before the project starts.
e. Prepare the recording sheet and appliances for labor protection for the construction.
f. Make preparation for the concrete fitting.
g. The construction site is smooth and flat. Road: know the entry road and arrange the
temporary road. Electricity: connect the power supply; Water: connect the water source
nearby.
h. Make a plan of the places for construction materials, slurry storage, arrangement of
temporary facilities and ground plan for the construction site.
i. Carry out the tests for training to special type of work.
j. Maintenance equipment and spare parts.
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Surveying & Levelling
Mixing
Casing Setting-out
Fabricating Steel Bentonite
Cage
Drilling
Reinforcement Pile Drilling

Cage Record Rock Socketing Record
Inspection
Cleaning Base
OK
Inspection
OK
Insert Steel Cage
Recycling Bentonite
nd
Cleaning 2 Time
Concrete Placing
Placing Concrete Record
Pile Construction Process Flow Diagram
6.1 Setting Up At the Pile Location

Prior to setting up of the drilling rig at the pile location all the existing utilities, obstacle and
any underground services (telephone lines, electric cables, drainage system, concrete parts,
fuel line etc.) are to be removed by the Main Contractor.
The pile location shall be set out in accordance with the approved Bored Pile Foundation
layout plan. All setting out reference points and related contractor drawings shall also be
referred. Setting out of pile location, ground level and ancillary control points shall be
checked and confirmed with the Engineer prior commencement of piling works. Once the
first section of pile casing is erected, the setting out with all ancillary control points and
vertically of the pile will be re-checked with the Engineer before piling works proceeds
further.
At least three ancillary control points offset from the pile should be established in its vicinity
for facilitating the execution of setting out and survey check related to the piling works. The
control points, which are established in the form of marking on wooden peg with concrete
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surround set on ground, should be guarded and regularly check for their accuracy during the
piling works.
6.2 Execution Tolerances of cast-in-situ bored pile

Piles will be cast within the tolerances given under the specifications or as mentioned below.
a. Pile centres shall be located within a tolerance of ± 75 mm of the locations shown in
the Contract Documents unless otherwise specified.
b. Vertical piles shall be plumb within 2%.
c. The final installed and after-shrinkage pile cut-off elevations shall be within a
tolerance of± 25 mm of the elevations shown in the Contract Documents.
6.3 Fabrication and Installation of Steel Casing

A temporary guide casing of internal diameter 600 / 900 mm according to the approved pile
layout drawing shall be installed to the pile center as previously marked on the working
platform. The casing shall be lowered to the ground with the help of turntable of the rotary
unit or with vibrator. Engineer’s approval will be sought prior to the use of vibrator. The
primary function of this casing is to support the loose soil close to ground level and enable
a sufficient head of slurry to be maintained during the works.
The temporary casing used will be free from any distortion and shall be uniform cross-
section throughout the length. The length of the casing will be approx. 6.0 meters, depending
on the cut-off level. The temporary steel casing will be driven in the pile center with a
minimum overlap of 50 cm below cut-off level. The top of the temporary casing should be
300mm over the ground.
Two numbers reference steel pins will be installed equidistant from the pile point. The
distance of the steel casing is measured from the reference pins and adjustment made so that
the reference pins are equidistant from the steel casing. The verticality of the steel casing is
checked with a spirit level in two perpendicular directions. Further the verticality can be
controlled by an inbuilt inclinometer fixed to the boom of machine. The verticality of the
drilled borehole will be recorded in the pile record sheet.
In the event that the location or verticality of a casing is out of tolerances as a result of
driving the casing should be vertically adjusted by use of an excavator. Alternatively the
casing will be backfilled, pulled out and re-driven if required. Otherwise, the contractor
would proposed alternative corrective method for the Engineer’s approval.
6.4 Excavation Procedure

After installation of the temporary guide casing, the borehole will be drilled using
appropriate drilling tools and the verticality of the drilled borehole shall be ensured to its full
depth. The Slurry Support System relies on the presence of a thixotropic mud-water mix to
maintain the stability of the sidewalls in a drilled borehole. Further the positive hydrostatic
pressure developed by the slurry also avoids ground water penetration in the drilled pile
shaft.
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Bentonite comply with Specification DFCP-4 drilling fluid materials will be used for the
slurry. Control tests will be performed on the bentonite suspension as per specifications. The
drilling fluid is prepared in mixers and kept in tanks for storage and hydration purpose for a
minimum period of 4 hours. After fixing of guide casing, the borehole will be drilled down
to its final level by means of bucket and auger.
The drilled borehole will be filled with bentonite slurry and the slurry level maintained at
working platform level at all times. Care shall be taken to maintain the slurry 1.50 m above
the ground water table. In the event of a rapid loss of drilling fluid, the borehole will be
backfilled without delay using the drilled material from heap near the boreholes. The
Engineer’s approval must be obtain before resuming boring in that location.
Drilling penetration rate and soil cuttings will be kept under observation to notice any change
in the sub-soil conditions from previous soil investigation. The record of strata will be made
during excavation of the pile and recorded on the pile record sheet.
Any noticeable variation shall be brought to the attention of the Engineer. The depth of
borehole shall be measured using an end weight measuring tape and to be recorded in the
pile record sheet. The verticality of the borehole will be guaranteed in two ways:
1. A hand held sprit level of 1.0 m length shall be used to check the verticality of mast and
thereby that of the casing at two directions of 90° to one another at intervals.
2. Some machines are equipped with in built inclinometers fixed to the boom of the
machine, which can monitor the drilling operations to keep the verticality within the
specified limits. The maximum out of verticality allowed as per specification is 12.5%
of the pile diameter or 1.5% of pile length whichever is smaller.
Excavate shafts for closely spaced drilled piles (<3 x diameter), only after adjacent drilled
piles are filled with concrete and allowed to set. (Normally after 12.0 hours)
The drilling will be continued till the bed rock is encountered. When the bore has reached
the bedrock level, Engineer will be informed for inspection of that, which combines with the
drawing and the actual condition of the stratum.
Measurement of depth are usually taken by using a tape measure or a marked chain. The
measuring instrument should be checked for accuracy prior to commencement, and
periodically thereafter.
Drilling in rock for Rock Socketing shall continue after determining the actual founding
level after examining the excavated material/rock samples. The authorized representatives
of both parties should agree the founding level. Written agreement is required to certify that
founding has been achieved.
6.4.1 Recycling of Bentonite
The process of cleaning the bentonite suspension from sands and silts to keep its quality
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within the allowable limits is called recycling. The bentonite quality will be verified by
checking the sample taken from the top and bottom of the borehole. If excessive sand
contents are noticed in the bentonite sample then fresh bentonite sample be pumped through
the sealed tremie pipe. The tremie pipe shall extend to the bottom of the borehole. The
sample from the borehole shall be checked for its compliance with specification
requirements.
Recycling will be performed after excavation has been completed and before the bentonite
slurry has been replaced by concrete. The suspension from the borehole will be pumped to
the desanding plant during concreting. After being cleaned in the plant, the bentonite will be
pumped to the bentonite tank for further use. For cleaning operation of the bottom of the
borehole cleaning bucket will be used.
Recycling or circulation method of bentonite shall be used to clean the bottom of bore hole.
Circulation will continue until debris suspended in the circulating water deposited in the
slurry channel is negligible, and ensure that heavily contaminated support fluid, which could
impair the free flow of concrete from the tremie pipe, has not accumulated in the bottom of
the hole.
BENTONITE SUSPENSION
We propose a bentonite concentration of 5%. Bentonite slurry will have the following
properties.
Supply to: Sample From:
Pile Borehole Pile Borehole
Density : < 1.10 g/cm3 < 1.15 g/cm3
Plastic Viscosity : < 10 CP < 20 CP
Viscosity : 30 to 40 seconds < 60 seconds
Ph value : 9.5 to 10.80 9.5 to 11.70
Sand Cement : < 1% < 3%
Shear Strength : 4 – 25 N/m2 4 – 25 N/m2
(10 Min.) Gel strength
Fluid loss : < 30 mil. < 40 mil
In order to achieve a concentration of 5%, 50 kg of bentonite will be added to approximately

1000 liters of water.
Mixing will take place in a mixing plant designed for this purpose. The bentonite slurry shall
rest in a tank for at least 4 hours to allow proper hydration.
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Figure 02: The schematic layout of the bentonite mixing arrangement.
6.4.2 Testing Frequency of Bentonite
The bentonite slurry shall be checked for specification compliance at suitable intervals. One
sample shall be taken from the top of the borehole and another sample from the bottom to
check compliance with the specification requirements. We propose the following sequence
of bentonite slurry testing for each pile.
1. Sample from the tank to the borehole

2. The sample during drilling of the borehole.
3. The sample prior to concreting (one sample from the top & one sample from the bottom).
The bentonite powder is supplied with the test certificate from independent agency. However
occasional testing can be carried out on powder sample if required by Engineer.
Figure 03: Funnel Viscometer
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6.5 Fabrication and Installation of Reinforcement Cage

Subsequent to the completion of the pile drilling, the borehole depth will be checked and
verified versus the depth given on daily piling sequence and pile data. Only after borehole
depth check can the cage be lowered into the borehole. A reference site datum level will be
given to ensure the correct positioning of the cage with respect to cut off level.
The reinforcement for the piles shall be according to the requirement of the specification and
the design of the pile. The reinforcement shall confirm to the mill certificate approved by
the Consultant. Reinforcement shall be free of mud, oil, other surface contamination and
excessive corrosion at time of concrete placement.
The reinforcement cages will be fabricated up to 12m length and rebar shall be lapped when
the requirement is more than 12m length, maintaining minimum lap length as specified. Full
length reinforcement cage fixed with helical shall be lowered to the borehole. The cage shall
be arrested in position when it reaches 2.0m above casing top level. Suitable crossbars shall
be provided to keep the cage hanging in position. The reinforcement segments for 600/900
mm diameter piles will be connected together using the couplers fixed to the end staggered
at a minimum clear distance of 70 cm c/c to receive the second segment pile cage. The helical
reinforcement / rings shall be fixed in place after connecting the two segments of
reinforcement for piles. The reinforcement shall be lowered to correct location and cage top
level and secured from movement using hangers and arresters.
A lifting platform shall be used for the lifting of the steel cage without distortion. The steel
cages will be lifted with the help of main crane (50 ton capacity) and an auxiliary crane
(service crane of 35 ton capacity) shall be used to lift the lifting platform along with the steel
cage. The lifting platform shall be released once the cage reaches 90°.
Precast concrete circular spacers with diameter150 mm will be provided at bottom of

reinforcing cage to ensure cover to the toe of cage. The first layer of spacers will be placed
at 20 cm below cut off level. The spacing between spacers should be within 3 to 4 m and
should terminate only 30 cm above pile toe. Final details of reinforcement cage in relation
with levels of casting and pile shaft will be recorded in the form of Steel Cage Records as
enclosed in Appendix C:
6.6 Concrete Placing

The pile concrete is delivered to site by means of truck mixers. The concrete will be received
on site and the delivery ticket will be checked for correctness in accordance with the
approved mix design. The quality checking and testing of the concrete (slump test) to be
carried out by laboratory engineer.
The concrete will be checked for the slump and temperature. Cubes will then be taken as per
specification. The concrete will be allowed to the site only after concrete quality has been
found in compliance with specifications. The concreting of the drilled piles should be
completed on the same date of completion of borehole. If there is an elapsed time of more
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than 6 hours between the completion of borehole & cage installation, cleaning bucket shall
be carried out to clean the borehole.
The concrete shall be placed by tremie tube method, the tremie size will not be less than 150
mm. The tremie pipe is made of sections with sufficient length to reach the toe of the pile
and the joints provided with seals. The tremie pipe will be inserted at the center of the pile
and the joints provided with seals. The concrete from the concrete mixer shall be delivered
directly to the pile through the funnel connected to the tremie pipe of 150 mm diameter. The
tremie pipe will be lifted 100 mm above pile toe level prior to concreting. A Styrofoam ball
having a diameter slightly larger than the diameter of the tremie pipe shall be placed at the
mouth of the tremie pipe to avoid contact of concrete with bentonite slurry in the tremie pipe.
While concreting the length of the tremie pipe will be shortened if necessary but the tremie
pipe will be maintained full time into the concrete of at least 2.0m length. During the
concreting the level of the concrete within the pile will be monitored by use of an end weight
tape measure.
A sufficient quantity of concrete will be maintained within the tremie to ensure that the
pressure from it exceeds that from the external water pressure. The concrete will be brought
up to minimum 1.30 m above cut-off level and overflowing of concrete above casing top
level will be carried out to ensure good quality and contamination free concrete at pile cut-
off level. The concrete above the cut –off level will be chipped by the Main Contractor. The
bentonite slurry displaced by the concrete will be pumped back to the desander or tank.
Figure 04: Sequence of Board Pile Construction
The quantity of poured concrete volume will be measured & it will be compared with the
theoretical quantity. The theoretical volume, actual volume & % over break will be recorded
in the pile record sheet and plotted on a graph sheet for the submission to the main contractor.
6.6.1 Disposal of Drilling Spoil
Spoil from drilling of boreholes shall be removed from site to designated disposal area
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provided by the local authorities and will be carried out by the Main Contractor.
6.7 Piling Records

Piling records, provided by the foremen to be checked by the site in charge before final
submittal to Engineer on the Bored Pile Record Sheet. The record include the following data:
• Pile number
• Pile date of completion
• Pile diameter
• Working platform level
• Pile design cut-off level
• Pile toe level
• Concrete top level
• Reinforcement cage details (length and bars diameters)
• Pile concrete length
• Pile bored length
• Ground water table
• Bentonite tests, if used
• Drilling time and piling rig in use
• Concreting time, concrete details and ticket no.
• Concrete cube Nos.
• Theoretical volume of concrete
• Actual volume of concrete
• Over break in percentage
• Drilling fluid
Any unexpected drilling condition encountered will be noted briefly in the records and
brought to the attention of Engineer immediately.
6.8 Cutting of Pile Heads

The main contractor shall cut off all undesirable concrete min. up to C.O.L. of the finished
piles to carry out integrity testing on piles.
6.9 Piling Problems and Risks during Execution Works

The following possible risks or problems are identified with the activities involved with pile
execution.
6.9.1 Survey – Out of Positioning of the Pile
The pile position shall be cross-checked by the Engineer, Contractor and Sub Contractor
before the installation of pile. If any out of position of the pile (more than the allowable
tolerance) has been noticed after the concreting of the pile, it shall be brought to the notice
of the Engineer through N.C.R.
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6.9.2 Drilling – Loss of Drilling Tools in Bore Holes
During the drilling operation there are remote chances for the loss of drilling tools in the
bore holes due to the high torque applied to cut the soil/rock. In order to avoid the same
periodic checking shall be carried out on drilling tools. If any drilling tool has been lost in
the bore hole then the issue to be brought to the notice of Engineer immediately and all the
activities around that pile shall be stopped. A method statement for the excavation of drilling
tools will be submitted to the Engineer for approval and further action.
6.9.3 Bentonite Drilling – Collapse of Borehole
The collapse of borehole may happen if the drilling is carried out through the unstable strata
and poor quality bentonite slurry has been used for the drillings. This can be avoided by
checking the bentonite slurry properties during drilling operations. In the case of collapse of
borehole & rapid loss of drilling fluid, the borehole will be back filled without delay using
drilled material from the heap, near the borehole.
The Engineer’s approval will be obtained before resuming boring in that location.
6.9.4 Reinforcement – Loss of Reinforcement Segment during Installation
During the installation of piling reinforcement cage support beams and jacks shall be
provided to hang the reinforcement segment in the bore hole in addition to the safety sling
from the service crane. The coupler connection between the reinforcement segments shall
be double verified by the Foreman before removing the support system for the bottom
segment. Any loss of reinforcement segment shall be notified immediately to the Engineer.
6.9.5 Concreting – Clogging of Tremie Pipe
The tremie pipe is made of segments of 1.5 m for diameter 150 mm and approximately 2.0
m length for diameter 250 mm. the connection between the pipes to be checked before
lowering to the bore hole. Rubber ‘O’ ring and trimie grease shall be provided to make the
joints watertight. The concrete shall be checked for the workability before permitting to the
site.
Low slump concrete will clog in the tremie pipe. The tremie pipe shall be removed
immediately from the bore hole on clogging of pipe and Engineer’s instruction shall be
followed for the further action.
6.9.6 Bursting of Bentonite Hoses / Lines
The bentonite slurry will be delivered to the pile bore by using a combination of flexible
hoses and steel pipes, connected with couplers.
As far as possible, hoses and pipes shall be placed below surface respectively shall be
covered by a rigid protection, such as casing etc. to avoid damage due to site traffic. In case
a hose / pipe bursts it shall be replaced immediately by a proper one and the spilled bentonite
shall be removed in order to clean the area.
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7.0 Quality Assurance and Control Measures

QA/QC will be adapted as a principal management tool and a number of standard manuals
and procedures are available for project execution. Other project specific documents will be
prepared during the project preparation.
7.1 The reinforcing steel, concrete and electrode at site should have certificates of
approval or warranty.
7.2 Temporary Bench Mark and setting-out points of the site should be re-surveyed.
When the survey points rechecked, the error should be within the scope allowed.
7.3 Check the position of the steel casing. It should be buried correctly and stably. The
space between the casing and wall should be fully filled with clay. The deviation
between the centre of the protective pipe and centre of pile should not be more than
50mm.
The drilling bit should be checked whether it is worn when it is going to be drilling.
It should be mended in time to ensure the quality of the construction.
7.4 After the bore hole is checked & qualified, the concrete should be poured at once.
7.5 Clean the hole: during the process, the thickness of the sediment at the bottom of the
borehole and sand-in-slurry volume should be usually measured. Once they meet the
requirements, the borehole cleaning should be stopped to prevent the wall from
collapsing.
7.6 The production and fixing of the steel reinforcement cage
1) The prefabricated steel reinforcement cage should be checked step by step with the
focus that the main steel, stiffened reinforcement stirrup, spiral reinforcement stirrup
spacing, the length of thickness area, the building of the main steels, the welding
quality of steel crossing points and anchorage length of the prefabricated steel
reinforcement cage should accord with the design requirements.
2) Check the position of the spacer blocks of the steel reinforcement cage. Spacer
blocks should be placed evenly to not only prevent the cage from collide with the
borehole wall but also ensure that the concrete covering is even and the right position
of the cage in the pile body.
3) The lifting of the steel reinforcement cage should be at two points: The cage axes
should be coincided with each other. It should remain vertical when it is lifted into
the hole and slowly put to the hole. It should not collide with the borehole wall.
Check the reasons once it is resisted. It is prohibited to be swayed or forcefully put
down. The height of the steel reinforcement cage should accord with the design
requirements.
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7.7 The pouring of concrete underwater
1) The pressure water test should be given to the tremie pipe before it is used to ensure
that it is not leaking and penetrating. It should be used after check and accepted for
approval. The connecting point of the joints should be fastened with seal ring and
buckle.
2) When the concrete is pouring, water stop plug should be put in location. The concrete
volume poured for the first time should be measured according to the borehole
diameter to ensure that the burial depth should be more than 1.3m. During the
pouring process, the concrete height should be measured when the pipe is removed
to control the number of the removed pipes so that the pipe will not be pulled out and
the concrete will not mixed with mud.
3) Check the real concrete pouring volume of each pile. The height of the pouring pile
top should be higher than that in the design, which should not be less than 0.5m to
ensure the concrete strength of the pile top.
4) During the concrete pouring process, the slump constant of the concrete should be
checked as the sample and taken from the concrete at the site.
5) Contractor shall make a record of each pile, which will be checked irregularly.
7.8 Check whether the site administrative staff is present and the special types of work,
for instance, whether the electric welder, electrician and machinist have a proficiency
certificate before they can take up the job.
7.9 The procedures of hole drilling, borehole cleaning, the fixing of the steel
reinforcement cage and concrete pouring should be considered as the focus and
supervised according to the quality control standards.
7.10 The measuring instruments at site, such as theodolite, level gauge and steel tape,
should have quality certification issued by technical supervision organizations. The
drilling machine and electric welder, etc. should have the quality certificate. Measure
whether the diameter of the drilling bit is in accordance with the requirement.
8.0 Health Safety and Environmental Monitoring

The safety of the work shall be clearly informed for every shift and the safety responsibility
shall be clearly stated for each work and position. The safety work record shall be well kept
and it shall be checked at least once a week including the condition and the correct use of
the safety equipment, the traffic safety along construction areas and the condition of the
safety devices for each machine and equipment.
Follow the principle of “Production with Safety” and push the safety worker to pay attention
to the safety for each step of work.
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 Standing under the lifting arm of the crane is prohibited; walking under the lifting
bucket is not allowed and the crane shall not be operated at random.
 A guard fence shall be built around the slurry tank.
 Binding the steel bar shall be separately placed in the fabricating workshop.
 All the constructors should wear the safety helmet, safety shoes and others. The
workers of special work type should wear the special protective appliance.
 The electric equipment shall be connected with earth device and there must be
protection measures. The switches in the control box shall be orderly installed.
 Regularly check and maintain the bolts connect the bottom of the drilling machine,
and install the safety device.
 A security man at the entrance to the construction site shall be employed.
 Try to avoid the concreting in the heavy rain.
 After the protective pipes are buried and the concrete is poured, the pile pit should
be protected to prevent people or objects from dropping.
 It should be mended once there is any trouble. It cannot operate with any fault and
rule violation. The machinery and traffic accidents are prohibited.
 The operator of the machines (or the driver) should join professional training and
acquire the operation performance of the machine. They can take up the job only
after they get the certificate approved by the professional management department.
 The operators of the machine and the directors should strictly abide by technical
safety operation specification. They should concentrate to work carefully. They
should not be absent without leave and not allowed to drunk driving. The
professional electrician should take the job after he gets the certificate. The
electrician has the right to refuse to accept the work which violates the security
standards. The safety officer is entitled to stop the behaviour which violates the
security standards. The violation of directing and working is not allowed.
17
9.0 Appendix A – Risk Assessment

Method
Name of the activity: Bored Piles Statement CHEC/CPCDP/P-V/ MS-01
Reference Rev (0)
No.
1. Safety Engineer
Date of Assessment: 14th March 2018 Name of Risk Assessor(s) 2. Site Engineer
3. Technical Manager
Revision Number: 00 Revision Date: 00 No of Pages: 03
Original Risk Residual Risk
Classification Classification
Likelihood
Consequenc
Risk Level
Likelihood
es
Consequenc
Risk Level
Activity and hazard Proposed Mitigation Measures Mitigation Control Unit
Item
(Consider the Worst Credible (What Precautions you are going to (Who is responsible for
Scenarios) implement?) doing this?)
Injuries due to not wearing All workers should wear prescribe 01 Safety Engineer
1. 04 04 16 04 04 Site Engineer
personal protective equipment. personal protective equipment. (Safety
helmet, safety shoes, gloves, high Sub-contractor’s
visibility jackets,) Supervisor
Operating heavy machine Only trained and licensed operators in Safety Engineer
2. 03 04 12 01 05 05 Site Engineer
(Crane) for lifting loads. operation. Daily Pre-Operational checks
by Operators. Sub-contractor’s
Supervisor
Equipment’s are provided with side
mirrors and reverse beepers.
Maintaining distance to excavated trench
banks and machine placing position.
Poor visibility in working area Adequate lighting shall be provided not 01 Safety Engineer
3. 03 05 15 05 05 Site Engineer
during night work less than 15 Lux. Illuminated warning
signs shall be placed. All the personal Sub-contractor’s
18
working in the area shall wear high Supervisor

visibility jackets.
Fall injury due to poor Providing safe access to site and safe Safety Engineer
4. 02 03 06 0 03 03 Site Engineer
housekeeping and working area work platform/area to work comfortably
disturbance. (slips and trips) during rebar, formwork and concreting. 1 Sub-contractor’s
Supervisor
No permission to store unnecessary
materials on the platform.
Human failures / Unsafe acts 1. Daily toolbox talks shall be conducted Safety Engineer
5. 04 04 16 0 04 04 Site Engineer
which may lead to accidents for all workmen by safety officers to
educate them on hazards and preventive 1 Sub-contractor’s
actions. Supervisor
2. Regular inspections by safety Officers
Operating under adverse Obtain daily weather forecast and plan 01 Safety Engineer
6. 04 04 16 04 04 Site Engineer
weather conditions works accordingly. Stop all works in
adverse weather conditions and evacuate Sub-contractor’s
workmen to a safe location. Supervisor
Contingency management plan in place
and communicated to all through toolbox
talks and induction training.
Lack of first aid facilities. Adequate number of trained First aiders Safety Engineer
7. 03 04 12 01 04 04 Site Engineer
and First aid boxes shall be in placed
according to directive given in OHSP-
CSCTP at the vicinity of works.
Stand-by vehicle shall be in place at the
vicinity of works in case of occupational
injury or medical emergency. Stretcher
shall be available close to works.
First aid procedures and emergency
19
contact numbers shall be communicated

to all workmen and prominently
displayed in the vicinity of work
Fall in to unfinished boreholes The piling area shall be marked with Construction manager
8. 4 3 12 1 3 3 Site Engineer
warning tapes / Warning signs in order
Safety Engineer
prevent accidents
Workmen exhausted due to 1. Provide 8 hrs. Work schedules. Two Construction manager
exposure to direct sunlight and shift operation.
windy conditions for extended Safety Engineer
working hours 2. Provide adequate drinking water
available at site
3. provide shelters in demarcated rest
areas
Fuel Leaks – Environment Catch trays shall be installed underneath Safety Engineer
Hazard the engine, Fuel supply tank and gear
Sub-contractor’s
box. Catch trays shall be 130% of sump Supervisor
capacity.
Contact with wet concrete may Wear suitable protective clothing, gloves Safety Engineer
cause irritation, dermatitis or and eye/face protection.
severe alkali burns Sub-contractor’s
Supervisor
20
10.0 Appendix B – Inspection and Test Plan for Piling work

Legends Used: CHEC = China Harbour Engineering Company Ltd.) PO = Procurement Officer SA = Site Agent TS = Technical Specification
SC = Sub-contract QE = Quality Engineer H = Hold Point GS = General Specification
PS = Conditions of Particular Application ENG = Engineer W = Witness Point SE/F = Site Engineer / Foreman
Item Description of works Applicable Inspection(s) Acceptance Frequency of The verifying Level of witness Responsibility
No. item on which the specification and/or Criteria inspection record(s) is required for for signature(s)
Inspection and/or and clause Test(s) required and/or testing inspection and/or on verifying
Testing Activity shall be reference testing record(s)
carried out SC CHEC ENG
Construction In accordance with RSCF +Interim
01 Setting-out and levelling Setting-out data Each Pile H H Survey + ENG
Drawing acceptable tolerance Survey Records
Casing driving / Board Pile
Relevant TS Casing position & In accordance with
02 Excavation down to Each Pile Excavation H W SE/F
sections verticality check set-out location
Rock Level record
Specific gravity,
Relevant TS In accordance with Instructed by the Excavation
03 Slurry test Viscosity, Sand W W ME + ENG
sections specification Engineer Records
content
Board pile founding
Visual Inspection In accordance with RICF + Pile
level Construction
04 of material from Engineer Each Pile Excavation H H SE/F + ENG
Inspection of material at Drawing
bottom of pile acceptance record
proposed founding level
In accordance with RICF + R/F
Construction
05 Fabrication of Steel cage Visual Inspection specification & Each Pile check list / Bar H H SE/F + ENG
Drawing
Drawing schedule
Cleanliness of Pile Correct depth of RICF +
Construction
06 Pre concrete check toe / top level of pile tor / steel cage Each Pile Concreting H H SE/F + ENG
Drawing
rebar installation record
21
satisfactory
1. Slump Test
RICF +
Concrete Sampling & In accordance each batch In accordance with
07 Each Pile Concreting W H SE/F + ENG
Testing with TS 2. Cube Test 7 mix designs
record
nos. per pile
1. Level check
Relevant TS & 2. Visual In accordance with
08 Pile cut-off level Construction inspection of tolerance given in Each Pile RSCF H H Survey + ENG
Drawing concrete TS
soundness
Relevant In accordance In accordance with
09 As-built survey Construction with survey tolerance given in Each Pile RSCF W H Survey + ENG
Drawing procedure TS
10
11
12
22
11.0 Appendix C – QA/QC Record Sheets
Board Pile Excavation Record
Rebar Cage Record
Board Pile Concreting Record
23
COLOMBO PORT CITY DEVELOPMENT PROJECT
INFRASTRUCTURE AND LANDSCAPE WORKS (PHASE 1)
PACKAGE V - PUMP STATIONS & STORAGE TANKS
BORED PILE EXCAVATION RECORD
AM Day:
Weather
PM Page No.:
Location: Commencement Date:
Pile No.: Completion Date:
Ground Level: Casing Length:
Casing Top Level Casing Internal Dia:
Proposed Founding Level
Excavation Level Material
Date Time Activity Remarks
Top Bottom Length Soil Sample Bentonite
Initial Setting-out: E: N: Deviation:

Finished Casing Position: E: N:
Prepaired By: CHEC Checked By: CHEC Verified By:
Name: Name: Name:
Position: Position: Position:
COLOMBO PORT CITY DEVELOPMENT PROJECT
REINFORCEMENT CAGE RECORD
Date:
Casing Length: Casing Top Level:
Proposed Top Level of Steel Cage Existing Ground Level:
Actual Top Level of Steel Cage
Pile Cut-off Level

Lap Length:
Total length of Steel Cage:
Proposed Rock Level

Actual Rock Level
Proposed Founding Level

Actual Founding Level
Reinforcement Cage Check List:

Bar Dia. (mm): Date:
Main Reinforcement: No. of Bars: Pile No.:
Lap Length (mm): Location:
Bar Dia. (mm): Total length:
Hoop Reinforcement: No. of Hoops: Lap Length:
Lap Length (mm): Recorded By:
Spacer Fixed:
Comments:
Checked By: CHEC Verified By:

Name: Name:
Position: Position:
COLOMBO PORT CITY DEVELOPMENT PROJECT Existing Ground Level:
BORED PILE CONCRETING RECORD
Location: Date: Actual Concrete Level:
Pile No.: Tremie Pipe Length: m
Existing Ground Level: m Casing Length: m
Cut-off Level: m Casing Top Level m Cut-off Level
Actual Founding Level: m Concrete Grade:
Anticipated Concrete Volume: m3 Finished Surface at: m
Time Depth of Concrete Tremie Pipe Concrete Volume (m3)
Truck Docket Quantity
Slump Theoritical Actual Actual Bottom Length in
No.: No.: In Out (m3) Individual Cumilative
(mm) (m) (m) Level Level Concrete
Bed Rock Level
Socket Length
Founding Level
Proposed:
Actual Concrete Volume: m3 Actual:
Prepaired By: CHEC Checked By: CHEC Verified By:

Name: Name: Name: PILE CONSTRUCTION
Position: Position: Position: RECORD
12.0 Appendix D – Sequence of Pile Construction

POTABLE AND FIRE WATER PUMPING STATION & ESERVOIR PH-1
IRRIGATION PUMPING STATION AND RESERVOIR PH – 1
SEWAGE PUMPING STATION - 1 (SPS-1)
SEWAGE PUMPING STATION - 2 (SPS - 2) (WET WELL)
ELECTRICAL BUILDING
24
POTABLE AND FIRE WATER PUMPING STATION & RESERVOIR
B
150 (TYP.) 1007
25 mm THK. EXPANSION GAP
150
P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2
5000 (TYP)
500
1000 MIN. CLEAR BETWEEN PILES
ZONE 2 ZONE 4 ZONE 6 ZONE 8

500
500 15000
150
COMPARTMENT-1
29300
(92000 x 29300)
P1 P1 P1 P1
P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2
300 (TYP)
P1 P1 P1 P1
P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2
-3.40
P1 P1 P1 P1 1625
5000
-1.94
500
2430
25000
A P2
1007
P1 P1 P1 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2
P1
2430
ZONE 1
5000
P1 P1 P1 P1 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2
COMPARTMENT-2
(92000 x 29300)
ZONE 9
150
P1 P1 P1 P1
150 2200 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2
ZONE 3 ZONE 5
500
ZONE 7
29300
-1.94
ZONE 2' C
1007
C
1007
P3 150
150
500 92000 500
B
1007
IRRIGATION PUMPING STATION & RESERVOIR
1 2 3 4 5 6 7 8 9 10 11
3550 5200 5250 5250 5200 5200 5200 5200 5200 5225 3375
B 350
C
350 1103 1103 375
TYP.
TYP.
375
375
TYP.
TYP. TYP.
A
P1 P1 P1 P1 P2 P2 P2 P2 P2 P2 P2
5225
P1 P1
-3.10 -2.40
1675
1675
P1 P1 P2 P2 P2 P2 P2 P2 P2
B
IRRIGATION RESERVOIR
-4.10
3285
PUMPING COMPARTMENT-1
ZONE 01 ZONE 02 ZONE 03

STATION
C
A A
1940
1103 P1 P1 P1 P1 P2 P2 P2 P2 P2 P2 P2 1103
D
1940
-3.10
E
1785
P1 P1 -2.40
P1
P1
F
1500
P2 P2 P2 P2 P2 P2 P2
G
350 UP
RESERVOIR
2250
TYP.
P1 P1 P1 -3.85
COMPARTMENT-2
H
TYP.
350
400
B
2975
TYP.
1103 P2 P2 P2 P2 P2 P2 P2 P2
J 150
TYP.
TYP.
375
(TYP.)
C
150
1103
1 PILE LAYOUT PLAN

SCALE 1: 100
PUMPING STATION - 1 (SPS-1)
E F G H J B K
A B C D 1216
3725 5350 5350 7425 6600 4250 4250 5600 8000

150
150 (TYP)
P3 P3 P3 P3 (TYP) P1 P1 P1
1
(TYP)
150
150
4200
(TYP)
(TYP)
P1
150
P3 P3 P3 P1 P1
2' 150 P4 P4
1100
P4 P4 P4 P3
(TYP)
2
RCW6
A
3500
1216
P4 P4 P4 P3 P3 P3 P3
P4 P4
3
P2 P2 P2
ZONE 1
(TYP)
150
A
P4 P4 P4 P4 P4
ZONE 2 ZONE 3
7100
1216
P4 P4 P4 P4 P4 P3 P3 P3 P2 P2
P3 P2
4
4800
RCW6
P4 P4 P4 P4 P4 P3 P3 P3 P3 P2 P2 P2
5
RCW5 RCW5
(TYP)
6600 4250 4250 1600 4000 4000 4000

150
H' J'
B
1216
1 PILE LAYOUT PLAN

SCALE 1: 100
ELECTRICAL BUILDING
B
1012
150
(TYP) 150
P1 P1 350 (TYP)
(TYP)
(TYP)
150
(TYP)
350
P1 P1 P1
PC1 PC1
4550
P1
2
P1
(TYP)
350
P1 P1 P1
5020
3
A
1012 P1 P1 P1 P1 P1 P1
PC1
5660
4
P1 P1 P1
P1 P1
2500
P1
5
2000
(TYP)
350
PC1 P1 P1 P1 P1 P1
(TYP.)
350
350
(TYP) B
1012

MS 01 - Bored Piles

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MS 01 - Bored Piles

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CHINA HARBOUR ENGINEERING COMPANY

REPRESENTATIVE OFFICE IN SRI LANKA

0 14-03-2018 Initial Issue Dinesh

2.0 Scope of Method Statement ........................................................................................................ 3

3.0 Documents to be referred with This Method Statement ............................................................. 4

4.0 Responsibilities ........................................................................................................................... 4

5.0 Resources .................................................................................................................................... 4

5.1 Manpower:- .................................................................................................................................. 4

6.1 Setting Up At the Pile Location ............................................................................................. 6

8.0 Health Safety and Environmental Monitoring .......................................................................... 16

9.0 Appendix A – Risk Assessment ................................................................................................ 18

11.0 Appendix C – QA/QC Record Sheets ...................................................................................... 23

12.0 Appendix D – Sequence of Pile Construction .......................................................................... 24

Figure 1: Colombo Port City Development Layout

2.0 Scope of Method Statement

SUMMARY OF PILE DETAILS

Scope could be slightly changed due to unforeseen site conditions.

3.0 Documents to be referred with This Method Statement

5.2 Machinery, Plants and Equipment & Tools:-

 Pile Rig - 02  Generator - 03

6.0 Installation Procedure

f. Make preparation for the concrete fitting.

i. Carry out the tests for training to special type of work.

j. Maintenance equipment and spare parts.

Surveying & Levelling

Reinforcement Pile Drilling

Pile Construction Process Flow Diagram

6.1 Setting Up At the Pile Location

6.2 Execution Tolerances of cast-in-situ bored pile

6.3 Fabrication and Installation of Steel Casing

6.4 Excavation Procedure

6.4.1 Recycling of Bentonite

In order to achieve a concentration of 5%, 50 kg of bentonite will be added to approximately

Figure 02: The schematic layout of the bentonite mixing arrangement.

6.4.2 Testing Frequency of Bentonite

1. Sample from the tank to the borehole

Figure 03: Funnel Viscometer

6.5 Fabrication and Installation of Reinforcement Cage

Precast concrete circular spacers with diameter150 mm will be provided at bottom of

6.6 Concrete Placing

Figure 04: Sequence of Board Pile Construction

6.6.1 Disposal of Drilling Spoil

6.7 Piling Records

6.8 Cutting of Pile Heads

6.9 Piling Problems and Risks during Execution Works

6.9.1 Survey – Out of Positioning of the Pile

6.9.2 Drilling – Loss of Drilling Tools in Bore Holes

6.9.3 Bentonite Drilling – Collapse of Borehole

6.9.4 Reinforcement – Loss of Reinforcement Segment during Installation

6.9.5 Concreting – Clogging of Tremie Pipe

6.9.6 Bursting of Bentonite Hoses / Lines

7.0 Quality Assurance and Control Measures

7.6 The production and fixing of the steel reinforcement cage

7.7 The pouring of concrete underwater

8.0 Health Safety and Environmental Monitoring

 A guard fence shall be built around the slurry tank.

 A security man at the entrance to the construction site shall be employed.

 Try to avoid the concreting in the heavy rain.

9.0 Appendix A – Risk Assessment

working in the area shall wear high Supervisor

contact numbers shall be communicated

10.0 Appendix B – Inspection and Test Plan for Piling work

11.0 Appendix C – QA/QC Record Sheets