ENGINEER’s RESPONSE

Project Construction of Mumbai-Ahmedabad High Speed Rail (MAHSR) Package P1B

Ref. No. MGCPL/SITE//HSR-PKG1B/2022-23/1047 Revision 2
Title Submission of Revised Method Statement for Rectification of Defective Pile (R-2). Received on 06-06-2022
Review Code Notice of No Objection (NONO) Reviewed on 11-06-2022
Other Ref. AMS-0000057

# Drawing / Document No. Observations / Comments

Notice of No Objection issued for “Submission of Revised Method Statement for Rectification of Defective Pile (R-
1
2).”
Note: Notwithstanding Engineer’s comments, responsibility of ensuring conformity to contractual, technical and functional requirements lies with the Contractor.
Any non-compliances on the part of the Contractor in the preparation, submission or resubmission of Contractor’s Documents shall not constitute a Variation.

_______________________________ ____________________________________
Nitish Pandey Dileep Nalawade
[Reviewed by] [Endorsed by]
 M.G. Contractors Pvt. Ltd.
MGCPL/SITE/HSR-PKG1B/2022-23/1047 DATE 06/06/2022

To,
Chief Contracts Manager,
TCEL-CEGL-AARVEE ASSOCIATE- PADECO JV
A-204, 2nd floor, Swatisk Universal,
Opposite Central Mall, Dumas Road,
New Magdalla, Piplod, Surat,
Gujarat – 395007.

Sub: Construction of Bridges for Double Line High Speed Railway for 04 No. PSC Bridges
(GAD 9, 10, 11 & 1441) and 07 No. Steel Truss Bridges (GAD 68, 1134, 12, 61, 14, 15
& 62) [excluding fabrication and transportation of steel truss girders] between Zaroli
Village at Maharashtra-Gujarat Border (MAHSR Km. 156.600) and Vadodara
(MAHSR Km. 393.700), in the State of Gujarat and the Union Territory of Dadra and
Nagar Haveli for the Project for Construction of Mumbai-Ahmedabad High Speed Rail
Package No. MAHSR-P-1(B) – “Submission of Revised Method Statement for
Rectification of Defective Pile (R-2)”

Ref.: (I) MGCPL/SITE/HSR-PKG1B/2022-23/744, dated 28/03/22

(II) NOO issued on Unifier, dated 06/04/22
(III) MGCPL/SITE/HSR-PKG1B/2022-23/1009, dated 26/05/22
(IV) NOO issued on Unifier, dated 01/06/22

Dear sir,
With reference to the above – mentioned subject reference, please find enclosed herewith the
revised method statement for Rectification of Defective Pile.

Submitting for your review & approval.

Thanking you & assuring you our best services at all the time.
For M.G. Contractors Pvt. Ltd.

(Vipin Kumar Agarwal)

Authorized Signatory

Encl.: - Revised Method Statement for Rectification of Defective Pile (R-2)

Head Office: M.G. House, Plot No- 376 Industrial Area Phase- 2, Panchkula – 134112 (Haryana), Tel: 0172-6731000, 6731025
Regd. Office: # 603, Ring Road Mall, Deepali Chowk, Sector – 3, Rohini, New Delhi – 110085 Tel: 011-47019300, Fax 011-43852385
CIN No.: U70101DL1997PTC091013, E-mail: [email protected] website: mgcpl.com
 NHSRCL

NATIONAL HIGH SPEED RAIL CORPORATION LIMITED (NHSRCL)

CONSTRUCTION OF
MUMBAI - AHEMADABAD HIGH SPEED RAIL
Package No: MAHSR-P1-(B)

MGCPL

II
 MUMBAI-AHMEDABAD HIGH SPEED RAIL Method statement for
Package No. MAHSR – P 1 (B) Rectification of Defective Pile.
Method Statement for Rectification of Defective
Pile MGCPL/MS/035 (REV-2)

NATIONAL HIGH SPEED RAIL CORPORATION LIMITED (NHSRCL)

NHSRCL

MGCPL

CONSTRUCTION OF
MUMBAI-AHMEDABAD HIGH SPEED RAIL
Package No. MAHSR – P1-(B)
METHOD STATEMENT FOR
RECTIFICATION OF DEFECTIE PILE

Document No.
MGCPL/MS/035, Rev. R2

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 MUMBAI-AHMEDABAD HIGH SPEED RAIL Method statement for
Package No. MAHSR – P 1 (B) Rectification of Defective Pile.
Method Statement for Rectification of Defective
Pile
MGCPL/MS/035 (REV-2)

REVISION RECORD SHEET

Revision No. Revision Date Description of change
R0 - Initial Submission
R1 26-05-2022 First Revision
R2 06-06-2022 Second Revision

Prepared by EHS Reviewed by Reviewed by Approved by

Name: Ravi Raushan Rajesh Shende Sujit Hajirnis Vipin Agarwal

Chief Quality Chief

Designation: Senior Quality Engineer Chief SHE Manager Manager Project
Manag
Signature: er

Date: 26-05-2022 26-05-2022 26-05-2022 26-05-2022

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 Method statement for Rectification of Defective Pile.
MUMBAI-AHMEDABAD HIGH SPEED RAIL Package No. MAHSR – P 1 (B)
Method Statement for Rectification of Defective Pile MGCPL/MS/035 (REV-2)

Comments Resolution Sheet (CRS No.-1)

Reference: MGCPL Letter No. - (i) MGCPL/SITE//HSR-PKG1B/2022-23/744, Dated 28/03/2022

(ii) TCAP Observations/ Comments in UNIFIER, Dated 06/04/2022

Sl. No. Document Clause Engineers Observation/Comments MGCPL Reply

NHSRCL Observations/ Comments

First categories the defect in BCIS Pile in terms of FAT
Have been Categorised in Clause 5.1
1 increase and Energy Reduction basis.
Then based upon the defect, the Repair Methodology should
2 Noted, and formulated accordingly
be formulated.
For cementitious grout by Pressure grouting with Packers and
3 material (Cementitious Microfine Injection) used should be Have been explained in Clause 6.6
General explained.
Comments
After drilling and grouting, the effectiveness of repair is to be
4 Noted, have been incorporated in Clause 9
demonstrated by repeat CHSLT.
If required and instructed by the Engineer Dynamic Load Test
5 Noted, have been incorporated in Clause 10
on the repaired pile should be carried out.
The balance drill hole may be filled with non-shrink
6 Noted.
cementitious material using Cebex 100.

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 Method statement for Rectification of Defective
MUMBAI-AHMEDABAD HIGH SPEED RAIL Package No. MAHSR – P 1 (B) Pile.
Method Statement for Rectification of Defective Pile
MGCPL/MS/035 (REV-2)

TCAP Observations/ Comments

NX size: In fact, NX is system programmer of drilling. Define The Drilling size of hole of 75 mm have
7 2
the same with drilling dia. been mentioned in Clasue 6.1 a.
Sub item may be added: e) Confirmation of effectiveness and
8 2. Sequence of Work Noted, have been incorporated in Clause 9
adequacy by CHSL Test
9 3 Cementitious materials change with micro fine cement Noted.
i. Please describe Major and Minor Defects with i. Have been rectified in Clause 5.
illustrations, charts, and values (for CHSLT as
well as PIT). ii. Have been incorporated in Clause 6.
3 CHSL and PIT Test ii. Implications of defect on serviceability and
10 iii. Have been incorporated in Clause 5.3
interpretation durability may be elaborated.
(table)
iii. Please provide action plan for minor defects.
iv. Please provide detailed explanation of defect iv. Have been incorporated in Clause 5.3
identified in PIT and its rectification method. (table)
11 4(i) Define machine – make and system of drilling. Have been Incorporated in Clause 6.2
Capacity of Grout Pump is 2000 l/hr
12 4(iii) Define the capacity of Grout Pump.
mentioned in clause 4.1-point iii
Define type and make of packers to be used. How much Technical Data sheet have been
13 4(v)
pressure they can sustain? incorporated
14 5.1 What is the definition of Defect? Have been defined in Clause 5
Redraft this clause. One activity is to be defined after the
15 5.III Noted and Incorporated in Clause 5
previous one is over, and no intermixing of points.
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 Method statement for Rectification of Defective Pile.
MUMBAI-AHMEDABAD HIGH SPEED RAIL Package No. MAHSR – P 1 (B)
Method Statement for Rectification of Defective Pile MGCPL/MS/035 (REV-2)

16 5.III Add: How the core/s will be labelled and stored. Have been mentioned in Clause 6.4
i. Tomography results to be used for defining the defect zone.
5.III Concrete coring ii. Please add “ If in visual inspection the concrete quality
17 Have been mentioned in Clause 6.4
in defective zone. appears good then strength test to be carried out to ensure
M40 concrete”
In case, 2 – 2.5” core is to be considered for compression
strength test then what would be the type of machine (Least
18 New addition Have been mentioned in Clause 6.4
Count) and how the strength would be related to 28d strength
of 150mm cube strength?
How be the grout mix of micro fine cement prepared? Define Have been explained in detail in clause 6.6
19 6.1 v
w/c ratio and equipment used to prepare mix. (d)
Have been explained in detail in clause 6.6
20 6.1 vi Define the minimum grout pressure to be used for grouting.
(f)
The heading and the para body are not matching.
21 7 Noted and Rectified.
To ensure the effectiveness of grouting:
i. Load Test (Static or Dynamic) to be carried out on few
22 7 repaired defective piles. Have been Noted and rectified in Clause 9
ii. On all rectified piles verification from CHSLT is to be
carried out.
CHSLT is much better/ superior test for quality assurance Noted and will be implemented as per
23 ITP SN 6
hence confirmation from CHSLT to be done instead of PIT. clause 9
24 Annexure 2 ITP
Storage and Handling: Please be specific. The general
24.1 1 Have been mentioned in Clause 6.4
statement is not enough.
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 Method statement for Rectification of Defective
MUMBAI-AHMEDABAD HIGH SPEED RAIL Package No. MAHSR – P 1 (B) Pile.
Method Statement for Rectification of Defective Pile
MGCPL/MS/035 (REV-2)

24.2 New Addition Add for Cleaning and drying of hole. Have been mentioned in Clause 6.5
Grouting: Specify the minimum pressure to be ensured at site Have been explained in detail in clause 6.6
24.3 5
and calibration of pressure gauge of the grout pump. (f)
24.5 6 Confirmatory CHSLT Have been incorporated in Clause 9
How the balance portion of drilled hole shall be filled? {If it is
25 New Addition MS for Filling of Sonic Tube then specify the same, Have been incorporated in Clause 6.6
appropriately}
If there is more than one defect in pile, then what would be the Have been explained in detail in clause 6.6
26 New Addition
methodology? (i)
27 New Addition Reference shall be added. References have been added clause 3
Sketch showing grouting arrangements for Pile shaft and toe
28 New Addition Have been incorporated.
repair shall be visible.
29 New Addition Procedure for rectifying the soft toe shall be added in this MS. Have been incorporated in clause 7

30 5 Numbering shall be in sequence in whole document. Noted and Rectified

Contractor shall note that any defects found during review of

31 General Noted.
CHSL / PIT test results will be dealt with NCR.

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 Method statement for Rectification of Defective Pile.
MUMBAI-AHMEDABAD HIGH SPEED RAIL Package No. MAHSR – P 1 (B)
Method Statement for Rectification of Defective Pile MGCPL/MS/035 (REV-2)

Comments Resolution Sheet (CRS No.-2)

Reference: MGCPL Letter No. - (i) MGCPL/SITE//HSR-PKG1B/2022-23/1009, Dated 26/05/2022
(ii) TCAP Observations/ Comments in UNIFIER, Dated 01/06/2022

Sl. No. Document Clause Engineers Observation/Comments MGCPL Reply

NHSRCL Observations/ Comments

The balance drill hole may be filled with non-shrink cementitious
material using Cebex 100 as per MS of Filling of Sonic tubes (Give Has been added to point j, in Clause 6.6. Page
1 General
MS No. …...) No. 16
Add this in MS appropriately.
Add:
The core set (Min. 3 Cores) used for Testing shall have L/D ≥ 2. Noted and incorporated to Clause 6.4, Page
2 6.4
The equivalent Cube strength shall be worked out as per IS: 516 No. 14
(Part 4)- 2018.
The heading should be: Confirmatory CHSL and PIT Test. and in
Noted and improvised in Clause 9, Page No.
3 9 body replace CHSL/PIT with CHSL and PIT.
18
Please note that Re-testing of Pile with CHSL Test is mandatory.
Correct as under:
As per instructions of the Engineer, the Contractor shall carry out Noted and improvised in Clause 10, Page No.
4 10
the Dynamic Pile Load Test on the Repaired Piles as selected by the 19
Engineer, to prove Pile integrity.

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 MUMBAI-AHMEDABAD HIGH SPEED RAIL Method statement for
Package No. MAHSR – P 1 (B) Rectification of Defective Pile.
Method Statement for Rectification of Defective
Pile
MGCPL/MS/035 (REV-2)

TABLE OF CONTENTS

Sl. No. Description Page No.

1. Introduction 10

2. Scope 11

3. Reference 11

4. Equipment & Material Required 11

5. Pile Classification / Identification of Major Defect 12

6. Procedure for Repair in the Pile Shaft 13

7. Procedure for repair of Soft Toe 17

Repair method for major Defect identified in PIT (Low strain
8. 18
Pile Integrity Test
9. Confirmatory CHSL and PIT Test 18

10. Routine Pile Load Test 19

11. Quality 19

12. Safety Precautions 19

13. Technical Data sheet for Inflatable Packers 20

14. Inspection Test Plan 21

15. Formats / Check list 22

Annexure- I Technical Data sheet for Grout Materials 24

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 MUMBAI-AHMEDABAD HIGH SPEED RAIL Method statement for
Package No. MAHSR – P 1 (B) Rectification of Defective Pile.
Method Statement for Rectification of Defective
Pile
MGCPL/MS/035 (REV-2)

1. INTRODUCTION:
Mumbai – Ahmedabad High Speed Rail (MAHSR) Project is the first High Speed Rail (HSR)
network planned to be constructed in India. The MAHSR Project line connects Mumbai, located
in Maharashtra State with Ahmedabad in Gujarat State, passing through one Union Territory,
Dadra and Nagar Haveli. The Project for Construction of Mumbai-Ahmedabad High Speed
Rail is divided into separate Contract packages. The Package P-1 (B) of High-Speed Rail
Project is awarded to M/S M G CONTRACTORS PVT LTD. The scope of work of [Package
No. MAHSR-P-1(B)] consists of Construction of Bridges for Double Line High Speed Railway
for 04 No. PSC Bridges (GAD 9, 10, 11 & 1441) and 07 No. Steel Truss Bridges (GAD 68,
1134, 12, 61, 14, 15 & 62) [excluding fabrication and transportation of steel truss girders]
between Zaroli Village at Maharashtra-Gujarat Border (MAHSR Km. 156.600) and Vadodara
(MAHSR Km. 393.700), in the State of Gujarat and the Union Territory of Dadra and Nagar
Haveli for the Project for Construction of Mumbai-Ahmedabad High Speed Rail.
Location Map

Figure 1 Complete Alignment of Mumbai-

Ahmedabad High Speed Rail Project Figure 2 Package P1(B)

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 MUMBAI-AHMEDABAD HIGH SPEED RAIL Method statement for
Package No. MAHSR – P 1 (B) Rectification of Defective Pile.
Method Statement for Rectification of Defective
Pile
MGCPL/MS/035 (REV-2)

2. Scope:
The purpose of this work procedure is to establish work sequence for rectification of defects in
Bored Cast In-situ Pile. Defects are considered as major when it falls in the category "Poor/Defect.

3. Reference:
1 . Tender Documents along with all Addendums.
2. Approved Construction Drawings.
3. IRS CBC - 2014 — Indian Railway Standard: Code of practice for Plain,
Reinforced & Prestressed Concrete for General Bridge Construction.
4. Technical data sheet of Alccofine 1108 SR microfine Cementitious grout.
5. Technical data sheet of Ultratech Powergrout NS3 SP (for Toe Grouting).

4. Equipment & Material Required:

4.1 Major Equipment

i. Drilling machine for concrete coring / drilling — Rotary drilling machine.
ii. Drilling rods
iii. Grout pump with accessories - 2000 1/hr. & pressure-7kg/sqcm
iv. Water pump and water tanks
v. Inflatable Packers — Details enclosed.

4.2 Material required

i. Alccofine — Micro fine cementitious injection grout
ii.Ultratech Power grout NSP SP3 — High performance precision grout (for Toe Grouting).

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 MUMBAI-AHMEDABAD HIGH SPEED RAIL Method statement for
Package No. MAHSR – P 1 (B) Rectification of Defective Pile.
Method Statement for Rectification of Defective
Pile
MGCPL/MS/035 (REV-2)

5. Pile Classification Identification of Major Defect:

5.1 Pile classification based on signal strength

Pile Classification FAT Increase Relative to Energy Reduction Relative to
Good Concrete Good Concrete
No.
1 Satisfactory/ Good 0-10% < 6 Db

2 Minor Defect 11-20 % < 9 Db

3 Poor/ Flaw 21-30 % 9 Db to 12 Db

4 Poor/Defect >30% > 12 Db

Defects are considered as major when it falls in the category "Poor/Defect.

5.2 CHSL test interpretation along with PIT:

Where the CHSL scan shows FAT >30 and Energy reduction >12db in few profiles and
not consistently in all the profiles, CHSL report shall be interpreted with PIT and submitted
to the Engineer for approval.

5.3 CHSL results with Major Defect:

Where the CHSL scan shows FAT >30 and Energy reduction >12db in all the profiles or
when major defect established by defect analysis (tomography), repair of pile shall be done
on case-to-case basis.

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 MUMBAI-AHMEDABAD HIGH SPEED RAIL Method statement for
Package No. MAHSR – P 1 (B) Rectification of Defective Pile.
Method Statement for Rectification of Defective
Pile
MGCPL/MS/035 (REV-2)

Based on the above-mentioned categories, following shall be the action plan to attend the defects
Category — Poor/Defect Category — Poor/Flaw Category - Minor Defect
Determination of location of A piling expert's A piling expert's
defects based on CHSL / recommendations shall recommendations shall
tomography reports, followed be taken. be taken.
by repair which has been
described in this method Review report based on the Review report shall be
statement. same shall be submitted for prepared based on the same
Engineer's review. Further and submitted for Engineer's
Pile Integrity verification by action shall be planned and review. Further action
Dynamic Load Test shall be undertaken as instructed by shall be planned and
done on the randomly the Engineer. undertaken as instructed by
selected piles, as instructed the Engineer.
by the Engineer.

6. Procedure for Repair in the Pile Shaft

6.1 Sequence of work for rectification of pile defect;
a) Drilling vertical hole of 75mm diameter using Concrete coring method in pile shaft.
b) Cleaning debris / loose materials by water flushing.
c) Pressure grouting with approved materials at identified locations to rectify the affected
portion of pile shaft.
d) Retest: Cross Hole Sonic logging (CHSL) / PIT test report.

e) Confirmation of effectiveness and adequacy by CHSL Test

6.2 Core drilling:
Drilling of 75mm diameter shall be carried out as per plan up to a depth 500mm below the
defective Zone to assess and to carry out pressure grouting.
The hydraulic drilling machine drilling rig should be firmly placed on/near pile. The level of
drilling machine base and pile top should be at equal level. Water tank required for shall be
connected to the drilling machine to ensure continuous water flow during coring.

Cored holes need to be in plumb to ensure that they do not cut into the adjacent access tube
or into any of the reinforcing steel.

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 MUMBAI-AHMEDABAD HIGH SPEED RAIL Method statement for
Package No. MAHSR – P 1 (B) Rectification of Defective Pile.
Method Statement for Rectification of Defective
Pile
MGCPL/MS/035 (REV-2)

6.3 Concrete Coring at defective Zone:

Cored holes shall be located based on CHSL report. Concrete core shall be retrieved at depth
500mm above & below the depth of defective zone concrete as per the procedure outlined
below:
i) 3-inch diameter minimum, double wall core barrel system utilizing a split tube type
inner barrel shall be used. This wilt give a 2 to 2-1/2-inch core sample that can be used
for assessment of concrete.
6.4 Sampling & Inspection of Concrete core:
All core pieces shall be placed in standard core boxes in a serial order in correct sequence from
top downwards. The shallowest core shall be placed to the top left-hand corner and for every
compartment the shallower core shall be to the left, the top being considered adjacent to the hinged
section. Core boxes shall be according to IS 4078-1980, soundly constructed of good quality
timber painted with good quality paint on both inside and outside surface. Each box shall have
following information painted with black enamel paint on the lid.
1. Name of the Project :
2. BH NO :
3. Chainage :
4. Core Box No. :
5. Depth of Core contained : From: m to m
6. Core No : From to

Core extracted from the pile shall be visually inspected. In case, the core extracted from the
identified defect zone is visually sound, the core shall be tested for compressive strength to
ensure compressive strength of pile concrete. 500 KN capacity compressive strength machine
will be used for testing of cores. If the concrete core is sound and the strength is satisfactory,
the drilled hole shall be filled with grout having equal strength to the concrete and the defect
shown shall be considered due to debonding. If the core extracted is having anomaly or the
core recovery is not good, then the pressure grouting process shall commence after cleaning
the bore.
The Core set (Min. 3 Cores) used for Testing shall have L/D ≥ 2. The Equivalent cube strength
shall be worked out as per IS:516 (Part 4)-2018.
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 MUMBAI-AHMEDABAD HIGH SPEED RAIL Method statement for
Package No. MAHSR – P 1 (B) Rectification of Defective Pile.
Method Statement for Rectification of Defective
Pile
MGCPL/MS/035 (REV-2)

6.5 Cleaning of Drilled Hole:

High Pressure water jet will be applied in the drilled hole to displace the existing debris
from inside the core.
Low-pressure high-volume air will be applied to displace the water along with debris from
inside the borehole to outside.
Process to be continuous till clean water free of debris is being displaced outside. > Water
jetting is stopped, and air blowing continued till maximum water is removed from the
borehole.
Cleaning till full depths of borehole and to surface dry the surface to best possible extent.

6.6 Cementitious (microfine) Grout by Pressure grouting

a) After ensuring the borehole cleaning, the grout pipe with packer shall be inserted in the drilled
hole.
b) The packer shall be fixed at the depth 500mm above the area to be rectified (500mm above
the anomalies/defects identified).
c) Venting port with ball valve for pressure containment shall be provided in the packer.
d) Grout mix shall be prepared using microfine cement and addition water (water cement ratio
not more than 0.5 as per manufacturer recommendation) and mixing it in the mechanical mixer
machine having capacity to a minimum of mixing 25 kg microfine material in one batch.
Marsh cone viscosity of the grout mix shall be 50-80 seconds as per manufacturer
recommendation.
e) Ensure that the cementitious grout shall freely flows out of the vent in a bubble free clear
stream and then close the air vent valve.
f) The pressure during grouting shall not exceeding 4 — 5 kg/sq.cm. The pressure of grout
during inflow of grout shall be 0.5 - 2 kg/sq.cm2
g) Keep pumping cementitious grout continuously, till the inflow of grout is stopped and the
pressure is maintained at 4-5 bars for at least 5 - 10 min. The pumping shall then be stopped.
h) The packer shall be removed from the position and fix it on the top of the drilled hole and the
balance portion of core hole shall be pressure grouted and the valve shall be closed, and the
packer shall be left in position until setting time of grout.
i) If the defect in pile is in multiple stage the lowest depth shall be filled first and then moving
towards the top. Repeating the points (f) to (h).

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 MUMBAI-AHMEDABAD HIGH SPEED RAIL Method statement for
Package No. MAHSR – P 1 (B) Rectification of Defective Pile.
Method Statement for Rectification of Defective
Pile
MGCPL/MS/035 (REV-2)

j) After completion of grout remaining depth of holes will be filled with non-shrink cementitious
material using Cebex 100 as per points d to g.

Sketch Showing Grouting arrangements for Pile Shaft Repair

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 MUMBAI-AHMEDABAD HIGH SPEED RAIL Method statement for
Package No. MAHSR – P 1 (B) Rectification of Defective Pile.
Method Statement for Rectification of Defective
Pile
MGCPL/MS/035 (REV-2)

7. Procedure for repair of Soft Toe:

When a blank portion is observed in the bottom of the scan, which could be attributed to
accumulation of silt or severe debonding of CHSL pipes. When major defect /soft toe is
established by defect analysis, repair of pile shall be done on case-to-case basis

7.1 Repair Process of Soft Toe:

For repair of soft toe, drilling shall be done puncturing the bottom of 150mm embedded CHSL
pipe and drill through it. In case of recovery of good solid core, then we can attribute the defect
shown in CHSL scan as debonding. The hole drilled shall be grouted and left.

On the other hand, if we get some soft or loose material, the pile bottom shall be repaired using
pressure grouting.

Flush the pile bottom with high pressure air and water and clean all the loose material
as much as possible.
ii. Pressure grouting of cleaned portion with approved grout mix under 4-5 kg/cm2
pressure.
The grouting shall be continued until the pressure is built up. Then the pressure
grouting shall be stopped and the volve shall be closed to ensure that the injected
grout is not returning through the pipe.
After 4-5 days of grouting, the test shall be carried out again for confirmation of
effectiveness of the grout.

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 MUMBAI-AHMEDABAD HIGH SPEED RAIL Method statement for
Package No. MAHSR – P 1 (B) Rectification of Defective Pile.
Method Statement for Rectification of Defective
Pile
MGCPL/MS/035 (REV-2)

Sketch Showing Grouting arrangements for Soft Toe of Pile

8. Repair method for major Defect identified in PIT (Low strain Pile
Integrity Test):
In case, where the PIT results indicate major defects, the pile shall be tested with CHSL, and
the report shall be reviewed. In case of major defect identified in CHSL report / defect
analysis, the procedure mentioned as above in Cl. 6, 7 & 8 shall be followed for rectification
of defects (as applicable).

9. Confirmatory CHSL and PIT Test:

After 4-5 days Post grouting, Cross Hole Sonic Logging test and PIT shall be conducted on the
repaired pile to check the effectiveness of the repair carried out to correct anomalies identified.
Based on pile classification, as mentioned in Cl.3 of this method statement, the report of the
CHSL and PIT test shall be submitted to the Engineer for approval.

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 MUMBAI-AHMEDABAD HIGH SPEED RAIL Method statement for
Package No. MAHSR – P 1 (B) Rectification of Defective Pile.
Method Statement for Rectification of Defective
Pile
MGCPL/MS/035 (REV-2)

10. Routine Pile Load Test:

As per the instructions of the Engineer, the contractor shall carry out the Dynamic Load Test
on the Repaired Piles as selected by the Engineer, to prove Pile Integrity.
11. Quality:
Materials & Grout shall be checked as per manufacturer guidelines.
The inspection reports and test records shall be maintained in the format (Annexure-I ).
Tests shall be carried out as per QAP (Annexture-2)
The guidelines for mixing grout shall be followed as per manufacturer's instruction.
(Annexure -3, Technical data sheet of Alccofine 1108 SR & Technical data sheet of
Ultratech Powergrout NS3

12. Safety Precautions

i) Workers should wear appropriate personal protective equipment (PPE)
Swing area of heavy machinery to be monitor closely.
iii) Checking of wire rope, webbing sling and tools are in good working condition.
iv) Adequate lighting if working during night-time.
v) Excavated pit/ trench will be inspected by supervisor to ensure safe working
environment prior to any further works within the pit/ trench.
vi) Guard for rotating parts.

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 MUMBAI-AHMEDABAD HIGH SPEED RAIL Method statement for
Package No. MAHSR – P 1 (B) Rectification of Defective Pile.
Method Statement for Rectification of Defective
Pile
MGCPL/MS/035 (REV-2)

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 MUMBAI-AHMEDABAD HIGH SPEED RAIL Method statement for
Package No. MAHSR – P 1 (B) Rectification of Defective Pile.
Method Statement for Rectification of Defective
Pile
MGCPL/MS/035 (REV-2)
 MUMBAI-AHMEDABAD HIGH SPEED RAIL Method statement for
Package No. MAHSR – P 1 (B) Rectification of Defective Pile.
Method Statement for Rectification of Defective
Pile
MGCPL/MS/035 (REV-2)

MAHSR-MGCPL/PKG
P1(B)/QAQC/ CFI 80
CHECKLIST FOR RECTIFICATION OF PILE BY DRILLING &
GROUTING Rev. No. 00

Project : Mumbai Ahmedabad High speed Rail (Package No. MAHSR –P1-B)
Client : National High Speed Rail Corporation Limited (NHSRCL)
Engineer : TCAP Consortium
Contractor : MGCPL

Location/Chainage Date of Rectification

Pile ID RFI NO
Grout Material / Mix Id Water Powder ratio

S.No. Description of Activity Yes No N/A Remarks

A. Drilling
1
Drilling bit is cleaned before start of drilling

2 Undulations of Pile surface is levelled

3 Location of bore hole for repair is marked

B. Grouting

1 Drilled hole is thoroughly cleaned by high pressure water jet or by

air compressor

2 Packer is fixed at required depth

3 Grout material is inspected & is Ok

Grout Pressure of 3-5 Mpa is maintained for 5-10 minutes after

4 inflow of grout is stopped

REMARKS :

MGCPL Execution Quality For Engineer / Engineers Representative

Name:

Sign:

Date:

Page | 22
 MUMBAI-AHMEDABAD HIGH SPEED RAIL Method statement for
Package No. MAHSR – P 1 (B) Rectification of Defective Pile.
Method Statement for Rectification of Defective
Pile
MGCPL/MS/035 (REV-2)

MAHSR-MGCPL/PKG P1B/QAQC/ CFI 81

GROUT POUR RECORD

Rev. No. 00

Project : Mumbai Ahmedabad High speed Rail (Package No. MAHSR –P1-B)
Client : National High Speed Rail Corporation Limited (NHSRCL)
Engineer : TCAP Consortium
Contractor : MGCPL

Location/Chainage Date
Pile ID Depth
Name of
Ambient temperature: Grouting Agency
Depth of Time Material Consumption
Hole No / Grout
Hole ID from Cementitious Consumption
Remarks
COL Start End Grout Qty (kg)

Grouting Record for Cementitious Grout

No of Cubes Cast:

REMARKS :

MGCPL Survey/Execution Quality For Engineer / Engineers Representative

Name:

Sign:

Date:

Page | 23
 MUMBAI-AHMEDABAD HIGH SPEED RAIL Method statement for
Package No. MAHSR – P 1 (B) Rectification of Defective Pile.
Method Statement for Rectification of Defective
Pile
MGCPL/MS/035 (REV-2)

Page | 24
 MUMBAI-AHMEDABAD HIGH SPEED RAIL Method statement for
Package No. MAHSR – P 1 (B) Rectification of Defective Pile.
Method Statement for Rectification of Defective
Pile
MGCPL/MS/035 (REV-2)

Page | 25
 MUMBAI-AHMEDABAD HIGH SPEED RAIL Method statement for
Package No. MAHSR – P 1 (B) Rectification of Defective Pile.
Method Statement for Rectification of Defective
Pile
MGCPL/MS/035 (REV-2)

Page | 26
 MUMBAI-AHMEDABAD HIGH SPEED RAIL Method statement for
Package No. MAHSR – P 1 (B) Rectification of Defective Pile.
Method Statement for Rectification of Defective
Pile
MGCPL/MS/035 (REV-2)

Page | 27
 MUMBAI-AHMEDABAD HIGH SPEED RAIL Method statement for
Package No. MAHSR – P 1 (B) Rectification of Defective Pile.
Method Statement for Rectification of Defective
Pile
MGCPL/MS/035 (REV-2)

Page | 28