material and equipment BCIS Pile

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Hello, welcome to this topic of construction of bored cast in-situ BCIS pile. At the end of this
topic, you should be able to understand about BCIS pile, explain the materials used in the
piling process, explain the equipment used in the piling process. The main function of the
BCIS pile is to transfer the load from the superstructure to the substructure, soil or rock by
skin friction along the pile shaft or by end bearing.

The function of end bearing or friction pile depends on the soil strata. When these holes are
stabilized using bentonite or polymer followed by reinforcement can be constructed
vertically and or creating line will be required. So, in this module, we will learn the
construction procedure of BCIS piles, how the bore holes are drilled, how the piles are
casted, steps and precautions involved, how the piles are chipped and how the pile caps are
casted.

Now, let us first start with materials and equipment. Let us now look at the materials used
in the process. First one is bentonite powder.

What is bentonite powder and why to use bentonite powder in piling? Bentonite powder is
a clay of Montmorillonite group. Due to its mechanical structure with electrostatic force, it
forms a jelly-like membrane. As the electrostatic forces are very weak, with slight agitation,
the jelly turns into a liquid again.

The main function of using bentonite as a drilling mud is to stabilize the bore hole during
installation of BCIS piles. When a bore hole is drilled or a tunnel is formed, then what force
comes into picture? Click the correct answer and click submit to learn more. Yes, that is
right.

The bentonite solution forms a jelly-like membrane on the sides of the wall to resist radial
pressures due to external soil and water. So, is there any alternative for bentonite? Yes,
polymer solutions have similar properties of bentonite or retaining properties can be used
as an alternative for bentonite solution. Next in materials is the reinforcement cage.

A reinforcement cage is a steel cage designed to take up the tensile forces of the pile and is
made up of longitudinal bars, transverse steel and stiffeners. The reinforcement steel should
be as per mild steel and medium tensile steel bars conforming to IS 432 part 1, high strength
deformed steel bars conforming to IS 1786. Longitudinal bars are placed in a circular or
rectangular pattern based on the cross section of the pile.

These bars are placed equally leaving the clear cover to the periphery of the pile. The
number of bars depends on the design. After the design is done accordingly, the drawing is
sent to the site and the reinforcement cages are made accordingly.

After the longitudinal bars are placed, the transverse reinforcement is placed around the
main longitudinal reinforcement in spirals and they are welded or tied with ties. To hold the
reinforcement cages in circular or rectangular shape intact, stiffener bars are used. These
stiffener bars only hold the reinforcement in position and do not add up to the strength of
the pile or in the design.
These stiffeners or additional tags can be added to lift the reinforcement cage. The next one
in materials is concrete. The whole piling process runs around concrete and it is the most
important material for the strength factor.

The requirements to be followed for BCIS piles are the concrete must be selected to have
adequate strength to meet the structural requirement of the pile. The concrete must be
selected to be self-compacting under the self weight as it is not feasible for vibration in the
borehole. The concrete should be resistant to bleeding and segregation and it should also be
resistant to leaching so that it does not mix with the external water.

The slump of concrete is also a major factor responsible for the free flow of concrete. The
settling of concrete should be uniform or should be in controlled manner throughout the
concreting operation. The trimming selection should be made in line with the size of
aggregate and should be feasible with respect to the pile diameter, and less than the
reinforcement cage without blocking the pathway.

The concrete to be selected with low heat of hydration to avoid the thermal cracking. All
these points should be kept in mind while selecting the grade and type of cement and
aggregates for the concrete. After materials, let us look at availability of equipment and
what can we do for our piling process.

Hydraulic rotary piling rig is used for drilling the borehole, crawler crane for rebar lowering,
trimmy concreting and for extraction of temporary casing. Temporary casing pipe of 8
millimeters thick and 3 to 4 meter long per pile to resist the radial forces. High pressure
vertical pumps, welding sets and reinforcement cutting sets for preparation of
reinforcement cage.

Truck mixers or tractor with trailer and trimmy pipes and hopper for concreting purpose.
Trucks for transporting bored muck, tankers for bentonite slurry disposal, electric
generators. The first equipment is hydraulic rotary piling rig.

Generally, a piling rig is an equipment used to drill pile boreholes using a sharp edge in the
soil to provide good foundation support. The name hydraulic rotary piling rig itself explains
that it is operated hydraulically and has a rotary action. It is not necessary that it should be
operated hydraulically, but it is the most efficient method available.

The basic principle behind these piling rigs is the application of torque. Torque is basically a
force applied to cause rotation or twist. One of the rigs is rotary systems.

This rotary rig uses the power unit to develop the required forces to create rotary action
through the Kelly bar. Then the rig is attached to the Kelly bar to drill the boreholes. For
greater powers and depths, high torque is required depending on the strata.

So, to develop high torque, hydraulic power is the best possibility available out there. Using
hydraulic power, it is easy to move the rig up and down easily. Now, let us look at some of
the advantages of the combination of hydraulic and rotary action.
Click each advantage to learn more. The lightweight design of these rigs makes the
installation and relocation easy which enables greater operational flexibility. Depending on
rigs and advancements, higher automation is achieved, high level of flexibility can be
ensured and even productivity is increased.

The drilling method varies from soil to soil and place to place and even depends on
availability. For suppose, if the strata is completely clay, then the long drilling tube can be
used for increasing efficiency and productivity. Different drilling bits can be used depending
on the strata, rock or soil.

Where the strata consists of sand and cobble, it is better to use a short drilling tube as it has
better control over the drilling speed. Due to the advancement in technology, the
operational efficiencies have been increased depending on the type such as diesel operated
or steam operated or hydraulic operated and so on. Before rotary rigs, there were various
types of rigs used for excavation or drilling of soil.

But rotary rigs were revolutionary as they cut into the soil enabling better penetration rates
and higher operational efficiency. One of the main features of this hydraulic rotary rigs is
they are eco-friendly and causes low environmental pollution. Compared to other methods,
they generate smaller vibrations and less operating noises.

After understanding the advantages of the hydraulic rotary rigs, let us look at some more
supportive equipment. One of them is truck mounted rigs. The name itself says that the rigs
are attached to the trucks and the drilling is done.

A truck being small in size is very feasible and has the mobility to reach the small corners
and do the drilling process and also have various range of capacities and sizes. At the
location where the soil condition is worse, the heavy drilling machines cannot be used as
they settle due to its own weight. In those conditions, these truck mounted rigs are of most
importance as the self-weight is less and can do the work quite comfortably.

The pace of doing work is also better than other rigs as the drilling process can be started
within minutes of reaching the location. Here is another image taken from one of our sites
operating in Kakinada, Andhra Pradesh. Coming to the augers, the first one is soil auger.

It is the most used auger all over wherever the soil is present and even in some places
where weathered rock is present. This auger works only when the soil has a considerable
amount of cohesion so that the cutting edge can penetrate into the soil or rock to break it.
The augers have a sharp edge at the bottom to cut into the soil.

These augers are attached to the piling rigs and with the help of torque provided by the rig,
the auger is drilled into the soil. After penetrating the auger into the soil, the soil gets into
the spiral shape of the auger due to cohesion and then it is lifted above the soil to remove
the soil. By spinning the rig and auger, the soil is removed from the auger.

This process is continued till the required depth is achieved. Next is soil bucket. So, what is a
soil bucket and what is the difference between a soil auger and a soil bucket? As displayed
in the image, the soil bucket is the same as the soil auger with additional coverage on the
outer edge.
This covering on the outer edge prevents the outfall of the soil during the withdrawal
process. This auger can be used when the soil without rock is present. Once the bucket is
loaded with soil, the bucket is pulled out from the hole and the soil is removed by opening
the bucket hinges at the bottom of the bucket.

This method can be preferred over the soil auger as it increases productivity as the soil once
entered does not fall during the withdrawal process. After soil auger, let us now look at the
rock augers. The rock auger is used to drill into the strata where soft rocks such as
limestone, sandstone and hard shales are present.

Rock augers are also called flight augers and these augers are made to drill into the rock
strata using the sharp conical teeth which are made up of tungsten carbide. This design of
hard teeth enables to fracture into the rock allowing the penetration into the ground which
is not feasible with the standard auger. This auger cannot be used where the hard rock is
present and if used the teeth will break and it has to be replaced.

So, here comes the role of the designer to decide which auger to use or auger can be used
or blasting can be used and so on. All these should be taken into consideration for getting an
optimum output and safety. Next in the list is core barrel.

This core barrel is generally used for rocks. The core barrel is a hollow structure with
pointed hard edges at the bottom. If the rock to be excavated is very hard then it is better to
use this core barrel for excavation.

This core barrel penetrates into the rock till the portion of core breaks off and then it is lifted
to remove the excavated material. Same as the other augers the barrel can be shaped or hit
down to remove the excavated material. The displayed image shows the thin cutting edge
which is penetrated into the rocky strata using the rotary action.

If this method also doesn't work then the rock is very hard and other techniques has to be
chosen. Till now the equipment used for the drilling process in various strata such as soil
and rock is discussed. Now after the drilling process the next step is to clean the borehole
before going to the next step.

So for this cleaning purpose the cleaning bucket is used. What to clean? During the drilling
process finer particles slip out of the augers and store down in the borehole. These small
particles along with the bentonite solution which is used to stabilize the surrounding soil get
mixed up and settle in the lower portion of the borehole.

So the cleaning buckets are the buckets used to clean the loose materials from the bottom
of the drilled hole and to have a flattened bottom. Flattening the bottom ensures that the
pile is formed on a firm flat surface. This cleaning bucket does not have any sharp edge like
augers but has a closing system that locks the bottom and retains the loose particles in it.

These buckets can also be called as muck out buckets as it allows the bentonite or fluids to
flow through retaining the tiny particles in it. The next equipment or tool is the casing. This
casing is used for stabilizing the shaft excavation during the drilling process and will be
removed after the concreting.
The casing is driven and removed so it is called a temporary casing. Contractors like to
emphasize the fact that the casing that is used temporarily in the drilling operation is
essentially a tool so it is sometimes termed temporary tool casing. Before the drilling
process starts the casing is driven into the soil and the drilling is started.

Verticality should be checked and it should be within the limit during the insertion of the
temporary casing because it defines the verticality of the pile shaft tool. The main function
of the temporary casing is to retain the sides of bore holes long enough till the fluid
concrete is placed to resist the radial forces. The temporary casing remains in place until the
concrete has been placed to a level sufficient to withstand ground and groundwater
pressures.

After the concrete pouring the casing is removed and due to the removal of the temporary
casing extra concrete is poured to balance it. The next equipment is the crawler crane.
Basically these crawler cranes are mounted with undercarriage weights which provides
mobility and stability to the equipment.

These cranes can move around the site and can perform lifts with little setup. An additional
advantage is that these crawler cranes are capable of traveling even by carrying a load.
Coming to BCIS piles the function of these crawler cranes is to lift the temporary casing and
reinforcement cage from storage place to the pile position and can be used for
reinforcement cage lowering.

One more function related to BCIS pile is for the shifting and arrangement of the kentel
edge or guide frame for the pile load testing setup. Next on the list is Trimi pile. Basically
Trimi is a watertight pile with varying inner diameters of 150 mm to 300 mm.

Mostly used is 250 mm and the selection of the diameter of Trimi also depends on the
diameter of the pile. In this attachment a conical hopper is also attached at the upper end
above the water level. This conical hopper has a loose plug or a valve at its bottom end.

This plug is removed after filling the hopper with concrete so that the concrete passes into
the Trimi pipes to the pile shaft. The length of Trimi pipe can be variable and depends on the
length of the borehole. So depending on the length of borehole the number of Trimi pipes
are attached one to another and achieve the required length.

If concrete is poured directly into the borehole without Trimi what will happen? The
concrete gets along with the side soils and the slurry and bentonite present in borehole and
segregates itself and does not obtain the target strength. So with Trimi the wet concrete is
flown in a defined manner which promises a more reliable strength. Let us check how well
you have understood the content covered thus far.
Transcribed by TurboScribe.ai. Go Unlimited to remove this message.