Npcil-Gorakhpur Haryana Anuvidyut Pariyojana

NPCIL-GORAKHPUR HARYANA ANUVIDYUT PARIYOJANA
PROJECT: CONSTRUCTION FOR MAIN PLANT BUILDINGS, STRUCTURES, AND OTHER ASSOCIATED WORKS (CIVIL PACKAGE-II) OF
GORAKHPUR HARYANA ANU VIDYUT PARIYOJANA-1&2 AT VILLAGE: GORAKHPUR, DIST. FATEHABAD, HARYANA.
WORK ORDER NO- GHAVP/1&2/CIVIL/WO-078
REPORT ON VERTICAL PILE LOAD TEST UNDER COMPRESSION CONDUCTED ON VT-04 DATE : 14.11.2019
DOCUMENT NO : GHAVP/2019/N12TPLCM100.3
NUCLEAR POWER CORPORATION OF INDIA LIMITED

(A GOVT. OF INDIA ENTERPRISE)
Gorakhpur Haryana AnuVidyutPariyojana (GHAVP),
Dist-Fatehabad, Haryana
DOCUMENT ACCEPTANCE NOTE
Name of Document : Report on Vertical Pile Load Test under Compression Conducted on
VT-04
Submitted By : M/s -TATA Projects Limited.
Name of Work: Construction for main plant building and structures and
otherassociatedWorks (civil package-II) of Gorakhpur Haryana
AnuVidyut pariyojana-1&2.
Work order No. : GHAVP-1&2/Civil/WO-78
Above procedure / proposal has been reviewed at our end, found conforming to the requirement
of NPCIL specification / relevant code, and hence accepted.
SIGNATURE WITH
NPCIL NAME AND DESIGNATION
DATE
CHECKED BY
REVIEWED BY
CONCURRED BY
APPROVED BY
1
NUCLEAR POWER CORPORATION OF INDIA LIMITED

(A GOVT. OF INDIA ENTERPRISE)
Gorakhpur Haryana AnuVidyutPariyojana (GHAVP),
Dist-Fatehabad, Haryana
Submitted By : M/s -TATA Projects Limited.
SIGNATURE WITH
M/s TPL NAME AND DESIGNATION
DATE
PREPARED BY
REVIEWED BY
CONCURRED BY
APPROVED BY
2
NPCIL PROPRIETARY
This document contains confidential and protected information and that the same are the
intellectual property of nuclear powerCorporation of India limited (NPCIL). No Part of this
document including notably and editorial elements, verbal and figurative Marks and images
included herein, shall be reproduced or transmitted or utilized or Published or stored in any form
or by any means now known or hereinafter invented, Electronic, digital or mechanical, including
photocopying, scanning, recording or by any Information storage or retrieval system, without prior
written permission from NPCILBy any person or entity. Unauthorized use, disclosure or copying is
strictly prohibited and may constitute unlawful act and can attract legal action.
3
REVISION CONTROL SHEET
WORK ORDER NO.: GHAVP/1&2/CIVIL/WO-078, DT.15.02.2019
TPL DOCUMENT NO: GHAVP/2019/N12TPLCM100.3
TATA PROJECTS LTD NPCIL
REV NO DESCRIP PREP'D REV'D CONCU APPR'D CHK'D REV'D CONCU APPRO'D
&DATE TION BY BY R'D BY BY BY BY R'D BY BY
4
TABLE OF CONTENTS
1BACKGROUND ............................................................................................................................ 7
2SCOPE ……………………………………………………………...……………………………….8
3REFERENCE DOCUMENTS............................................................................................................ 9
4PILE TEST DETAILS .................................................................................................................... 10

4.1 Test pile details................................................................................................................................. 10
4.2 Anchor pile details ........................................................................................................................... 11
4.3 Pile test location details .................................................................................................................. 11
4.4 Ground condition at test pile location .......................................................................................... 12
4.5 Material details for test and anchor piles .................................................................................... 12
4.6 Load application and measurement system ................................................................................ 12
4.7 Settlement measurement system ................................................................................................. 13
5LOAD TEST SET UP ARRANGEMENT........................................................................................... 13
6LOAD TEST PROCEDURE ............................................................................................................ 15
7LOAD TEST RESULTS ................................................................................................................. 16

7.1 Load vs. settlement.......................................................................................................................... 16
8OBSERVATIONS AND INFERRENCES .......................................................................................... 17
5
ANNEXURE 1 SITE PHOTOGRAPHS

ANNEXURE 2(A) FIELD DATA-DIAL GAUGE, LVDT VS. LOAD AND ANCHOR PILE
UPLIFT
ANNEXURE 2(B) PILE INTEGRITY TEST REPORT
ANNEXURE 2(C) CROSS HOLE SONIC LOGGING
ANNEXURE 3
ANNEXURE 3(A) BORE LOG DATA
ANNEXURE 3(B) CONCRETE CUBE TEST RESULTS AND REINFORCEMENT TEST
CERTIFICATES
ANNEXURE 4 CALIBRATION CERTIFICATES
LIST OF TABLES
Table 1: Scheme of Initial Pile load Test at GHAVP-1&2 for 1500 mm dia. Test piles ............................. 7
Table 2: Loadvs. Average settlement ............................................................... Error! Bookmark not defined.
LIST OF FIGURES
Figure 1: Layout of anchor pile w.r.t. test piles. ............................................................................................ 8

Figure 2: Test pile and its location ................................................................................................................. 11
Figure 3: a) Plan, b) Elevation; Arrangement of vertical compression load test. ................................... 14
Figure 4: Load vs. Settlement curve ................................................................. Error! Bookmark not defined.
ABBREVIATIONS
NPCIL : Nuclear Power Corporation of India Limited

GHAVP : Gorakhpur Haryana Anu Vidyut Pariyojana
RAB : Reactor auxiliary building
HSDPT : High Strain Dynamic Pile Test
CSL : Cross hole sonic logging
PIT : Pile integrity test
LVDT : Liner variable displacement transducer
GI : Ground Improvement
TS : Total Station
6
1. BACKGROUND
Nuclear Power Corporation of India Limited (NPCIL) proposes to set up Gorakhpur Haryana
AnuVidyut Pariyojana-1&2 (GHAVP-1&2) - Two units of 700 MWe Nuclear Power Plant at
Gorakhpur, Fatehabad District of Haryana. GHAVP site comes under the Gorakhpur block of Bhuna
Tehsil in the District of Fatehabad and it is about 28 km from Fatehabad. The site is situated to the
left bank of the Fatehabad branch of Bhakra Canal near running distance (RD) of 48159m. The
nearest village to the site is Gorakhpur.
08 Nos. 40m deep reinforced concrete bored cast in situ piles with 1500 mm shaft diameter have
been installed to assess their load carrying capacities by performing Vertical load Test, Lateral
Load Test & High Strain Dynamic Pile Test (HSDPT)on specified piles. Piles have been installed in
NB Area of GHAVP-1&2 where ground improvement had already been done using compacted soil
cement layers up to EL 84.00m (RL 203.600 m).
Load tests on eight numbers of 1500 mm diameter test piles are being performed as per the
scheme provided at “Dwg. GHAVP1-2 / 21210 / 2001 / DD (Ref. Cl: 3(k))”. Table 1 includes the
summary of tests to be conducted on 1500 mm diameter test piles. As per Table 1, Initial vertical
compression pile load test is to be performed on VT-04, VT-05, VT-06, HS-05 and HS-06. This
report provides observations and inferences of the test conducted on VT-04.
Load test on VT-04 was started on 17.11.2019 and test was successfully completed on 19.11.2019.
Table 1: Scheme of Initial Pile load Test at GHAVP-1&2 for 1500 mm dia. Test piles
TEST PILE PILE TEST TEST INTEGRITY

INSTRUMENTATION DETAILS
SETUP DIA LENGTH PILE ID LOAD TEST
NOs MM M ID MT LSIT CSL VWSB PTPC INCLINOMETER
VT-04 4750 Y Y - - -
4 1500 40
LT-04 490 Y Y 24 Y
-
5 1500 40 VT-05 4750 Y Y - -
7
LT-05 490 Y Y Y
1500 40
HS-05 2850/4750 Y Y 29 -
VT-06 4750 Y Y -
-
6 1500 40 LT-06 490 Y Y Y
HS-06 2850/4750 Y Y 29 -
Legend:
VT- Vertical Pile Load Test (Compression); LT- Lateral Pile Load Test; HS – High Strain Dynamic Pile
Test; LSIT– Low Strain Pile Integrity Test; CSL – Cross-Hole Sonic Logging; PTPC- Pile Tip Pressure
Cell; VWSB – Vibrating wire sister bar
At test setup -4, four number of anchor/reaction piles of 1500 mm diameter and 47 m length are
installed for taking reaction during testing of piles at that location. Arrangement of anchor piles
w.r.t. test piles are provided at
Figure 1.
8
Figure 1: Layout of anchor pile w.r.t. test piles.
2. SCOPE
Scope of this report includes the outcome of vertical pile load test under compression conducted
on VT-04 in NB area of GHAVP-1&2 as per NPCIL specifications and IS 2911: Part-4.
3. REFERENCE DOCUMENTS
Following documents and drawings were referred:
Document/drawing Number Name of document/drawing

a) PC_M-00023 Technical Specification for piling works
b) IS 2911 Part-4 Design and construction of pile foundations-

code of practice Part 4: Load test on Piles
c) DRG. No. Layout of test pile & Anchor pile with test girder
TPL/340082/CV/GA/001 (Sheet 1of2 & 2of2) for 1500mm dia Initial vertical load test pile (Test
Load 4750T)
9
d) DRG. No. Layout of Test Piles and anchor piles for

TPL/340082/CV/GA/002 1500mm Dia.
e) Doc. No.: Procedure to be adopted to isolate reaction piles

TPL/340082/CV/GA/003 in Soil-Cement layer.
f) Doc. No. Work procedure for Construction of bored cast
GHAVP/2019/Methodology/N12TPLCM104 in-situ piles
g) Doc. No.: Work procedure for Low strain Pile Integrity test
GHAVP/2019 /N12TPLCM100.2 (PIT) and Integrity Testing by Sonic Logging (CSL)
h) Doc. No. : Design of Anchor Pile & test girder for 1500mm
GHAVP/2019 /N12TPLCM100.3 dia Initial Load test
i) Doc. No. Work Procedure for vertical Pile load test.

GHAVP/2019 /N12TPLCM100.4
j) Doc. No. Work procedure for Construction of bored cast

GHAVP/2019/Methodology/N12TPLCM104 in-situ piles
k) DRG. No. : Layout of Test Piles and anchor piles of NB-1&2

GHAVP-1&2/21210/2001/DD
l) Doc. No.: Report on jack efficiency test.
m) Doc. No.: Report on hydraulic jack efficiency test

conducted at VT-04 setup.
4. PILE TEST DETAILS

Construction of test and anchor piles was done as per the following schedule.
10
Test pile details

Test pile number : VT-04
Pile type : Bored cast in situ
Test load : 4750 MT
Diameter of test pile : 1500 mm
Length of pile : 40.0 m
Date of completion of pile casting : 19/07/2019
Date of completion of testing : 19/11/2019
Test pile cutoff level (EL) : 84.00m
Theoretical concrete quantity of test pile : 70.71 cum
Actual concrete poured in test pile : 72.00 cum
Age of the test piles when tested : 122 days
Average concrete cube strength of test pile at28
: 44.48MPa
days
Anchor pile details

Age of Anchor Piles during tested :
AP1A : 112 days
AP1B : 111 days
AP2A : 119 days
AP2B : 114days
Average concrete cube strength of anchor piles
:
at 28 days)
AP1A : 46.50MPa
AP1B : 41.60MPa
AP2A : 41.12MPa
AP2B : 41.99MPa
Pile test location details
Test piles at setup 4 are located in NB area of Nuclear Building of GHAVP-1&2 as shown in
11
Figure 2 below:
Figure 2: Test pile and its location
Ground condition at test pile location

VT-04 is located within the vicinity of borehole BH-67 of GHAVP-1&2. Bore log data is enclosed in
Annexure-3 (A). Within the vicinity of this test pile, Ground improvement was carried out upto EL
84.00 m where the depth of GI is 3.6 m.
Water Table at VT-04 location was at 3.6m below existing GI level before installation.
Material details for test and anchor piles

Grade of concrete : M35
Reinforcement : Fe 500
HT Strand : Conforming to class II of IS 14268
Measured strength of concrete cubes and reinforcement test certificates are provided at
Annexure-3 (B).
Load application and measurement system

Number of anchor piles : 4 Nos.
Diameter of anchor piles : 1500 mm
12
Length of anchor piles : 47.0 m

HT strand in each anchor pile : 4 x 27 numbers of 15.2 mm diameter
Capacity of each hydraulic jack : 800 MT
Number of hydraulic jack used : 4 Nos.
Bore area of each jack (area of cross section) : 1176.3 cm2
Total bore area of all jack : 4705.2 cm2
Efficiency of hydraulic jacks considered for plotting
load settlement curve based on test conducted up to : 97.78 %
125 MT load.
Average efficiency of all jacks (based on test
conducted on all jacks up to664.6 MT load) : 97.82 %
Pressure gauge range : 0 to 1000 Kg/cm2
Least count of main pressure gauge : 10 Kg/cm2
Least count of redundant pressure gauge : 10 Kg/cm2
Settlement measurement system
Range of dial gauge : 0 to100 mm (4 nos.)
Range of LVDT : 0 to 50 mm (2 nos.)
Range of LVDT : 0 to 300 mm (2 nos.)
Least count of all the above devices is 0.01 mm.
5. LOAD TEST SET UP ARRANGEMENT

The test pile is jacked against the main girder at centre of the span to obtain desired reaction for
test load. The main girder was supported temporarily on concrete blocks. Main girder derived its
reaction from two secondary girders which in turn are anchored to four number of anchor piles
with HT Strands as shown in Figure-3 below.
13
(a) Plan
14
(b)Elevation
Figure 3: a) Plan, b) Elevation; Arrangement of vertical compression load test.
Total four numbers of 1500mm diameter anchor piles of 47.0m length were provided. Reaction
system arrangements including anchor piles, HT Strands, main girder and two secondary girders
were provided as per design reports referred at Cl.: 3g and 3h.
Anchor piles have been isolated in the top portion where ground improvement (GI) is done with
soil-cement mix by boring larger diameter (1800 mm) throughout the depth of GI, using 1500 mm
15
diameter casing for concreting. The annular gap between anchor pile and improved ground (GI) is
filled with compacted sand as per approved procedure (Ref.Cl.: 3.i).
6. LOAD TEST PROCEDURE

Load test procedure was followed as per “Work Procedure for vertical Pile load test; Doc.
No.GHAVP-1&2/CIVIL/20000/PT-65/WP/10 (Ref. Cl 3(e))”. Pile integrity tests (low strain integrity
test and sonic logging) were carried out as per above reference Cl. 3(f) and reports of the same are
enclosed atAnnexure-2(B) and 2(C). Brief of procedure followed for initial pile load test is as
provided below:
a) The complete set up was set at initial reading before start of load application
b) For application of load, four number of hydraulic jack each having a capacity of 800 MT along
with a power pack and duly calibrated pressure gauges were used. Total three pressure gauges
were used to verify the load imparted through hydraulic jacks
c) Load increments were applied as per Error! Reference source not found..
d) For measurement of settlement following arrangements were used:
i.Two numbers of LVDTs of 0 - 50 mm measurement range
ii.Two numbers of LVDTs with 0 - 300 mm measurement range
iii.Four number of dial gauge with measurement range of 0-100mm
Least count of all above devices was 0.01 mm. Measuring devices were placed on top of plate duly
held by magnetic bases, fixed on two rigid and immovable datum bars. Datum bar supports were
placed more than 3D (D-diameter of pile) away from all the piles.
e) As an additional safety measure, dial gauge readings were taken remotely using cameras closely
placed against each dial gauge ensuring no parallax error. The live displays of readings were
available in a container cabin safely placed sufficiently away from test setup. The setup can be
clearly seen at Annexure-1.
16
f) Displacement data of LVDTs were stored in PC in retrievable format with input channel
identification and with measurement data and time record.
g) Each stage of loading was maintained till the rate of movement of the pile top is not more than
0.2 mm/hr. or until 2 hr. have elapsed, whichever is earlier subjected to a minimum of 1 hr.
h) After application of each stage of loading, continuous logging of LVDT readings were done at
intervals of 5 min using data logger and dial gauge readings were taken at about every 15 min
interval.
i) When measurement ranges of the displacement measuring devices were exhausted, they were
reset for taking further measurement.
j) As settlement of pile top crossed 10% of pile diameter that is 150 mm at xxx MT (0.9778 x xxxxx
MT), after one hr. of loading, further increment of load was stopped.
k) Peak load corresponding to pressure of xxxx kg/cm2 (xxxx MT) could not be maintained beyond
17 hrs. due to increase in the settlement beyond 10% of pile diameter and combined
displacement of the reaction system& pile reached the maximum available travel length of the
ram of Jack. With subsequent increase in displacement of pile and reaction system, jack
pressure reduced slightly and stabilized at around 380 kg/cm2 (corresponding load of 1788 MT),
which was maintained upto 24hours. After 24 hours, the pressure was released in decrements
of about 10% of final applied load with one hour waiting time in between each stage and
rebound observations were recorded and plots of load (MT) vs. settlement (mm) curve
prepared.
7. LOAD TEST RESULTS

Load vs. settlement
Field data recorded during the test are provided at Annexure-2 (A). Summary of average total
settlement at each step of loading and unloading are provided at Error! Reference source not f
ound.. Load vs. settlement plots corresponding to Error! Reference source not found.are
provided atError! Reference source not found..
17
The final applied load recorded was xxxx MT (0.9778 x xxxx MT) and corresponding average
settlement recorded by dial gage was xxxx mm at 17th hr. of final applied load. However, the
maximum recorded settlement by dial gauge was xxxx mm. The average rebound of pile based on
dial gauges readings from maximum measured settlement is xxxx mm.
8. OBSERVATIONSANDINFERENCES
i. The initial pile load test on test pile VT-04 was taken up on 17/11/2019. The load on the test pile
was applied in stages as per the approved procedure and was measured with the use of pressure
gauge. Two additional pressure gauges were also connected to verify the applied load. Main
Pressure gauge reading were in close match with one alternate pressure gauge. 2 nd alternate
pressure gauge reading was varying @ about 10 kg/cm2 on lower side. There was a close match
among settlement readings of dial gauges and LVDTs.
ii. The load v/s settlement readings of test pile, both during loading and unloading steps are
presented at Error! Reference source not found.. The Settlement values observed at maximum l
oad of xxxx MT after 17th hr. of stabilization are presented below:
i) With 100mm Dial Gauges : mm

ii ) With 300mm range LVDT : mm
iii) With 50mm range LVDT : mm
However, the maximum recorded settlement by dial gauge was xxxxx mm.
iii. The average rebound of pile based on dial gauges readings from maximum measured settlement
is xxxx mm.
iv. No uplift was recorded by total station (TS) on anchor piles uptoxxxx MT applied load on test pile.
However, at final applied load on test pile (xxxx MT), total measured uplifts of anchor piles were
as follows: AP1A: 3 mm; AP1B: 2 mm; AP2A: 2 mm and AP2B: 1 mm (details enclosed at
Annexure-2(A)).
18
ANNEXURE 1
SITE PHOTOGRAPHS
19
ANNEXURE 2
ANNEXURE 2(A) FIELD DATA-DIAL GAUGE, LVDT VS. LOAD AND ANCHOR PILE
UPLIFT
ANNEXURE 2(B) PILE INTEGRITY TEST REPORT
ANNEXURE 2(C) CROSS HOLE SONIC LOGGING
20
ANNEXURE 3
ANNEXURE 3(A) BORE LOG DATA

ANNEXURE 3(B) CONCRETE CUBE TEST RESULTS AND REINFORCEMENT TEST
CERTIFICATES
21
ANNEXURE 4
CALIBRATION CERTIFICATES
22

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NPCIL-GORAKHPUR HARYANA ANUVIDYUT PARIYOJANA

NUCLEAR POWER CORPORATION OF INDIA LIMITED

DOCUMENT ACCEPTANCE NOTE

Submitted By : M/s -TATA Projects Limited.

Work order No. : GHAVP-1&2/Civil/WO-78

NUCLEAR POWER CORPORATION OF INDIA LIMITED

Submitted By : M/s -TATA Projects Limited.

REVISION CONTROL SHEET

WORK ORDER NO.: GHAVP/1&2/CIVIL/WO-078, DT.15.02.2019

TPL DOCUMENT NO: GHAVP/2019/N12TPLCM100.3

TATA PROJECTS LTD NPCIL

4PILE TEST DETAILS .................................................................................................................... 10

5LOAD TEST SET UP ARRANGEMENT........................................................................................... 13

6LOAD TEST PROCEDURE ............................................................................................................ 15

7LOAD TEST RESULTS ................................................................................................................. 16

8OBSERVATIONS AND INFERRENCES .......................................................................................... 17

ANNEXURE 1 SITE PHOTOGRAPHS

Figure 1: Layout of anchor pile w.r.t. test piles. ............................................................................................ 8

NPCIL : Nuclear Power Corporation of India Limited

TEST PILE PILE TEST TEST INTEGRITY

NOs MM M ID MT LSIT CSL VWSB PTPC INCLINOMETER

w.r.t. test piles are provided at

Figure 1: Layout of anchor pile w.r.t. test piles.

Following documents and drawings were referred:

Document/drawing Number Name of document/drawing

b) IS 2911 Part-4 Design and construction of pile foundations-

d) DRG. No. Layout of Test Piles and anchor piles for

e) Doc. No.: Procedure to be adopted to isolate reaction piles

i) Doc. No. Work Procedure for vertical Pile load test.

j) Doc. No. Work procedure for Construction of bored cast

k) DRG. No. : Layout of Test Piles and anchor piles of NB-1&2

l) Doc. No.: Report on jack efficiency test.

m) Doc. No.: Report on hydraulic jack efficiency test

4. PILE TEST DETAILS

Test pile details

Anchor pile details

Figure 2: Test pile and its location

Ground condition at test pile location

Material details for test and anchor piles

Load application and measurement system

Length of anchor piles : 47.0 m

5. LOAD TEST SET UP ARRANGEMENT

6. LOAD TEST PROCEDURE

7. LOAD TEST RESULTS

i) With 100mm Dial Gauges : mm

ANNEXURE 3(A) BORE LOG DATA

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