Piling & Foundations
QA inspection checklist

Setting Out & Setup

1. 1.

   Pile positions set out and checked against drawings
   What to look forEach pile position pegged from setting-out grid. Number reference matches pile schedule. Position checked by independent surveyor or second pair of eyes. Reference taken from solid datum, not from temporary works that may move.
   Acceptable whenPer BS EN 1536:2010 (bored piles) / BS EN 12699 (driven piles): plan position tolerance ±75 mm at platform level; per ICE Specification for Piling (SPERWALL) ±50-75 mm depending on diameter. Verified before drilling.
   StandardBS EN 1536:2010 — Bored piles. BS EN 12699:2015 — Displacement piles. ICE Specification for Piling and Embedded Retaining Walls (SPERWALL) 3rd Edition.
   Common defectsPile position out of tolerance — eccentricity creates pile cap loading not designed forSetting-out from a wandering control point — cumulative drift across siteWrong pile number installed at a position — schedule confusedNo witness check after auger removed — position drifted in soft ground
2. 2.

   Platform level and adequate for rig
   What to look forWorking platform designed by competent person, signed off. Granular fill to spec, compacted. CBR/bearing capacity matches platform design. No standing water. Edge of platform stable for rig outrigger.
   Acceptable whenPer FPS Working Platforms Guide: platform designed for the rig's ground bearing pressure (typically 100-300 kPa). CBR ≥ 30% typical, depth 600 mm-1 m. BRE 470 / Working Platform Certificate signed by designer.
   StandardFPS (Federation of Piling Specialists) Working Platforms Guidance. BRE BR 470 — Working platforms for tracked plant. CIRIA C703 — Site investigation in construction.
   Common defectsNo working platform certificate — rig overturning riskPlatform too thin for rig pressure — punching shear failureStanding water — CBR collapses, rig sinksReused platform from another rig — different bearing pressure not assessedEdge of platform not battered — rig outrigger sinks at boundary
3. 3.

   Services check completed (CAT scan)
   What to look forCAT/Genny scan at every pile position. Scan radius minimum 2 m around pile centre. Suspect signals trial-pitted to confirm. Service drawings overlaid on pile plan. Permit-to-dig issued.
   Acceptable whenPer HSG47 — Avoiding danger from underground services. CAT scan in two modes (power + radio) covering full footprint of dig. Trial pits where signals indicate. Permit-to-dig issued before pile installation begins.
   StandardHSG47:2014 — Avoiding danger from underground services. CDM Regulations 2015. NJUG (National Joint Utilities Group) Volume 1.
   Common defectsCAT scan only at pile centre, not full diameter — adjacent service hitService drawings out of date — uncharted services existPlastic gas pipes not detected (no metal trace) — burst on drillingNo trial pit where strong signal — assumed to be steel meshPermit-to-dig not signed before drilling

Pile Installation

1. 4.

   Pile type and size correct per design
   What to look forPile type matches design (CFA, bored cast in place, driven precast, driven steel, sheet pile). Diameter measured at auger or casing. Reinforcement cage matches pile schedule (length, bar size, helical stirrups).
   Acceptable whenPer design drawings and pile schedule. Tolerance on diameter ≤ +50 mm / -10 mm (CFA per BS EN 1536). Reinforcement length ≥ design depth, cage cover spacers adequate. Bar grade per design (typically B500B).
   StandardBS EN 1536:2010 — Bored piles. BS EN 12699:2015 — Displacement piles. BS 4449 — Reinforcement steel.
   Common defectsWrong auger diameter used — pile undersizedReinforcement cage too short — does not extend to design depthCover spacers missing — cage drops to one side, low coverSubstituted bar grade or bar size — capacity reducedCage damaged during installation, bars displaced
2. 5.

   Pile installed to correct depth / set

   Record: Depth (m)
   What to look forFor bored/CFA: depth measured by drill string or penetration into auger. For driven: set per blow count, hammer energy. Founded in correct stratum (engineer to confirm). Auger withdrawal rate matched to concrete pump rate (CFA — no over-bored "necking").
   Acceptable whenPer design depth or to set per BS EN 12699 (driven). CFA per BS EN 1536: positive concrete pressure during withdrawal (typically 0.1-0.3 MPa). Driven pile final set: typically 25 mm/10 blows for end-bearing pile; SPT/CPT-based design for friction piles.
   StandardBS EN 1536:2010. BS EN 12699:2015. BS EN 1997-1 (Eurocode 7).
   Common defectsCFA auger withdrawn faster than pump rate — necking or voidPile founded short of design stratum — capacity inadequateDriven pile final set not achieved at design depth — geotechnical re-designSet measured by eye, not gauge — unreliableNo log of concrete volume vs pile theoretical — over-supply hides defect
3. 6.

   Pile verticality within tolerance

   Record: Rake deviation
   What to look forVerticality checked by inclinometer on the kelly bar/leader before and during drilling. Inclined piles checked against design rake angle. Drift correction applied if needed.
   Acceptable whenPer BS EN 1536 / SPERWALL: vertical piles ≤ 1 in 75 (≈ 13 mm/m). Raked piles ±2° from design rake. Out-of-vertical at pile head ≤ 75 mm typical for cast-in-place.
   StandardBS EN 1536:2010. BS EN 12699:2015. ICE Specification for Piling (SPERWALL).
   Common defectsPile leans into stronger ground — no continuous inclinometer monitoringVerticality measured only at platform — drift below ground undetectedRaked pile angle out by 5-10° — design assumed perfect rakeInclinometer not zeroed correctly
4. 7.

   Concrete grade correct (CFA/bored)
   What to look forDelivery ticket inspected — grade, slump class, max aggregate, designed for piling (high cement, retarder, plasticiser). Tested for slump/flow. Cubes taken from each truck or every 50 m³.
   Acceptable whenPer BS EN 1536: concrete with high workability — slump class S4 (160-210 mm) or self-compacting (SCC). Strength typically C28/35 or C32/40. Max aggregate 20 mm for typical CFA (10 mm for slim cages). Workability retention ≥ 3 hours.
   StandardBS EN 1536:2010 cl.7.4. BS 8500-1 — Concrete specification. BS EN 206.
   Common defectsWrong slump — too dry, does not flow round cage, voidsConcrete > 3 hours old — workability lost, voidsNo retarder in hot weather — concrete sets in pump lineCubes not taken — no proof of strengthWrong grade delivered — visible on ticket
5. 8.

   Pile log completed
   What to look forPile log per pile: position, depth, time, concrete volume, concrete pressure (CFA), penetration rate, founding stratum description (where confirmed), reinforcement cage details. Signed by piling engineer and contemporaneous.
   Acceptable whenPer BS EN 1536 / SPERWALL: pile log mandatory for each pile. Records depth, time, concrete volume per metre depth (vs theoretical), penetration rate, soil strata. Concrete volume monitoring catches voids early.
   StandardBS EN 1536:2010 cl.10. ICE SPERWALL.
   Common defectsPile log filled in retrospectively — not contemporaneousConcrete volume figures suspiciously round — not actually meteredNegative differential (theoretical > actual) — pile under-supplied, voidStrata description missing — no record of foundingHand-written illegibly, no engineer sign-off

Testing & Completion

1. 9.

   Integrity test completed
   What to look forLow-strain (sonic echo / TDR) integrity test on percentage of piles per spec. Test report shows each pile signature, reflections at base, no anomalies indicating necking, void, or cross-section change.
   Acceptable whenPer ICE SPERWALL / Class A piling: low-strain integrity testing on minimum 25% of piles (often 100% on critical piles). Tested at minimum 7 days age. Reflections from anomaly < 10% of pile diameter typically acceptable.
   StandardBS EN 1536:2010 cl.10. ICE SPERWALL — Integrity testing. ASTM D5882 (low strain).
   Common defectsAnomaly indicating necking or void — investigation required, possibly excavate to inspectCross-section change at depth — concrete pumping interruptedTest reading too short — pile longer than reflection time, indicates major loss of cross-section near surfaceTest scope below specified percentageAnomalies "interpreted away" without investigation
2. 10.

   Load test completed (if required)
   What to look forStatic maintained-load test (kentledge or reaction pile system) or dynamic load test. Loaded to design verification load (typically 1.5 × SWL). Settlement measured at multiple stages. Test pile not used in permanent works unless specifically allowed.
   Acceptable whenPer ICE SPERWALL / BS EN ISO 22477-1: preliminary load test to 2.0-2.5 × SWL; working load test 1.5 × SWL. Acceptance: total settlement ≤ specified (typically 10-25 mm), residual settlement ≤ 50% of total.
   StandardBS EN ISO 22477-1:2018 — Testing of geotechnical structures — Pile load tests. ICE SPERWALL.
   Common defectsTest load not maintained for required durationSettlement gauges drifting — kentledge frame movingLoad test pile re-used in permanent works without re-designExcessive settlement at design load — capacity reduction neededNo load test programme on critical structures
3. 11.

   Pile head trimmed to correct level

   Record: Level (m AOD)
   What to look forCropping cuts pile back to a sound concrete level — no soft, contaminated material at top. Reinforcement projects to correct length for cap connection. Level measured to design.
   Acceptable whenPer BS EN 1536 / SPERWALL: pile cut-off level ±25 mm to design. Top concrete sound (compressive strength matched to body of pile). Starter bars project to length per pile cap design. No mud or contaminated concrete at top.
   StandardBS EN 1536:2010 cl.9. ICE SPERWALL.
   Common defectsPile cut high — pile cap reinforcement clashesContaminated concrete at top — mud/laitance ring, cropped insufficient depthReinforcement starter bars too short — no anchorage in capCropping with hammer damages concrete below cut-off — cracks below ground levelFinal level not surveyed — assumed only
4. 12.

   Pile schedule and as-built records complete
   What to look forPile schedule shows each pile: position (designed and as-built), depth, concrete volume, founding stratum, integrity test result, load test result (where applicable), trim level. Bound report with engineer's certification.
   Acceptable whenPer CDM 2015 Health & Safety File. ICE SPERWALL — pile records. Includes designed vs as-built positions, all logs, all test results, sign-off by competent piling engineer.
   StandardICE SPERWALL. CDM 2015 — Health and Safety File. BS EN 1536:2010 cl.10.
   Common defectsAs-built positions not surveyed and recorded — pile cap design may need revisionRecords missing for "rejected" piles — replacement pile not documentedIntegrity test results not in packNo engineer sign-offPile log gaps — entries marked "as designed" with no actual data

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