Apply Corrosion Protection at Pile Heads – QA Checklist

Definition: Apply corrosion protection at pile heads for steel and concrete interfaces using specified coatings or cathodic connections, ensuring verified DFT, batch traceability, and exclusion of jackets for QA teams.

Verify scope, materials, and methods per approved project specifications.
Control surface prep, environment, and DFT for durable protection.
Install cathodic interfaces with verified continuity and isolation.
Interactive, commentable, export options with QR code verification.

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Checklist

Apply corrosion protection at pile heads is a focused quality-control activity covering pile head coating application and cathodic protection interface works where specified. This checklist addresses surface preparation, environmental controls, DFT verification, holiday testing, electrical continuity/isolations, and documentation of coating batch numbers. It applies to steel and concrete pile head interfaces adjacent to caps, plinths, or slabs, and expressly excludes pile jackets or encasement systems. By following these steps, teams reduce early coating failures, underfilm corrosion, and CP malfunction caused by poor bonding, moisture entrapment, or inadequate thickness. Outcomes include traceable coating lots, reproducible DFT measurements in micrometres, defect-free film via holiday detection, and proven CP terminations with secure torque values and low resistance paths where required. Use this interactive checklist to assign tasks, tick items, add field comments, attach photos and readings, and export to PDF/Excel with a QR for authentication.

Ensure compliant corrosion protection at pile heads by controlling surface cleanliness, profile, ambient conditions, and dry film thickness. Achieve defect-free coatings and reliable cathodic interfaces while documenting batches, tools, and calibrated measurements for full traceability.
Avoid premature coating failure and CP issues by verifying dew point separation, moisture-free substrates, stripe coats at edges, curing windows, and zero-holiday results. Capture photo evidence, meter readings, batch labels, and sign-offs at each stage.
Confirm correct cathodic connections and isolations at the pile head, including verified torque, protected terminations, and continuity values within specified limits. Prevent inadvertent shorts to reinforcement and preserve designed electrical pathways.
Interactive online checklist with tick, comment, and export features secured by QR code. Share records instantly with stakeholders and archive verified PDFs/Excels for closeout and authority submissions without rework.

Pre-Work Verification

1. Confirm scope, materials, drawings, and exclusions.
2. Confirm scope excludes jackets; do not plan or install pile jackets or encasements; record supervisor confirmation and photo of area.
3. Verify latest approved method statement and project specifications are available on site; record document numbers and revision dates.
4. Check coating materials and thinners match the approved data sheet; photograph batch/lot numbers and expiry dates for each container.

Environmental and Surface Conditions

5. Measure air/substrate temperature and relative humidity with a calibrated thermo-hygrometer; ensure substrate is at least 3 °C above dew point; log readings with time.
6. Confirm wind, spray, and dust control (sheathing or windbreaks) are in place; attach photos of protection and note start/stop times.
7. Verify surface is dry and salt-free at pile head; conduct soluble salt test if required; record result within the specified limit per approved project specifications.
8. Mask adjacent concrete/cap interfaces to maintain clean boundaries; photograph masking lines and label measurement offsets from reference points.

Surface Preparation

9. For steel pile heads, abrasive blast to the specified cleanliness; record compressor dew point, abrasive type, pressure, and visual comparators; attach pre/post photos.
10. Measure surface profile on steel using a replica tape or comparator; record average profile within specified range; attach readings and tape impressions.
11. For concrete pile heads, mechanically prepare surface to sound substrate; remove laitance; document pull-off soundness checks and dust removal method.
12. Clean prepared surfaces by oil-free blow-down and solvent wipe where required; use lint-free cloths; photograph cleanliness prior to first coat.

Coating Application and Curing

13. Verify mixing ratios, induction time, and pot life per data sheet; record start time, ambient, and batch numbers; attach mixing photos.
14. Apply stripe coat to edges, welds, and sharp transitions at pile head; note coverage method/brush/roller and time applied; photograph targeted areas.
15. Spray or roll first full coat to achieve specified wet film thickness; record WFT checks with comb gauge at 5+ locations; log values.
16. Measure DFT after cure with a calibrated gauge; record min/avg/max DFT in µm across 5+ spots; acceptance within specified range.
17. Respect overcoat and cure times based on ambient conditions; record time stamps between coats; verify final cure per manufacturer guidance.

Cathodic Interface Installation

18. Install CP connection pad or lug at pile head as detailed; clean contact area to bright metal; photograph before/after contact surface.
19. Terminate CP cable with approved lug, heat-shrink, and mechanical protection; torque fasteners to specified value; record torque and tool serial.
20. Verify electrical continuity from lug to pile steel; measure resistance with a calibrated meter; acceptance ≤ 0.1 Ω or per specification; log reading.
21. Apply dielectric/insulating coating where isolation is required from adjacent reinforcement; document boundaries and confirm no bridging to rebar.

Inspection, Testing, and Documentation

22. Perform holiday test on final coating thickness with appropriate voltage; acceptance: zero holidays; mark and repair any pinholes; retest and record.
23. Affix durable label or stencil with system, number of coats, total DFT, date, and inspector initials; photograph for records.
24. Compile batch certificates, calibration records (DFT gauge, hygrometer, torque tool), photos, and signed ITP check sheets; export and attach QR-authenticated report.

Scope, Interfaces, and Exclusions

This checklist governs corrosion protection at pile heads where coatings and cathodic protection interfaces occur. It focuses on the immediate head zone at steel or concrete interfaces with caps or slabs. Tasks include environmental control, surface preparation, coating application, DFT verification, holiday testing, and cathodic connection termination or isolation work. Jackets or encasements are outside scope; confirm they are excluded before starting. Success relies on clear boundaries, correct masking at construction joints, and coordination with structural and electrical teams to avoid clashes. Field teams should align on acceptance thresholds per approved project specifications and authority requirements. Practical outcomes include a defect-free film in micrometres, proven electrical continuity where required, and traceable material records. The flow moves from verification to preparation, application, testing, and documentation—minimizing rework and ensuring durable protection in aggressive environments such as marine splash or de-icing exposure.

Work only at pile heads and adjacent cap interfaces.
Exclude jackets and encasement systems from this scope.
Coordinate with CP, structural, and coatings teams.
Define acceptance limits per approved specifications.
Mask boundaries to maintain clean interface lines.

Surface Preparation and Coating Controls

Durable protection starts with clean, profiled substrates and controlled ambient conditions. For steel, abrasive blasting to the specified cleanliness removes mill scale and rust; measure anchor profile with comparators or replica tape and record averages. For concrete, mechanically abrade to a sound surface, removing laitance and dust. Control moisture by verifying the substrate is at least 3 °C above dew point and salt contamination is within limits. Apply a stripe coat to edges and transitions, then full coats to the specified wet film thickness. Calibrate gauges, record WFT during application, and confirm DFT after cure using multiple readings. Respect recoat windows and minimum cure times to avoid intercoat adhesion failures. Conduct holiday testing on the finished film and repair any defects promptly before retesting. Label the completed system clearly for future maintenance reference.

Maintain ≥ 3 °C dew point separation.
Record WFT during application and DFT after cure.
Stripe coat edges and discontinuities first.
Repair and retest any holiday indications.
Calibrated instruments with current certificates.

Cathodic Interface and Documentation

Where cathodic protection is specified, the pile head interface must provide reliable electrical performance and long-term durability. Prepare the contact surface to bright metal, install the correct lug or pad, and protect the termination with heat-shrink and mechanical guards. Verify fastener torque and measure resistance from lug to pile steel to confirm continuity; also confirm isolation from adjacent reinforcement when required, avoiding unintended shorts through concrete interfaces. After coating and CP works, compile a complete record pack: batch labels, product data sheets, calibration certificates, environmental logs, DFT and holiday test results, continuity readings, and photographs before, during, and after each operation. Finally, generate an exportable report with signatures, timestamps, and a QR code to authenticate the record for handover and future audits.

Clean, bright-metal contact at CP pads.
Record torque and continuity resistance.
Protect terminations with heat-shrink/guards.
Confirm isolation from reinforcement where required.
Export signed pack with QR authentication.

How to Use This Interactive Pile Head Corrosion Protection Checklist

Preparation: Assemble approved specifications, drawings, ITP, SDS, and data sheets. Gather tools: DFT gauge, WFT comb, thermo-hygrometer, dew point calculator, replica tape, holiday detector, torque wrench, multimeter, blasting/abrasion tools, masking, PPE.
Open the checklist and select the work location and pile ID. Confirm that jackets are excluded and the correct coating/CP interface details apply to this pile head.
Using the Interactive Checklist: Start interactive mode, tick each item as performed, and add time-stamped comments with photos of readings, batch labels, and surface condition evidence.
Enter numerical measurements directly into fields (DFT in µm, dew point separation in °C, torque in N·m, resistance in Ω). Attach instrument calibration certificates.
If an item fails, flag it, add a corrective-action comment, and assign it to the responsible party. Retest and document closure with new readings and photos.
Export the completed record as PDF/Excel with embedded photos and measurement logs. Enable QR code to authenticate the exported file against the online record.
Sign-Off: Obtain digital signatures from contractor, QC inspector, and client representative. Include date/time stamps and role titles.
Archive: Store the signed checklist in the project document system and link it to the as-built record and maintenance plan for future reference.

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Lila Gonzalez Lila Gonzalez

Feb 04, 2026

FAQ

Question: What DFT should I target at the pile head and how many readings are required?

Target the total DFT specified in the approved project specifications and manufacturer data sheet. Take multiple readings per area to capture min/avg/max values; five or more across the pile head zone is typical. Record each µm measurement with location references and confirm all values meet the allowable tolerance band.

Question: How do I verify environmental conditions before coating the pile head?

Use a calibrated thermo-hygrometer to measure air temperature and relative humidity, and determine dew point. Confirm the substrate is at least 3 °C above dew point and the surface is visibly dry and salt-free. Log readings with date/time, instrument serial, and photos of the prepared surface before applying any coat.

Question: What tests confirm the cathodic interface is correctly installed?

Clean the contact surface to bright metal, torque the connection to the specified value, and measure electrical continuity from the lug to pile steel using a calibrated meter. Acceptance is a low resistance path per specification. Where isolation is required, confirm no continuity to adjacent reinforcement or embedded steel.

Question: Why are jackets excluded from this checklist?

This checklist focuses on pile head coatings and cathodic interfaces only. Jackets involve different materials, installation methods, and acceptance criteria. Excluding jackets prevents scope overlap and ensures each system is installed and inspected per its dedicated procedure and approval requirements.

Question: What documentation is needed for closeout and audits?

Provide coating batch/lot photos, product data sheets, calibration certificates, environmental logs, WFT/DFT records, holiday test results, torque and resistance readings, annotated photos, and signed ITP check sheets. Export the interactive checklist as PDF/Excel with a QR code to authenticate the record against the online source.