Install shear keys/dowels at pile heads – checklist

Definition: Install shear keys/dowels at pile heads checklist guides site engineers to drill, clean, epoxy grout, align, and verify embedment, ensuring compliant shear transfer without starter bars on pile cap interfaces.

Defines steps for drilling, cleaning, epoxy anchoring, and alignment.
Prevents rebar strikes, poor bond, and insufficient embedment depth.
Evidence-based QA with measurements, photos, batch numbers, and approvals.
Interactive, commentable checklist; export results with QR code.

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Checklist

Install shear keys/dowels at pile heads is a focused installation and QA process for transferring shear across the pile-to-cap interface. This checklist covers drilled dowel installation, epoxy anchoring, and embedment verification while explicitly excluding reinforcement starters. It guides site engineers and inspectors through layout, rebar scanning, drilling, hole cleaning, adhesive injection, bar alignment, and post-cure checks. By standardizing dowel installation at pile heads, teams reduce risks like striking reinforcement, voided adhesive bonds, inadequate embedment, misalignment, and early loading before full cure. The result is reliable shear transfer and orderly records ready for quality and compliance reviews. Practical cues—such as angle tolerances, brush–blow cycles, moisture control, and proof testing if specified—are paired with photo evidence, batch tracking, and signatures. Use this interactive checklist to tick each step, comment on anomalies, attach photos and reports, and export your completed records to PDF/Excel with a secure QR link.

A disciplined method for drilling, epoxy anchoring, and aligning dowels at pile heads that avoids reinforcement strikes, prevents voids and under-embedment, and documents temperatures, batch numbers, and approvals for robust shear transfer performance.
Field-proven sequence with acceptance tolerances for angle, spacing, hole preparation, and cured embedment. Includes hold points, optional proof pull testing, and clear evidence requirements—photos, measurements, and signatures—to streamline quality assurance and audits.
Interactive online checklist with tick, comment, and export features secured by QR code. Capture bore photos, adhesive lot numbers, and alignment readings, then export to PDF/Excel for distribution to contractors, consultants, and authorities.
Scope stays specific to shear keys/dowels at pile heads and excludes reinforcement starters. The checklist supports compliant installation per approved project specifications and authority requirements without prescribing project-specific design clauses.

Pre-Installation Verification

1. Confirm the activity excludes reinforcement starters; only shear keys/dowels at pile heads per approved drawings. Mark up plan showing excluded starters; capture supervisor sign-off and photo of markings.
2. Verify dowel diameter, grade, and coating per bar schedule using callipers and mill certificates; record heat/lot numbers and acceptance signature in the ITP.
3. Measure ambient and substrate temperatures with an infrared thermometer; confirm within adhesive manufacturer’s application range; log readings and hold work if out-of-range.
4. Set out dowel centres and edge distances with a rigid template and steel tape; tolerance ±5 mm from drawings; photograph layout with a visible scale.
5. Scan pile head using ferroscan/GPR to avoid existing reinforcement; adjust hole positions if required; attach scan images and revised markup approved by the engineer.

Drilling and Hole Preparation

6. Fix a drill stand or jig to maintain the design angle (typically perpendicular); verify with a digital angle gauge; tolerance ≤ 2° from design; photo evidence.
7. Drill to specified diameter and depth per drawings and adhesive TDS; measure depth with a calibrated gauge rod; tolerance ±5 mm; record measurements per hole.
8. Control breakout near surfaces by moderating hammer action and respecting minimum edge distances; inspect for spalls; record condition photos and proposed repairs if needed.
9. Clean each hole with brush–blow cycles using a nylon brush and oil-free compressed air until dust-free; minimum two full cycles; attach bore photos for evidence.
10. Confirm hole moisture condition matches adhesive requirements (dry or SSD); verify with lint-free swab; if wet beyond limits, dry with a heat gun; log method and result.

Bar Preparation and Epoxy Grout

11. Cut and deburr dowels to achieve design embedment and projection; tolerance ±5 mm; mark insertion depth line with permanent marker; photograph bar markings.
12. Degrease and abrade the bonding length to bright metal; ensure surfaces are free of oil and rust bloom; capture close-up photos of prepared bars.
13. Trial fit each bar to confirm embedment and projection using a depth stop or collar; acceptance: mark aligns with surface; record pass/fail per hole.
14. Condition adhesive cartridges to TDS temperature range; check expiry; fit a new mixing nozzle; purge until uniform colour; record batch/lot numbers and purge length.
15. Inject adhesive from hole bottom while withdrawing nozzle to avoid voids; fill approximately two-thirds of the hole; photograph filled hole prior to insertion.

Installation and Alignment

16. Insert the dowel while rotating slowly to wet all surfaces; seat to the marked line; acceptance: depth line flush within ±3 mm; record insertion time.
17. Install temporary jigs or clamps to prevent movement during gel time; verify bar angle with a magnetic level; tolerance ≤ 2°; photo evidence of gauge reading.
18. Check centre-to-centre spacing and edge distances after insertion using a steel tape; tolerance ±5 mm from drawings; capture scaled photos of measurements.
19. Remove excess expelled adhesive and form a clean fillet at the annulus; avoid contaminating adjacent concrete; dispose of waste per SDS; photo of finish.

Embedment Verification and QA

20. Maintain an exclusion zone until full cure; log ambient and substrate temperatures and adhesive cure time; confirm cure complete per TDS before any load or impact.
21. Verify embedment after cure using a depth probe or endoscope where accessible; acceptance: embedment meets or exceeds design; record measurements with photos or video.
22. If specified, conduct proof pull-out tests with a calibrated tester; acceptance per approved project specifications and authority requirements; attach test report and calibration certificate.
23. Complete ITP hold points and obtain installer, supervisor, and engineer approvals; notes must confirm exclusion of starters; upload signed records to the checklist.

Finishing and Documentation

24. Fit protective caps or foam sleeves to protruding dowels to prevent damage before pile cap works; photo evidence of protections in place.
25. Apply specified temporary corrosion protection to exposed steel if required; record product name, lot number, and application date; capture photos after application.
26. Update as-built records with dowel sizes, locations, embedment, adhesive batch numbers, and tests; export the interactive checklist and photos to PDF/Excel with a QR-secured link.

Scope, boundaries, and intent

This checklist controls the installation of shear keys/dowels at pile heads to provide reliable shear transfer into the pile cap. It explicitly excludes reinforcement starters; only drilled dowels bonded with epoxy/grout are within scope. The process emphasizes coordinated setout, reinforcement scanning, controlled drilling, hole cleaning, adhesive handling, bar insertion, and alignment holding until full cure. By focusing on bond quality and embedment confirmation, it avoids common failures such as dust-contaminated holes, rebar strikes, under-embedment, and premature loading. Acceptance cues are practical: angle and spacing tolerances, brush–blow cycles, depth measurements, temperature logs, and photographic evidence. The outcome is a verifiable installation trail suitable for engineer review and regulatory audits. Use it for new works, remediation, or interface detailing where dowelled shear transfer is specified, always aligning details with approved drawings and manufacturer technical data sheets.

Scope: pile head dowels only, exclude reinforcement starters.
Use ferroscan/GPR to avoid hitting existing reinforcement.
Maintain angle ≤ 2° and setout tolerance ±5 mm.
Record temperatures, batch numbers, and cure times.
Capture scaled photos before and after insertion.

Drilling, cleaning, and adhesive bonding essentials

Bond quality depends on precise drilling and immaculate hole preparation. A stable drill stand and digital angle gauge hold orientation; a calibrated depth rod confirms embedment within ±5 mm. Near edges, moderate percussion to minimize spalls and maintain required distances. Clean each hole with nylon brush and oil-free compressed air in repeated brush–blow cycles until dust-free. Control moisture to the adhesive’s requirements—dry or SSD—documented with swab checks. Prepare bars by abrading to bright metal, degreasing, and marking the insertion line. Condition cartridges, fit a new nozzle, and purge until colour is uniform. Inject adhesive from the hole bottom, withdrawing the nozzle to eliminate voids, then rotate the bar during insertion to wet all surfaces. Hold alignment with jigs through gel time, prevent disturbance, and tidy expelled adhesive into a neat fillet.

Stable jig; verify angle with digital gauge.
Depth within ±5 mm using a calibrated rod.
Brush–blow cycles until holes are dust-free.
Control moisture per adhesive TDS requirements.
Purge nozzle; inject from hole bottom upward.

Verification, tolerances, and evidence-driven QA

Quality assurance pairs measurable tolerances with clear evidence. Verify setout (±5 mm), angle (≤ 2°), and projection against bar markings. Log ambient and substrate temperatures influencing cure; respect gel and full-cure times before any load or impact. After curing, confirm embedment by probe or endoscope where accessible. Where specified, execute proof pull tests with a calibrated rig and retain the calibration certificate. Every hole should carry traceable records: adhesive batch and expiry, purge length, insertion time, photos of bore cleaning, filled hole, depth mark alignment, and finished annulus. Capture approvals at ITP hold points and clearly state that reinforcement starters are excluded. Package all evidence into an exportable report for the engineer, client, and authority reviewers.

Angle ≤ 2°; spacing tolerance ±5 mm.
Cure per TDS before load or vibration.
Probe/embedment verification with photos or video.
Proof pull testing if project specifications require.
Export QA pack with batches, photos, signatures.

How to use this interactive checklist for dowel installation

Preparation: Brief the team on scope (exclude starters). Assemble drill stand, rotary/diamond drill, nylon brushes, oil-free air, ferroscan, depth rod, infrared thermometer, adhesive system with nozzles, jigs, PPE, and forms. Confirm drawings, ITP, and TDS.
Project setup: Enter project, pile IDs, dowel sizes, design embedment, and hold points. Preload acceptance tolerances (±5 mm, ≤ 2°) and required evidence (photos, batch numbers, signatures).
Using the Interactive Checklist: Start interactive mode, tick steps as completed, add comments for deviations, attach photos/scans, and tag responsible parties. Generate interim exports to PDF/Excel for daily reviews.
Sign-Off and Archiving: Capture digital signatures from installer, supervisor, and engineer. Lock the record with a QR-secured link, distribute to stakeholders, and archive with attachments for audits.

Install shear keys/dowels at pile heads checklist, QA

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Pile Head Shear Key/Dowel Installation

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Aria Cohen Aria Cohen

Feb 06, 2026

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FAQ

Question: What embedment depth should I use for dowels at pile heads?

Use the embedment specified on approved drawings and the adhesive manufacturer’s design guidance for the bar diameter and concrete strength. Do not substitute rule-of-thumb values. Measure with a calibrated depth rod, mark the insertion line on the bar, and record readings and photos for each hole.

Question: Can I install epoxy dowels if the holes are damp or the weather is cold?

Only if the adhesive technical data sheet permits it. Many systems allow dry or saturated-surface-dry holes within defined temperature ranges. Measure ambient and substrate temperatures, confirm moisture condition, and document both. If conditions fall outside limits, pause work or use approved cold-weather procedures and materials.

Question: How do I avoid striking existing reinforcement while drilling pile heads?

Scan the pile head with ferroscan or GPR, mark detected bars, and adjust hole positions while maintaining design spacing and edge distances. Obtain engineer approval for any shifts before drilling. Use a drill stand for control, reduce percussion near edges, and photograph the revised setout with a scale.

Question: When is it safe to load or pour the pile cap after installing dowels?

After the adhesive reaches full cure as stated in the technical data sheet. Record ambient and substrate temperatures, insertion time, gel time, and full-cure time. Maintain an exclusion zone to prevent vibration or impact until curing is complete, then verify embedment and alignment before proceeding.

Question: Are proof pull-out tests required for these dowels?

Perform proof pull-out tests only if specified in the project documents. Use a calibrated tester, follow the adhesive manufacturer’s method, and apply acceptance criteria per approved project specifications and authority requirements. Attach the load–displacement record, tester calibration certificate, and test photos to your QA package.