Pile Casing Inspection Checklist for Straightness, Joints, and Extraction

Definition: Pile Casing Inspection Checklist guides site engineers and inspectors to assess temporary and permanent pile casings for straightness, joints and weld quality, alignment, and planned extraction, excluding drilling logs.

Verify straightness and alignment to prevent off-axis bored piles.
Inspect joints, welds, collars, and locks for integrity and leaks.
Plan casing extraction with equipment limits, timing, and contingencies.
Interactive, commentable checklist with export and QR code traceability.

Start Interactive
Checklist

Pile Casing Inspection Checklist helps teams verify temporary and permanent pile casings for straightness, alignment, joint integrity, and extraction readiness. This focused pile casing inspection addresses casing alignment verification, weld inspection, ovality, and sealing needs without covering drilling logs or bore records. By controlling geometry and joints before installation, you reduce risks of eccentric piles, soil inflow, bent rebar cages, trapped casings, inadequate cover, and concrete contamination. During installation, continuous plumbness checks keep the casing within tolerance; after placement, a clear extraction plan prevents overstressing equipment or disturbing fresh concrete. Outcomes include concentric, plumb, and leak-tight casings that can be safely withdrawn (for temporary use) or left as permanent liners per approved project specifications and authority requirements. Use this interactive checklist to capture measurements, photos, NDT reports, and sign-offs, then tick items, comment on issues, and export PDF/Excel with a QR-secured record for traceability.

Ensure casing geometry meets project tolerances before use, preventing crooked piles, reinforcement clashes, and lost cover. Structured checks on straightness, squareness, ovality, and end preparation reduce rework and delays while improving concrete placement reliability and shaft stability.
Validate joint fit-up, welding, and sealing with clear acceptance cues and required evidence. Visual, MPI/DPT, and optional hydrostatic tests confirm integrity in water-bearing soils, limiting laitance, inflow, and segregation risks during concreting and subsequent casing withdrawal.
Interactive online checklist with tick, comment, and export features secured by QR code.
De-risk extraction by sizing equipment to anticipated pull, setting timing and pull-rate limits, and defining stop criteria and contingencies. The plan minimizes damage to cages and fresh concrete while avoiding stuck casings and unplanned abandonment.

Pre-Use Verification

1. Confirm casing identification, dimensions, and condition before mobilization.
2. Measure outer diameter and wall thickness at 4 quadrants using calipers/ultrasonic gauge; acceptance: within project tolerance (e.g., wall ±0.5 mm). Record readings and photos.
3. Roll casing on level skids and check straightness with laser line/3 m straightedge; acceptance: bow ≤ 3 mm/m and total run-out ≤ 10 mm. Log measurements and images.
4. Assess dents and ovality by measuring OD at 0°, 90°, 180°, 270°; acceptance: ovality ≤ 1% of nominal diameter. Mark repair/reject areas and photograph.
5. Verify lifting eyes/collars and shackles are certified; SWL exceeds lifted mass by ≥ 25%. Capture tag photos and certificate numbers.

Geometry and Straightness

6. Check end squareness with machinist square/laser; acceptance: out-of-square ≤ 2 mm across diameter. Record gap readings at 4 points.
7. Verify toe ring/shoe concentricity and run-out by rotating on rollers; acceptance: run-out ≤ 5 mm. Photograph index marks and readings.
8. Confirm total casing length meets required embedment and stick-up per method statement; include calculation sheet and marked length photo.
9. Ensure internal bore is clean and free of slurry, rust scale, and debris; acceptance: visibly clean, dry or as specified. Attach before/after photos.

Joints, Welds, and Integrity

10. Prepare joint bevels and mating surfaces: remove paint/rust, achieve correct bevel angle; acceptance: bright metal, no contaminants. Photo evidence.
11. Fit-up alignment: measure hi-lo with bridge cam gauge; acceptance: ≤ 1 mm offset, root gap 2–3 mm unless specified. Record gauge readings.
12. Welding per approved WPS by qualified welder; record WPS ID, welder ID, preheat/interpass temperatures. Capture weld parameter snapshot.
13. Visual inspection (VT): continuous bead, uniform profile, no undercut > 0.5 mm, no porosity clusters. Upload close-up photos around full circumference.
14. Non-destructive testing (MPI/DPT) as specified; acceptance: no relevant linear indications. Attach NDT report with technician certification and marked locations.
15. If water cut-off required, hydrostatic check: seal joint, fill to target head, hold 10 min; acceptance: no visible leakage or head loss. Photos and readings.

Installation and Alignment Control

16. Set guide frame/clamps; verify top frame level within ±3 mm using digital level. Photograph level display and frame setup.
17. Check plumbness at start with 2-axis inclinometer/spirit levels on opposite faces; acceptance: tilt ≤ 1:200. Record both axes.
18. Monitor plumbness every 2 m of advance; acceptance: maintain ≤ 1:200; correct using clamps/guide frame. Log readings with depth markers.
19. Verify casing seal against ground/slurry to prevent inflow; acceptance: no sand pumping or water jets observed. Capture video/photo evidence.
20. Confirm stick-up height and edge protection: minimum 150 mm above platform; install protective cap/guard. Photo with tape measure.

Extraction Plan and Contingencies

21. Approve extraction method (vibrator/rotary pull) and equipment capacity; acceptance: rated pull exceeds calculated friction by defined margin. Attach calculation and equipment datasheet.
22. Set timing: begin withdrawal while concrete remains workable per approved project specifications and authority requirements. Record placement and start times.
23. Define pull rate/vibration settings to avoid cage movement; acceptance: no cage uplift/tilt; monitor with reference marks. Record machine settings.
24. Apply approved release agent to casing exterior if permitted; document product, batch, and application time. Photo label and coverage.
25. Establish stop criteria: max pull force, tilt deviation, or loss of head; define thresholds and escalation. Capture supervisor approval.
26. Contingency if stuck: re-vibrate, partial re-drive, grout backfill, or cut/abandon as approved. Record chosen action, approvals, and photos.

Documentation and Sign-Off

27. Assign unique casing ID and mark with durable paint; cross-reference to pile ID and drawings. Upload ID photo.
28. Upload calibration certificates for measuring tools and NDT equipment; verify validity dates. Attach files to inspection lot.
29. Complete checklist with measurements, photos, and comments; inspector and contractor representatives sign digitally. Export PDF/Excel with QR.
30. Conduct task-specific briefing (pinch points, vibration, noise); record attendees and PPE compliance. Attach signed attendance sheet.

Control Geometry: Straightness, Squareness, and Ovality

Geometry control begins before the casing reaches the guide frame. Rolling the tube on skids with a laser line or a 3 m straightedge reveals bows and flat spots that can force the pile off-axis. Measure OD and wall thickness at four quadrants to detect ovality and thin sections, which compromise seal performance and cause vibration chatter. End squareness is critical for concentric starts; even a few millimetres of bevel error can induce tilt. Verify toe ring/shoe concentricity so the cutting edge doesn’t track eccentrically. During installation, use a two-axis inclinometer or matched spirit levels to confirm tilt in orthogonal directions, and keep the guide frame level to within a few millimetres. These checks reduce rework, shorten setup times, and protect reinforcement. Record all measurements with photos and tie them to a unique casing ID for traceability and later comparison after extraction.

Bow ≤ 3 mm/m; total run-out ≤ 10 mm.
Ovality ≤ 1% from four-quadrant OD readings.
End out-of-square ≤ 2 mm across diameter.
Guide frame level within ±3 mm across span.
Plumbness maintained at or better than 1:200.

Joints, Welds, and Sealing Integrity

Where casings are extended, reliable joints prevent leakage and misalignment. Start with clean bevels and proper gaps; document fit-up with a bridge cam gauge. Welding must follow an approved WPS with qualified welders, controlling preheat and interpass temperatures to avoid cracking. Visual inspection catches undercut, overlap, and porosity, while MPI or dye penetrant finds surface-breaking defects on ferromagnetic or nonmagnetic materials, respectively. In water-bearing strata, hydrostatic checks verify water-tightness before lowering. Keep a continuous evidence trail: WPS and welder IDs, VT photos around the circumference, NDT reports with indications and accept/reject fields. Address defects immediately to avoid delays during installation or extraction when rework is costly and disruptive.

Record WPS ID, welder ID, and parameters.
Use VT then MPI/DPT as specified.
No relevant linear indications allowed.
Hydro test joints where water cut-off required.
Log and repair defects before use.

Plan and Control Casing Extraction

A proactive extraction plan minimizes damage to fresh concrete and reinforcement and prevents stuck casings. Size the vibratory hammer or puller to exceed anticipated skin friction with a clear margin, accounting for embedment length, soil type, and wall thickness. Time withdrawal while concrete remains workable as permitted, maintaining head to prevent necking. Set pull-rate and vibration limits to avoid cage uplift or lateral movement, using reference marks for visual confirmation. Establish stop criteria and contingencies: re-vibration, partial re-drive, backfilling with grout, or cutting and abandonment with approvals. Capture machine settings, start/finish times, and any anomalies. This documentation protects schedule and quality while providing a defensible record for stakeholders.

Capacity > calculated pull with safety margin.
Start withdrawal while concrete is workable.
Monitor cage movement; stop if uplift occurs.
Define stop criteria and escalation steps.
Record settings, times, and outcomes.

How to Use This Interactive Pile Casing Inspection Checklist

Preparation: review drawings, method statement, and specifications; gather tools (laser, straightedge, inclinometer, calipers, ultrasonic gauge, bridge cam, MPI/DPT kit), and PPE (helmets, gloves, hearing protection, eye protection). Confirm tool calibrations.
Access the interactive checklist on your device, select project/pile ID, and enable offline mode if connectivity is unreliable. Scan or enter the casing’s unique ID.
Tick items as you inspect. Enter numeric readings where prompted and attach photos or short videos for each check (geometry, welds, plumbness, seals). Add comments for nonconformities.
Link supporting documents: WPS, welder qualifications, NDT reports, equipment datasheets, and calculation sheets. Tag files to the corresponding item.
During installation and extraction, log time-stamped plumbness readings and machine settings. Note corrective actions taken and obtain supervisor acknowledgements in-app.
Resolve findings: assign actions, set due dates, and record verification evidence. Use the comments thread to capture approvals and clarifications.
Export results as PDF/Excel with embedded photos and measurements. Share to stakeholders and reference the QR for authentication in the field.
Sign-off: inspector and contractor representatives apply digital signatures. Archive the completed checklist in the project QA repository for audit readiness.

Call to Action

Tatiana Ivanova Tatiana Ivanova

Dec 26, 2025

FAQ

Question: What tolerances are commonly used for casing straightness and plumbness?

Typical site targets are bow ≤ 3 mm per metre, total run-out ≤ 10 mm, end out-of-square ≤ 2 mm across the diameter, ovality ≤ 1%, and plumbness within 1:200. Always adopt values per approved project specifications and authority requirements, and record actual readings with photos for traceability.

Question: How should I inspect welds on-site when conditions are wet or raining?

Protect the joint with temporary covers, dry and clean the surface, then perform visual inspection. Use MPI with suitable yokes/consumables for ferromagnetic materials or dye penetrant for nonmagnetic materials, ensuring surfaces are dry per test method. Document WPS, welder ID, VT photos, and NDT reports. Defer testing if conditions compromise results.

Question: When is the right time to extract temporary casing during concreting?

Begin withdrawal while the concrete remains workable and self-supporting, maintaining head and stability per approved project specifications and authority requirements. Control pull rate and vibration to prevent cage uplift or segregation. Record start/finish times, settings, and any adjustments, and stop if defined criteria are exceeded.

Question: What evidence should I capture to satisfy quality assurance and audits?

Collect calibrated measurements (diameter, thickness, straightness), plumbness logs, end-squareness checks, VT photos, NDT reports, hydro test results if applicable, equipment capacity calculations, extraction timing/settings, and digital sign-offs. Export the completed, commentable record as PDF/Excel with a QR-secured link for verification.