Repair Driven Pile Heads/Splices: Weld, QA and Coating

Definition: Repair driven pile heads/splices checklist for site engineers and inspectors, covering damage assessment, weld rectification, QA documentation, and protective coatings, while excluding production pile driving logs.

Identify and record damage with measurable evidence and photos.
Align and rectify splices using WPS-driven methods and NDT acceptance.
Seal repairs with compliant protective coatings and traceable batch records.
Interactive, commentable, export options with QR code verification.

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Checklist

Repair driven pile heads/splices is a focused jobsite process to restore integrity of driven steel pile heads and welded splices after driving. This checklist addresses pile head repair, pile splice welding, weld rectification, protective coating application, and QA records. It explicitly excludes driving logs and production data, concentrating instead on defect identification, alignment and fit-up, qualified welding, nondestructive testing, and corrosion protection. By following these steps, teams reduce structural risk from crack propagation, misalignment, and coating failure, while creating a defensible audit trail. Each instruction pairs a method or tool with acceptance evidence—measurements in millimetres, temperature readings, NDT reports, coating thicknesses, photos, material heat numbers, and signatures—per approved project specifications and authority requirements. Use this checklist to organize work zones, capture approvals, and prevent rework, ensuring consistent, traceable repairs that stand up to independent review. Start in interactive mode to tick tasks, add comments, and export PDF/Excel with a secure QR for field sign-off.

Ensure damaged pile heads and splices are restored with controlled alignment, qualified weld rectification, and validated protective coatings. Each action captures measurable evidence and traceable approvals, reducing rework and strengthening compliance without mixing in pile driving logs or production metrics.
Document welds with WPS/PQR references, welder IDs, preheat and interpass temperatures, and calibrated NDT. Visual, MT/PT, and UT where specified provide objective acceptance, while NCR closures and RFIs are consolidated into a single QA record ready for client review.
Seal repaired zones with correctly prepared surfaces, verified profile, and coating systems applied to data sheet requirements. Environmental conditions, wet and dry film thicknesses, holiday testing, and batch numbers produce a corrosion-control record that supports long-term durability in aggressive environments.
Interactive online checklist with tick, comment, and export features secured by QR code.

Damage Assessment

1. Isolate the work area with barriers and signage; verify permits and task risk assessment completed and signed. Record permit number, supervisor signature, and site photos showing isolation boundaries.
2. Perform visual inspection of pile head/splice using flashlight and mirror; map cracks, bends, and burrs. Capture close-up photos and a defect sketch with unique defect IDs referenced to grid coordinates.
3. Measure misalignment, bevel damage, and end squareness with straightedge, spirit level, and feeler gauges. Record measurements in mm against project tolerance; upload instrument calibration certificates and readings.
4. Conduct dye penetrant (PT) screening on suspected surface cracks; clean, apply penetrant, dwell, remove, and develop. Attach PT report with indication sizes and disposition per approved project specifications.

Splice Alignment and Fit-Up

5. Verify splice components, backing rings, and consumables match approved submittals. Photograph labels and upload MTR heat numbers and consumable batch numbers for traceability.
6. Trial-fit members; use chain blocks, strongbacks, and clamps to bring faces flush. Measure root gap and offset with feeler gauges and straightedge; record mm values against specified tolerances.
7. Prepare weld zone by grinding 25–50 mm back to bright metal; remove rust, oil, and coatings. Upload before/after photos and note abrasive wheel grade used.
8. Confirm fit-up tacks follow WPS; place, size, and grind stops/starts smooth. Record tack locations on sketch and capture photos showing continuity and fusion.

Weld Rectification

9. Verify welder qualifications and WPS/PQR approvals are current and applicable. Upload welder IDs, expiry dates, and approved WPS number referenced on the repair record.
10. Set preheat and monitor interpass temperature per WPS using contact thermometer or pyrometer. Record temperatures in °C each pass; attach temperature crayon confirmation photos.
11. Remove defective weld metal by air carbon-arc gouging to sound base; grind smooth. Perform MT/PT to confirm defect removal; attach NDT report with inspector signature.
12. Deposit root and fill passes per WPS parameters (amperage, voltage, travel speed). Log actual parameters by pass, welder ID, and sequence; upload machine calibration evidence.
13. Control distortion using balanced welding sequence and cooling intervals; recheck alignment after each segment. Record offset and gap in mm; include photos of strongbacks/clamps in place.
14. Conduct post-weld visual inspection; remove spatter, blend tie-ins, and dress sharp edges. Record acceptance per approved project specifications; attach high-resolution weld photos.

Nondestructive Testing and QA Records

15. Perform MT/PT on accessible surfaces and UT/RT if specified; use calibrated equipment. Upload NDT reports, calibration certificates, indications map, and acceptance disposition.
16. Verify weld size/length with fillet/bridge cam gauges and tape; mark with paint pen. Record actual vs specified; obtain inspector acceptance initials and date on the joint.
17. Close out NCRs and RFIs with supporting evidence. Upload correspondence, approvals, and inspector sign-offs; note explicitly that driving logs are not part of this record.

Protective Coatings and Corrosion Control

18. Prepare surfaces to specified cleanliness; verify surface profile using replica tape or gauge. Record profile in µm and attach photos showing uniform preparation.
19. Measure ambient temperature, steel temperature, RH, and dew point before coating. Record values and confirm compliance with product data sheet; attach instrument calibration.
20. Apply primer/intermediate/topcoat by brush/roller/spray as approved. Record batch/lot numbers, wet film thickness (µm), recoat intervals, and coverage photos each coat.
21. Verify dry film thickness (DFT) with calibrated gauge; spot map readings. Conduct holiday testing if required and repair pinholes; upload DFT logs and holiday test report.

Handover and Closeout

22. Compile repair dossier: defect maps, WPS, welder IDs, parameter logs, NDT, DFT, photos, approvals. Export PDF/Excel with QR authentication and archive in project QA system.

Assess Damage and Prepare Pile Heads/Splices

Start by safely isolating the work area and confirming permits are in place. Thoroughly inspect the pile head and splice using visual methods, mirrors, and lighting to identify cracks, lamination, and deformation from driving. Quantify misalignment, root gaps, and end squareness with a straightedge, feeler gauges, and level; log measurements in millimetres against project tolerances. Where surface cracking is suspected, apply dye penetrant to reveal indications before any grinding. Remove contamination—rust, mill scale, oil, and old coatings—within 25–50 mm of the intended weld area by controlled grinding. Clearly tag the repair with a unique ID and sketch its location relative to survey grid lines so teams can coordinate access and materials. This disciplined front-end assessment prevents chasing hidden defects or welding over contamination, both of which cause rework. Evidence is essential: take clear photos, note instrument serial numbers, and collect signatures to build a defensible QA record per approved project specifications and authority requirements.

Isolate, permit, and document the work zone.
Map defects with photos and unique IDs.
Measure misalignment and gaps in millimetres.
Use PT to reveal surface cracking early.
Grind 25–50 mm to bright metal.

Rectify Welds and Control Alignment

Execute weld rectification under an approved WPS using qualified welders. Verify preheat and interpass temperatures with calibrated devices and document readings for each pass. Remove unsound metal by air carbon-arc gouging, then grind smooth and confirm soundness with MT/PT before rewelding. For fit-up, hold alignment with strongbacks and clamps; use a balanced weld sequence to limit distortion and remeasure offsets throughout. Log actual parameters—amperage, voltage, travel speed—and the welder ID on every pass. After welding, perform thorough visual inspection, blending starts and stops and removing spatter. Apply NDT as specified: MT/PT on surfaces and UT or RT where required. Acceptance is based on the project specification; record pass/fail decisions with signatures. This methodical approach safeguards load transfer through the splice and prevents long-term fatigue issues caused by misalignment or residual defects.

Follow WPS with qualified welders.
Record preheat and interpass temperatures.
Gouge, grind, and verify defect removal.
Balance welding to reduce distortion.
Document NDT results and acceptances.

Protective Coatings and Quality Records

After acceptance, protect repaired areas against corrosion. Prepare surfaces to the specified cleanliness and verify surface profile using replica tape or a profile gauge; record the profile in micrometres. Check environmental conditions—steel temperature, ambient temperature, relative humidity, and dew point—ensuring they meet coating data sheet limits. Apply the specified system by brush, roller, or spray, documenting batch numbers, wet film thickness, and recoat intervals. Measure dry film thickness at multiple points, mapping results and repairing any low readings. Perform holiday testing where required and retest after touch-ups. Finally, consolidate the QA package: WPS/PQR references, welder and inspector credentials, parameter logs, NDT reports, coating logs, photos, NCR closures, and approvals. Export the verified dossier to PDF/Excel and secure with a QR code to authenticate the record trail.

Verify surface profile in micrometres.
Record environmental conditions before coating.
Log batch numbers and film thicknesses.
Map DFT readings and repair lows.
Export a QR-secured QA dossier.

How to Use This Interactive Repair Checklist

Preparation: Gather straightedge, feeler gauges, thermometers/pyrometers, welding gear, NDT kits (PT/MT/UT as specified), DFT gauges, holiday detector, coating tools, PPE, permits, and approved WPS/PQR. Confirm access, lighting, and isolation are set.
Project setup: Create a repair record with pile ID, coordinates, defect description, and photos. Add responsible engineer/inspector, target tolerances per approved project specifications, and required attachments.
Using the Interactive Checklist: Start interactive mode, tick completed tasks, add time-stamped comments, attach photos/readings, and request approvals. Assign follow-ups for any rework or NCRs.
Export and share: Generate a consolidated report and export to PDF/Excel. Include photos, measurements, calibration certificates, and approvals for client, contractor, and authority stakeholders.
Sign-Off: Capture digital signatures from the inspector and responsible engineer. Archive the record with a QR code for authentication and future audits.

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Jhon Kovacis VibrationJhon

Jan 28, 2026

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FAQ

Question: What defects typically require weld rectification at driven pile heads or splices?

Common rectification triggers include surface or toe cracks, lack of fusion, porosity clusters, undercut, excessive root gap, and measurable misalignment. Confirm defects with visual examination and PT/MT, then remove unsound metal and reweld per an approved WPS. Acceptance is determined per approved project specifications and authority requirements.

Question: How do I choose between grinding out a small defect and removing the entire weld segment?

Base the decision on defect size, location, and NDT confirmation. Small, isolated surface indications may be removed by local gouging and grinding, then verified with PT/MT. Larger or repeated indications, or any UT-reported planar defects, typically justify removing a longer segment and fully rewelding per the WPS to restore integrity.

Question: What environmental limits should I observe before applying protective coatings?

Verify steel temperature, ambient temperature, relative humidity, and dew point against the coating product data sheet. Ensure the steel is at least above the specified dew point margin, and avoid application outside the temperature and humidity ranges. Record measured values and instrument calibrations so that compliance is traceable during audits.

Question: Which QA records are essential to close a pile head/splice repair?

Include permits, defect maps, measurement logs, WPS/PQR references, welder qualifications, parameter logs, NDT reports and calibrations, NCR/RFI closures, coating batch numbers, environmental records, wet and dry film thickness logs, holiday testing, and final acceptance signatures. Export the complete dossier to PDF/Excel for distribution and archiving.