Drilled Shaft Foundation Construction Inspection

ILLINOIS DEPARTMENT OF TRANSPORTATION
SPECIFIC TASK TRAINING PROGRAM
DRILLED SHAFT
FOUNDATION CONSTUCTION
INSPECTION
S 32
CLASS REFERENCE GUIDE
BY:
Bureau of Bridges and Structures

Foundations and Geotechnical Unit
And
Bureau of Construction
Project Review Unit
INSTRUCTORS:
Brad Hessing (217) 782-2704 [email protected]
Jeff Harpering (217) 782-5283 [email protected]
Revised April 2015
Specific Task Training Program Drilled Shaft Foundation Construction Inspection S-32 Class Reference Guide
Revised April 2015
TABLE OF CONTENTS
1
Introduction to Drilled Shaft Inspection

1.1 Role and Responsibilities of the Inspector
1.2 Introduction to Drilled Shafts
1.3 Plans, Specifications and Reports
1.4 Equipment
1.5 Additional References
Shaft Excavation Tools and Methods

2.1 Drill Rigs
2.2 Drilling Tools
2.2.1 Earth Drilling Tools
2.2.2 Rock Drilling Tools
2.2.3 Clean Up Tools
2.3 Shaft Excavation Methods
Shaft Excavation Inspection

3.1 Obstructions
3.2 Shaft Sizes and Tolerances
3.3 Squeezing, Necking and Cave-Ins
3.4 Rock Sockets
3.5 Shaft Acceptance
3.5.1 Friction Shafts
3.5.2 End Bearing Shafts in Soil
3.5.3 Shafts in Rock and Top of Rock Shafts
3.5.4 Bottom Cleanliness
Rebar and Concrete Inspection and Installation

4.1 Rebar
4.2 Concrete
4.2.1 Concrete Mix Design
4.2.2 Concrete Placement
4.2.3 Removal of Temporary Casing
Documentation
NDT and Load Testing

6.1 Non-Destructive Testing
6.1.1 Impulse Echo or Impulse Response
6.1.2 Cross-Hole Sonic Logging
6.1.3 Gamma-gamma Logging
6.2 Load Testing
6.2.1 Static Load Test
6.2.2 Lateral Load Test
6.2.3 Bi-Directional Load Test
6.2.4 High Strain Dynamic Load Testing
6.2.5 Role of the Inspector
7
8
Trouble Shooting
Appendix
8.1 2010 Standard Specifications: Drilled Shafts (516), Reinforcement Bars (508), Metals
(1006), Portland Cement Concrete (1020)
8.2 Construction Inspection Forms: BBS 134-Drilled Shaft Installation Plan, BBS 135Drilled Shaft Excavation and Inspection Record, BBS 136-Drilled Shaft Concrete
Placement Log
8.3 Drilled Shaft Inspectors Checklist
8.4 Drilled Shaft Concrete Volume Calculation Tables
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INTRODUCTION TO DRILLED SHAFT INSPECTION
1.1 Role and Responsibilities of the Inspector

The role of the inspector is to observe and report on the construction activities at the site. As the
inspector, it is your responsibility to confirm that the drilled shaft construction was performed in
accordance with the plans and specifications. This task is completed through a combination of
observations, recording and testing. The inspector is responsible for recording the means and
methods by which a drilled shaft is constructed. In effect, you will create an as-built plan of the
foundations at the site. It is also the responsibility of the inspector to measure and record the soil
and rock conditions which support the drilled shaft. The drilled shaft inspector is the eyes and ears
of the geotechnical and structural engineers who designed the drilled shaft foundations for the
project. You have the responsibility to report any deviations from the plans and specifications or
deviations from the contractors approved work plan to the engineer in charge. The drilled shaft
inspector should realize they have the authority and responsibility to observe every aspect of the
foundation construction process. By reporting to the engineer in charge, the inspector has the
authority to stop work if construction is not being performed in accordance with the design, plans or
specifications.
1.2 Introduction to Drilled Shafts

A drilled shaft is a foundation element composed of cast-in-place reinforced concrete that is placed
into an open drilled excavation. In general, drilled shafts will have a higher resistance against axial
and lateral loads than driven piles. The additional capacity is a result of the size of the drilled shaft.
Drilled shaft diameters can range from 1 to 10 feet, and lengths up to 150 feet can be achieved
using common drilled shaft construction equipment. Even larger shafts are possible with
specialized equipment. An additional benefit to the use of the drilled shafts is the relatively low
vibration levels which are induced during construction compared to driven pile installation.
Drilled shafts can be constructed in soil or in rock. For drilled shafts in soil, the resistance to load is
developed along the perimeter of the shaft through friction and also bearing on the end of the shaft.
In certain situations, the capacity of the shaft can be increased by increasing the size of the base of
the drilled shaft. Increasing the size of the base is commonly referred to as under-reaming or
Revised April 2015
belling. Bells can be constructed at 45 degree or 60 degree angles. For higher bearing stress
applications, a 60 degree bell is required. Bells can be up to three times the diameter of the shaft.
Drilled shafts in rock are constructed similarly to drilled shafts in soil. The drilled shaft extends
through the overburden soils to the surface of the rock. A rock socket is excavated to a diameter
and length necessary to meet the required design. The rock socket will generally be a slightly
smaller diameter than the portion of the shaft in the soil. In some cases no socket will be
constructed and the drilled shaft can bear on the surface of the rock after it has been cleaned.
Shafts in rock support load similarly to shafts in soil. Loads are resisted by a combination of friction
along the shaft in the soil and the shaft in the rock. End bearing resistance is also developed in the
rock. In most cases, the majority of the load will be supported by shaft friction and end bearing in
the rock socket and the contribution of the soil above may be ignored.
1.3 Plans, Specifications and Reports

The construction of drilled shafts is controlled by design drawings and plans and the IDOT Standard
Specifications for Road and Bridge Construction. The geotechnical aspects of the drilled shaft
design are controlled by the Structure Geotechnical Report.
When preparing for a drilled shaft inspection, the instructor must review the design plans and
drawings before the start of the project. From the design drawing package, important information
such as drilled shaft diameters, rock socket diameter, drilled shaft length and rock socket length can
be obtained. The design drawings will also give information related to the type and configuration of
reinforcing steel which will be installed.
The IDOT Standard Specifications for Road and Bridge Construction provide details regarding the
drilled shaft construction process. Before arriving on site, the inspector should be familiar with
Section 516 of the Specification. Additionally, Section 1020 and 1006 should be reviewed. Section
1020 will provide details regarding Portland Cement Concrete and Section 1006 should be referred
to for information regarding reinforcing steel and permanent steel casing.
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Before arriving on-site, the inspector should also review the Structure Geotechnical Report for the
project. The inspector should review the entire report to become familiar with the site conditions.
The inspector should pay special attention to the soil conditions section which will provide a general
description of the soil conditions at the site. The inspector should also pay special attention to the
design recommendations section as this may be the only source for information related to the
bearing pressure assumed in the design. Finally, the inspector should pay special attention to the
construction considerations section of the report. The construction considerations section may
provide valuable information related to the use of temporary or permanent casing for the shafts and
provide information on potential drilled shaft construction problems like caving soils and water
infiltration.
After reviewing the text of the report, the inspector must carefully review the soil boring and rock
core logs. The logs will be included in the attachments to the Structure Geotechnical Report and
should also be included in the design drawings package. Important items to note on the soil boring
logs include the soil types and strengths which will be encountered especially at the bearing level.
The inspector should also pay close attention to the water levels encountered during drill
operations. Two soil types which may be of concern during construction are soft clays and granular
soil below the groundwater table.
When exploratory soil borings are extended into rock, coring is generally completed to evaluate the
type, strength and consistency of the rock. The findings of the rock coring are summarized on rock
core logs. The rock core logs will also be included in the attachments to the Structure Geotechnical
Report and should be included in the drawing package as well. When reviewing the rock core logs
the inspector should check which type of rock will be encountered at the site. Two common rock
types encountered in Illinois are shale and limestone (sometimes referred to as dolomite). Shale is
a relatively soft rock; it should be excavated relatively easily with rock drilling equipment.
Limestone tends to be a much harder rock; excavation in limestone will be a slower process. It is
also important to note the RQD on the rock core log. The RQD is a measure of the quality of rock
that as encountered. RQD is presented as a percentage. It is the percent of the rock core that was
collected that consists of solid pieces greater than 4 inches in length. When the RQD is high
(greater than 50 percent) the rock will be fairly solid and massive. Low RQD indicates the rock is
weathered and fractured.
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The rock compressive strengths should also be reviewed. Shale strength may be on the order of
750 psi while limestone or dolomite may exceed 10,000 psi. Fractured rocks with unconfined
compressive strengths below 1000 psi may be excavatable with rock augers, while hard rocks
greater than 3000 psi may require coring.
1.4 Equipment
At a minimum, Level D Personal Protective Equipment (PPE) is required on drilled shaft
construction sites. Required safety equipment includes, steel toed boots, hard hat, safety glasses,
high visibility vest, and hearing protection. Gloves may also be required depending on the job site
requirements. All inspection work will be completed from the ground surface. Entry into the
excavation is very uncommon for the inspector and should only be done if steel casing is installed.
Job site safety is beyond the scope of this document, but all normal safety procedures for
construction sites with large equipment, excavations, cranes, end loaders, etc apply. Specific
safety risks peculiar to drilled shaft construction also exist and the inspector must be aware of
these. When drilling and tools are tripped in and out of the hole, the rig will swivel side to side. Do
not stand at the side of a drill rig or behind the operators cab in a position where the operator
cannot see you. Also, when spoil is spun off an auger, flying debris can be a hazard. Large chunks
of clay could weigh hundreds of pounds and would break bones if they hit you. An end loader will
constantly be working at the side of the rig to remove spoil. Stay out of its way. When approaching
the top of the shaft to look into the shaft, be sure that the operator sees you. Also, be careful when
a belling tool is being lowered into the shaft. If the tool hits the surface casing, the wings will spring
out and if you are standing at the side of the shaft you could be severely injured. Do not stand next
to the shaft when tools are being lowered into the hole. Entry into the shaft excavation is very
uncommon for the inspector and should only be done if steel casing is installed and if the bottom of
the shaft is checked for combustible gas and oxygen level. When cages, casing or tremie pipes are
lifted stand away and to the side. Anticipate where the object will fall if a cable breaks and be
elsewhere.
Since the role of the inspector is to observe and report, some of the most important pieces of
equipment for the inspector are the field book, checklist and forms. Without these tools you will not
be able to document the construction completed at the site. To aid in the documentation process a
camera may be useful. To accurately fill out the forms and field notes, it will be necessary for the
inspector to measure the lengths and diameters of the shaft and rebar cage. A 25 foot tape
measure is useful to measure diameters and check the rebar. In many cases, the length of the
shaft will be longer than 25 feet so a 100 foot tape measure should also be available for the
inspector. Since the shaft will be measured from the surface and in some cases, water may be
present in the excavation, it is necessary to provide a weight on the 100 foot tape. A small piece of
rebar or a heavy bolt taped to the end of the tape is generally sufficient. The contractor will usually
supply a weighted tape in addition to an explosion proof light to lower to the bottom of the shaft for
inspection.
For drilled shafts bearing in clayey soils, it is necessary to measure and record the strength of the
materials encountered at the base of the excavation. The strength will be measured on auger
cuttings recovered from the base of the excavation. An initial check of the unconfined compressive
strength of the soil can be performed using a hand penetrometer. Most hand penetrometers can
only measure up to an unconfined compressive strength of 4.5 tsf, though some are available that
extend to 7 tsf, and some dial gauge penetrometers reach as high as 14 tsf. When high bearing
pressures are utilized, a RIMAC unconfined compression testing device is recommended to check
the unconfined compressive strength of clayey soil. The inspector should have a calculator to aid in
computing the unconfined strength as well as for volume calculations.
When inspecting shafts in rock, a rock probe should be utilized. A rock probe consists of a piece of
round steel or rebar attached to the end of a steel cable. The rock probe will be heavier than the
weighted tape so that the rock surface can be probed and sounded.
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In some instances the bottom of the drilled shaft can be inspected using an explosion-proof downhole camera. For deep holes which are free from water and for belled shafts it is difficult to visually
observe the base of the excavation from the top of the excavation. A camera can be lowered to the
base of the shaft to evaluate the bottom condition and cleanliness.
1.5 Additional References
The intent of this manual and course is to provide an introduction to the construction and inspection
of drilled shafts. Additional references are available which provide greater detail and explanation of
the construction procedures and inspection requirements are readily available.
We recommend the following documents for review:
IDOT Standard Specifications for Road and Bridge Construction
o Section 516 Drilled Shaft Construction
o Section 1020 Portland Cement Concrete (Class DS Concrete for Drilled Shafts)
o Section 1006.10 Steel Reinforcement
o Section 1006.05 Permanent Steel Casing
ADSC/DFI Drilled Shaft Inspectors Manual
FHWA Drilled Shaft Inspectors Tutorial
http://www.fhwa.dot.gov/infrastructure/tccc/tutorial/shafts/index.htm
Drilled Shafts: Construction Procedures and Design Methods (FHWA 1997)
http://www.fhwa.dot.gov/engineering/geotech/library_arc.cfm?pub_number=1
ACI 336 Design and Construction of Drilled Piers (American Concrete Institute 1993)
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Shaft Excavation Tools and Methods
2.1 Drill Rigs

Drill rigs used for construction of drilled shafts come in many types and sizes; however, they all
have common components which are used for the drilled shaft excavation process. The power unit
is the engine which powers the drilling equipment. In some cases, the power unit can be
hydraulically powered off of the main engine for the equipment. In other cases, dedicated engines
are provided for the drilling equipment. For large drilling equipment, two engines may be provided.
The energy developed by the power unit is transferred to the drilling tools through the Kelly bar.
Kelly bars can be round or square in section and are generally composed of multiple telescoping
sections to minimize the over head requirements of the equipment and maximize the drilling depths.
The excavation is performed by tools connected to the end of the Kelly bar. Tools can consist of
augers, core barrels, hammers or buckets. The type of tool utilized is dependent on the drilling
conditions. All the drilling equipment is mounted to a body or carrier. The body can consist of a
truck, crawler body or for large drilling equipment an attachment to a crane.
Truck mounted drilling equipment is generally used for small diameter short shafts. The truck
carrier provides easy mobilization to sites and moves easily between widely spaced foundation
locations. Truck mounted equipment is often self-servicing as winches are generally attached for
lifting and placing rebar cages.
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Crawler-body-mounted drill rigs are suited for larger diameter and deeper shafts than truck mounted
equipment. The Kelly bar is generally larger diameter and often has more telescoping sections.
Crawler mounted equipment is usually capable of providing downward pressure on the drilling tools
through hydraulic rams acting on the Kelly bar. This additional pressure often referred to as
crowd, can be useful when drilling on rock or in hard soils. Another benefit of crawler mounted
equipment is the body is track mounted which can be beneficial in difficult site conditions. Service
winches are generally attached to crawler mounted equipment so they can place rebar cages and
do other lifting.
The largest piece of drilling equipment available is a crane mounted drill rig. The power unit is
attached to the body of the crane by a table. The Kelly bar is then controlled via the boom and
cables of the crane. Crane mounted equipment provides the largest amount of torque and can
excavate the largest diameter shafts. The crowd of crane mounted equipment is limited to the
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weight of the Kelly bar and drilling tools. Weighted Kelly bars are available for rock drilling
applications. Crane mounted equipment mobilizes to the site in multiple pieces and sections and
requires assembly once on site. Service cranes for lifting and setting rebar cages are also required
as crane mounted drilling equipment is not equipped with service winches. The size of the drilling
equipment along with the requirement for a service crane creates the need for a large working
footprint. If the project site is small and congested, crane mounted drilling equipment may not fit on
the site.
2.2 Drilling Tools
Drilling tools can be lumped into three broad categories including earth drilling tools, rock drilling
tools and cleanup tools. The use of earth and rock drilling tools is fairly self-explanatory. Clean up
tools are used for final bottom clean up. Earth and rock drilling tools are efficient at removing large
amounts of soil or rock; however, they often leave thin layers of sediment and loose soil or rock at
the base of the excavation. Earth and rock tools are also incapable of removing any standing water
from the base of the excavation. For these final clean up tasks, clean up tools are required.
2.2.1 Earth Drilling Tools
The most common earth drilling tool is the earth auger. Earth augers are available in single and
double flight (cut) varieties. A single flight auger contains a single helix up the stem of the auger. A
double flight auger has two helixes up the stem of the auger. Single cut augers only have teeth on
one side of the center of the auger stem while double cut augers have two sets of cutting teeth at
the base of the auger. The auger shown in the above picture is a double flight, double cut auger.
The stinger is located below the center of the auger stem to create a pilot hole for the auger and to
help prevent the auger from walking along the bottom when drilling in hard soil.
Earth Drilling Tools Earth Auger
Flights
Single flight
Double Flight
Teeth - usually
spade-type
hardened steel
Stinger
Photo from www.paladinbrands.com
This is a double-flight, double cut auger
When creating an enlarged base for a shaft bearing on soil a belling bucket or under-reamer is
required. The belling bucket consists of two pieces: the bucket and the wings. The movement of
the wings is controlled by the Kelly bar. As the Kelly bar is pushed downward the wings extend out
of the bucket creating the enlarged base, when the Kelly bar is pulled up, the wings retract. As the
wings cut the bell, the spoil collects in the bucket and is removed when the bucket is pulled out of
the shaft. Prior to excavation, the bell size is set by attaching a chain to prevent over-excavation.
To ensure the proper bell size is constructed, it is important to measure the travel of the Kelly bar
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12
which is required to achieve the design diameter. Alternatively a marker bar on the side of the
belling bucket will indicate how far the wings opened. If no marker bar is available, heavy grease
can be placed on the bucket in the wing slot. When the wings open, the grease will be smeared to
the maximum opening point and will indicate the size of the bell.
Shaft Excavation Belled Shaft
Belling Bucket
Wings controlled by movement

of Kelly bar
Bucket
Wings
Kelly bar down, wings come out

Kelly bar up, wings come in
Kelly bar travel required to

reach design diameter can be
measured
Chains are installed to set
maximum bell size
Bells are often oversized in the
field up to 1 ft to compensate
for limited cleaning ability
Because, the quality of clean up is limited with a belling tool, bells are often over-sized 1 foot to
provide additional bearing area. The spoil at the bottom can sometimes be back-bladed to the bell
periphery.
2.2.2 Rock Drilling Tools
Augers can also be used for rock excavations. The primary differences between a rock auger and
an earth auger are the teeth and flights. An earth auger will usually have spade-shaped hardened
steel teeth. A rock auger will often have carbide-tipped, bullet-shaped or chisel-shaped teeth which
are better suited for rock excavation than the spade-shaped teeth generally utilized on an earth
auger. Since rock drilling is harder than excavation in soil, the flights of a rock auger are thicker,
heavier and often harder than those on an earth auger and may also be tapered. Rock augers can
be used in any rock type but are most efficient in soft rocks such as shale or highly fractured and
weathered rocks. Rock augers are also used to grind the surface of harder rock like dolomite when
little penetration is required. When large sockets are required in harder rock such as dolomite
specialized equipment such as a core barrel or a downhole hammer are required. A core barrel
consists of heavy casing with carbide teeth attached to the bottom. A core the diameter of the rock
socket is created then the rock remaining in the center is removed with augers or broken up with a
drop chisel. A downhole hammer is a hydraulic or pneumatic powered piece of equipment that
consists of multiple cutting heads and a hammer. The cutting heads combined with the hammer
effect break and crush the rock at the base of the excavation and remove the small rock fragments
that remain. Down-hole hammers are relatively rare and will only be used on large rock sockets in
hard rock. Down-hole hammers are used with reverse circulation or air circulation drilling
processes which are unlikely to be encountered on IDOT projects.
2.2.3 Clean Up Tools
The best clean up tool for a dry shaft or shaft with a small amount of water is a clean out bucket.
Clean out buckets are also commonly referred to as a one eye bucket or a muck bucket. The clean
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out bucket has a flat bottom with an opening which is covered by a sliding plate. The bucket is
lowered to the bottom of the excavation and rotated in the normal direction to collect any water and
loose material off the bottom of the excavation. The bucket is then rotated in the opposite direction
which slides the plate across the opening on the bottom capturing the material and water inside.
Clean out buckets can also be used to clean the base of excavations which are full of water.
Two other options exist for excavations which are full of water or fluid. The two options are an airlift
pump and a down-hole pump. These tools are typically only recommended in rock sockets since
they can cause excavation of the side walls or bearing soil if used in a shaft founded in soil. A
down-hole pump is lowered to the base of the excavation. The pump forces fluid and sediment at
the base of the excavation up a hose to the surface. The pump should be lifted and moved around
the base of the excavation to help ensure the entire shaft base is cleaned.
An airlift pump is more effective that a down-hole pump and works like a giant vacuum. The airlift
pump consists of a steel lift pipe 6 to 12 inches in diameter which is lowered to the base of the
shaft. Compressed air is blown into the side of the lift pipe near the base of the excavation. The
upward movement of the air creates suction in the lift pipe which pulls water and sediment from the
base of the excavation up to the surface. The pipe must be lifted and moved around the entire
shaft base until no more sediment (only fluid) comes to the surface.
2.3 Shaft Excavation Methods
The excavation method for drilled shaft construction is dependent on a combination of two factors:
cased or open, and wet or dry. The following sections and figures from the FHWA Drilled Shaft
Tutorial illustrate the most common combinations.
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Open dry excavations are the simplest option for drilled shaft construction. Only a small surface
casing is utilized if any casing at all. Surface casings are often used to protect works from a fall
hazard and also prevent soils form the surface from falling back into the excavation. This
construction method is suited for stiff to hard clayey soils which can stand vertically without
sloughing or bulging. This method may also work in cemented sands or rock above the water table.
Concrete placement in open dry excavations is by freefall methods. IDOT specifications permit free
fall placement up to a drop height of 60 feet however current FHWA procedures allow free fall to 80
ft. IDOT recommends a drop chute to reduce the freefall height to 60 feet for deeper excavations.
Cased excavation methods can be used for wet or dry construction. Casing is used to prevent
caving in unstable soils and can also be used as a groundwater cutoff for intermediate water
bearing granular layers. Casing can be temporary or permanent. Temporary casing is installed to
stabilize the excavation then is removed as the concrete is placed in the excavation. Permanent
casing becomes a part of the final drilled shaft. Permanent casing is often used adjacent to critical
structures or structures supported on shallow footings. Permanent casing reduces the risks of
ground movement due to the excavation process. Permanent casing may also be used to extend
the shaft above the ground surface or the water surface if constructing in a river.
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When temporary casing is used and the top of the shaft is within an unstable layer, a liner may be
installed within the temporary casing. The diameter of the liner is selected to be the design
diameter of the shaft. The liner will also be a minimum of 6 inches smaller diameter than the
temporary casing it is placed within. A liner is generally thinner steel than permanent steel casing
and is usually constructed from corrugated metal pipe. Once the shaft excavation is completed, the
corrugated liner is set to the appropriate level and should extend a minimum of 2 feet below the
base of the temporary casing. The shaft and liner are then filled with concrete to the design level.
The shaft concrete should be allowed to set overnight and the following day the space between the
liner and the permanent casing (annulus) should be backfilled with cement-sand grout. The
temporary casing can then be removed while the grout is still fluid. Backfilling the annulus with
grout and pulling the casing while the grout is fluid helps prevent a gap from developing between
the liner and the surrounding soil. This also limits surface settlement which would occur over time if
the annulus is left unfilled. Direct contact between the shaft or grout and the surrounding soils is
imperative when shafts will support lateral loads.
The most complicated construction method for drilled shafts for both the contractor and the
inspector is wet construction. For wet methods, construction is being completed in the blind. The
fluid in the shaft prevents direct observation of the base and sides of the shaft. Careful construction
and detailed inspection is required for successful shaft construction.
Wet construction methods are used when the excavation extends into water bearing granular soils.
The shaft excavation progresses to, or slightly above the water bearing layer using cased or open
hole methods. The shaft is then flooded with water or drilling slurry. The level of the water or
drilling fluid in the excavation must be maintained above the surrounding groundwater level. By
maintaining this higher fluid level, groundwater infiltration into the excavation is prevented.
Infiltration into the excavation is undesirable as it can soften and loosen the material at the base
and on the side walls of the excavation. The pressure of the water or drilling fluid acting on the
walls of the excavation stabilizes the excavation and limits the material from sloughing or caving
into the excavation.
The use of solely water as the drilling fluid should only be completed with the permission of the
design engineer. The presence of free water against some clayey soils and rocks such as shale
can cause the materials to soften. A soft layer along the shaft will reduce the amount of friction that
is developed in the shaft and reduce the axial load resistance. To prevent this softening from
occurring additives are introduced to the water creating drilling slurry. The two most common
additives are bentonite clay and polymer. Polymer is becoming more common in drilling as it is
easier to handle, and requires less equipment for cleaning and reusing the slurry, than bentonite
slurry. One advantage of polymer over bentonite is that sand will settle out of the polymer slurry
while sand and silt become suspended in bentonite slurry. It is important to control the sand
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content of the drilling fluid especially prior to concrete placement. High sand content will affect the
quality of the concrete and integrity of the shaft. Slurry with a high sand content will often be too
dense or too viscous to be displaced by the concrete placement operations which can create voids
in the shaft. In addition, the high sand content can settle in the concrete and create soil inclusions
or contaminate the surface of the concrete during the pour which can affect the unconfined
compressive strength of the concrete. Over the course of a few hours, sand will settle out of
polymer slurry and can be removed from the base of the excavation using clean up tools. To
remove the sand from bentonite slurry, the fluid must be circulated with pumps through screens and
a centrifuge (de-sanding unit) to remove the sand particles and then be pumped back into the shaft
excavation.
Strict quality control of the drilling fluid is required regardless of the type of fluid (even water). While
the testing is generally the responsibility of the drilling contractor it is important for the inspector to
monitor the test results to verify the slurry meets the specified properties. The following table
presents the range of acceptable slurry properties which should be expected.
The specific gravity of the drilling slurry is checked with a mud balance. The specific gravity is the
ratio of the unit weight of the drilling fluid to the unit weight of water. The relative viscosity of the
drilling fluid is determined by measuring the amount of time required for a quart of drilling fluid to
flow through a specially sized (Marsh) funnel. The pH of the drilling fluid is used to determine how
acidic or basic the drilling fluid is. Digital pH meters or test strips are common methods used to
evaluate the pH of the fluid. The sand content of the drilling fluid is determined by passing a
specific volume of drilling fluid through a screen which captures all sand sized and larger particles.
The volume of sand retained is then determined using a measuring cylinder. When sampling slurry
from a shaft excavation, it is important to sample slurry within 12 inches of the base of the
excavation just before the concrete is placed. Specially designed slurry samplers are available for
bottom sampling.
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Shaft Excavation Inspection
During the shaft excavation process it is important to record the construction as it proceeds. The
inspector needs to observe and record the soil conditions which are encountered. It is important to
compare these conditions to the soil boring logs in the vicinity to confirm that the encountered soil
conditions match the conditions that were used to develop the design of the shaft.
It is also important to record the dimensions of the excavation. In cased excavations, the diameter
of the shaft may vary with depth. The inspector needs to records the levels at which the casings
extend to and the depths and diameters of the casings. If any other changes in diameter occur,
such as a rock socket, they must also be recorded.
The length of the shaft in the soil and the rock also needs to be recorded accurately. If the lengths
are different than those indicated on the design drawings, the inspector needs to call the resident
engineer.
Once the shaft excavation has reached the design depths the inspector needs to confirm that the
material at the base of the excavation meets the requirements of the design and that the base of
the shaft is sufficiently clean.
3.1 Obstructions
During the course of the excavation process obstructions such as boulders or old foundation
elements may be encountered. In some cases, the foundation contractor is eligible for additional
compensation for the time required to remove the obstruction. IDOT Standard Specifications define
an obstruction as any object that cannot be removed with normal earth drilling procedures, but
requires special augers, tooling, core barrels, or rock augers to remove. When an obstruction is
encountered, the resident engineer should be notified and the time of obstruction removal should be
recorded.
3.2 Shaft Sizes and Tolerances
During construction it is important to record the length and diameter of the shaft. In some cases,
the diameter of the shaft may be slightly larger than the diameter indicated on design drawings.
When telescoped casing sections or a casing with a liner is installed some portions of the shaft may
be larger than the design diameter of the shaft. Oversizing the diameter of the top of the shaft is
required so that the base of the shaft meets the minimum design diameter requirements.
The length of the shaft may vary slightly from the design length. Shafts are often designed to bear
at or near the top of a hard layer. Slight over excavation is sometimes necessary to meet the
required bearing condition. For rock socketed caissons, the constructed length of the rock socket
must be at least the length indicated on the design drawings regardless of the overall shaft length.
Section 516.13 of the Standard Specifications provides the specific requirements related to
construction tolerances. The requirements are summarized in the following slide.
Revised April 2015
18
3.3 Squeezing, Necking and Cave-Ins

A contractor using the proper size excavation equipment does not necessarily insure that the shaft
excavation will be the required diameter. A number of problems can occur during the excavation
process that will provide a larger or smaller shaft. In soft cohesive soils, squeezing or necking or
the shaft can occur if the shear strength of the soft clay is not sufficient to support the weight of the
overburden soils at the free face of the excavation. The weight applied to these low strength soils
could cause the clay wall to squeeze into the shaft creating a smaller diameter. Squeeze is more
likely to occur the longer a shaft is kept open. To preventing necking, casing should be extended
into the soft layer to provide stability.
A simple formula for predicting clay squeeze relates the clay unconfined strength to the depth of the
excavation:
Qu required (tsf) H (ft) / 50
If the measured unconfined compressive strength of a clay sample taken off an auger flight is less
than the depth of the shaft divided by 50, there is a risk of squeeze occurring. Clay with a water
content that exceeds 30% is also an indicator of potential squeeze problems.
Example:
A boring log shows soft clay with an unconfined strength of 0.4 tsf at a depth of 40 ft
below grade. The contractor intends to open drill through the material. The water
content of the soft clay is 35%. Based on the formula, the necessary unconfined
strength to resist squeeze at 40 ft would be 40/50 or 0.8 tsf. The strength shown on
the boring log is 0.4 tsf or that predicted for stability. Also the high water content
(> 30%) is an indicator of potential squeeze. Thus, squeeze is likely if casing or
slurry is not used.
In some soils, typically more granular materials, caving and sloughing of material off the sides of the
excavation can occur. Caving of clayey soils can also occur when excavations are left open for
long periods of time. The excavation process disturbs the soils on the shaft walls which loosens
them. As the auger comes in and out of the excavation, or if groundwater flow is present, these
loosened soils will slough off the side of the excavation and fall in.
Revised April 2015
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To identify if necking or caving is occurring it is necessary to pay close attention during excavation
especially as the excavation tools are entering and leaving the excavation. If the shaft is
experiencing necking the auger will consistently hang up at the same level. If caving is occurring,
materials from the upper parts of the shaft will fall onto the auger, drilling bucket or belling bucket as
they enter and leave the excavation. Also, after the tool is out of the hole, you will be able to hear
caving soils falling into the base of the excavation.
If necking is occurring, casing should be installed into the excavation to below the level
experiencing squeezing. Casing should also be installed when sloughing soils are encountered or
drilling slurry will be needed. If squeezing soils are not supported by casing, the shaft section could
be inadvertently reduced which will lower the capacity of the shaft. If caving occurs during concrete
placement, the resulting soil inclusions would represent a major defect and the shaft capacity would
be reduced.
3.4 Rock Sockets
As previously discussed, rock socketed drilled shafts often develop the majority of their capacity in
the rock socket. Therefore, it is very important to make sure the rock socket is the proper length
and diameter. The rock socket length is measured from the rock surface to the bottom of the rock
socket. To accurately determine the socket length, it is necessary to accurately determine the
location of the top of rock. The IDOT Standard Specification defines rock as bedded and
conglomerate deposits exhibiting the physical and excavation characteristics of rock. Essentially,
the top of rock surface is defined when the excavation can no longer proceed using conventional
earth excavation equipment. When refusal is encountered with an earth auger and rock drilling
equipment such as rock augers or coring equipment is required to continue the excavation, rock
has been encountered.
When rock is encountered, the elevation of the top of rock should be compared to the elevation rock
was encountered at in the nearby soil borings. If the rock is encountered higher than expected the
shaft excavation may be resting on shelf rock or a boulder. The inspector should observe that the
degree of drilling difficulty does not reduce substantially while drilling the rock socket.
For end bearing drilled shafts on the top of rock, confirmation that the shaft is supported on bedrock
and not just a boulder or shelf rock over soil is even more important. The inspector can ask the
contractor to use a core barrel to extend a shaft a few feet deeper into bedrock when unusual
conditions are encountered or when doubt exists.
3.5 Shaft Acceptance
3.5.1 Friction Shafts
The first step in evaluating the acceptance criteria for a shaft is determining if the shaft develops its
capacity through skin friction or end bearing. If you cannot determine this based on the Structure
Geotechnical Report or the Design Drawings you should contact the design engineer. For friction
shafts, it is necessary to evaluate the soil profile over the entire shaft length. The type or material,
layer thicknesses and material strengths need to correlate to the conditions encountered in the
nearby soil borings. If the conditions dont match or if you are unsure about the conditions, contact
the resident engineer immediately. The resident engineer will need to know what the encountered
conditions were so be prepared. Accurate records of the encountered conditions are essential.
3.5.2 End Bearing Shafts in Soil
For end bearing shafts in soil two essential items need to be checked. First, the inspector needs to
determine if the materials encountered at the base of the excavation are strong enough to support
the loads that will be imposed by the shaft and is the correct material based on the design
Revised April 2015
20
assumptions. If the shaft bears in sand or silt, it is not possible to test the base material other than
confirming that the material type is correct. In clayey soils the unconfined compressive strength of
the base material can be estimated by testing the auger cuttings from the bottom of the shaft. A
number of tools are available for the testing including hand penetrometers and a RIMAC. The
allowable bearing resistance can be approximated as 1.5 times the unconfined compressive
strength.
3.5.3 Shafts in Rock and Top of Rock Shafts
As previously discussed for shafts bearing in or on rock, the majority of the shaft resistance is
developed within or on the rock. The following slide provides an explanation of the items to be
checked for rock shafts.
3.5.4 Bottom Cleanliness

For all shafts which are supported partially or entirely supported by end bearing, bottom cleanliness
is a critical issue. Loose auger cuttings at the base of the excavation create a compressible layer
which is not suitable to support the foundation loads. For open dry shafts, visual inspection of the
base of an excavation is often possible. The base of the excavation can be lit when necessary buy
reflecting sunlight with a mirror or by lowering an explosion proof light to the base of the excavation.
For extremely deep excavations or excavations with an enlarged base, an explosion proof camera
can be lowered to the base of the excavation for direct observation of the base cleanliness.
When direct observation of the base of the excavation is not possible because of the use of drilling
slurry, sounding the base of the excavation with a weighted tape or rock probe is necessary. The
base of the excavation should be sounded at five locations as shown on the following slide.
Revised April 2015
21
The IDOT bottom clean up requirement are based on the recommendations created by the FHWA.
The requirements are intended to provide the best possible bearing conditions for a shaft; however,
they may be very difficult to achieve depending on the equipment available at the site. The
following slides provides some additional discussion and alternate clean up requirements if the
IDOT requirements cannot be meet with reasonable effort.
Bottom Clean Up - Discussion
The IDOT spoil requirements (based on FHWA) are very strict

and unlikely to be achievable without hand cleaning or the
use of an airlift
For straight shafts in rock cleaned with a cleanout bucket,
the following criteria should not compromise shaft
performance:
Revised April 2015
For end bearing, no more than 1 inch of spoil over the entire
base
For friction, no more than 2 inches of spoil over the entire base
Sediment thickness should be checked with a rock probe
For belled shafts, bell area should be increased by 15% and

clean with belling bucket as best as possible. Remaining
spoil can be back-bladed to bell periphery
22
Rebar and Concrete Inspection and Installation
Once the shaft excavation is completed the role of the inspector is not completed. The inspector
also needs to confirm that the concrete and reinforcing steel are placed properly in the drilled shaft
and meet the project requirements.
4.1 Rebar
Reinforcing steel (rebar) for drilled shafts is typically tied in a circular cage. The cages consist of
vertical reinforcing bars tied together with circular hoop ties or spiral ties. The following items need
to be checked when inspecting a rebar cage.
After you have confirmed at the rebar cage meets the design requirements, additional
considerations related to the installation are required. It is important that the cage is lifted and
installed properly. The cages should be picked up and moved from multiple lifting points. Cross
bracing should be installed within the cage to prevent deformation. Once the cage has been lifted
and set in place, no visual permanent deformation should be noted. In some cases, a lifting cradle
can be attached to the cage to prevent the cage from deforming.
Cage centralizers are also required for drilled shaft construction. Centralizers ensure that the
minimum cover is provided around the perimeter of the cage. Centralizers should be round and roll
freely around the bars they are attached to. The centralizers should be attached to the hoop or
spiral ties so that they roll vertically along the shaft wall. Centralizers should be constructed from a
non-corrosive material such as plastic. No metallic elements should be used as centralizers. The
centralizers should be attached at multiple points (approximately one spacer for every 3 perimeter
feet with a minimum of four per level) around the perimeter of the cage and at a maximum spacing
of 10 feet along the length of the cage. The centralizers should be a minimum of 6 inches in
diameter to provide a minimum 3 inch concrete cover.
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Rebar spacing is also very important and must be designed to work with the concrete mix design.
The clear spacing between rebar should not be less than 3 to 5 times the maximum aggregate size.
Thus, if a cage includes a tight spiral with a clear spacing of only 1.5 inches, the concrete mix
should have a maximum aggregate size of less than inch. This issue should be addressed
during the shop drawing approval stage and preferably before the pre-construction meeting.
When non-destructive testing tubes are added to a cage they would typically be placed midway
between vertical bars. However, if the clear spacing between the tube and bar drops below the
recommended spacing, concrete placement problems could occur. Bundling of the rebar on both
sides of the tube to create a greater clear space between the tube and bar may be a solution. Any
filed changes to the cage need to be approved by the design engineer.
4.2 Concrete
Multiple items need to be checked related to the concrete. All stages of the concrete design and
installation need to be checked and monitored. Items need to be checked starting at the mix design
stage all the way through placement and curing.
4.2.1 Concrete Mix Design
As previously discussed, one crucial issue in the concrete mix design is related to the maximum
aggregate size used relative to the rebar spacing. Even more important, is that proper slump be
maintained. IDOT Specifications require a slump of 7 to 8 inches, but this is a tight criterion and
many authorities recommend 7 to 9 inches for tremie or pumped concrete used in the wet method.
Mix designs should be cohesive. For free-fall placement of concrete into clean and dry shafts
research has shown that slumps of 5 to 7 inches are acceptable.
4.2.2 Concrete Placement
Concrete placement is a critical stage of the shaft construction. Many problems can be avoided
and solved before concrete placement. Once placement starts, it becomes very difficult to
troubleshoot. The first item to check once the concrete arrives on site is the batch time. No more
than 90 minutes should elapse between when concrete is batched and when it is placed. In
addition, IDOT requires that the total time of concrete placement from initial placement to final
placement not exceed two hours. If a drilled shaft is so large that placement time would exceed 2
hours, a special mix design with retarders may be needed. Slump loss tests are required for
special situations where an other-than-standard mix design is proposed.
A typical situation that can develop at a site is that the concrete arrives before the shaft is ready to
be poured. If this batch time to pour time begins to exceed 90 minutes, it may be typical that the
slump will be lower than required. The crew may suggest adding water at the site to raise the
slump. However, this situation now makes a bad situation worse by raising the water/cement ratio
and possibly weakening the final concrete further. For this reason, no water should be added to
concrete on site. If the concrete does not meet the required slump, the resident engineer should be
contacted.
For open dry shafts, concrete can often be placed by free fall. A critical issue with free fall
placement is not allowing the concrete to fall through standing water. If a small amount of standing
water is present in the base of the excavation free fall placement can continue. No more than 3
inches of water should be at the base of the excavation. Research has shown that concrete falling
through as little as 6 inches of water can reduce the unconfined compressive strength of the
concrete by half.
Another important consideration during free fall placement is that the concrete needs to be directed
down the center of the excavation. Concrete should not hit the side walls of the excavation or the
rebar cage as it falls down the excavation. IDOT requirements state that concrete should not be
allowed to fall more than 60 feet. Current FHWA requirements allow free fall heights as great as 80
Revised April 2015
24
feet while research and experience has shown that drop heights of 120 ft or more are permissible
provided that the concrete does not hit the cage. If the shaft length is greater than the allowable
free fall height a drop chute can be used to decrease the free fall height to within allowable limits.
When concrete must be placed in an excavation with more than 3 inches of standing water,
concrete must be placed by tremie methods or using a concrete pump. Concrete placed by tremie
or pump should have a slump at the upper limit of the allowable slump range. The concrete should
have a minimum slump of 7 inches. The shaft and top of concrete will be obscured from view for
the majority of the concrete placement. It will not be possible to visually monitor the excavation as
the concrete placement continues. To monitor the integrity of the shaft, the volume of concrete
placed should be monitored along with the height of the concrete in the shaft. A theoretical line
relating volume to depth can be created and compared to the recorded values. An example of the
calculations required to perform this task are included in the appendix of this manual.
At the beginning of tremie placement, a separator plug (often referred to as a pig) should be placed
in the tremie pipe. The separator displaces the water inside the tremie pipe as the concrete falls to
prevent the concrete from free falling through the water in the tremie pipe. The plug will generally
float to the surface once it has been displaced from the end of the tremie. As the concrete
placement continues the tip of the tremie pipe must remain 5 ft (and preferably 10 ft) below the
concrete level. The concrete should be overpoured beyond the design level. The concrete at the
surface of the pour will have been in contact with and contaminated by the drilling fluid. This
contaminated concrete will not meet the design strength requirements and must be removed.
4.2.3 Removal of Temporary Casing
A common technique during drilled shaft construction is the removal of temporary casing during
concrete placement. This technique is often referred to as the pour and pull method. The method
can be used with single temporary casing or multiple, telescoped casings. The temporary casing
was installed to retain a squeezing layer, water bearing layer or caving layer. The casing for these
layers cannot be removed until the concrete level is above the layer of concern a sufficient level to
maintain the stability of the layer. As the concrete level rises in the shaft and into the casing, the
casing is generally broken loose to relieve some of the friction along the side of the shaft. The
concrete should be at least 5 ft into the shaft before the casing is broken loose. Concrete
placement should then proceed up to or slightly above the design concrete level. Once the final
concrete level is achieved the distance from the ground surface to the top of concrete should be
measured. Prior to pulling the casing, the concrete level in the casing must be at least 5 ft above
the natural ground water level, 5 ft above the level of water or slurry outside the casing, or 5 ft
above the level of any artesian pressure level that existed while drilling. The casing can then be
completely removed. After casing removal the concrete level should again be checked. The
concrete level should drop slightly as the space created by the casing is filled. If the concrete level
rises, it would be an indication that soil or water outside the casing has collapsed into the concrete
forming a defect. In this situation, the casing should be re-inserted and the resident engineer
should be notified. The contractor will likely need to muck out all of the concrete and start the pour
over since the location of the defect would not be known.
Revised April 2015
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Appendix
Revised April 2015
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Revised April 2015
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Documentation
Accurate and timely documentation of the drilled shaft construction process is an essential part of
the drilled shaft inspectors job. All forms and documentation should be performed as the work
progresses. All forms for the project must be filled out completely.
There are a total of three forms which will be required. Some additional forms may be required on a
project or engineer specific basis. The first form to fill out is the Drilled Shaft Field record. This
form will provide an as-built plan for the drilled shaft and compares the as-built condition to the
design dimensions.
The second required form is the Drilled Shaft Inspection form. This form provides a record of the
condition of the base of the drilled shaft excavation. In addition, the types, size and quantity of
rebar in the drilled shaft is recorded on this form.
The final required form is the Concrete Placement Log. This form provides a log of all the concrete
placed on the job. Information such as batch to placement time, time of placement, volume of
concrete and concrete test results are provided on this form.
If a project involves tremie pouring or pumping of concrete under slurry, it will also be necessary for
the inspector to graph the theoretical concrete volume and placed concrete volume versus the
height of the shaft. This information is shown on the Drilled Shaft Concrete Volume form.
Copies of the three required forms are provided in the appendix of this manual. Two of the more
common optional forms are also included.
Additionally, a drilled shaft inspectors checklist is included in the attachments to the report. The
checklist was prepared by the FHWA and presents a list of items to complete before, during and
upon completion of construction at the site.
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NDT and Load Testing
To confirm the quality of construction of drilled shafts, post construction testing can be utilized.
Testing can be performed to confirm the integrity of the shaft. Testing can also be performed to
determine the capacity of a constructed shaft to confirm the design assumptions which were made.
6.1 Non-Destructive Testing
Non-destructive testing (NDT) is the general term used for a number of testing techniques which
evaluate the condition of the drilled shaft without directly impacting the load carrying ability of the
shaft. NDT is utilized to confirm the integrity of the constructed shaft. NDT can be performed on
any type of shaft but is most common, and should be required, for shafts which are constructed by
the wet methods. If NDT is required for an IDOT job, one of four common techniques will most
likely be employed.
6.1.1 Impulse Echo or Impulse Response
Impulse echo and impulse response are two similar techniques for evaluating the length and
condition of a drilled shaft. For both testing types, a hammer is used to strike the top of the drilled
shaft. An instrument is attached to the top of the drilled shaft which measures the behavior of a
wave, induced by the strike of the hammer, traveling through and reflecting off the base of the shaft.
In the impulse echo method, an ordinary hammer is used for the testing; in the impulse response
method, the hammer is instrumented to measure the force of the strike.
The data from a test generally consists of the initial strike, followed by a reflected wave. For an
intact shaft, the reflection will be from the base of the shaft at the soil/concrete interface. If there is
a defect in the shaft such as a void or reduction in section the reflection will occur at the defect.
Based on the time required to measure the reflected wave, the depth to the point of reflection can
be determined. The following slide presents a schematic of the test setup and some additional
information related to the test.
Impulse Echo or Impulse

Response Method
Data
Hammer is used to strike the
Acquisition
head of the drilled shaft
System
Accelerometer measures the
wave reflection from the shaft
Hammer
The shaft toe, changes in
geometry or significant
defects cause reflections
which can be detected
Penetration depth is limited to
Accelerometer
10 to 30 D, depending on soil
stiffness
While the inspector does not generally perform the actual testing, there are a few items you should
be aware of if impulse echo of impulse response will be used on your job.
Revised April 2015
29
Impulse Echo or Impulse Response

Method
Inspector Issues:
Review test procedures in

ASTM D 5882-07
Shaft head must be prepared
as shown
Large jack hammers should
not be used because they can
cause micro-cracking of the
concrete which may prevent
penetration of the signal
The results of impulse echo and impulse response testing are highly dependent on the size of the
shaft and the soil conditions. These testing methods also only provide an estimate of the depth to a
defect if one exists but no information is provided on the type or size of the defect in the shaft.
Other testing methods are available which can potential provide more detailed information.
6.1.2 Cross-Hole Sonic Logging
Cross-hole Sonic Logging (CSL) is a non-destructive test method which can provide more detailed
measurements of the shaft integrity and any defects which are encountered in the shaft. A brief
description of the testing methods is provided on the following slides.
Cross-hole Sonic Logging Method
Performed in tubes tied to the

rebar cage cast directly into the
concrete for the full depth of the
shaft
A transmitter and receiver are
lowered in tube pairs to discrete
depths to measure the Ultrasonic
Pulse Velocity of the concrete
between the tubes
UPV is recorded every 2 to 3
inches in depth for every tube
pair
Tubes should be diametrically
opposed and spaced about every
3 to 4 ft on the perimeter
A minimum of four tubes is
recommended for most situations
Cross-hole Sonic Logging Method

Inspector Issues:
Concrete
Review test procedures in

ASTM D 6760-07
Tubes should be 2-inch I.D. steel
with water-tight connections without
rubber gaskets or tape
If tubes are not steel, record the
elevations of the tube connectors
Tubes must be capped at bottom,
be filled with water, and be capped
at top before pouring concrete
Ensure all required profiles are
recorded at the specified depth
interval
After testing and RE approval, tubes
should be grouted
3 to 4 ft
Four tubes = six profiles
With the close testing increment along the length of the shaft and the multiple profiles developed
across the shaft, more details on the size and the location of possible shaft defects can be
determined. Tubes should extend all the way to the base of the shaft so that the bottom condition
can also be assessed.
Revised April 2015
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6.1.3 Gamma-gamma Logging

The final common testing procedure which may be used on a drilled shaft project is gamma-gamma
logging. Gamma-gamma logging uses a technology similar to a nuclear density gage to measure
the density of the concrete surrounding the test location. Low density measurements are an
indication that a shaft defect is present. One advantage of this test method is it allows the concrete
outside the rebar cage to be evaluated; however, the diameter of the tested zone is limited to only a
few inches outside the access tube. Like CSL, gamma-gamma logging is performed inside full
length tubes attached to the rebar cage. However, these tubes must be plastic (typically PVC) and
not steel. The following slides provide additional information on the testing method and the issues
the field inspector should watch for if gamma-gamma testing is to be performed on their project.
Gamma-gamma Logging Method
Performed in PVC tubes tied to

the rebar cage cast directly into
the concrete for the full depth of
the shaft
A probe with a radioactive source
and a receiver is lowered in a
tube to discrete depths to
measure the back-scatter
radiation (concrete density)
within 4 inches of the tube
Testing is performed every 1 to 2
ft in depth for every tube
This method allows concrete
quality outside the rebar cage to
be evaluated
A minimum of two to four tubes
is typical
Gamma-gamma Logging Method

Inspector Issues:
Concrete
Review test procedures

Tubes should be 2-inch I.D. PVC
positioned as shown
Tubes, however, should not block
concrete flow in a tight cage
Steel tubes cannot be used because
the gamma radiation will not
penetrate the steel
Tubes must be capped at bottom,
be filled with water, and be capped
at top before pouring concrete
Ensure all tubes are tested at the
specified depth interval
After testing and RE approval, tubes
should be grouted
Tubes away from longitudinal rebar

Use constant spacing x from rebar
NDT is used to evaluate the condition of the shaft but does not provide a direct measurement of the
resistance of the shaft to axial or lateral loads. If the shaft resistance is in question, load testing
needs to be performed. Also, when non-destructive testing indicates an anomaly or possible low
strength zone, full length coring along with compressive strength testing of recovered cores will
usually be performed to check the concrete and to compare to the NDT results.
6.2 Load Testing
Load testing is a direct measurement of the resistance that a drilled shaft can provide. In some
cases, the load testing will be performed on a sacrificial test shaft so the ultimate load capacity can
be determined. In other cases, a production shaft may be used and the load tests may extend to
slightly above the working load applied to the shaft. When a test shaft is utilized, it is critical that the
inspector be present for the construction of that shaft to observe the construction methods and
procedures. A test shaft must be constructed using the same procedures as the final production
shafts.
6.2.1 Static Load Test
The simplest load test method is the static load test. In procedures for static load testing are
described in ASTM standards D 1143 and D 3689 for compression and tension loading,
respectively. For a static test, the load is applied via hydraulic rams resisted by reaction piles,
shafts or anchors, dead weight or a combination of the two. Load increments are applied for a
specified time increment and the deflection of the shaft under the load is measured and recorded.
6.2.2 Lateral Load Test
Revised April 2015
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Lateral load tests are similar to static load tests. The testing procedures are covered in ASTM
standard D 3966. The load is again applied to the drilled shaft using hydraulic rams resisted by a
reaction shaft, reaction piles, or a deadman cast into the soil.
6.2.3 Bi-Directional Load Test
Bi-direction load testing, also referred to as Osterberg Cell of O-Cell testing, is a load testing
procedure which does not require weights, reaction frames or reaction piles. The O-cell is a
hydraulic jack which is cast directly into the shaft concrete, usually below the midpoint of the shaft.
When the jack is pressurized it pushes up against the upper portion of the shaft and pushes down
against the lower portion. At an intermediate level, the test has the effect of splitting the shaft at the
cell location. The jacking forces applied in the cell are resisted by the weight of the shaft and the
friction and end bearing resistance of the shaft. The capacity of resistance of a discrete portion of
the shaft can be measured by installing cells at multiple levels. The following slide provides a
schematic of a bi-directional load test.
Bi-Directional (O-cell) Testing Method
Hydraulic jack is attached to

rebar cage and is embedded in
the drilled shaft concrete
Jack is pressurized which splits
the shaft and simultaneously
loads the two parts of the shaft
in opposite directions
No reaction system, weights or
anchors are needed
Very high test loads can be
achieved (greater than 30,000
tons) with multiple jacks
Measures shaft friction, end
bearing and displacement
separately using instrumentation
6.2.4 High Strain Dynamic Load Testing

High strain dynamic load testing is similar to the dynamic load testing performed during pile driving.
The procedures are presented in ASTM standard D 4945. A large weight is dropped onto the top of
the drilled shaft which is instrumented to measure the force imparted by the weight and the
displacement of the shaft. Based on these measurements, the load carrying capacity of the drilled
shaft can be calculated
6.2.5 Role of the Inspector
In most cases, the drilled shaft inspector will not be an active participant in the load testing process.
Some issues do exist, however, that the inspector needs to be aware of as they will be onsite for
test shaft construction and may be onsite during the load testing process. The one crucial issue is
that the construction of the production shafts must follow the procedures which were utilized during
test shaft construction. Other items for an inspector to be aware of are presented in the following
slide.
Revised April 2015
32
Load Testing
Inspector Issues:
Revised April 2015
Review ASTM test procedures if available

Review with R.E. specifications, loading schedule and
contractors procedures
Check that shaft is constructed the same as a production shaft
Confirm that all required instrumentation is installed
Reference beams should be supported at least 8 ft from the test
shaft
Reaction shafts should be at least 5 D away from the test shaft
but not less than 7 ft clear
Independent monitoring of reference beam (survey) should be
done
Separately record the load increments, time and deflections
33
Trouble Shooting
The following chapter presents some common construction issues which may arise on a drilled
shaft project along with the recommended steps to address these issues.
Problem 1:
Top of rock elevation varies from design drawings
Solution:
At beginning of job, discuss with design engineer and R.E. the likely rock
elevation variation to be expected based on the geotechnical information
and project geology
Review the geotechnical report for nearest boring log for rock elevations
Is the rock elevation within the variation found within all borings for the
project site?
If yes then no issue. Complete the shaft

If rock is deeper, then extend shaft deeper (see Trouble Shoot Problem 2)
If rock is shallower than expected, you may need to verify that you are on
bedrock and not a boulder or shelf rock. Possible remedies:
For friction design, confirm entire socket length is in rock

For an end-bearing design, confirm that refusal occurred with a rock auger
Sound bottom at multiple places with Kelly bar or weighted probe.
Have contractor take a smaller diameter core several feet deep
If all indicates rock, call RE for approval
Problem 2:
Bearing soil does not meet requirements at specified depth
Solution:
Discuss with design engineer and R.E. and have a contingency plan which
is discussed with contractor at the pre-construction meeting
Review the geotechnical report for recommendations and nearest boring
log for soil conditions
Is going deeper an option or is there a depth restriction due to
encountering possible water bearing soils, weaker soils or caving soils?
If shaft cannot extend deeper because of soil conditions call RE
Revised April 2015
If no depth restriction, extend shaft 5 ft to 10 ft deeper to find suitable bearing

material
If still no bearing, call RE. Shaft may need to be abandoned and backfilled
Possible remedies:
New procedures: use casing or slurry to extend deeper
New design: larger shaft or larger bell
34
!
Problem 3:
Base of shaft is not clean
Solution:
Standard IDOT Specifications require that at least 50% of the shaft base
have less than inch of sediment. In addition, no point of the shaft shall
have more than 1.5 inches of sediment
A clean base is more critical for end-bearing shafts than friction shafts
Check that the clean-out bucket has a flat bottom, that the base of the
shaft was level within 6.25% and the cleanout tool is not riding up and
down on a boulder or uneven rock
Perform extra passes of the muck bucket until the shaft is clean
An air lift may be needed in rock sockets to achieve IDOT requirements
For belled shafts in soil it will not be possible to achieve IDOT
requirements with the belling bucket. Belled shafts should be over-sized
one foot and the remaining spoil can be back-bladed to the bell periphery
Problem 4:
Water at base of shaft with free-fall concrete
Solution:
Check water depth after cage is installed and just before pouring
concrete
If water depth is less than 3 inches pour the concrete

If water depth exceeds 3 inches, contractor may elect to
1.
2.
3.
4.
Revised April 2015
use smaller diameter muck bucket within the cage to remove water
insert air-lift (if available) through cage to dewater
pull cage to dewater with muck bucket
in a rock socket, lower a dewatering pump through the cage
If water cannot be controlled, switch to a tremie or pumped

procedure (wet method)
35
Problem 6:
Sand content is too high in slurry before concrete pour
Solution:
Sample slurry 1 ft above bottom of shaft after cage is installed and
just before pouring concrete
For bentonite:
If sand content > 4%, contractor should circulate slurry by pumping

from bottom, de-sand slurry and fill with fresh slurry from top
Re-sample slurry and repeat until sand content is within spec
For polymer:
If sand content > 1%, allow sand and sediment to settle out of slurry
up to two hours
Contractor should clean bottom thoroughly and re-sample the slurry
Problem 7:
Concrete placement is interrupted during a tremie pour under
water or slurry
Solution:
Any blockage when pumping or tremie pouring concrete under water or

slurry can cause shaft failure
Measure top of concrete and confirm that tremie is not pulled out of placed
concrete
If pour can be resumed within 15 minutes recheck concrete elevation to
confirm no change. Resume pour
If tremie is pulled out of concrete only two methods are acceptable to
complete pour:
Revised April 2015
Pull and clean tremie of blockage, water and slurry

Attach a sacrificial steel bottom plate to clean tremie pipe, reinsert 5 to 10 ft
into fresh concrete (within 15 minutes), and restart concrete pour
Over pour concrete at least 5 ft or as needed to flush contaminated concrete
above cut-off
If less than 5 ft of concrete in shaft, concrete in shaft has set >15 mins, or
no bottom plate available, pull cage, muck out wet concrete and start over
36
!
Problem 8:
Concrete rises when pulling casing
Solution:
Revised April 2015
Concrete mix design must be appropriate for pulling casing. Slump should
be 7 to 9 inches, casing should be clean and concrete should not set in the
casing more than about 30 minutes. It is very important to tape the top of
concrete before and after pulling the casing
The concrete surface should lower while pulling casing as the concrete
flows outward to fill the annular space outside the casing
If the concrete has risen, it is a definite indicator that water/slurry or soil
has been sucked into the shaft. This could result in necking of the shaft or
complete loss of concrete in a section of the shaft
Casing must be reinserted and concrete should be mucked out and be repoured
37
Appendix
For use during the test and future reference, we have included the following in the appendix.
8.1 2010 Standard Specifications for:
516-Drilled Shafts,
508-Reinforcement Bars
1006-Metals
1020-Portland Cement Concrete
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8.2 Construction Inspection Forms:

BBS 134-Drilled Shaft Installation Plan
BBS 135-Drilled Shaft Excavation and Inspection Record
BBS 136-Drilled Shaft Concrete Placement Log
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8.3 Drilled Shaft Inspectors Checklist

State of Illinois
Department of Transportation
CONSTRUCTION INSPECTORS CHECKLIST
FOR
DRILLED SHAFTS
While its use is not required, this checklist has been prepared to provide the field inspector a summary
of easy-to-read step-by-step requirements relative to the proper construction of Drilled Shafts (Section
516 of the Standard Specifications). The following questions are based on information found in
Standard Specifications, Project Procedures Guide, Construction Manual and current policy
memorandums and letters.
1) Pre Construction
a)
Have you reviewed the Contract Plans, Special Provisions, Standard and Supplemental
Specifications?
___
b) Has the Contractor submitted Drilled Shaft Installation Procedures (516.04(b))?
___
c) Has the Drilled Shaft Installation Procedure been approved?
___
d) Does the Contractor have an approved concrete mix design?
___
2) Arrival of Contractor and Equipment on Site

a) Does the Contractor have all the equipment/tools in the Shaft Installation Plan?
___
b) If the Contractor proposed a slurry, do they have a Slurry Management Plan (516.07)
___
c) Does the contractor have the proper equipment for mixing slurry?
___
d) Is a desander required and if so does the Contractor have it on site and operational?
___
e) Is casing correct diameter, thickness and length (1006.05(d)) and plans?
___
f)
___
Is the diameter of the tremie greater than 10 inches and per 503.08 and 516.12(b)?
g) Are sections of the tremie properly connected with flanges and gaskets?
___
h) If a pump is used, are the lines larger than 4 inches in diameter?
___
i)
___
Do you have and understand all drilled shaft forms to be filled out during construction?
3) Shaft Excavation & Cleaning

a) Is the shaft being constructed within 3 inches of the plan location (516.13)?
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98
___
b) Does the Contractor have a benchmark to construct and inspected the shaft elevations? ___
c) If using slurry, can they perform tests and report sand content, pH, unit weight and viscosity?
__
d) Is the slurry level being properly maintained in accordance with 516.07?
___
e) Is slurry testing being performed during excavation and immediately before concrete placement
by sampling within 12 inches of the bottom of the shaft?
___
f)
Are you filling out the Shaft Excavation and Inspection form?
___
g) If belling is required, does the bell size and geometry match the plans?
___
h) Is the shaft within plumb to with 1.5% (516.13)?
___
i)
Is the shaft of proper depth below top of rock encounter or to plan tip when in soil?
___
j)
Does the shaft bottom have less than 1/2 inch of sediment across 50% of the bottom (516.08
Excavation Cleaning and Inspection)?
___
k) Is the maximum sediment thickness less than 1.5 inches (516.08)?
___
l)
___
Did you complete the Shaft Concrete placement form?
4) Reinforcing Cage
a) Is the rebar the correct sizes and configured in accordance with the project plans?
___
b) Are the bars tied at every intersection (Section 508)?
___
c) If not, is the spacing between ties less than 12 inches (Section 508)?
___
d) Is the contractor using non-metallic 6 inch diameter spacers for the steel cage (516.11)? ___
e) Are the spacers no greater than 10 feet apart along the length of the cage?
___
f)
Are sufficient spacers present around the perimeter of the cage to allow plan cover?
___
g) Was steel cage spliced in accordance with contract documents and standard specs?
___
h) Is the steel cage secured from settling and from floating during concrete placement?
___
i)
Is the center of the cage within 1.5 inch of the plan location?
___
j)
Is the cage plumb to within 0.1 inch per foot depth?
___
k) Is the top of the cage no more than 1 inch above or 3 inches below the plan elevation?
5) Concreting Operations
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99
___
a) Prior to concrete placement, has the slurry been tested?
___
b) During casing removal, was concrete a minimum of 5 feet above the base of the casing before
breaking it loose (516.06(c))?
___
c) Was this minimum embedment maintained as the casing was pulled?
___
d) Was the discharge end of the tremie or pump embedded at least 5 feet into the concrete
throughout the pour (516.12(b))?
___
e) Did tremie or pumped concrete placement occur without interruption?
f)
___
For Free Fall Placement, was there less than 3 inches of standing water in the base of the
shaft (516.12 (a))?
___
g) Was the flow of concrete directed down the center of the shaft to avoid rebar?
___
h) Was the placement time less than 2 hours (516.12)
___
i)
Are you filling out the Concrete Placement form?
___
j)
Did the Contractor overflow the shaft to remove surface contamination?
___
k) Were test cylinders cast and concrete acceptance tests performed as required?
___
l)
___
Was the concrete temperature checked?
m) Was the air content checked?
___
n) Was any water added while onsite?
___
6) Post Installation
a) If shaft is constructed in open water, is the shaft protected for seven days?
___
b) If removable forms are used has the concrete reached a minimum compressive strength of
2,500 psi before the forms are removed?
___
c) Is all casing removed to the proper elevation?
___
d) Has the contractor performed any required Non-Destructive Testing?
___
e) Have you documented the pay items?
___
8.4 Drilled Shaft Straight and Belled Concrete Volume Calculation Tables
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Drilled Shaft Foundation Construction Inspection

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What are the main steps involved in drilled shaft construction inspection?

What are the main steps involved in drilled shaft construction inspection?

What are some common issues inspectors check for during shaft excavation?

What are some common issues inspectors check for during shaft excavation?

ILLINOIS DEPARTMENT OF TRANSPORTATION

SPECIFIC TASK TRAINING PROGRAM

Bureau of Bridges and Structures

Revised April 2015

Revised April 2015

Introduction to Drilled Shaft Inspection

Shaft Excavation Tools and Methods

Shaft Excavation Inspection

Rebar and Concrete Inspection and Installation

NDT and Load Testing

Revised April 2015

Revised April 2015

INTRODUCTION TO DRILLED SHAFT INSPECTION

1.1 Role and Responsibilities of the Inspector

1.2 Introduction to Drilled Shafts

1.3 Plans, Specifications and Reports

Revised April 2015

Revised April 2015

Shaft Excavation Tools and Methods

2.1 Drill Rigs

Revised April 2015

Earth Drilling Tools Earth Auger

Photo from www.paladinbrands.com

This is a double-flight, double cut auger

Shaft Excavation Belled Shaft

Wings controlled by movement

Kelly bar down, wings come out

Kelly bar travel required to

Revised April 2015

Revised April 2015

Revised April 2015

Shaft Excavation Inspection

Revised April 2015

3.3 Squeezing, Necking and Cave-Ins

3.5.4 Bottom Cleanliness

Revised April 2015

Bottom Clean Up - Discussion

The IDOT spoil requirements (based on FHWA) are very strict

Revised April 2015

For belled shafts, bell area should be increased by 15% and

Rebar and Concrete Inspection and Installation

Revised April 2015

Revised April 2015

Revised April 2015

Revised April 2015

Revised April 2015

NDT and Load Testing

Impulse Echo or Impulse

Revised April 2015

Impulse Echo or Impulse Response

Review test procedures in

Cross-hole Sonic Logging Method

Performed in tubes tied to the

Cross-hole Sonic Logging Method

Review test procedures in