TS 02025:1.
0
BTD 2011/08
Standard
Testing of Cast-In-Place Concrete
Piles
Issue date: 22 March 2023
Effective date: 22 March 2023
© State of NSW through Transport for NSW 2023
TS 02025:1.0
Testing of Cast-In-Place Concrete Piles
Effective date: 22 March 2023
Disclaimer
This document has been prepared by Transport for NSW (TfNSW) specifically for its own use
and is also available for use by NSW public transport agencies for transport assets.
Any third parties considering use of this document should obtain their own independent
professional advice about the appropriateness of using this document and the accuracy of its
contents. TfNSW disclaims all responsibility and liability arising whether directly or indirectly out
of or in connection with the contents or use of this document.
TfNSW makes no warranty or representation in relation to the accuracy, currency or adequacy
of this document or that the document is fit for purpose.
The inclusion of any third party material in this document, does not represent an endorsement
by TfNSW of any third party product or service.
For queries regarding this document, please email Transport for NSW Asset Management Branch at
[email protected] or visit www.transport.nsw.gov.au
© State of NSW through Transport for NSW 2023
TS 02025:1.0
Testing of Cast-In-Place Concrete Piles
Effective date: 22 March 2023
Document information
Owner: Principal Engineer Geotechnical
Asset Management
Safety Environment and Regulation
Mode: Multimodal
Discipline: Civil
Document history
Revision Effective date Summary of changes
1.0 22 March 2023 First issue as TS 02025. Version recommenced in line with new designation.
© State of NSW through Transport for NSW 2023 Page 3 of 13
TS 02025:1.0
Testing of Cast-In-Place Concrete Piles
Effective date: 22 March 2023
Preface
This document is a first issue as TS 02025:1.0 and supersedes BTD 2011/08 Testing of
Cast-In-Place Concrete Piles.
This standard sets out detailed requirements for both strength and integrity testing for
cast-in-place concrete piles, either as foundation and/or laterally loaded piles. It also clarifies the
options of PE and CSL integrity test methods in various soil/rock consistencies including
nonhomogeneous materials, limitation of testing on large diameter piles, and acceptance criteria
from various test methods.
© State of NSW through Transport for NSW 2023 Page 4 of 13
TS 02025:1.0
Testing of Cast-In-Place Concrete Piles
Effective date: 22 March 2023
Table of contents
1 Scope ........................................................................................................................................................ 6
2 Application ............................................................................................................................................... 6
3 Referenced documents ........................................................................................................................... 6
4 Terms, definitions and abbreviations .................................................................................................... 7
5 General ..................................................................................................................................................... 7
6 Testing requirements .............................................................................................................................. 8
6.1 General .................................................................................................................................................. 8
6.2 Design geotechnical strength and/or serviceability testing for foundation pile ...................................... 8
6.3 Pile integrity testing for foundation and retaining wall piles ................................................................... 9
7 Acceptance criteria ............................................................................................................................... 12
7.1 Acceptance criteria – geotechnical strength and/or serviceability load test ........................................ 12
7.2 Acceptance criteria – integrity test ....................................................................................................... 12
8 Dealing with non-conformity ................................................................................................................ 13
© State of NSW through Transport for NSW 2023 Page 5 of 13
TS 02025:1.0
Testing of Cast-In-Place Concrete Piles
Effective date: 22 March 2023
1 Scope
This standard specifies detailed requirements for both strength and integrity testing for
cast-in-place concrete piles either as foundation and/or laterally loaded piles. It explains in detail
the different options of PE and CSL integrity test methods in various soil/rock consistencies
including nonhomogeneous materials and limitation of testing on large diameter piles.
Requirements for acceptance criteria from various test methods and how to deal with
non-conformity are also specified in this document. This standard also covers testing of
reinforced concrete infill pile section of steel tubular pile. It does not cover the testing
requirements of CFA piles and other ground improvement columns (for example, CIC, CMC).
2 Application
This multimodal standard applies to roads, bridges, heavy rail, light rail, metro, tunnelling,
buildings, car park basements and any other relevant projects of TfNSW requiring testing of
cast-in-place concrete piles.
3 Referenced documents
The following documents are cited in the text. For dated references, only the cited edition
applies. For undated references, the latest edition of the referenced document applies.
Australian standards
AS 1726 Geotechnical site investigations
AS 2159–2009 Piling – Design and installation
Transport for NSW standards
TS 01621 (BTD 2008/11) Lists of Transport for NSW (TfNSW) Approved Bridge Components
and Systems
TS 01730.1 (B59) Bored Cast-In-Place Reinforced Concrete Piles (Without Permanent Casing)
TS 01729.2 (B58) Bored Cased Cast-In-Place Reinforced Concrete Piles (With Permanent
Casing)
Other referenced documents
CIRIA, Integrity testing in piling practice (Report 144)
National Highway Institute, U.S. Department of Transportation, Federal Highway Administration,
Drilled Shafts: Construction Procedures and LRFD Design Methods (FHWA-NHI-10-016)
© State of NSW through Transport for NSW 2023 Page 6 of 13
TS 02025:1.0
Testing of Cast-In-Place Concrete Piles
Effective date: 22 March 2023
4 Terms, definitions and abbreviations
The following documents are cited in the text. For dated references, only the cited edition
applies. For undated references, the latest edition of the referenced document applies.
ARR average risk rating as defined in AS 2159–2009
CFA continuous flight auger
CMC controlled modulus column
CIC concrete injected column
CSL cross-hole sonic logging
PE pulse echo
Ps maximum test load
TfNSW Transport for NSW
φgb basic geotechnical strength reduction factor
5 General
Cast-in-place concrete piles, with or without permanent casing, are often used for bridge
foundation and retaining wall construction and are founded in wide ranges of soil and rock
materials. However, examination of these piles is always challenging arising from construction
such as pile hole collapse, high ground water table, tremie concreting, and so on. Furthermore,
TS 01729.2 and TS 01730.1 do not specify pile testing in detail.
AS 2159–2009 has guidance on pile testing, which depends on the site conditions, extent of
investigation, the design assumptions and construction methods. AS 2159–2009 specifies
integrity testing where basic geotechnical strength reduction factor (φgb) > 0.4 and geotechnical
strength testing where both φgb > 0.4 and the average risk rating (ARR ≥ 2.5. AS 2159–2009
allows designers only to specify integrity and/or geotechnical strength testing, where φgb ≤ 0.4
and when considered necessary.
Lessons learnt from TfNSW projects indicate the current version of BTD 2011/08 requires
detailed clarification on both integrity and strength testing of cast in-place concrete piles (except
CFA piles), either as foundation or laterally loaded piles.
This standard clarifies detailed requirements of both strength and integrity testing for
cast-in-place concrete piles, choice of PE and CSL integrity test methods in various soil/rock
consistencies. This includes nonhomogeneous materials, limitation of testing on large diameter
piles and acceptance criteria from various test methods.
© State of NSW through Transport for NSW 2023 Page 7 of 13
TS 02025:1.0
Testing of Cast-In-Place Concrete Piles
Effective date: 22 March 2023
6 Testing requirements
6.1 General
Cast-in-place concrete piles for TfNSW works or those that will be the asset of TfNSW, shall be
tested as follows:
• design geotechnical strength and/or serviceability testing, φgb > 0.4 (for foundation piles)
• pile integrity using low-strain impact testing or cross hole sonic logging methods regardless
of φgb value (for both foundation and retaining wall piles).
All testing shall be carried out by organisations listed in TS 01621.
Piles for testing shall be nominated on design drawings or as determined in agreement with
TfNSW’s geotechnical representative. Additional site-specific locations of integrity testing may
be directed after pile construction, as required by the TfNSW. In addition, special design (for
example, additional reinforcement or extra pile length) shall be carried out on representative
piles for geotechnical strength and/or serviceability testing.
6.2 Design geotechnical strength and/or serviceability
testing for foundation pile
The minimum percentage and number of piles shall be tested at each structure for strength
and/or serviceability in accordance with Table 1.
Table 1 – Minimum percentage1 and number of piles2 to be tested for design geotechnical
strength and/or serviceability
Rock classification3 ARR4 < 3.0 3.0 – 3.99 4.0 – 5.0
Medium or better Minimum % 0 0 1
Medium or better Minimum number of piles 0 0 1
Low5 Minimum % 1 2 3
Low5 Minimum number of piles 1 2 3
Very low5 Minimum % 2 3 4
Very low5 Minimum number of piles 2 3 4
Extremely low5 Minimum % 3 4 5
Extremely low5 Minimum number of piles 3 4 5
Notes:
1. fractions shall be rounded up to the next integer
2. the higher of these two values shall be adopted for testing
3. rock classification in accordance with AS 1726 (not for pile design purposes)
© State of NSW through Transport for NSW 2023 Page 8 of 13
TS 02025:1.0
Testing of Cast-In-Place Concrete Piles
Effective date: 22 March 2023
4. average risk rating in accordance with AS 2159–2009.
5. extent of testing for piles founded in low to extremely low strength rock may be
increased depending on site specific conditions in agreement with TfNSW’s
geotechnical representative.
Testing may comprise static loading, high-strain dynamic testing, bi-directional load testing or
rapid load testing as detailed in AS 2159–2009. Unless otherwise specified on the drawings, the
maximum test load (Ps) shall be as specified in clause 8.3.3 of AS 2159–2009.
For dynamic testing, the hammer mass shall be such that the net energy imparted to the pile is
sufficient to mobilise the design pile resistance corresponding to the maximum test load. Testing
shall not result in the allowable concrete stresses being exceeded.
The above testing requirements are not applicable to laterally loaded piles, unless otherwise
specified on the design drawings.
6.3 Pile integrity testing for foundation and retaining wall
piles
Integrity testing shall be carried out using only low strain PE or CSL methods in accordance with
AS 2159–2009 for testing full length of the piles. The use of CSL or PE methods of integrity
tests shall be determined at the design stage and shown on the construction drawings.
The testing methods shall be determined based on the pile diameter and site conditions as
follows:
• pile diameter ≤ 900 mm: PE or CSL method shall be used, depending on the site
conditions (for example, pile construction methodology, ground water table, geology,
possibility of pile hole collapse, pile length to diameter ratio and so on)
• pile diameter > 900 mm: CSL method shall be used.
TfNSW’s geotechnical representative may request integrity testing using only CSL.
6.3.1 PE test
In the PE test method, a hand-held hammer shall be impacted on the pile head (before
constructing pile cap, capping beam, head stock, and so on) at or near the pile centre in such a
manner that generates stress wave for the full length of the pile, considering the specific rate of
energy dissipation of the surrounding soil and rock materials. Therefore, the maximum length to
diameter ratio (L:D) of a pile shall be used using PE method. This may conform to Table 2 and
Table 3 as a guide. Where Table 2 and Table 3 do not satisfy for each structure using PE
method, the CSL method (see Section 6.3.2) of integrity testing shall be used.
© State of NSW through Transport for NSW 2023 Page 9 of 13
TS 02025:1.0
Testing of Cast-In-Place Concrete Piles
Effective date: 22 March 2023
Table 2 – 1Maximum L:D of piles for integrity testing using PE method for uniform
material
Material type and Low strength Stiff to hard Medium stiff Very soft to
consistency2 or better clayey soil, clayey soil, soft clayey
rock3 dense to very medium dense soil, very
dense sandy or sandy or loose to
gravelly soil4 gravelly soil loose sandy
or gravelly
soil
PE 10 20 40 50
Notes:
1. in accordance with Drilled Shafts: Construction Procedures and LRFD Design Methods
(FHWA-NHI-10-016) and Integrity testing in piling practice (Report 144)
2. uniform material that the pile passes through from ground surface to the pile toe (or
from bottom of the capping beam to the pile toe for retaining wall)
3. rock classification in accordance with AS 1726
4. very low to extremely low strength rock in accordance with AS 1726 to be considered as
stiff to hard or dense to very dense consistency soil.
Table 3 – Maximum L:D of piles for integrity testing using PE method for non-uniform
material
Maximum L:D Maximum pile Maximum length of the pile Maximum length of
of piles diameter (mm) in soil2 the pile in rock1
20 900 20D minus pile length in rock1 5D
Notes:
1. low strength or better rock classification in accordance with AS 1726
2. all consistencies of soils (that is, soft/loose to dense/hard) including very low to
extremely low strength rock (rock classification in accordance with AS 1726).
The minimum percentage and number of piles to be integrity tested at each structure using PE
method shall conform to Table 4.
© State of NSW through Transport for NSW 2023 Page 10 of 13
TS 02025:1.0
Testing of Cast-In-Place Concrete Piles
Effective date: 22 March 2023
Table 4 – Minimum percentage1 and number of piles2 to be integrity tested using PE
method for each structure or for each 30m length of retaining wall site
Minimum (%) 25
Minimum number of piles3 5
Notes:
1. fractions shall be rounded up to next integer
2. the higher of these two values shall be adopted for testing
3. the number of piles to be tested shall be distributed uniformly along the length of each
structure or wall type structures at every 30 m length.
6.3.2 CSL test
The number and length of the cast-in round steel logging tubes in the CSL method shall be
selected so as to cover the entire cross-section of the pile, taking into account the pile diameter,
ground condition and construction methodology. The logging tubes shall be selected at every
250 mm to 300 mm of pile diameter (for example pile diameter in mm/300 mm) and spaced
equally around the circumference of the pile, with a minimum of four logging tubes, whichever is
greater. The tubes shall be free of corrosion and checked for watertightness before concreting.
The diameter of the logging tubes shall be appropriate for the sonic logging probes used
(between 38 mm and 50 mm). The exterior surface of the tubes shall be free from
contamination (for example, oil, dirt, loose rust, mill scale, and so on) to ensure a good bond
between the tube and the surrounding concrete. The ends of the tubes shall be undamaged and
prepared for the end caps and coupling system adopted. The tubes shall be close ended at the
bottom and fitted with removable end caps at the top to prevent entry of concrete or foreign
objects, which could block the tubes prior to testing operations. Where any of the logging tubes
become blocked or not working, TfNSW may require further integrity testing.
The logging tubes shall be extended to a depth of 100 mm (or as close as practical) above the
pile toe to enable testing along the whole length of the pile. The logging tubes shall be secured
to the interior of the reinforcement cage attached to the longitudinal bars.
After completion of the CSL testing, the logging tubes shall be dewatered and filled with
pourable shrinkage compensated grout acceptable to TfNSW. The grout shall be pumped into
the tubes from the bottom to the top to eliminate air entrap.
At a minimum, the following items shall be submitted to TfNSW for approval before using CSL
method of integrity testing:
• number, diameter, location and length of the logging tubes
• procedure for securing the tubes in location during concreting; and
• grout material details and procedure for filling the tubes after the completion of CSL testing.
© State of NSW through Transport for NSW 2023 Page 11 of 13
TS 02025:1.0
Testing of Cast-In-Place Concrete Piles
Effective date: 22 March 2023
The extent of CSL testing at each structure and retaining wall site shall be in accordance with
Table 5.
Table 5 – Minimum percentage1 and number of piles2 to be integrity tested using CSL
method at each structure and for each 30m length of retaining wall site
ARR < 2.5 2.5 – 2.99 3.0 – 3.49 3.5 – 3.99 4.0 – 4.49 4.5 – 5.0
Minimum (%) 15 15 20 20 25 25
Minimum number of 3 3 4 4 5 5
piles
Notes:
1. fractions shall be rounded up to next integer
2. the higher of these two values shall be adopted for testing.
7 Acceptance criteria
7.1 Acceptance criteria – geotechnical strength and/or
serviceability load test
The acceptance criteria for geotechnical strength and/or serviceability load test shall be in
accordance with clauses 8.4.3, 8.5.2 and 8.7.2 of AS 2159–2009.
7.2 Acceptance criteria – integrity test
The acceptance for integrity test results shall satisfy the following criteria:
1. The results shall not indicate likely impediment of the ability of pile to perform its intended
function. Examples of impediment include but are not limited to the following:
a. Lack of structural integrity.
b. Disadvantages change in physical dimension.
c. Discontinuity or inconsistency of material used in piles.
2. Where the initial integrity test results of the piles are not deemed to be satisfactory as
interpreted by the TfNSW geotechnical representative, further integrity testing shall be
carried at the contractor’s own cost, as approved by TfNSW. The further integrity testing
may include but not limited to the following:
d. Retrimming of the pile head and retesting.
e. Coring of the pile.
f. High strength dynamic pile testing.
© State of NSW through Transport for NSW 2023 Page 12 of 13
TS 02025:1.0
Testing of Cast-In-Place Concrete Piles
Effective date: 22 March 2023
8 Dealing with non-conformity
Where piles do not meet the acceptance criteria as mentioned in Sections 7.1 and 7.2 , the
contractor shall propose other means to demonstrate that the design intent of the piles is not
compromised or carry out remedial measures, as approved by TfNSW. The non-conformity shall
be dealt with at the contractor’s own cost.
© State of NSW through Transport for NSW 2023 Page 13 of 13
