Hand Dug Caisson Piles are one of the established common deep foundation systems used in Malaysia. Although modern piling methods such as RC concrete piles, bored piles and micropiles are very common, hand-dug caissons remain an effective solution where large load capacities, minimal vibration, and direct inspection of founding strata are required.
This guide explains the construction sequence used by Shinei Geotechnique for hand-dug caisson foundations. It provides consultants, engineers, developers and contractors with an overview of the construction methodology, equipment, quality control measures and safety considerations involved in hand-dug caisson works.
A hand-dug caisson pile is a large diameter cylindrical shaft excavated manually by experienced workers.
Unlike bored piling, where drilling is performed using heavy machinery, excavation progresses manually inside the shaft while reinforced concrete lining rings are constructed progressively to support the excavation and prevent soil collapse.
Once the required founding level or rock socket has been achieved, the shaft is cleaned, reinforcement is installed and the caisson is concreted to form the permanent foundation.
Hand-dug caisson piles are commonly used for:
This method statement covers:
The following equipment is typically required for hand-dug caisson construction:
Step 1 – Site Preparation and Setting Out
The working platform is levelled and prepared to provide a safe working area.
Using survey equipment, the exact centre of each caisson is established before excavation begins.
A pilot excavation is then carried out.
Typically:
A circular steel mould is installed inside the pilot excavation.
Concrete is then poured between the mould and the excavated soil to form the first reinforced concrete lining ring.
After sufficient strength has been achieved, the steel mould is removed and reused for the next stage.
The concrete lining prevents:
This process is repeated throughout excavation.
Once the first lining is complete, a temporary steel or timber gantry frame is erected above the shaft.
The gantry supports:
Safety barriers are also installed around the shaft opening before excavation continues.
Step 4 – Manual Excavation
Experienced workers enter the shaft and excavate manually using:
Excavated material is loaded into a steel bucket and lifted to the surface using the electrical chain hoist.
Excavation proceeds in stages.
Each stage is followed immediately by installation of another concrete lining ring before excavation continues deeper.
Step 5 – Rock Excavation (Where Required)
When hard material, boulders or bedrock are encountered, excavation continues using:
Rock socket lengths are excavated according to the project design.
If actual ground conditions differ significantly from the site investigation report, the supervising engineer should be informed for review before excavation continues.
Step 6 – Ventilation and Groundwater Control
Because workers operate inside a confined shaft, continuous ventilation is essential.
Fresh air is supplied using mechanical air blowers connected directly to the bottom of the shaft.
If groundwater or seepage is encountered:
Gas detectors should be used throughout excavation to monitor confined-space safety.
After the required founding level has been reached:
Concrete spacers are installed to maintain the specified concrete cover (typically 75 mm).
Additional temporary welds provide sufficient rigidity during lifting and installation.
Concrete is placed using the tremie method.
The tremie pipe is lowered until it reaches the base of the caisson before being raised slightly to initiate concrete flow.
During concreting:
This method prevents segregation and ensures continuous concrete placement throughout the shaft.
Quality control typically includes:
Hand Dug Caisson Pile Construction setup
Hand Dug Caisson Pile before Tremie Grouting
Hand-dug caisson pile construction involves confined-space working and therefore requires rigorous safety procedures.
Typical safety measures include:
Method statement usually includes emergency evacuation drills conducted with emergency responders, highlighting the importance of rescue preparedness.
Hand-dug caisson piles continue to be selected because they offer several advantages:
What is the typical diameter of a hand-dug caisson?
Hand-dug caissons are commonly constructed between 900 mm and 3,000 mm in diameter, depending on design requirements and site conditions.
Hand-dug caissons are often preferred where direct inspection of the founding strata is required, where vibration must be minimized, or where access for large drilling rigs is limited.
The shaft is excavated in stages, with each stage immediately lined using approximately 150 mm thick in-situ reinforced concrete before excavation continues.
Safety measures include confined-space procedures, mechanical ventilation, gas detection, emergency rescue systems, safety harnesses, communication equipment, and continuous supervision throughout the excavation process.
Shinei Geotechnique has extensive experience delivering hand-dug caisson pile foundations across Malaysia for buildings, infrastructure and specialist foundation projects.
Our experienced site supervisors, trained excavation crews and strict safety procedures ensure every caisson pile is constructed to the required engineering standards while maintaining the highest levels of safety and quality.
Whether your project requires a single caisson or a large foundation package, our team can advise on the most suitable construction methodology based on your ground conditions and project requirements.
For consultants, main contractors, engineers, and project owners who require a formal reference document, you may download our typical Hand Dug Caisson Pile Method Statement PDF.
Need help reviewing a micropile method statement for your project?
Contact Shinei Geotechnique for technical support.
Ir Tan Chin Shu is a Geotechnical Engineer with over 40 years’ experience in the foundation and geotechnical engineering industry. He is the founding Director of Shinei Geotechnique, a specialist contractor in Malaysia.
