Soil plugging is a key mechanism governing the behaviour and load-bearing performance of open-ended piles driven into sandy soils. During installation, sand may intrude into the pile, forming a soil plug that alters pile–soil interaction and modifies the load transfer mechanism. In this study, the formation and evolution of soil plugs in open-ended piles embedded sand are investigated using Discrete Element Method (DEM) simulations. The numerical framework enables detailed tracking of particle-scale interactions and soil intrusion patterns that are difficult to observe experimentally. A comprehensive parametric study is conducted to examine the effects of relative density, particle size distribution (PSD), penetration depth, driving rate, and pile geometry on soil plugging behaviour. Plug development is quantified through the Plug Length Ratio (PLR) and Incremental Filling Ratio (IFR), allowing systematic evaluation of plugging intensity under varying conditions. The simulation results reveal tha sand characteristics, pile geometry, and applied driving energy play a dominant role in controlling plug initiation and growth. The insights gained from the DEM analyses enhance the understanding of the soil plugging mechanism and offer improved guidance for the design and prediction of axial capacity in offshore and onshore pile foundations.