In large-scale and industrial construction projects, choosing the right foundation is critical to ensuring structural integrity, safety, and longevity. Among these, deep foundations are commonly used when the upper layers of soil are not strong enough to support the structure. Unlike shallow foundations, which rely on surface-level soil, deep foundations transfer the load deeper into the ground, where soil or rock layers are more stable.

This article explores the four most widely used deep foundation types, analyzing their effectiveness based on factors like soil conditions, load-bearing requirements, environmental constraints, installation processes, cost-efficiency, and long-term performance.

TL;DR — 4 Deep Foundation Types

1. Helical Piles

Helical piles, also known as screw piles, are a highly versatile deep foundation option used in industrial construction projects, especially in soft or unstable soil conditions. These piles consist of steel shafts with helical (screw-shaped) plates attached, which are driven into the ground using hydraulic motors.

Key Benefits

• Ease of Installation: Helical piles can be installed quickly with minimal vibration, making them a suitable choice in urban areas or projects close to existing structures.
• Cost-efficiency: The speed and simplicity of installation, along with the minimal excavation required, contribute to reduced costs.
• Load-bearing Capability: Helical piles can handle both compression and tension loads, making them suitable for a range of applications, from foundations to retaining walls.
• Environmental Impact: With minimal disturbance to the surrounding soil and no need for concrete curing, helical piles are an environmentally friendly solution.

Best Used For

• Ideal for projects where soil conditions are weak or inconsistent.
• Used extensively in areas with limited access or environmentally sensitive regions, such as wetlands.
• Suitable for industrial applications requiring deep support, such as pipelines, bridges, and communication towers.

Long-term Performance

Helical piles offer long-term durability, as they resist corrosion with proper coatings and can be easily monitored and adjusted over time if necessary. Their adaptability to changing ground conditions makes them a reliable long-term option.

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2. Drilled Shafts (Caissons)

Drilled shafts, also known as caissons, involve drilling a deep hole into the ground and filling it with reinforced concrete. They are one of the most effective solutions for transferring large structural loads to deeper, more stable layers of soil or rock.

Key Benefits

• Load-bearing Capacity: Drilled shafts can be designed to handle extremely heavy loads, making them suitable for industrial facilities and skyscrapers.
• Versatility: Can be customized in terms of diameter and depth based on the specific load-bearing requirements of the project.
• Suitability for Rocky Terrain: Drilled shafts can be installed in hard soil or rock, where other deep foundation types might struggle.

Best Used For

• Best suited for high-load projects, such as bridges, large buildings, and dams.
• Works well in stable soil conditions where lateral forces, such as wind or seismic activity, need to be resisted.
• Ideal for projects requiring foundations that can handle substantial compression loads.

Long-term Performance

Drilled shafts provide exceptional durability and strength. When properly designed and installed, they offer excellent long-term performance with minimal maintenance.

Installation Considerations

Drilled shaft installation requires heavy machinery and precise engineering. The process involves drilling, casing the hole, and pouring concrete, which can be time-consuming and costly compared to other methods.

3. Driven Piles

Driven piles are long, slender columns, usually made of steel, concrete, or timber, that are driven into the ground using a pile driver. These piles displace the soil around them as they penetrate, creating friction that helps support the structure.

Key Benefits

• Cost-effective for Large Projects: Due to their relatively fast installation process, driven piles are a cost-effective choice for large projects.
• Load Distribution: Driven piles distribute the load through both end-bearing (to the bedrock) and friction along the pile shaft, providing solid support.
• Wide Range of Materials: Driven piles can be made from concrete, steel, or timber, allowing flexibility depending on the project’s needs.

Best Used For

• Suitable for coastal and waterfront projects where the foundation needs to be installed below the water table.
• Effective in areas with sandy or loose soils where other foundation types may struggle.
• Commonly used for bridge abutments, industrial plants, and offshore platforms.

Long-term Performance

Driven piles offer excellent long-term stability, especially in areas where they can reach a solid bedrock layer. Their resilience to environmental factors like erosion or corrosion (if made from treated materials) enhances their durability.

Installation Considerations

One of the main drawbacks is the significant vibration and noise caused during installation, which may not be suitable for projects near residential areas or sensitive equipment. Additionally, the displacement of soil can cause issues in densely built environments.

4. Micropiles

Micropiles are small-diameter, high-capacity drilled piles used for foundations where space is restricted or where ground conditions are challenging. They are often used in retrofit projects, where adding additional foundation support is required.

Key Benefits

• Minimal Disruption: Due to their small size, micropiles can be installed in tight spaces with minimal disruption to the surrounding environment.
• Versatility: Micropiles can be used in a wide variety of ground conditions, from soft soils to hard rock, making them a flexible solution for difficult sites.
• High Load Capacity: Despite their small diameter, micropiles can bear significant loads, providing reliable support for a wide range of structures.

Best Used For

• Suitable for projects in restricted spaces, such as urban redevelopment or sites with existing infrastructure.
• Effective in locations where ground conditions are unstable or contain obstructions like underground utilities or boulders.
• Ideal for retrofitting and upgrading foundations in existing structures.

Long-term Performance

Micropiles are highly durable and perform well over the long term, especially when used to reinforce or retrofit existing structures. Their ability to withstand lateral and seismic forces enhances their resilience.

Installation Considerations

Micropiles require specialized equipment for drilling and installation, which can increase upfront costs. However, their minimal footprint and adaptability typically offset these initial expenses.

Experience the Benefits of Helical Piles for Yourself

Choosing the right deep foundation type for a construction project depends on multiple factors, but helical piles often stand out for their versatility, ease of installation, and environmentally friendly nature, making them a popular choice in both industrial and urban projects.

If you need a deep foundation solution and think helical piles might be your answer, contact our team. With over 50 years of combined industry experience, we’re here to be a turnkey resource — from design aid, to supply, installation, and beyond.

Pipelines are foundational to the oil and gas industry, facilitating the efficient and safe transportation of essential resources from production sites to refineries and distribution centers. However, these critical infrastructures can face obstacles such as soil erosion and ground movement that compromise their stability. To address these challenges, pipeline anchoring has become essential for preventing displacement and ensuring structural integrity.

What is Pipeline Anchoring?

Pipeline anchoring is the process of securing pipelines in place to prevent movement and ensure their stability against various destabilizing factors. This could include environmental variables due to extreme weather events. Displacement pipe leaks and bursts can occur when the pressure from the oil or gas flowing through them is unbalanced.

Various types of pipeline anchoring systems can be used to promote stabilization. Deadweight anchors, for example, use heavy concrete weights to hold the pipeline down. Drilled piers involve drilling deep holes and filling them with concrete to create sturdy supports. While traditional anchoring methods can be effective, they often come with significant limitations, such as high costs and a long installation time. These drawbacks have led to more advanced and efficient anchoring solutions, like helical piles.

Helical Piles

Helical piles, also known as screw piles, are used to provide strong, stable foundational solutions for structures of all shapes and sizes. These anchors have helical bearing plates attached to a central rod. The plates dig into the ground like screws, transferring the pipeline’s weight from the rod to the soil. Unlike traditional anchors that push into the earth, this helical design minimizes disruption to the surrounding soil.

How Are Helical Piles Used in the Oil and Gas Industry?

Helical piles offer significant benefits for pipeline anchoring in the oil and gas industry. Their efficient installation process and adaptability to various soil conditions make them an ideal choice for ensuring the structural integrity and safety of pipelines. They can even support coastal areas prone to erosion. In soft soil, a helical design allows for deep penetration and firm anchoring. Helical piles solve pipeline challenges and contribute to the longevity of pipeline infrastructure, and are widely used in various applications within the oil and gas industry. 

Upstream Applications for Helical Piles

In the upstream sector, helical piles play a crucial role in supporting exploration and production facilities. Separation vessels, crude oil storage tanks, pump houses, control rooms, and other structures are critical for upstream operations. Helical piles can provide secure foundations for these various structures within production facilities.

Pumpjacks that pump oil and gas from wells often need stability. Helical piles can be used to secure a pumpjack, preventing movement caused by the pumping action. Helical piles can also create stable platforms for workers to access and maintain pumpjacks.

Midstream Applications for Helical Piles

Pipelines are the most common application for helical piles in midstream. They are ideal for quickly and efficiently establishing foundations for new pipelines, both above and below ground. When existing pipelines need upgrades or repairs, helical piles can be used to reinforce foundations or create additional support. Especially in areas with low soil shear strength or high water tables, helical piles can be a form of buoyancy control. They are a more economical alternative to concrete dead weights used to prevent pipelines from floating. In compressor stations, the installation process for helical piles creates minimal vibration, which is crucial to protecting sensitive equipment.

Downstream Applications for Helical Piles

Refineries are massive facilities with essential equipment. Helical piles can provide secure support for various refinery equipment, including storage tanks, processing units, and piping systems. During maintenance or expansion projects, helical piles can create foundations for temporary structures like work platforms or equipment shelters.

Safe and Effective Helical Anchor Installation With Elite Helical

When designing helical piles for oil and gas applications, several considerations are crucial, including the load requirements of the pipeline, the soil conditions at the installation site, and the potential environmental impacts. These factors ensure that the helical piles provide the necessary support and durability to maintain pipeline integrity and safety.

If you need foundational support for an application in the oil and gas industry, helical piles are the ideal solution. They can be custom designed to support your project’s specific needs, be installed within less than a day, and withstand the rigorous wear and tear of harsh environmental conditions. Whether you need support for pipelines, compressor stations, or rig supports, reach out to Elite Helical. Along with installing a quality pipeline anchoring solution, we’ll make sure your workers and the environment are protected.

Helical piles have a rich history dating back to the 1830s. Originally designed for mooring and lighthouses, these deep foundation elements have evolved into modern engineering marvels. Comprised of a central shaft adorned with one or more helix-shaped plates, helical piles are screwed into the ground just like a giant screw, providing a secure anchoring system for various structure

As a preferred deep foundation solution, helical piles offer exceptional stability and strength, particularly in challenging soil environments. They are engineered to transfer the weight of a structure to more suitable soil layers, thereby ensuring durability and safety. Let’s drill down into the specifics and unearth why helical piles in challenging soils could be the bedrock of your next construction project.

Understanding Different Soil Conditions

Soil type and condition are essential factors to consider when selecting the appropriate foundation solution for any construction project. Helical piles, known for their versatility, can be particularly effective in challenging soil types, such as rocky or hard soils. By understanding the soil conditions, engineers and contractors can optimize the design and installation of helical pile systems for maximum efficiency and performance.

Soft Soil

• Characteristics and challenges: Soft soil, often characterized by its high clay or silt content, may have poor load-bearing capacity and can be prone to shifting or settling. This poses a significant challenge for traditional foundation methods which may not provide the stability needed for long-term structural integrity.
• Solutions and strategies for piling in soft soil: The use of helical piles can mitigate these issues as they can be screwed deep into the ground, bypassing the weak soil layer and transferring the load to more stable strata. The design and length of the piles can be tailored to ensure they reach load-bearing soil, offering a secure and durable foundation.

Rocky Soil

• Challenges posed by rocky soil: Rocky soil conditions can be difficult for foundation installation due to the presence of hard rock layers which may impede the penetration of conventional piles or cause damage to the installation equipment.
• Advantages of helical piles in rocky soil: However, helical piles are equipped with sturdy helix-shaped blades that can cut through the soil and grip onto rocks allowing for secure anchoring. This method reduces installation time and minimizes the need for extensive excavation or drilling.

Hard Soil

• Characteristics and challenges: Dense and hard soils, such as some types of clay or compacted earth, can pose their own challenges. Pilings may be difficult to drive through such soils, requiring more force or specialized techniques to ensure proper placement.
• Techniques for dealing with hard soil conditions: With helical piles, installers can adjust the torque applied during installation to adapt to varying soil density. The installation equipment can apply a significant amount of force, ensuring the helical piles cut through the hard soil and attain the required depth for a secure foundation.

By understanding the intricacies of different soil conditions, professionals can enhance their approach to setting deep foundations. Helical piles offer flexible and reliable solutions to overcome the challenges presented by varied ground conditions, including the sometimes difficult rocky soil.

Adapting Helical Piles Installation for Seasonal Shifts

The performance of helical piles is closely related to soil conditions, which can vary greatly with the seasons. Understanding how seasonal changes impact soil properties is crucial for determining the right installation approach for helical piles, particularly in challenging soil environments.

Adaptations and Considerations for Different Seasons

• Spring Thaw: As the ground thaws, soil can become soft and muddy. Helical piles must be installed with attention to immediate load-bearing capacities, as well as the potential for soil drying and hardening later in the season.
• Summer Dryness: Soil may become denser and more unyielding in dry conditions. During installation, additional torque might be required to achieve the desired depth and capacity.
• Fall Preparation: Before the ground freezes, it’s essential to assess the soil’s readiness for winter. Helical piles may need to be driven deeper to account for potential frost heave.
• Winter Frosts: In frozen conditions, pre-drilling through soil can make helical pile installation more effective. Ensuring the piles penetrate below the frost line is critical for long-term stability.

Proper planning and adaptation for seasonal variations are paramount when working with helical piles in challenging soil. Each season requires its own set of strategies to optimize the installation and performance of helical pile foundations.

In the world of large industrial structures, the stability and safety of the building are of utmost importance. When existing structures show signs of distress, such as settlement, cracking, or uneven floors, it’s vital to address these issues promptly. 

One solution to reinforce and stabilize these structures is underpinning. This article explores:

• What underpinning is
• Various underpinning methods (with a special focus on helical piles)
• How underpinning works
• Key signs to look out for that indicate when a structure requires underpinning

Understanding Underpinning

Underpinning is a construction technique employed to strengthen the foundation of an existing building or structure. It is a critical process for maintaining the structural integrity of large industrial or commercial buildings. 

The primary goal of underpinning is to provide additional support to the foundation, effectively preventing further settlement and structural damage.

Underpinning Methods

Several methods can be used for underpinning, but one of the most versatile and efficient techniques, especially in large structures, is helical piles. Helical piles, also known as screw piles, are steel shafts with helical flights that are mechanically installed beneath the foundation. These piles are a cost-effective, low-impact solution that provides exceptional load-bearing capacity and stability.

• Helical piles are installed by drilling them into the ground beneath the foundation.
• The helical flights provide additional stability by anchoring the piles deep into the soil.
• They are an excellent choice for retrofitting and repairing existing structures due to their minimal disturbance and versatility.

Other popular underpinning techniques are: 

• Mass Concrete Underpinning – A traditional method that involves excavating sections of the existing foundation and pouring new, reinforced concrete under them.
• Mini-Piled Underpinning — A method that uses slender piles that are drilled into the ground using specialized equipment. It’s similar to helical piles but a little less strong.

How Underpinning Works

The process of underpinning typically involves the following steps:

1. Site Assessment

A thorough inspection of the structure and its foundation is conducted to determine the extent of damage and the required underpinning method.

2. Excavation or Drilling

Depending on the chosen underpinning method, excavations may be made around the existing foundation, or piles (e.g., helical piles) may be drilled into the ground.

3. Installation of Piles

In the case of helical piles, they are mechanically rotated into the ground until they reach a stable soil layer, effectively underpinning the structure.

4. Load Transfer

The weight of the structure is transferred from the damaged or weakened foundation to the newly installed underpinning elements.

5. Monitoring and Testing

The underpinned structure is continuously monitored and tested to ensure that it is stable and any further movement has been halted.

5 Signs a Structure Requires Underpinning

Identifying when a large structure requires underpinning is crucial for maintaining safety and preventing further damage. Here are some key signs to look out for.

1. Visible Cracks: Cracks in the walls, floors, or foundation that are increasing in size or number may indicate foundation settlement.
2. Uneven Floors: Floors that are sloping or uneven can suggest foundation issues.
3. Settling or Shifting: If you notice your building settling or shifting, it’s a clear sign of foundation problems.
4. Doors and Windows Sticking: Difficulty in opening and closing doors and windows can be a result of a shifting foundation.
5. Structural Instability: Any noticeable structural instability or leaning should not be ignored.

Choose Elite Helical for Stronger Structural Solutions

By addressing foundation issues promptly, you can prevent further damage and maintain the integrity of your industrial structure. When it comes to underpinning, helical piles are a better choice compared to concrete solutions. 

Get in touch with our team to learn more about helical piles and our process. 

Foundation repair for residential properties is widely discussed, but foundation issues don’t just affect older homes. Commercial buildings and structures can also be subject to foundation issues, sometimes with financially devastating consequences.

Some of the most common foundation problems include

• Damage from natural disasters, including earthquakes and hurricanes.
• Settlement, where the soil contracts or becomes compacted beneath the structure and the structure sinks down.
• Heave, where the soil expands when saturated and the structure lifts up.
• Washout, where the soil is washed out from underneath the structure, leaving unsupported voids in the soil.
• Age, as foundation materials will degrade over time.

When one of these issues occurs, repairing it quickly and cost-effectively is important to keep your operations going. Keep reading for three of the best foundation repair solutions for commercial applications.

The Best 3 Solutions for Commercial Foundation Repair

Our top recommendations for commercial foundation repair are underpinning, carbon fiber, and deep injection, or void fill.

1. Underpinning

Underpinning involves shoring up an existing foundation by expanding the depth or breadth of the foundation, thereby giving it more foundation over which to distribute the load of the supported structure. There are several types of underpinning: pit, mass pouring, beam and base, and pile underpinning. 

• In pit underpinning, a pit is excavated beneath the original foundation, then filled with concrete and connected to the original foundation. This deepens the foundation and increases its load-bearing capacity. 
• Mass pouring entails excavating shallowly beneath the structure and removing compromised soil, then filling the excavated space with concrete. 
• Beam and base underpinning require the construction of a reinforced concrete beam above, beneath, or replacing the original footing.

• Pile underpinning can include multiple different methods, using different piles, including helical piles. These piles or piers are attached to the existing structure of the foundation and installed into the soil, deepening or widening the foundation and spreading out the load over a greater area.

Helical Pile Underpinning

Helical piles are best known as a foundation in and of themselves, but they aren’t just for new construction; helical piles can help repair existing building foundations. Because poor soil conditions are the main cause of foundation failure, it makes sense to repair foundation issues with helical piles, which are designed to work in poor soil conditions.

To repair damaged commercial building foundations, helical piles can be installed into the soil with adequate bearing capacity and anchored to the existing structure, supporting it. These pile systems use the friction between the screwed-in pile and the soil into which it has been installed to not only support the pile but also keep the soil in place, preventing future issues due to soil expansion or saturation.

Helical piles are an excellent solution for foundation repair for the same reasons they’re good for new foundations: strength, durability, ease, speed of installation, and low construction footprint. Helical piles don’t require as much heavy equipment as other foundations and can be installed with minimal equipment in limited space, as well as installed at an angle — which is often necessary for commercial foundation repair situations. Helical piles have a long lifespan and can last over 100 years, ensuring that repairs last.

2. Carbon Fiber 

Carbon fiber foundation repair works by epoxying ultra-strong carbon fiber, woven into a fabric strip, to walls that have cracked, bowed, bulged, or turned in. Carbon fiber is incredibly strong and lightweight, and the carbon fiber strips will prevent the wall from further bending or movement.

While carbon fiber repair is valued for its low cost, low profile, ease, and speed of installation, it does have limitations. This method can only be used to repair foundation walls that have deflected by only two inches or less. It is also only effective for structures with accessible foundation walls (i.e., basements), which not all commercial structures have.

3. Deep Injection and Void Fill

Deep injection or void fill is a process wherein polyurethane is injected in liquid form into voids that have formed underneath foundations. The polyurethane then expands as a foam, filling the space, and hardens. This can reinforce soils that have washed out or settled beneath a foundation, as polyurethane does not react with water or soil. 

Lighter structures may use mud jacking to repair similar foundation issues, which involves raising the structure and filling the voids beneath it with concrete. This may result in other issues, however, as the concrete is heavy and may cause further settling. For commercial structures, mudjacking may be impossible, due to the size and nature of the structure in question. Since polyurethane can be injected into hard-to-reach voids, it may be the right solution for some commercial foundation repair applications.

Contact Elite Helical for Reliable Commercial Foundation Repair 

If your commercial building or structure is suffering from foundation issues, don’t wait until the problem gets any worse—get in touch with Elite Helical today to discuss how our helical pile offerings can repair your foundation issues. We focus exclusively on helical pile foundations and foundation repair, and we serve the needs of the commercial and industrial sectors, from oil and gas to manufacturing and more.