Helical Pier Installation on Mill Street
Challenge
Madole Construction was contacted by Furst Construction for a project involving a new access point from Mill Street to the SAIA facility. The project required constructing a 40-foot-wide driveway that could support heavy loads while working within significant environmental and spatial constraints. The biggest challenge was that the Pioneer Ditch, a regulated waterway under the Army Corps of Engineers, ran adjacent to the project site, restricting excavation and foundation work. Given these constraints, Madole Construction proposed an innovative solution using helical piers, which provided high-load capacity while adhering to environmental regulations and avoiding disruption to the protected waterway.
Challenges and Constraints
One of the primary challenges was the strict environmental restrictions associated with the Pioneer Ditch. Because it is a protected waterway, any significant ground disturbance was prohibited, eliminating the possibility of using traditional excavation and concrete footings. Additionally, space limitations posed another major challenge, as the ditch was too close to the road, making a conventional spread footing impractical. A traditional concrete footing would have required 408 square feet to support the necessary load, which was not available within the site. Furthermore, a conventional footing would have only supported 1,500 lbs per square foot, which was inadequate given the structural demands of the new driveway access point.
To properly distribute weight, the driveway would have required a 10-foot-wide footing, which was impossible due to space constraints. The challenge, therefore, was to create a stable foundation within a limited footprint, while ensuring compliance with Army Corps of Engineers regulations and maintaining structural integrity for long-term use.
Solution
To overcome these challenges, Madole Construction opted for helical piers, an advanced foundation system that provides high load capacity with minimal ground disturbance. Unlike traditional foundations, helical piers could be installed without excavation, preventing any disruption to the Pioneer Ditch while still delivering the necessary support for the driveway.
A total of 12 helical piers were installed, each designed to support at least 60,000 lbs, resulting in a total system capacity of 720,000 lbs. This eliminated the need for a large concrete spread footing, which would have required 408 square feet of space—a footprint that simply wasn't available at the site. The compact and efficiency of helical piers allowed for greater weight distribution in a smaller area, ensuring the driveway foundation could handle heavy traffic and long-term use.
Additionally, helical piers offered fast and efficient installation. Each pier was placed within three inches of the planned location and within two degrees of the designed inclination angle, ensuring precise placement. Unlike traditional deep foundation methods, which require heavy excavation and curing time for concrete, helical piers could be installed quickly, reducing both labor costs and project timelines.
Job Execution
Madole Construction ensured that all helical piers were installed correctly and met industry safety and quality standards. The HP350 helical pile system was chosen because it could support heavy loads and provide a strong, stable foundation. Each pier was designed to hold at least 60,000 pounds, with an extra safety margin built in to ensure long-term durability.
To protect against rust and corrosion, all metal parts were hot-dip galvanized, meaning they were coated with a protective layer to help them last longer, even in harsh conditions. Additionally, all brackets and hardware were coated with zinc, further ensuring that the foundation remains strong and reliable for years to come.
Project Outcome and Impact
By utilizing helical piers, Madole Construction successfully provided Furst Construction with a high-strength foundation system that overcame the space and environmental constraints of the project. The new driveway access from Mill Street was constructed without disturbing the Pioneer Ditch, ensuring full compliance with Army Corps of Engineers regulations. Additionally, the space-saving design of the helical pier system eliminated the need for large concrete footings, while still providing a structurally sound and reliable foundation. The efficiency of the installation process reduced labor costs and shortened the project timeline, making it a cost-effective and sustainable solution.
Beyond the immediate success of this project, the use of helical piers demonstrates Madole Construction’s expertise in foundation engineering and problem-solving. Helical piers are an ideal solution for projects where space constraints prevent traditional footings, environmental regulations limit excavation, or high load-bearing capacity is required in a compact area. Given their durability, ease of installation, and minimal environmental impact, helical piers offer a future-proof foundation solution for a wide range of construction projects.
Madole Construction successfully designed and implemented a helical pier foundation system for the Mill Street project, ensuring structural stability while maintaining environmental compliance. The project highlights the effectiveness of helical piers in constrained and regulated environments, providing a durable, space-efficient, and environmentally responsible foundation solution. By delivering high-quality engineering solutions, Madole Construction continues to lead the way in foundation innovation.
For more information about Madole Construction’s foundation engineering solutions, contact us today.
