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Essroc Facility Services
The original scope of work for this project was for the design and installation of approximately 800 micropiles for roughly one half of the intended plant expansion. The micropiles were designed for 350tons axial compression, 125tons axial tension and 15tons lateral load capacity. The design called for the use of a minimum 11-3/4in OD casing and corresponding core steel to meet the required design capacities. With pile lengths from 50 to 150ft in length due to the karst characteristics of the local geology, drill casing availability became a major concern. With shortages in the supply of the 11-3/4in pipe, Brayman utilized other available sizes (11-7/8in & 12-3/8in) to meet the demands of the project.
During the course of the work, exposed foundation areas began to show signs of sinkhole development. This prompted the owner to institute a low mobility grouting (LMG) program at sinkhole locations. Working closely with the owner and their engineers, Brayman developed a Low Mobility Grouting program to address the concerns related to the sinkholes. As to not impact the micropile production schedule, Brayman mobilized additional drill rigs and crews to the site to perform the LMG work ahead of the micropile installation. On occasion, it was necessary to stop micropile installation in particular areas due to the development of sinkholes around the drill rig jeopardizing the safety of the crews. Thus requiring the need to LMG grout those areas before continuing with micropile work.
As the first phase of the work began to wind down foundation designs for the next phase became available, Essroc asked Brayman to remain on site and continue with the LMG and micropile work through the entire expansion. In all, over 1600 micropiles were installed on the project totaling over 93,000lf of piles. Numerous pile load tests (compression, tension and lateral) were performed throughout the life of the project.
