Document 429354

FOREWORD
The contents of this manual were specifically compiled in
response to the positive request of many professional engineers
desiring a general knowledge of helical units, without the intense
detail of analysis and theory found in earlier design manuals.
However, for those who prefer a more comprehensive analysis,
there is a section titled “Resources” in the back of the manual
referencing some of the information relevant to the design of
helical projects.
In conclusion, a geotechnical and structural engineer’s analysis,
combined with experience and on-site testing, are the governing
factors of a successful helical installation.
The information contained in this manual is the sole property of
Ideal Manufacuring Incorporated. Any reproduction in part or
as a whole without the written permission of Ideal Foundation
Systems is prohibited.
DISCLAIMER:
The content presented in this manual is derived from generally accepted engineering
practices. The suggested specifications are written as a guide to assist the engineer
in design and writing their own specifications. The final design of any Helical Unit
System requires knowledge specific to the soil properties and structural conditions
for a particular site. The design of any Helical Unit System is the full and complete
responsibility of the designer. Ideal Foundation Systems assumes no responsibility or
liability for the adoption, revision, implementation, use or misuse of these suggested
specifications. Ideal Foundation Systems’ sole responsibility shall be with respect to
products, and any such responsibility shall be subject to and limited by Ideal conditions
set forth in Ideal Foundation Systems/Ideal Manufacturing, Inc. “Product Policy
Statement.”
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
FOR IMMEDIATE
PROJECT ASSISTANCE
If you require immediate assistance to evaluate helical
units for your project, please fill out the
PROJECT FEASIBILITY REVIEW FOR HELICAL UNITS
located on the opposite page and fax to Ideal at 585-8723032. One of our representatives will review the project requirements and contact you with any questions without delay.
You may also call 1-800-789-4810 at any time to speak with
an Ideal representative or send an email to
[email protected]
PROJECT FEASIBILITY REVIEW
FOR HELICAL UNITS
DATE:
PROJECT NAME:
PROJECT OWNER:
PH
ENGINEER OF RECORD:
PH
GEOTECHNICAL ENGINEER:
PH
DRILLER:
PH
IDEAL FOUNDATION SYSTEMS CERTIFIED REPRESENTATIVE:
COMPANY NAME:
CONTACT NAME:
PH
STRUCTURE TYPE:
DESIGN LOAD REQUIREMENTS:
APPROX. NUMBER OF HELICAL UNITS:
LOAD TRANSFER BRACKET REQUIRED:
APPROX. DEPTH OR LENGTH OF UNITS:
ACCESS TO WORK AREA:
REMARKS:
TOLL FREE: 800-789-4810
FAX: 585-872-3032
ATTACHMENTS REQUIRED:
____SOIL BORING LOGS
____SIMPLE DESIGN SKETCH
____OTHER RELATED INFORMATION
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
Table of Contents
Tab
Section
HELICAL PILES AND ANCHORS
Introduction/Overleaf
Application and Uses ..................................................................................... 1
Advantages of Helical Units .......................................................................... 2
(and round shaft/square shaft comparison)
The Design of Helical Units ............................................................................. 3
Product Selection Guide ............................................................................... 4
Ideas for Design .............................................................................................. 5
STELCOR Drilled-In Displacement Micropiles
Overview and Specifications ........................................................................ 6
GREENWALK Boardwalk, Deck, and Dock System
Overview.......................................................................................................... 7
ASTM Load Test Specifications...................................................................... 8
Forms – Reproducible .................................................................................... 9
Resources....................................................................................................... 10
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
INTRODUCTION
TO HELICAL PILES AND ANCHORS
• History
The helical screw foundation was invented and patented by Alexander Mitchell in
England in 1833. He installed screw piles to support lighthouses in the tidal basins of
England. One such lighthouse with a similar foundation is still in use at Key Biscayne,
Florida.
• Helical Units
The unit is called a helical pier if it resists compressive loads, which are usually
downward. It is called a helical anchor if it resists tensile loads, which are usually upward
or inclined. Many helical units function as both piers and anchors.
A helical unit is installed by simply screwing it into the ground. The central shaft may be
round or square and it may be hollow or solid. Hollow (pipe shafts) are often preferred,
because they provide a greater section modulus for the same cross-sectional area of
steel. Pipe shafts, as compared to solid shafts, generally provide greater resistance to
installation torques and buckling under compressive loads.
A typical helical unit is shown in Figure 1.1. It consists of a central steel shaft, to which
can be attached one or more steel helices. The central shaft can be lengthened by
adding extension pieces as necessary.
Pipe shafts are seldom less than about 3 inches in diameter. If necessary, shafts greater
than
12 inches in diameter can be used.
Helices are seldom less than 8 inches in diameter, and seldom less than 3/8 inches in
thickness. If necessary, helices greater than 36 inches in diameter can be used.
Experience and theory have combined to suggest that the preferred spacing between
multiple helices is equal to 3 helix diameters of the preceding helix.
The final component to the helical unit is the Load Transfer Device (LTD). This is the final
component to transfer the tension or compression load from the structure to the helical
unit. (Helical anchor shown in figure 1.2 and helical pier for underpinning shown in figure
1.3.)
Simply put, the helical unit transfers tension or compression load to competent soil strata
below incompetent soils.
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
EARLY SCREWPILES
APPLICATIONS –
LIGHTHOUSE
FOUNDATIONS
NEW
CONSTRUCTION
LTD
FIRST
GENERATION
SCREWPILE
FIGURE 1.1
EXTENSION
FIGURE 1.3
BOLTED
COUPLING
COUNTERFORCE™
UNDERPINNING
BRACKET (PATENT
PENDING)
LEAD
SECTION
TENSION ANCHOR LTD
(LOAD TRANSFER DEVICE)
FIGURE 1.2
HELIX
APPLICATION & USES
OF HELICAL PILES AND ANCHORS
EXPRESSWAY BRIDGE REMEDIATION FOR
D.O.T.
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
1.1
APPLICATION & USES
OF HELICAL PILES AND ANCHORS
A helical pier is a deep foundation. Its purpose is to transfer a structural load to deeper,
stronger, and less compressible materials bypassing weaker and more compressible
materials that would be unsuitable for the support of a conventional shallow foundation.
As a deep foundation, a helical pier should be considered for most applications that
would call for a driven pile, drilled pier, or minipile.
Uses of helical piers include the support of new structures and the underpinning of
existing structures that have settled excessively.
Helical anchors are used for resisting upward forces, lateral forces, and overturning
moments. Applications include communications towers, advertising signs, silos, belowgrade tanks subjected to hydrostatic uplift, and tieback anchors for both permanent
and temporary
earth-retaining structures.
It is important to note that the uses of the helical unit continue to expand with product
developments and engineering experience.
1.2
UNDERPINNING COMMERCIAL BUILDING
SHOT-CRETE RETAINING WALL
MUNICIPAL PIPELINE SUPPORT
MUNICIPAL BOARDWALKS, DECKS, AND DOCKS
FABRIC STRUCTURE FOUNDATIONS
TENSION ANCHORS FOR MOTOR SPEEDWAY STRUCTURE
SOLAR PANEL FOUNDATIONS
LIGHT POLE BASES
CONCRETE SLAB JACKING
RESIDENTAIL FOUNDATIONS
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
AIRPORT CONTROL TOWERS
1.3
APPLICATION & USES
OF HELICAL PILES AND ANCHORS
MACHINE BASES AND STORAGE TANK FOUNDATIONS FOR TREATMENT PLANTS, FACTORIES, AND REFINERIES.
1.4
ADVANTAGES
OF HELICAL UNITS
INSTALLATION IN COLD AND SNOWY CONDITIONS.
NEW PILES (120 KIP) INSTALLATION FOR
TRANSFORMER BASE.
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
2.1
ADVANTAGES
OF HELICAL UNITS
For many applications helical units may offer significant
advantages over other systems. Some of these include:
• Wide range of allowable loads
• Adaptability to a variety of installation angles
• Lower cost than driven or drilled piles – do not go as deep to reach the same capacity
• Ease and speed of installation
• Minimal support equipment
• Suitability for low-headroom and other limited-access areas
• Easy cutoffs
• No concrete-related delays
• Little or no dependence on weather
• Little or no earthwork and spoil material (a particular advantage at contaminated sites)
• Minimal vibration and noise
• Easily removed and reused in temporary applications
2.2
ECO-SENSITIVE INSTALLATION
20 KIP PILES FOR BOARDWALK/DECK,
IN DIFFICULT TO ACCESS ECO
SENSITIVE WATERWAY
FOUNDATION SUPPORT FOR TV NETWORK
SATTELITES
DIFFICULT ACCESS - UNDERPINNING IN
ELEMENTARY SCHOOL
TIE BACK ANCHOR INSTALLATION WITH DIFFICULT ACCESS
30 TON PILES INSTALLATION FOR SLAB SUPPORT IN A VERY
LOW CLEARANCE ENVIRONMENT
DIFFICULT ACCESS - UNIVERSITY SWIMMING POOL
CONVERSION
30 TON PILES INSTALLATION IN A DIFFICULT-TO-ACCESS AND
LOW CLEARANCE ENVIRONMENT
NOISE AND VIBRATION SENSTIVIE AREAS - REMEDIATION
WORK IN HOSPITAL COURYARD
DIFFICULT-TO-ACCESS AREAS - SLAB SUPPORT IN A CRAWL
SPACE UNDER A PERFORMING ARTS CENTER
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
2.3
ADVANTAGES
OF HELICAL UNITS
TOP SHAFT O.D. INCREASED TO
8-5/8 INCH FOR SUPERIOR LATERAL
STABILITY IN SOFT SOILS.
LEAD PILE SECTION IS
2-7/8 INCH - 80 KIP
MATERIAL
200 TON LOAD TEST SYSTEM
7-INCH PILES TESTED TO 205 TONS
2.4
• 7-INCH O.D. PILE SHAFT WITH 20-INCH BY 1-INCH HELIX
• UP TO 300 TON ULTIMATE CAPACITY FILLED WITH HIGH-STRENGTH GROUT
• LARGER SHAFT SIZES AND HELICES AVAILABLE
• NOISE AND VIBRATION SENSITIVE AREAS
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
2.5
ADVANTAGES
OF HELICAL UNITS
300 TON CAPACITIES
DIFFICULT-TO-ACCESS AND LOW
CLEARANCE TRAIN BRIDGE
2.6
ADVANTAGES
OF HELICAL UNITS
SHORING TO PROTECT DANGEROUS EXCAVATIONS - REMOVABLE
EASY CUTOFFS
PILES INSTALLED AND READY FOR FOOTING BEHIND EXISTING RETAINING WALL ON LAKE.
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
2.7
ADVANTAGES
OF HELICAL UNITS
PIPE SHAFTS HAVE THE FOLLOWING ADVANTAGES
OVER SQUARE SHAFTS:
• Greater section modulus - increased lateral stability
• Greater ultimate and allowable loads - 7-inch standard material - 300* ton ultimate capacity
• Less eccentricity (straighter)
• Greater resistance to buckling
• Higher torque capacity
• Inspectability - post installation depth and plumb
• Can be filled with grout or concrete for increased capacity
ALLOWS FOR POST-INSTALLATION DEPTH
AND PLUMBNESS INSPECTION
SQUARE:
MAX 5500 FT LBS.
TORQUE
ROUND:
MAX 8000 FT LBS.
TORQUE
ROUND AND SQUARE VISUAL COMPARISON
OF LEAD SECTIONS ON A MARINE BREAKWALL
PROJECT - TIEBACK ANCHORS
ROUND AND SQUARE LATERAL STABILITY
2.8
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
3.1
THE DESIGN PROCESS OVERVIEW
You may find the following instructions useful to achieve an orderly
progression of the design process.
1) Read the following four (4) pages for a basic comprehension of helical design
2) Copy work sheets from section 7 titled “Forms”
3) Use worksheets to compile information for the project design and to interact
with your Ideal Representative.
4) Use the page titled “Resources” at the end of this manual to research areas
of
concern in greater detail
5) Contact an Ideal Representative at any time: 1-800-789-4810
3.2
THE DESIGN
OF HELICAL UNITS
• General
The steps in the design of a helical unit are typically as follows:
1. Computation of the design load
For most helical piers and many helical anchors, the design loads are computed by the
structural engineer. On some projects, and frequently on those involving tieback anchors,
the loads are computed by a geotechnical engineer.
2. Selection of the required structural shaft
The selected shaft should have an allowable load that exceeds the computed design
load.
Information on various shafts and their allowable loads is presented in the following section titled “Product Selection Guide.” On many projects, the shaft can be selected by the
structural engineer.
3. Geotechnical analysis and design of the helices
This is typically performed by a geotechnical engineer or by a structural engineer with sufficient
geotechnical experience.
• Geotechnical Design
The geotechnical design of a helical unit is based on the required design load and on
information regarding the subsurface conditions. This design results in the selection of the
number, sizes, and depths of the helices. The theoretical safety factor against geotechnical failure (the ratio of ultimate capacity to allowable load) should be at least 2.
The load capacity of a helical unit will depend on factors including soil strength (friction
and/or
cohesion), soil density, helix depth(s), and groundwater level. There are several theories
and
methods for the geotechnical analysis and design of helical units. Furthermore, the analyses for piers and anchors are not the same.
For helical piers, one commonly used method
of analysis is shown on the following page.
More detailed analyses of helical piers, and any analyses of helical anchors, are beyond
the scope of this publication. A list of references titled “Resources” is provided at the end.
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
3.3
Load Capacity Example
Q t =  Q h = Total Ultimate Multi-Helix Capacity
Q h= Individual Ultimate Helix Capacity
Q h= 9Ac for Cohesive Soil
Q h= A q N q for Granular Soil
Where
A = Helix Area
c = Soil Cohesion
q = Effective Overburden Pressure
Nq = Bearing Capacity Factor Based on
Friction Angle (o) of Soil
o (degrees)
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
3.4
Nq
10
12
14
16
18
20
23
26
30
34
39
44
50
57
65
74
85
97
THE DESIGN
OF HELICAL UNITS
• Torque-Capacity, Buckling
Installation Torque and Load Capacity
A helical unit’s installation torque can provide an indication of the load capacity. One empirical
and widely used equation indicates that the ultimate load capacity (in pounds) is approximately equal to ten times the installation torque (in foot-pounds) observed on the last 3-5
feet of
embedment.
The installation torque should be monitored for all helical units. The installation torque
alone,
however, should not be relied upon in the absence of adequate subsurface information
and
engineering analysis. On some projects, a limited number of load tests may also be appropriate.
Buckling
There are several theoretical methods addressing the below-ground buckling failure of long
and slender foundation elements, and there is considerable variation in the conclusions
reached by these various methods. In actual practice, buckling failures of deep foundations have been very rare.
Experience and theory combine to suggest that below-ground buckling need not be considered unless a very slender foundation element is surrounded by significant depths of soft
cohesive soil, very soft cohesive soil, and/or or very loose granular soil. These soils are generally associated with a Standard Penetration N value of 4 blows per foot, or less. Even in
the presence of these weak soils, the actual incidents of buckling have been few.
With regard to the buckling resistance of helical piers, a round shaft is often preferable to a
solid shaft. The pipe shaft provides a greater section modulus, and therefore greater buckling
resistance, for the same cross-sectional area of steel.
Additional analysis on buckling can be provided by a geotechnical or structural engineer.
ROUND SHAFT
SQUARE SHAFT
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
3.5
THE DESIGN
OF HELICAL UNITS
• Corrosion
For more than 100 years, steel piles have established an exceptional record of long-term
performance in soil and freshwater environments. This includes driven H piles and pipe piles,
installed without any form of corrosion protection. The performance generally exceeds that
which would be predicted on the basis of theory.
Many helical units are now provided with a galvanized coating. Uncoated units, however,
are also used. A conservative amount of sacrificial steel is sometimes provided in the design.
The most corrosive environments are generally those involving salt water, chemically-aggressive fill materials, and some organic soils.
Additional analysis on corrosion, if necessary, can be provided by a geotechnical or corrosion
engineer.
As indicated in the Corrosion Resistance of Zinc and Zinc Alloys: “Of all the anions, chloride is
the most corrosive to zinc in water (and soil), especially if it is present in amounts
exceeding 50 mg/L. The softer the water, and the lower it is in carbonate, the more pronounced is the effect of chloride. Thus a chloride content of 80 mg/L in soft water causes
quite severe
corrosion, while in hard water no corrosion occurs even with 700 mg/L.” Hard water forms a
scale
of insoluble salts on the galvanized coating and combines with the zinc, forming a protective
barrier of zinc carbonate and calcium carbonate. This layer greatly increases the corrosion
resistance of the galvanized pile.
All Ideal hot-dipped galvanized piles shall conform to ASTM A123.
As may be observed from the table above, galvanized coatings may provide a 100-year
design life in most soils. Alternate protective coatings* should be used in extremely corrosive
soils. If corrosion is a critical consideration, a specialist on corrosion should be consulted.
*See section P.2 of Product Selection
Guide
3.6
THE DESIGN
OF HELICAL UNITS
DESIGN PROCEDURE FOR HELICAL PILES/ANCHORS (HP/HA)
1. DETERMINE LOADS:
a) Dead load
b) Live load
c) Safety factors
d) Required Design load ___________
e) Ultimate or Test load ____________
2. SOILS INFORMATION
a) Soil type
b) Soil description
c) Soil classification
d) Water table levels
e) Frost penetration
f) N valves in pile locations
3. PILE/ANCHOR SPACING
a) Calculate for group effect
b) Re-design or compensate
c) Consider larger pile in lieu of grouping
4. DESIGN OF HELICAL UNIT (minimum safety factor = 2.0)
a) Select a CENTRAL SHAFT capable of ultimate load from the table on page A1
in the Product Selection Guide.
b) Design HELICAL LEAD SECTION (HLS) using design criteria in the Product
Selection Guide, page B.1 from table titled HELICAL PLATE SELECTION GUIDE
c) Select a LOAD TRANSFER DEVICE (LTD) from the Product Selection Guide,
subsections H, I, J, K, N, and M or design one compatible with the shaft selected
d) Re-evaluate helical unit design, in assembly, for this specific site.
[IF QUESTIONABLE, REPEAT STEP #4]
5. Establish installation criteria and unit specifications using:
STANDARD TECHNICAL SPECIFICATION, page 3.9 or comprehensive, page
3.10-11 in the Design of Helical Units. You may also call 800-789-4810 to r
quest an electronic template of 3.8 and 3.9.
6. OTHER
a) Is project practical as designed?
b) Are there seismic considerations?
c) Is there extreme soil chemistry, corrosive elements, etc.?
d) Can desired penetration or embedment be accomplished with your helix and
shaft selection?
e) Is there adequate installation equipment/capabilities/power?
DESIGN MANUAL
*COPY THIS PAGE AND FILL IN AS REQUIRED
©2014 Ideal Manufacturing Inc.
3.7
THE DESIGN
OF HELICAL UNITS
HELICAL PROJECT DESIGN PROCESS GUIDELINE
ASSIGNMENT
PARTY
1. Perform thorough site investigation including potential restrictions
and encumbrances
2. Outline scope of necessary geotechnical investigation
3. Perform geotechnical investigation and submit reports
4. Evaluate requirements for pre-contract testing
5. Outline general scope of work
6. Design helical unit system including design loads, safety factor,
helical unit locations and spacing
7. Obtain necessary easements
8. Formulate acceptance criteria using calculations of allowable
movement in service
9. Define long-term monitoring methods
10. Define service life
11. Define corrosion protection based on site conditions
where required
12. Define number and type of pre-production tests
13. Define number and type of in-production tests
14. Define helical unit length or depth to bearing stratum
15. Design helical components and load transfer device
16. Design details for connection to structure including
torsional and seismic considerations
17. Prepare design drawings
18. Provide evaluations and reports of test results
19. Define installation procedure
20. Outline of installation schedule and sequencing
21. Provide installation log including installation torque and
helical unit depth or length
22. Provide field production control and inspection
23. Provide field supervision of installation team
24. Perform post-installation monitoring
TOLL FREE: 800-789-4810
FAX: 585-872-3032
3.8
THE DESIGN
OF HELICAL UNITS
STANDARD TECHNICAL SPECIFICATIONS
(HELICAL PIERS FOR NEW CONSTRUCTION)
Helical piers and related hardware by Ideal manufacturing Inc., 999 Picture Parkway,
Webster NY 14580, 1-800-789-4810.
Each helical pier shall have a steel shaft with an outside diameter of at least _____ inches, and
a cross-sectional area of at least _____ square inches. Steel shall be Grade _____.
Each pier shall have _____ helices. From the bottom
upward, the helix diameters shall be _____, _____, and _____ inches. The thickness of each steel
helix shall be at least _____ inch. Steel shall be Grade _____.
Helical piers shall be installed at the locations shown on the accompanying drawing. The deviation of the top of each pier from the design location shall not exceed _____ inches.
Each pier shaft shall be inclined at an angle of zero to 4 degrees from vertical.
All piers shall be advanced into stable natural soil or rock, below any compressible materials.
Based on the available subsurface information, each pier should be advanced to or below
Elevation _____ feet.
Each pier shall be installed using a combination of torque and downward force. The minimum
final torque shall be _____ foot-pounds. The maximum torque shall be _____ foot-pounds.
Each pier shall achieve an ultimate capacity of at least _____ pounds, and an allowable working capacity of at least _____ pounds.
The top of each pier shaft shall be equipped with a snug-fitting load-distribution bracket. The
bracket shall include a horizontal steel plate having a thickness of at least _____ inch. The plate
shall be square or rectangular in plan view, shall have a minimum width of _____ inches, and
shall have a top area of at least _____ square inches. The deviation of the top of each plate
from the design `elevation shall not exceed _____ inches.
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
3.9
COMPREHENSIVE TECHNICAL SPECIFICATIONS
SECTION (
) – HELICAL PILES/ANCHORS
PART 1 – GENERAL
1.01
SUMMARY
A. Section Includes
tral
1. Helical Piles/Anchors consist of one of more helically shaped steel plates attached to a censteel shaft. Extend piles by adding shaft extensions.
2. Helical piers and related hardware by Ideal manufacturing Inc., 999 Picture Parkway,
Webster NY 14580, 1-800-789-4810.
B. Related Sections
1.
Section _____ - Earthwork
2.
Section _____ - Structural Concrete
1.02
REFERENCES
A. Conform to applicable requirements of State Building Code and applicable requirements
of other referenced documents.
B. References include documents from:
1. ASTM – American Society for Testing and Materials
a. ASTM A36/A 36M – “Structural Steel”
b. ASTM A29/A 29M – “Steel Bars, Carbon and Alloy, Hot-Wrought and
Cold Finished”
c. ASTM A53 – “Pipe, Steel, Black and Hot-Dipped, Zinc-Coated Welded
and Seamless”
d. ASTM A123 -Zinc Coatings (Hot-Dip Galvanized) on Iron and Steel Products
e. ASTM A153 – “Zinc Coating (Hot-Dip) on Iron and Steel Hardware”
f. ASTM 572 – “Latest Revision, HSLA Columbium-Vanadium Steels of
Structural Quality”
g. ASTM A607 – “Steel, Shaft and Strip, High-Strength, Low-Alloy
Chromium or Vanadium, or Both, Hot-Rolled and Cold-Rolled”
h. ASTM SAE J429 – “Mechanical and Material Requirements for
Externally Threaded Fasteners”
2. ACI – American Concrete Institute
a. ACI 301 – “Specifications for Structural Concrete for Buildings”
3. PTI – Post Tensioning Institute
4. API – American Petroleum Institute
3.10
1.03
SYSTEM DESCRIPTION
A. Furnish all labor, materials, equipment and services for the design (including design submittals) and
installation of all helical piles, in accordance with Drawings and Specification, including cut-offs and
Load Transfer Device installation.
B. Design helical pile system to support loads as indicated on Drawings and outline in this Section. Submit
helical pile design calculations and other pertinent data for approval as specified in Submittals below.
1.
1.04
Obtain Architect’s approval of design calculations and drawings before commencing pile
installation. Approval of submittals does not relieve Contractor of responsibility for performing
the pile installation in accordance with Contract Documents.
SUBMITTALS
A. Comply with requirements of Section __________
B. Pre-Installation Submittals: Submit following items for approval not less than 14 days prior to commencing pile installation.
1. Delegated Design Data – Submit following data, sealed by Professional
Engineer registered in the state where the project is located:
a. Calculations for pile design capacities
b. Shop drawings showing pile shaft diameters, helical plate data, length, and other
pertinent data.
c. Details of installation sequence and equipment to be used in pile construction.
d. Sample copies of daily pile reports/field reports to be used
C. Construction Submittals: Submit following items on regular and timely basis:
1. Record of daily pile installation
D. Post-Installation Submittals: Submit following items upon completion of pile installation:
1. Record drawings showing location of piles as specified in Part 3 – Field
Quality Control
E. Quality Control Submittals
1. Qualifications Certification: Submit written certification or similar documentation signed by
applicable Subcontractor, Prime Contractor and Manufacturer (where applicable) indicating
compliance with applicable “Qualifications” requirements specified below in “Quality
Assurance” section.
2. Installer Experience Listing: Submit list of completed projects using products proposed for
this Project, including owner’s contact and telephone number for each project, demonstrating
compliance with applicable “Qualifications” requirements specified below in “Quality
Assurance” article.
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
3.11
1.05
QUALITY ASSURANCE
A. Qualifications
ble of
1. Installer: Certified Installer (Certified by Helical Pile Manufacturer), with a minimum 5 years
experience in type of design and construction specified in this Section and able to
demonstrate sufficient competent personnel to complete specified construction. Capaproviding job superintendent or foreman with at least 5 years construction experience in
construction specified in this section and ensuring such supervision will be present at site
during pile construction.
PART 2 – PRODUCTS
2.01
MANUFACTURERS
A. For convenience, details and specifications have been based on the following specified
product/manufacturer: [see products to fill this section]
(example: Ideal Foundations Systems Product 278 High Torque, 2.875 O.D. Central Shaft with a 12”
O.D. x 1⁄2” thick helix as manufactured by Ideal Manufacturing, Inc.)
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
2.02
MATERIALS
A. Helical Plate:
1. Cold Rolled A36
B. Pile/Anchor Shaft:
1. See table in section 4, page A.1 in Products to fill this section
(Sample: API 5CT J55 Structural Grade)
a. Lead section of shaft to be minimum ___ in length
C. Steel Pile Cap:
1. Plate ASTM A36
2. Pipe: API 5CT J55 Structural Grade
*Optional
D. Helical piles, extensions, caps, and appurtenances are to be hot-dipped galvanized steel in accordance with ASTM A153.
3.12
PART 3 – EXECUTION
3.01
EXAMINATION
A. Verification of Conditions: Examine conditions under which piles are to be installed in coordination
with Installer of materials and components specified in this Section and notify affected Prime Contractors and Architect in writing of any conditions detrimental to proper and timely installation. Do not
proceed with installation until unsatisfactory conditions have been corrected in a manner acceptable
to Installer.
1.
When Installer confirms conditions as acceptable to ensure proper and timely installation and to
ensure requirements for applicable warranty or guarantee can be satisfied, submit to Architect written
confirmation from applicable Installer. Failure to submit written confirmation and subsequent installation will be assumed to indicate conditions are acceptable to Installer.
*Optional – May be another party responsible for this item
3.02 PREPARATION
A. Employ licensed land surveyor or registered professional engineer to establish all lines and grades
required for pile installation.
3.03
INSTALLATION
A. Pile Installation:
1. Provide installation equipment capable of installing pile of required minimum diameter to
design depth, and to meet the required minimum torque.
2. Position Helical pile in accordance with the contract documents.
3. Use only manufacturer-approved connectors, adapter and accessories.
4. All welding to be in accordance with AWS D1.1 Welders must be certified in accordance
with AWS.
5. Provide torque monitoring device as part of the installing unit. Monitor and record torque
applied during the installation of each pile.
6. Remove encountered obstructions, or relocate helical piles as required. Relocation of helical
pile must be approved by A/E. Obstructions and relocations shall be considered “extra work.”
3.04
FIELD QUALITY CONTROL
will be same contractor as item 3.02
A. Survey of Piles (Record Drawings) – Prime Contractor
1. Testing and survey work required to establish pile locations and elevations.
Record drawings and other ancillary operations required for completion of pile installation.
2. Accurately locate each pile by means of survey performed by licensed surveyor or registered
professional engineer. Record survey data with other required information on
reproducible drawing.
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
3.13
3. Include following information on record drawings:
a. Each pile identified by separate number
b. Angle of pile installation
c. Elevation of each pile top
d. Plan location of each pile
e. Deviation from plan location in inches, measured to neared 1⁄4 inch
f. Torque reading for the last three feet of installation
g. Description of lead section and extensions installed
h. Helical plate size and shaft size
4. Furnish prints of record drawings to Architect at completion of pile installation.
B. Tolerances and Criteria for Acceptance
1. Minimum torque of ____ foot-pounds, with a minimum depth of ____ feet.
2. Install piles as close as practical to design location. Do not exceed ___ inches
lateral deviation from center of pile design location.
3. Piles improperly installed because of mislocation, misalignment, or failure to
meet other specified design/installation criteria are not acceptable. Abandon
rejected piles and install additional piles as required.
C. Pile Installer Records – Maintain daily record of all data pertinent to installation of piles, including:
1. Pile number
2. Date of installation
3. Helical plate diameter
4. Pier shaft size
5. Pile length
6. Torque readings during installation
7. Description of any unusual occurrences during pile construction
*Optional
D. Load Tests – Requirements
1. Provide compression pile load tests by Pile Installer in accordance with ASTM Load Test
Specifications. At each location, test a minimum of two piles.
2. Load test piles incrementally on __ times design load with deflection measured at each
addition of load.
3. Submit detail drawings, design data and installation procedures pertaining to proposed
pile load by Pile Installer for approval 14 days prior to initiation of pile installation.
4. Furnish and install complete load test system including jacks, reaction beam, dial indicators,
spherical bearing plate, load cell, reference beams, test enclosure, and all other equipment,
materials and labor that will satisfactorily perform required pile load test.
5. Test piles, if successfully tested and properly located, will be accepted as permanent and
may be left in place.
E. Quality Control/Inspection:
1. Owner’s Geotechnical Engineer is to observe all pile installations and load tests.
End of Section
3.15
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
4.1
• General
Our standard pipe shafts are listed on page A.1. Other pipe shafts can be provided
as necessary.
Helices are commonly fabricated using ASTM 572 Grade 50 steel. Helices are
provided
with diameters of 6 inches and larger, and with thicknesses of 1/2 inch and larger.
A helical selection guide is on page B.1.
New construction brackets are fabricated, using ASTM 572 Grade 50 steel, to fit
the
corresponding pipe shafts. The minimum thickness of the horizontal top plate is
3⁄4 inch, with greater thicknesses necessary depending on design loads. The
area
of each top plate is such that, under the maximum allowable load, the stress
against the overlying concrete will not exceed 750 psi.
Underpinning brackets are designed and constructed to accommodate the
sizes
and loads of the corresponding pipe shafts.
Helical units can be galvanized if desired.
The entire helical system may also be coated with elastomeric polyurea for use
in very corrosive and salt water environments.
(see page P.2)
DESIGN MANUAL
4.2
©2014 Ideal Manufacturing Inc.
• Product Listing
Central Shaft Selection Guide Table ......................................................... A
Helical Plate Selection Guide ......................................................................B
Standard Products
80 KIP ULT. 2.875 ............................................................................................C
120 KIP ULT. 3.50 ............................................................................................ D
180 KIP ULT. 5.00 .............................................................................................E
380 KIP ULT. 7.00 .............................................................................................F
420 KIP ULT. 8.625 ......................................................................................... G
530 KIP ULT. 10.75 .......................................................................................... H
800 KIP ULT. 12.75 ............................................................................................I
800 KIP ULT. 16.00 ...........................................................................................J
1000 KIP ULT. 20.00 ........................................................................................ K
IDT – Increased Diameter Top Section........................................................ L
New Construction Brackets ....................................................................... M
Tie Back Adaptors ........................................................................................ N
Underpinning Systems................................................................................. O
Slab-jacking Brackets .................................................................................. P
Light Pole Base ............................................................................................ Q
Guy Wire Adaptors ...................................................................................... R
Boardwalk Brackets ......................................................................................S
Corrosive environment coatings ................................................................. T
Pile steel and plate specifications ............................................................. U
4.3
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
2.875
3.5
3.5
278
312
312
0.300
0.254
0.276
0.217
60
30
45
20
DESIGN
120
60
90
40
ULTIMATE
STRUCTURAL
CAPACITY (TONS)
32
24
29
20
DESIGN
64
48
58
40
ULTIMATE
CAPACITY BY
TORQUE (TONS)
7
8.625
10.75
12.75
16
20
700
858
1034
1234
1600
2000
0.375
0.312
0.625
0.365
0.322
0.408
0.304
290
200
250
150
115
140
72
DESIGN
580
400
500
300
230
280
145
ULTIMATE
STRUCTURAL
CAPACITY (TONS)
175,000
125,000
150,000
90,000
82,000
64,000
32,000
MAX
TORQUE
(FT. LBS.)
52,000
50,000
50,000
52,000
55,000
70,000
65,000
MIN
YEILD
16,000
12,000
13,000
9,000
8
8
9
9
MAX
CAPACITY
TORQUE TO TORQUE
(FT. LBS.)
RATIO
This table is a guide only. Other sizes, up to 36, and various wall thicknesses can be utilized for specific projects.
5.5
512
IDEAL
O.D.
WALL
PRODUCT PILE SIZE THICKNESS
CODE
(INCHES) (INCHES)
LARGE CAPACITY HELICAL PILES ARE DESIGNED ON A PROJECT SPECIFIC BASIS THE NUMBERS BELOW ARE FOR QUICK REFERENCE ONLY
2.875
278
IDEAL
O.D.
WALL
PRODUCT PILE SIZE THICKNESS
CODE
(INCHES) (INCHES)
CENTRAL SHAFT SELECTION GUIDE TABLE
80,000
55,000
80,000
55,000
MIN
YEILD
A.1
Disclaimer:
The content presented in this manual is derived from generally accepted engineering practices. The
suggested specifications are written as a guide to assist the engineer in design and writing their own
specifications. The final design of any Helical Unit System requires knowledge specific to the soil
properties and structural conditions for a particular site. The design of any Helical Unit System is the full
and complete responsibility of the designer. Ideal Foundation Systems assumes no responsibility or
liability for the adoption, revision, implementation, use or mis-use of these suggested specifications.
Ideal Foundation Systems sole responsibility shall be with respect to products, and any such
responsibility shall be subject to and limited by Ideal conditions set forth in Ideal Foundation
Systems/Ideal Manufacturing, Inc. Product Policy Statement.
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
HELICAL PLATE SELECTION GUIDE
B.1
The table below shows pipe shaft sizes and the applicable helix plate sizes.
Helix diameters range from 6” - 48”.
Helix plate thickness: 3/8, 1/2, 5/8, 3/4, 1, 1-1/4, 1-1/2 inches.
Plate material: ASTM A36 or CSA G40.21 44W hot-rolled structural steel plate.
FOR 2 7/8” – 8 5/8” O.D. PIPE
PIPE
SIZE
O.D.
2.875
3.5
4.5
5.0
6.625
7.0
8.625
HELIX DIAMETER (inches)
6
x
8 10 12
x x x
x x x
x x
x
14
x
x
x
x
x
x
x
16
x
x
x
x
x
x
x
18 20 22 24 26 28 30 32 34 36 38 40 42 44
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
Helix Bearing Area Table
Rounded To 1 Decimal Place
2 7/8"
Series
Full Plate in
Square
Inches
Less Shaft
in Square
Inches
8"
10"
12"
14"
16"
50.2
78.5
113.0
153.9
201.0
43.8
72.0
106.6
147.4
194.5
3 1/2"
Series
Full Plate in
Square
Inches
Less Shaft
in Square
Inches
8"
10"
12"
14"
16"
18"
20"
50.2
78.5
113.0
153.9
201.0
254.3
314.0
40.6
68.9
103.4
144.2
191.3
244.7
304.4
5"
Series
Full Plate in
Square
Inches
Less Shaft
in Square
Inches
12"
14"
16"
18"
20"
22"
24"
26"
28"
30"
113.0
153.9
201.0
254.3
314.0
379.9
452.2
530.7
615.4
706.5
93.4
134.2
181.3
234.7
294.4
360.3
432.5
511.0
595.8
686.9
B.2
FOR 10-3/4” – 36” O.D. PIPE
PIPE SIZE HELIX DIAMETER (inches)
O.D.
6 8 10 12 14 16 18
10 3/4
X X
12 3/4
X
14
16
20
24
30
36
20
X
X
X
22
X
X
X
24
X
X
X
X
26
X
X
X
X
28
X
X
X
X
X
30
X
X
X
X
X
X
32
X
X
X
X
X
X
34
X
X
X
X
X
X
36
X
X
X
X
X
X
X
38
X
X
X
X
X
X
X
40
X
X
X
X
X
X
X
42
X
X
X
X
X
X
X
X
44
X
X
X
X
X
X
X
X
46
X
X
X
X
X
X
X
X
48
X
X
X
X
X
X
X
X
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
C.1
C.2
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
C.3
C.4
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
D.1
D.2
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
D.3
D.4
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
E.1
E.2
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
E.3
E.4
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
F.1
F.2
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
F.3
F.4
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
G.1
H.1
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
H.2
H.3
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
I.1
I.2
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
J.1
J.2
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
K.1
K.2
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
L.1
L.2
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
M.1
M.2
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
M.3
M.4
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
M.5
M.6
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
N.1
N.2
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
O.1
O.2
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
O.3
O.4
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
PATENT PENDING
P.1
P.2
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
Q.1
Q.2
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
Q.3
Q.4
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
R.1
R.2
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
R.3
R.4
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
S.1
S.2
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
HOT DIPPED GALVANIZING
Parts designated as “galvanized” are hot dipped galvanized in a accordance with ASTM
A153.
Ideal’s manufactured prime tube parts achieve an actual galvanized coating thickness of 4
mils.
T.1
T.2
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
PIPE MANUFACTURER’S SPECIFICATIONS
A252 Piling Pipe
Covers nominal (average) wall steel pipe piles of cylindrical shape and applies
to pipe piles in which the steel cylinder acts as a permanent load-carrying
member or as a shell to form cast-in-place concrete piles.
Kinds of Steel Permitted Open-hearth
For Pipe Matedal
Basic-oxygen
Electric-furnace
Permissible Variations in Not more than 12.5% under the nominal wall thickness specified.
Wall Thickness
Chemical Requirements Seamless and Welded Pipe:
Phosphorus max. %
Open-hearth, Electric-furnace or 0.05
Basic-oxygen
Hydrostatic Testing
None specified
Permissible Variations in The weight of any length of pile shall not vary more than 15% over or 5% under
Weights per Foot
the weight specified. Each length shall be weighed separately
Mechanical Tests
Tensile Test – Either longitudinal or transverse at option of manufacturer.
Specified
Minumum yield determined by the drop of the beam, by the halt in the gage of
the testing machine, or by the use of dividers.
Number of Tests
One tensile property test per 200 lengths
Required
General Information
Surface imperfections exceeding 25% of the nominal wall in depth are
considered defects. Defects not exceeding 33.5% of the nominal wall in depth
may be repaired by welding. Before welding, the defect shall be completely
removed
Grade 1
50,000 Psi min. Tensile/30,000 Psi min. Yield
Grade 2
60,000 Psi min. Tensile/35,000 Psi min. Yield
Grade 3
66,000 Psi min. Tensile/45,000 Psi min. Yield
Scope
PIPE SPECIFICATIONS
Grade J55 Pipe
API 5CT Grade J55 pipe
(API - American Petroleum Institute)
Chemical Specifications (%):
Grade
J55
C
0.35 - 0.45
Si
0.15 - 0.35
Mn
0.90 - 1.30
Cr
max 0.25
Ni max
0.25
Mo
n/a
Cu max
0.2
Al
min 0.015
P max
0.02
V
n/a
S max
0.015
Sn max
0.03
Mechanical Specifications:
Yield Strength
min Psi (MPa)
55000 (379)
max Psi (MPa)
80000 (552)
Tensile Strength
Psi (MPa)
75000 (517)
Outside Diameter
API 5CT
Varies
Wall Thickness
Varies
Tolerances:
U.1
GRADE 50 CARBON STRUCTURAL PLATE STEEL
Grade 50 is a high strength, low alloy steel that finds its best application where there is need
for more strength per unit of weight. Less of this material is needed to fulfill given strength
requirements than is necessary with regular carbon steels. Grade 50 is used in general plate
applications when the plate will be riveted, bolted, or welded. Grade 50 is a ColumbiumVanadium steel that offers a minimum yield of 50,000 PSI. In addition, ASTM A572 Grade 50 is
noted for its increased resistance to atmospheric corrosion. Grade 50 contains more alloying
elements than plain carbon steel and thus is somewhat more difficult to form. Grade 50 is
more difficult to cold work, but can be successfully bent or shaped but requires more force
than plain carbon steel.
OVER 1-½"
UP TO 1-½"
ANALYSIS
MECH. PROPERTIES
Carbon (C)
Manganese (Mn)
Silicon (Si)
Vanadium (V)
Niobium (Nb)
Phosphorus (P)
Sulfur (S)
0.23
1.35
0.15-0.4
0.01-0.05
0.005-0.05
0.04
0.05
0.23
1.35
0.4
0.01-0.05
0.005-0.05
0.04
0.05
Tensile Strength (PSI)
Yield Strength (PSI)
Elongation in 2"
Brinell Hardness
65,000
50'000
19
135
The above values are average and
may be considered as representative of ASTM A572 Grade 50 Elongation in 8": 16%
Grade 50 conforms to ASTM A572
APPLICATIONS
ASTM A572 Grade 50 is considered a "workhorse" grade and is widely used in many applications. Steel mills produce channel and heavy beams with Grade 50. It is commonly used in
structural applications, heavy construction equipment, building structures, heavy duty anchoring systems, truck frames, poles, liners, conveyors, boom sections, structural steel shapes,
and applications that require high strength per weight ratio.
MACHINEABILITY AND WELDABILITY
Machinability is rated at 66% of B1112. Average cutting speed 110 ft/min. Easily welded by all
commercial methods.
GRADE A36 CARBON STRUCTURAL PLATE STEEL
ASTM Grade A36/A36M - 58 - 80,000 Psi Tensile, 36,000 Psi min Yield
U.2
Carbon, max, %
Manganese, %
Phosphorus, max, %
Sulfur, max, %
Silicon, %
Copper, min, %
when copper steel is specified
0.25
0.80 - 1.20
0.04
0.05
0.40 max
0.2
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
GRADE 50 CARBON STRUCTURAL PLATE STEEL
ANALYSIS
OVER 1-½"
UP TO 1-½"
MECH. PROPERTIES
Carbon (C)
Manganese (Mn)
Silicon (Si)
Vanadium (V)
Niobium (Nb)
Phosphorus (P)
Sulfur (S)
0.23
1.35
0.15-0.4
0.01-0.05
0.005-0.05
0.04
0.05
0.23
1.35
0.4
0.01-0.05
0.005-0.05
0.04
0.05
Tensile Strength (PSI)
Yield Strength (PSI)
Elongation in 2"
Brinell Hardness
Grade 50 conforms to ASTM A572
65,000
50'000
19
135
The above values are average and
may be considered as representative of ASTM A572 Grade 50 Elongation in 8": 16%
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
5.1
DESIGN MANUAL
5.2
©2014 Ideal Manufacturing Inc.
5.3
DESIGN MANUAL
5.4
©2014 Ideal Manufacturing Inc.
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
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©2014 Ideal Manufacturing Inc.
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©2014 Ideal Manufacturing Inc.
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©2014 Ideal Manufacturing Inc.
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©2014 Ideal Manufacturing Inc.
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©2014 Ideal Manufacturing Inc.
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
PROJECT FEASIBILITY REVIEW
FOR HELICAL UNITS
DATE:
PROJECT NAME:
PROJECT OWNER:
PH
ENGINEER OF RECORD:
PH
GEOTECHNICAL ENGINEER:
PH
DRILLER:
PH
IDEAL FOUNDATION SYSTEMS CERTIFIED REPRESENTATIVE:
COMPANY NAME:
CONTACT NAME:
PH
STRUCTURE TYPE:
DESIGN LOAD REQUIREMENTS;
APPROX. NUMBER OF HELICAL UNITS:
LOAD TRANSFER BRACKET REQUIRED:
APPROX. DEPTH OR LENGTH OF UNITS:
ACCESS TO WORK AREA:
REMARKS:
TOLL FREE: 800-789-4810
FAX: 585-872-3032
ATTACHMENTS REQUIRED:
____SOIL BORING LOGS
____SIMPLE DESIGN SKETCH
____OTHER RELATED INFORMATION
DESIGN PROCEDURE FOR HELICAL PILES/ANCHORS (HP/HA)
1. DETERMINE LOADS:
a) Dead load
b) Live load
c) Safety factors
d) Required Design load ___________
e) Ultimate or Test load ____________
2. SOILS INFORMATION
a) Soil type
b) Soil description
c) Soil classification
d) Water table levels
e) Frost penetration
f) N valves in pile locations
3. PILE/ANCHOR SPACING
a) Calculate for group effect
b) Re-design or compensate
c) Consider larger pile in lieu of grouping
4. DESIGN OF HELICAL UNIT (minimum safety factor = 2.0)
a) Select a CENTRAL SHAFT capable of ultimate load from table
in section 4, page A.1
b) Design HELICAL LEAD SECTION (HLS) using design criteria in section 4,
page B.1 from table titled HELICAL PLATE SELECTION GUIDE
c) Select a LOAD TRANSFER DEVICE (LTD) from section 4, subsections
H, I, J, K, N, and M or design one compatible with the shaft selected
d) Re-evaluate helical unit design, in assembly, for this specific site.
[IF QUESTIONABLE, REPEAT STEP #4]
5. Establish installation criteria and unit specifications using:
STANDARD TECHNICAL SPECIFICATION, page 3.9 or comprehensive, page
3.10
6. OTHER
a) Is project practical as designed?
b) Are there seismic considerations?
c) Extreme soil chemistry, corrosive elements, etc.
d) Can desired penetration or embedment be accomplished with your helix
and
shaft selection?
e) Installation equipment/capabilities/power?
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
HELICAL PROJECT DESIGN PROCESS GUIDELINE
ASSIGNMENT
1. Perform thorough site investigation including potential restrictions
and encumbrances
2. Outline scope of necessary geotechnical investigation
3. Perform geotechnical investigation and submit reports
4. Evaluate requirements for pre-contract testing
5. Outline general scope of work
6. Design helical unit system including design loads, helical unit
locations, and spacing
7. Obtain necessary easements
8. Formulate acceptance criteria using calculations of allowable
movement in service
9. Define long-term monitoring methods
10. Define service life
11. Define corrosion protection based on site conditions
where required
12. Define number and type of pre-production tests
13. Define number and type of in-production tests
14. Define helical unit length or depth to bearing stratum
15. Design helical components and load transfer device
16. Design details for connection to structure including
torsional and seismic considerations
17. Prepare design drawings
18. Provide evaluations and reports of test results
19. Define installation procedure
20. Outline of installation schedule and sequencing
21. Provide installation log including installation torque and
helical unit depth or length
22. Provide field production control and inspection
23. Provide field supervision of installation team
24. Perform post-installation monitoring
PARTY
STANDARD TECHNICAL SPECIFICATIONS
(HELICAL PIERS FOR NEW CONSTRUCTION)
Helical piers and related hardware by Ideal manufacturing Inc., 999 Picture Parkway,
Webster NY 14580, 1-800-789-4810.
Each helical pier shall have a steel shaft with an outside diameter of at least _____ inches,
and a cross-sectional area of at least _____ square inches. Steel shall be Grade _____.
Each pier shall have _____ helices. From the bottom
upward, the helix diameters shall be _____, _____, and _____ inches. The thickness of each
steel helix shall be at least _____ inch. Steel shall be Grade _____.
Helical piers shall be installed at the locations shown on the accompanying drawing. The
deviation of the top of each pier from the design location shall not exceed _____ inches.
Each pier shaft shall be inclined at an angle of zero to 4 degrees from vertical.
All piers shall be advanced into stable natural soil or rock, below any compressible materials.
Based on the available subsurface information, each pier should be advanced to or below
Elevation _____ feet.
Each pier shall be installed using a combination of torque and downward force. The minimum final torque shall be _____ foot-pounds. The maximum torque shall be _____ footpounds.
Each pier shall achieve an ultimate capacity of at least _____ pounds, and an allowable
working capacity of at least _____ pounds.
The top of each pier shaft shall be equipped with a snug-fitting load-distribution bracket.
The bracket shall include a horizontal steel plate having a thickness of at least _____ inch.
The plate shall be square or rectangular in plan view, shall have a minimum width of _____
inches, and shall have a top area of at least _____ square inches. The deviation of the top of
each plate from the design elevation shall not exceed _____ inches.
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
FAX: 585-872-3032
TOLL FREE: 800-789-4810
5’ TORQUE
GROUT
FINAL
READING TAKE PER FT. TORQUE
PILE TYPE:
TYPE OF STRUCTURE:
PILE
LENGTH
PILE CAP:
DATE:
PILE
DISPLACEMENT STEEL CORE
NUMBER HEAD DIAMETER DIMENSION
ENGINEER:
JOB NAME:
INSTALLATION
NOTES
STELCOR PILE INSTALLATION RECORD
FAX: 585-872-3032
TOLL FREE: 800-789-4810
REFERENCES
Bobbitt, D.W. and S.P. Clemence. 1987. Helical Anchors: Application and Design Criteria. Proceedings of the 9th Southeast Asian Geotechnical Conference. Vol. 2: 6-105
- 6-120.
Clemence, S.P., L.K. Crouch, and R.W. Stephenson. 1994. Uplift Capacity of Helical
Anchors in Soils. Proceedings of the 2nd Geotechnical Engineering Conference. Cairo.
Vol. 1: 332-343.
Ghaly, A.M. and S.P. Clemence. 1998. Pullout Performance of Inclined Helical Screw
Anchors in Sand. Journal of Geotechnical and Geoenvironmental Engineering. ASCE.
Vol. 124, No. 7: 617-627.
Hoyt, R.M. and S.P. Clemence. 1989. Uplift Capacity of Helical Anchors in Soil. Proceedings of the 12th International Conference on Soil Mechanics and Foundation Engineering. Vol. 2: 1019-1022.
Leonards, G.A., ed. 1962. Foundation Engineering. McGraw-Hill.
Mitsch, M.P. and S.P. Clemence. 1985. The Uplift Capacity of Helix Anchors in Sand.
Uplift Behavior of Anchor Foundations in Soil. ASCE. 26-47.
Mooney, J.S., S. Adamczak, .Jr., and S.P. Clemence. 1985. The Uplift Capacity of Helix
Anchors in Clay and Silt. Uplift Behavior of Anchor Foundations in Soil. ASCE. 48-72.
Naval Facilities Engineering Command. 1986. Design Manual 7. Washington: Government Printing Office.
Peck, Ralph B., Walter E. Hanson, and Thomas H. Thornburn. 1974. Foundation Engineering. 2nd ed. Wiley.
Porter, Frank. 1994. Corrosion Resistance of Zinc and Zinc Alloys. Marcel Dekker Inc. 275.
Poulos, H.G. and E.H. Davis. 1980. Pile Foundation Analysis and Design. Wiley.
Terzaghi, Karl and Ralph B. Peck. 1967. Soil Mechanics in Engineering Practice. 2nd ed.
Wiley.
Use this section to compile relevant design information.
APPLICATION & USES
OF
™
DDM PILES
STELCOR Drilled-In Displacement Micropiles are the perfect solution for
achieving high axial load capacities in extremely poor soils at very shallow
depths.
Where other piles fail to perform, STELCOR Drilled-In Displacement Micropiles
have delivered higher than expected load test results in both compression
and tension, time after time.
ADVANTAGES
OF

™
DDM PILES
Vibrationless installation

No spoils or cross contamination

Can be installed in high water tables

Positive grout placement

Higher capacities for comparable cross sectional area of steel and grout

No disruption to the surrounding properties

No removal costs or environmental concerns

Lower cost per KIP of support

Exceptional lateral capacity

Predictable grout volumes and placement, unlike other grouted systems.

Saves cost of casing the hole
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
COMPARISON
OF
STELCOR
™
DDM PILES
AUGER-CAST PILES
No soil is removed during pile installation; even
contaminated soils are not an issue.
Soils are augered up out of the hole and need to
be hauled away. Contaminated soils need to
be properly disposed of.
During installation, soil density is greatly improved
around the pile through the lateral displacement
of the soil.
Soil is sheared and pulled up out of the hole to
form a void for the grout. Soil value is decreased
through the loosening caused by the auger action.
A continuous and contiguous grout column is
created with the soil displacement head and
structural reverse flighting.
Grout column may be variable as a result of
cave-in and necking.
80 KSI structural steel core extends the entire
length of every pile, ensuring unbroken structural
integrity.
Effective placement of steel rebar cages into
the wet grout may be questionable. There is no
guarantee of continuous and reliable placement of structural steel.
Fully welded reverse flighting on the shaft provides structural load transfer from the grout column into the steel core.
There is no continuous steel column to ensure
transfer of load for the length of the pile.
The STELCOR soil displacement head design
incorporates a deformation structure to produce
a ribbed effect in the soil, and thereby in the
grout column, greatly enhancing the bond and
load transfer into the soil.
Grout cylinder is poured against a soil wall
formed through an Auger action with relatively
smooth appearance. Transfer of load into soil
from grout is compromised.
™
NOTES:
1. DISPLACEMENT DRILLED, FULL
LENGTH STEEL CORE WITH SOLID
GROUT FILL AND UNCASED OUTER
GROUT COLUMN.
2. GROUT COLUMN DEFORMATION
SHALL BE NOMINAL 12" O.D.
3. STEEL CORE SHALL BE 5.50'' O.D.
.304W 80 KSI MIN. YLD. - FULL LENGTH
4. LATERAL DISPLACEMENT DRILL
HEAD SHALL BE FABRICATED OF
ASTM A572 GR. 50 PARTS.
5. ALL WELDING TO BE PERFORMED
BY CERTIFIED WELDER IN
ACCORDANCE WITH AWS D1.1 STRUCTURAL WELDING CODE- STEEL
6. OPTIONAL THREADBAR IN CENTER
OF STEEL CORE
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
NOTES:
1. DISPLACEMENT DRILLED, FULL
LENGTH STEEL CORE WITH SOLID
GROUT FILL AND UNCASED OUTER
GROUT COLUMN.
2. GROUT COLUMN DEFORMATION
SHALL BE NOMINAL 12" O.D.
3. STEEL CORE SHALL BE 5.50'' O.D.
.304W 80 KSI MIN. YLD. - FULL LENGTH
4. LATERAL DISPLACEMENT DRILL
HEAD SHALL BE FABRICATED OF
ASTM A572 GR. 50 PARTS.
5. ALL WELDING TO BE PERFORMED
BY CERTIFIED WELDER IN
ACCORDANCE WITH AWS D1.1 STRUCTURAL WELDING CODE- STEEL
6. OPTIONAL THREADBAR IN CENTER
OF STEEL CORE
™
COMPREHENSIVE TECHNICAL SPECIFICATIONS
NOTES TO DESIGN ENGINEER:
Blue information = notes for you, which you can delete before printing.
Red blanks are for you to fill in with the appropriate information.
SECTION ( ) STELCOR – DRILLED-IN DISPLACEMENT MICROPILES/ANCHORS (DDM)
PART 1 - GENERAL
1.01 SUMMARY
A.
Section Includes
1. DDM/Anchors consist of one soil displacement head and continuous reverse grout feed
flighting attached to a central steel shaft. Extend piles by adding shaft extensions.
2. DDM piles and related hardware by Ideal Manufacturing, Inc.
999 Picture Parkway, Webster, NY 14580 1-800-789-4810
B.
Related Sections
1. Section _______ - Earthwork
2. Section _______ - Structural Concrete
1.02 REFERENCES
A.
Conform to applicable requirements of the Building Code of _____________ and applicable
requirements of
other referenced documents.
B.
References include documents from:
1.
ASTM - American Society for Testing and Materials
a. ASTM A36/A 36M - “Structural Steel”
b. ASTM A29/A 29M - “Steel Bars, Carbon and Alloy, Hot-Wrought and Cold Finished”
c. ASTM A53 - “Pipe, Steel, Black and Hot-Dipped, Zinc-Coated Welded and Seamless”
d. ASTM A153 - “Zinc Coating (Hot-Dip) on Iron and Steel Hardware”
e. ASTM 572 - “Latest Revision, HSLA Columbian-Vanadium Steels of Structural Quality”
f. ASTM A607 - “Steel, Shaft and Strip, High-Strength, Low-Alloy Chromium or Vanadium,
or Both, Hot-Rolled and Cold-Rolled”
g. ASTM SAE J429 - “Mechanical and Material Requirements for Externally Threaded
Fasteners”
2. ACI - American Concrete Institute
a. ACI 301 - “Specifications for Structural Concrete for Buildings”
3. PTI - Post Tensioning Institute
4. API - American Petroleum Institute
3.13
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
1.03 SYSTEM DESCRIPTION
™
A.
Furnish all labor, materials, equipment and services for the design (including design submittals)
and installation
of all DDM, in accordance with Drawings and Specification, including cut-offs and Load Transfer
Device
installation.
B. Design DDM pile system to support loads as indicated on Drawings and outline in this Section. Submit
DDM pile design calculations and other pertinent data for approval as specified in Submittals below.
1. Obtain Architect’s approval of design calculations and drawings before commencing
pile installation.
Approval of submittals does not relieve Contractor of responsibility for performing the pile
installation
in accordance with Contract Documents.
1.04 SUBMITTALS
A.
Comply with requirements of Section ________
B.
Pre-Installation Submittals: Submit following items for approval not less than 14 days prior to commencing
pile installation.
1. Delegated Design Data - Submit following data, sealed by Professional Engineer registered in
__________:
a. Calculations for pile design capacities
b. Shop drawings showing grout column diameters, steel core diameter/wall thickness
yield/tensile and grade, displacement head plate configuration, length, and reverse grout
feed flighting detail.
c. Details of installation sequence and equipment to be used in pile installation
d. Sample copies of daily pile reports/field reports to be used
C.
Construction Submittals: Submit following items on regular and timely basis:
1. Record of daily pile installation
D.
Post-Installation Submittals: Submit following items upon completion of pile installation:
1. Record drawings showing location of piles as specified in Part 3 - Field Quality Control
E.
Quality Control Submittals
1. Qualifications Certification: Submit written certification or similar documentation signed by
applicable subcontractor, Prime Contractor and manufacturer (where applicable) indicating
compliance with applicable “Qualifications” requirements specified below in “Quality Assurance”
section.
2. Installer Experience Listing: Submit list of completed projects using products proposed for this
project, including owner’s contact and telephone number for each project, demonstrating
compliance with applicable “Qualifications” requirements specified in “Quality Assurance”
article.
3.14
1.05 QUALITY ASSURANCE
™
A. Qualifications
1. Installer: Certified Installer (Certified by DDM Pile Manufacturer), with a minimum 5 years experience in type of design and construction specified in this Section and able to demonstrate sufficient
competent personnel to complete specified construction. Capable of providing job superintendent or
foreman with at least 5 years construction experience in construction specified in this Section and ensuring such supervision will be present at Site during pile construction.
PART 2 - PRODUCTS
2.01 MANUFACTURERS
A. For convenience, details and specifications have been based on the following specified
product/manufacturer:
See products to fill this section.
Example: Ideal Foundation Systems Product 1400-500 DDM being 14” STELCOR unit with 5.00 inch 304
wall 55ksi min. yld. with a minimum bearing capacity of 100 kips allowable, as
Manufactured by Ideal Manufacturing, Inc. 1-800-789-4810
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
2.02 MATERIALS
A. Soil Displacement Head:
1. Cold Rolled ASTM A572 Gr.50
B. Pile/Anchor Shaft:
[See table in section 4, page A.1 in Products to fill this section.
Example: API 5CT J55 Structural Grade]
1. Lead section of shaft to be minimum _____ in length
C. Steel Pile Cap:
1. Plate ASTM A572 Gr.50
2. Pipe: API 5CT J55 Structural Grade
Optional
D. DDM, extensions, caps, and appurtenances are to be hot-dipped galvanized steel in accordance
with ASTM A153. (grouted components are not galvanized unless specifically requested)
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
PART 3 - EXECUTION
™
3.01 EXAMINATION
A. Verification of Conditions: Examine conditions under which piles are to be installed in coordination
with Installer of materials and components specified in this Section and notify affected Prime Contractors and Architect in writing of any conditions detrimental to proper and timely installation. Do not proceed with installation until unsatisfactory conditions have been corrected in a manner acceptable to
Installer.
1.
When Installer confirms conditions as acceptable to ensure proper and timely installation
and to ensure requirements for applicable warranty or guarantee can be satisfied, submit
to Architect written confirmation from applicable Installer. Failure to submit written
confirmation and subsequent installation will be assumed to indicate conditions are
acceptable to Installer.
Optional - May be another party responsible for this item
3.02 PREPARATION
A. Employ licensed land surveyor or registered professional engineer to establish all lines and grades
required for pile installation.
3.03 INSTALLATION
A.
Pile Installation:
1.
Provide installation equipment capable of installing pile of required minimum
diameter to design depth.
2.
Position DDM pile in accordance with the contract documents.
3.
Use only manufacturer-approved connectors, adapter and accessories.
4.
All welding to be in accordance with AWS D1.1 Welders must be certified in
accordance with AWS.
5.
Monitor and record depth of pile penetration. Provide torque monitoring device as
part of the instaling unit. Monitor and record torque applied during the installation of
each pile at specific depths. Torque monitoring is purely informational as a resource
to engineering and installation contractor. All design capacities are derived from
engineering calculations and verified by load testing.
6.
Remove encountered obstructions, or relocate helical piles as required. Relocation
of DDM must beapproved by A/E. Obstructions and relocations shall be
considered “extra work.”
7.
Provide high shear grout mixer and pump with a minimum three cubic feet per
minute.
8.
Provide record book for all pile installation information.
3.04 FIELD QUALITY CONTROL may be same contractor as item 3.02
A.
Survey of Piles (Record Drawings) - Prime Contractor
1. Testing and survey work required to establish pile locations and elevations. Record
drawings and other ancillary operations required for completion of pile installation.
2. Accurately locate each pile by means of survey performed by licensed surveyor or
registered professional engineer. Record survey data with other required information on
reproducible drawing
3.
Include following information on record drawings:
a.
Each pile identified by separate number
b.
Angle of pile installation
c.
Elevation of each pile top
d.
Plan location of each pile
e.
Deviation from plan location in inches, measured to nearest 1/4 inch
f.
Grout take and torque reading for entire pile installation
g.
Description of lead section and extensions installed
h.
Soil Displacement Head size and shaft size
4.
Furnish prints of record drawings to Architect at completion of pile installation.
™
B. Tolerances and Criteria for Acceptance
1.
Minimum grout take of _____ cubic ft. per lineal foot, with a minimum depth of _____ feet.
2.
Install piles as close as practical to design location. Do not exceed _____ inches lateral deviation
from center of pile design location.
3.
Piles improperly installed because of mislocation, misalignment, or failure to meet other specified
design/installation criteria are not acceptable. Abandon rejected piles and install additional piles
as required.
C. Pile Installer Records - Maintain daily record (using Ideal Pile Installation Record, attached) of all
data pertinent to installation of piles, including the following:
1.
Pile number
2.
Date of installation
3.
Soil Displacement Head diameter
4.
Pile shaft size
5.
Pile length
6.
Torque readings during installation
7.
Grout take per foot during installation
8.
Description of any unusual occurrences during pile construction
D. Load Tests - Requirements
1.
Provide compression pile load tests by Pile Installer in accordance with ASTM Load Test
Specifications. At each location, test a minimum of two piles.
2.
Load test piles incrementally on _____ times design load with deflection measured at each
addition of load.
3.
Submit detail drawings, design data and installation procedures pertaining to proposed
pile load by Pile Installer for approval 14 days prior to initiation of pile installation.
4.
Furnish and install complete load test system including jacks, reaction beam, dial
indicators, spherical bearing plate, load cell, reference beams, test enclosure, and all
other equipment, materials and labor that will satisfactorily perform required pile load test.
5.
Test piles, if successfully tested and properly located, will be accepted as permanent and
may be left in place
E. Quality Control/Inspection:
1.
Owner’s Geotechnical Engineer is to observe all pile installations and load tests.
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
Boardwalk Systems
Ideal Boardwalk Systems are state of the art systems with seven patents
pending. We also offer an array of options including continuous foot
lighting, pathway lighting, benches, seats, gazebos, deck areas and
trash containers.
Seven Patents Pending
Boardwalk Systems
GALVANIZED
steel helical pile
foundations and
header brackets
provide superior
strength and
corrosion
resistance.
ALL ALUMINUM structural framing and railing members.
100PPSF rating. For consistently strong and positive
connections at critical points in the framing with no possibility
for poor workmanship.
6’ x 10’ sections – standard
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
Boardwalk Systems
POSITIVELY the strongest header to joist
connection. Does not rely on nails through joist
hangers into end grain.
SPEEDY INSTALLATION and minimal
ground disturbance means you can
get the necessary approvals quickly
because of less on-site exposure to
liability as well as a very green-friendly
product.
Boardwalk Systems
PATENTED Curbing profile
that receives LED lighting
for safety at night.
PATENTED decking attachment system with strong,
positive connection. No nails or screws through
finished surfaces. No rusting fasteners or surface
splitting and countersink holes.
SUPERIOR QUALITY greenwalk™
decking is not a composite. Unlike
composite decking materials,
greenwalk™ decking is a highly
engineered non-porous polymer that
will not rot, chip, or fade. This unique
material enables us to deliver the
enduring beauty and natural wood
grain in a wide variety of colors.
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
Boardwalk Systems
STRUCTURAL RAILING system with maintenance-free aluminum
members. Limited liability with lateral loading rated at 1200 lbs.
• Custom designed railings
• Aluminum, wood or plastic
• Choice of configurations
O.4
DESIGN MANUAL
©2014 Ideal Manufacturing Inc.
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