Case Studies

Case Studies

Altium Packaging Addition

Challenge

Located in Phoenix Arizona, the Altium Packaging facility is one of the largest suppliers of plastic containers and rigid plastic packaging. A 40,000 square foot addition was planned to the north of the existing building, which would almost double the facilities’ production area. The addition was designed as a slab-on-grade foundation system with 40-foot-high tilt-up panel exterior walls. A geotechnical investigation at the addition area showed uncontrolled fill to a depth of 1.5 feet underlain by soft to medium stiff clay to a depth of about 10 feet where loose sand was encountered to the termination of borings at 15 feet. Based on the poor bearing soils encountered during the investigation, the geotechnical engineer recommended removal of the soil to a depth of about 5 feet and replacement with engineered fill. With this recommendation, the allowable bearing capacity for a shallow foundation was limited to 2,000 pounds per square foot. Based on previous wall repairs at the existing north wall, a method to provide uplift capacity along the existing north wall was needed prior to construction of the addition. It was also necessary to underpin the existing north wall and provide a deep foundation alternative at the south wall of the addition prior to any excavation activities.

Solution

Helical piles were selected as the best option for providing the tension and compression capacity needed for underpinning the existing building and at the south wall of the addition. Helical piles are often preferred over other deep foundation alternatives given the ability to work around tight access areas, quick installation, and lower costs relative to other systems. After comparing the cost of helical piles as a deep foundation alternative to the cost of the shallow foundation system recommended at the other area of the project, helical piles were selected for the foundation system at the exterior walls of the entire building addition. The final design included 43 helical retrofit pile locations along the north wall of the existing building and 189 new construction helical pile locations for the building addition. A custom uplift bracket attachment was designed to provide a service tension capacity of 6 kips at the retrofit pile locations. The service compression loads for the helical piles ranged from 22 to 41.2 kips. Given the lack of quality soil strength information below a depth of 15 feet, a factor of safety of 2.5 on the service load was used for the pile design and a minimum pile termination depth of 15 feet was required. The Model HP350 (3.5-inch O.D by 0.340-inch wall hollow round shaft helical pile system with an 8”-10” helical plate configuration was used for the retrofit piles and the new construction piles at the south wall of the addition. The Model HP288 (2.875-inch OD by 0.276-inch wall) hollow round shaft helical pile system with an 8”-10” helix plate configuration with new construction brackets was selected for the remaining building addition piles. The helical piles were installed to an average depth of 19 feet after achieving a torque-correlated ultimate capacity of at least 2.5 times the service load. The 232 helical piles were installed over a period of 18 days.

Project Summary

Products Installed:: (232) Foundation Supportworks® Model 288 and Model HP350 Helical Piles, Service Compression Loads of 22 to 41.2 kips, Maximum Service Tension Loads of 6 kips, Installed Average Depth of 19 feet.