Large Diameter Helical Piles for Refinery Expansion

"A refinery expansion project for Marathon Petroleum Company in Southern Louisiana required existing medium to large pipe racks to be expanded for additional capacity. Foundation modifications were necessary in order to add levels to the existing pipe racks. New piles were added and existing pile cap foundations were expanded. Several different pile types were considered. Custom designed large diameter helical piles were chosen, because they can be installed quickly with low overhead restrictions, produce minimal soil spoils, and are cost effective. The load capacity required for piles was higher than typical, off-the-shelf helical piles. In particular, the lateral load capacity demand was high due to wind loads of a hurricane prone region. Methods used to design and size helical piles are summarized including capacity to torque ratio estimation for composite helical piles. Pile load testing was performed in order to confirm design capacities of the helical piles under axial and lateral loading. Measured axial and lateral deflections compared well with predicted values. This case history evaluates the effectiveness of modern helical pile design methods within the context of a real and practical example.INTRODUCTIONAs the capacity of modern installation equipment increases, large-diameter helical piles are being used to support higher loads in more diverse applications. Currently, large-diameter high-capacity helical piles are used for electrical power transmission, power generation, high-rise buildings, bridges, and industrial applications. This case study regards a 2.5-mile pipe rack modification project within an existing refinery. One of the many challenges for engineering and construction of refinery revamp projects is determining how to effectively expand the capacity of existing foundations for additional equipment, piping, and other facilities. Custom designed large-diameter helical piles provided an effective solution to the challenges faced when expanding the capacity of existing pipe racks."