Foundation Accessibility Archives

Why is Structural Load Testing Important for Foundations?

May 10, 2018May 10, 2018 Updated May 10, 2018by Conte Company

Load testing, when performed professionally, can help a contractor meet complex code requirements. By confirming certain calculations and providing additional information about the deep foundation plan, a well-performed load test is essential to ensure that the foundation is strong enough to pass all structural requirements and inspections.

Load Testing 101

A load test is performed by applying pressure to a specific pile in predetermined directions; either by compression (push), tension (pull), or laterally. The load is generally applied via a hydraulic jack to make sure the pressure is equal to the final load requirement. A reaction frame is then applied against the hydraulic jack. Once activated, any movement of the pile or the test apparatus is monitored and logged, and the results are used to determine the capacity of the pile being tested.

Load Testing Accessibility

One of the main challenges to safe load testing is having enough space for the reaction beam and other equipment. Whether it’s inside a building, twenty feet below grade or someplace with limited access to utilities, Conte Company can perform challenging load tests accurately and safely. With our custom-designed reaction beam, we’ll get everything in place with no surprises and test to over 200 kips.

As you can see in the job below, load testing was pretty tight at this natural gas substation, where caution, safety and accurate load test results were an absolute MUST, which is why they hired Conte Company.

Load Testing Services from Conte Company

Conte Company has the engineering experience and the required tools to perform geotechnical load tests on a variety of deep foundation systems. We’ve done hundreds of load tests on everything from micropiles and helical piles, to augercast, vibro stone columns and aggregate pier systems. While we do provide deep foundation installation services as well, many of our load testing clients come to us for accurate, unbiased, 3rd party data.

Our tests are performed following ASTM, D1143, D36889 and D3966.

need Reliable load testing?

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What are Displacement Piles?

March 21, 2018May 7, 2019 Updated March 21, 2018by Nate Kruska

Generally, displacement piles are load-bearing columns designed to be installed without spoil material (soil that’s removed from the ground). Instead, special equipment is used to displace soil laterally, compacting it into the surrounding terrain. While not ideal for every situation, displacement piles can sometimes support higher capacities than alternative helical piles or bored piles, as more of the load is placed on the grout and dissipated evenly into the earth.

Over the years, commercial construction engineers have created dozens of displacement pile styles, all of which are either pre-cast or cast-in-place, and most are either driven, drilled or screwed into the ground.

The most common and generally accepted types of displacement piles fall into the following 4 categories:

Precast Driven Displacement Piles

Preformed concrete piles have wide application in a variety of soil conditions. Concrete pillars are hammered into the ground until enough friction or an end-bearing point can support the required capacity. Because of the enormous force and violent vibration on the pile during installation, pre-cast driven concrete piles are almost always pre-stressed or reinforced in some way.

Cast-in-place Driven Displacement Piles

Another form of driven pile requires large, hollow steel tubes to be driven into the ground, creating a void to be filled on-site with concrete. These tubes are capped on the nose to force the soil outwards in the same way a nail is driven into wood. For uncased piles, the tube is removed while the concrete is being poured, and reused to form each new grout column. In other situations, the tube is left underground, as a permanent casing for the pile.

Cast-in-place Drilled Displacement Piles

Drilled displacement piles are similar to fully bored piles, except without the spoils. Specially designed displacement tools are drilled into the ground and force soil outward, creating a more compact and stable column for the concrete. Once the drill has reached the appropriate depth, grout is pumped in continuously as the drill is extracted. This ensures the column stays intact and the grout has a chance to fill every available crevice. A rebar cage is also typically used to reinforce the remaining concrete column.

Cast-in-place Screw Displacement Piles

As the name suggests, these piles are installed similarly to the very popular screw pile. Permanent steel pipes are twisted into the ground with specially designed screw flight attachments which also displace the soil laterally. As the pile spirals its way down, concrete is continuously gravity fed into the voided column. Once the piles has achieved its required depth, it is left there as reinforcement to the concrete column. This method is particularly useful in areas with limited accessibility, as only small machinery is needed to install screw piles.

Need advice on the right types of piles for your job?

Displacement piles are a valuable tool in an engineer’s toolbox when devising structurally sound foundations. Which style of displacement pile will depend on the project, soil conditions, load bearing requirements and accessibility for installation.

Talk to Conte Company Today

Don’t Delay Construction Until Spring: Helical Pile Foundations can be Installed in the Dead of Winter

January 12, 2018January 12, 2018 Updated January 12, 2018by Conte Company

These days, there’s really no reason to wait through the entire frozen season before starting that major construction project you’ve been thinking about. The deep freeze which has held much of the U.S. in its grip this January might be a deterrent to building in some respects, but it certainly should not prevent you from installing pile foundations in winter, especially if you intend to use helical piles. When helical piles are being used, there’s simply no need to wait for the ground to thaw out – they can be installed in most frozen ground.

Installing Pile Foundations in Winter

Admittedly, there can be an added expense to winter installation of foundations, particularly if really frozen conditions prevail. Like almost every other outdoor pursuit in the dead of winter, there are special considerations necessary, which translate to a slightly higher cost for helical piles. For instance, in those cases where the ground is frozen solid, a more powerful pile might be needed to penetrate the frozen soil, after which it would be replaced with a ‘production pile’ for the actual foundation.

In really cold weather, it may also be necessary to keep concrete grout mixture warm for a period of time, after mixing and before it is placed in the ground. For this process, heaters have to be setup at the mixing site, and the concrete mixture must be entirely contained within this area prior to having it poured into the pile. While there would be some added expense associated with these measures, you can literally save months of construction time by installing pile foundations in winter, and not having to wait for favorable weather.

Pouring Concrete Foundations in Winter

It’s certainly possible to install concrete foundations in the winter, but some extra consideration is necessary for the whole process. For instance, the concrete supplier would have to mix the concrete with hot water, so it could survive the temperature drop when it comes in contact with the outdoor air.

Since it usually takes twice as long or longer for concrete to set in cold air, it might be necessary to use an accelerant in the mixture to speed up the setting process. It may also be necessary to install windbreaks or temporary enclosures, along with heating systems, to prevent the concrete from drying out too quickly, and to prevent sudden temperature drops from cracking the concrete before it has a chance to set.

Extra Installation Costs vs. Waiting Until Spring

If you really need to keep your building project on schedule, and don’t want to wait until a springtime thaw provides you with ideal conditions, you can definitely get your foundation in place during even the harshest winter conditions. And you can install a concrete foundation if you don’t mind all the added expense of winter excavation, warm concrete delivery, treatment with accelerants for fast setting, and all the protective measures that will be needed to maintain sufficient warmth for an extended period of curing.

The truth is, from almost every angle you look at it, employing helical piles offer significant advantages, especially in the winter. Even if you have your piles encased in grout, the concrete mixture settles below the frost line, where it can cure naturally without any artificial heat. And although larger structures typically require concrete slabs to be poured to complete the foundation, most of the foundational support lies well below surface, where temperatures are stable year round.

As always, there is far less disturbance to the surrounding area with helical piles, since they do not require any major excavation, and can be installed with much smaller equipment—this also allows for better accessibility for hard to reach areas. Installing pile foundations in winter can be done rapidly, and if there is ever a need to remove or replace them, that can be easily done.

Construction Doesn’t Need to be Seasonal

What would the financial cost be if you had to wait several months for warmer weather, before proceeding with your construction project? That doesn’t have to happen when you opt for installing helical piles during the winter months. With a cost that is only slightly higher, all the same terrific advantages can be realized by installing pile foundations in winter – with fewer worries about massive snow removal, properly curing concrete, or moving major pieces of equipment around on a construction site.

While everyone else is watching the snow fly and the ground freeze, you can be getting a foundation in place, and planning for all the other steps which follow afterward.

Ready to Start Thinking About Your Next Construction Project?

Talk to Conte Company. We can help you choose a stable, cost effective foundation for your next job.

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5 Innovative New Ways to Use Helical Piles

December 15, 2017December 15, 2017 Updated December 15, 2017by Nate Kruska

Many contractors already know about the tremendous advantages offered by using helical piles (or screw piles) as foundations for homes and buildings. But there are many more ways to use helical piles than just securing large structures in a variety of soil conditions. Some of these innovative applications are beginning to find favor with knowledgeable construction professionals and general contractors around the country.

Benefits of Using Helical Piles

It has long been known that helical piles are an ideal system to use in locations where the type of soil makes a traditional foundation more risky. Many residents of New Jersey discovered after Hurricane Sandy that helical piles could be used to great advantage for elevating their homes above storm surge levels, providing a level of safety and peace of mind.

Since installation of helical piles is generally much quicker than other deep foundation solutions, many builders appreciate using them when time constraints are involved with their construction projects. In neighborhoods of existing housing, where there is little room between buildings for equipment to operate, helical piles can be a much easier install than a conventional foundation. The same is true for foundation repair work – helical piles can be installed much more easily in confined spaces.

Helicals are an ideal solution when building on water or wetlands. For typical construction, when building on good, dry soil, traditional concrete foundations are a cost-effective choice, but in certain situations, where the ground will be less accepting of concrete, screw piles are the perfect alternative.

Unlike most other foundation methods, helical piles can also be removed and recycled with very little effort. Since, in many cases, they were only screwed into the ground in the first place, it is only necessary to ‘un-screw’ them, and use them again somewhere else. The versatility provided by helical piles is unmatched in building circles, since they can be easily configured to adapt to removable structures, and provide tremendous value however they’re being used.

Finding New Ways to Use Helical Piles

The truth is, there are endless ways to use helical piles whenever any kind of anchoring or foundation is needed for structures large or small. In fact, they are fast changing the way that foundations are installed for many structures. It may be a cliché, but the only real limitation is a builder’s imagination and creativity. Here are some non-traditional ways we use helical piles…

Fencing Posts

When fencing posts or deck foundations are attached to helical piles – they aren’t going anywhere. Even when fencing has to be setup in some marshy or soft soils, the fence posts can be attached to the mounting brackets on helical piles secured deep in the ground, where a stable layer of soil exists. Not only is there stability for the posts, but maximum support is also delivered.

Solar Farms

As the demand for clean energy increases, so does the need for expansive solar farms around the country. There are a few fast, reliable, and cost-effective methods to anchor free-standing solar arrays, including h-piles and helical piles. Both are capable of withstanding tremendous stresses applied by tensile, compressive, and lateral forces. With no real need for concrete, they can be installed very quickly, allowing more time for the other aspects of solar array construction.

When expanding an existing solar farm, it may be difficult to navigate big, pile-driving equipment around existing solar arrays. In cases like this, the small, agile machinery required to drive helical piles may be the only option. A mini-excavator is usually all that’s necessary.

Playgrounds

Of all the potential ways to use helical piles, you might not immediately think of a playground. However, anchoring a modern playground couldn’t be simpler than using helical piles. Mounting bracket can connect to the installed piles before securing the recreational equipment. With a totally reliable anchoring system, a playground can be made safe from all manner of forces which might act on it, and when children’s safety is an issue, total reliability is always the first priority.

Party Tents

When you setup party tents in the same location time and time again for a recurring event, or series of events, it makes sense to provide a more permanent anchoring system for those party tents. The perfect solution to the problem is to install however many helical piles are needed to accommodate the number of tents which get erected, and simply attach the tents to the semi-permanent helical piles. Not only will there be great stability for the tents, but it won’t be necessary to re-invent the wheel for each year’s setup. As an added bonus, by using semi-permanent piles, certain styles of tents may allow you to eliminate or reduce the number of wires for patrons to trip over.

Boardwalks

Boardwalks are generally located in close proximity to some body of water, usually an ocean, and that makes securing them a bit of a challenge. Not a problem for an experienced helical pile installer. The boardwalk structure itself can be safely installed well above the normal water line, and can be attached with brackets to the piles. Flood-prone areas may even be zoned to mandate helical pile usage in the future, because they are so effective at anchoring structures on or around water. Also important to note is the eco-friendliness of helical piles for wetland boardwalks. It’s unmatched by other foundation methods, as there’s no grout necessary, no spoils from drilling and only the piles are left behind. As a result, the project has a very low environmental impact and poses no threat to surrounding wildlife.

Innovating Foundations Everywhere

Granted, not all projects are appropriate ways to use helical piles. But they are an incredibly useful and effective solution when construction needed to start yesterday. This is especially true for above-grade structures, when building on sites near water, and on projects with access limitations which can hinder larger machinery.

Conte Company has a line of Shallow Helical Piles, which cost less to produce and install than their larger counterpart. These shorter piles work in exactly the same way and are a great solution for all sorts of light-structure foundations. Our subsidiary company, Innovative Foundation Systems, specializes in pile foundations for fencing and solar, as well as other applications where concrete has traditionally been used. Contact us for more information.

Do you have a creative way to use helical piles?

Let’s talk! We can help you think it through…

Growing a Small Construction Company with a Quality Product and Valuable Partners

October 24, 2017December 6, 2017 Updated October 24, 2017by Catherine Stone

Ask Conte Company how they grew their small construction company into one of the leading installers of helical piles in the Northeast, and you’ll always get the same answer. Deep roots in the community, powerful innovation… and their incredible team.

A big part of Conte’s great team are the valued strategic partnerships they’ve built over the years. In particular, Hubbell-Chance®, Caterpillar®, Earth Anchoring Suppliers and H.O. Penn top the list. These legendary companies have formed a team that supports Conte with timely innovation, fantastic customer service and loyal friendship.

Hubbell-Chance: The strongest, longest-lasting piles on earth

Since 2007, Conte has grown its helical pile work steadily from a small construction company, and is now the foremost installer of Chance helical piers in New England. This newer type of business specializes in design-build installation of helical pile foundations, which are steel screw-in ground anchored systems used for building and repairing deep foundations. This geotechnical/structural work is led by third-generation, Matt Conte, who received an engineering degree from Syracuse University.

“With the type of industrial work that we do, a driven pile or a vibratory pile is not allowed. The helical pile system is not as cumbersome on a site that’s more sensitive because it’s just screwed into the ground with very small equipment. And the soils in the northeast actually work pretty well with the helical pile system.”

Conte is often the first choice of general contractors in need of helical piles for deep foundations, because few have the expertise and partnership support of a great company like Chance.

Caterpillar: Equipment that gets the job done… day-after-day

Many foundation jobs require equipment that must fit into very small spaces. And, while Chance helical piles are the best in the industry, they might never get drilled into the ground if it weren’t for Caterpillar machines.

Caterpillar has a tremendous selection of small equipment that keeps Conte Company working in places that other small construction companies dare not go! For example, Conte uses the versatile Cat®314C Small Excavator to bore into the soil and drive the helical piles deep underground.

“We own nothing but Cat equipment in all different shapes and sizes. All our machines are equipped with quick couplers, which make switching attachments easy. Each machine is able to operate with the various attachments, which is one thing we’ve always liked about Caterpillar—with our backhoe and wheel loader the attachments work on all the machines. And all three of our mini excavators can use the same attachments.”

Today, Matt’s brother Anthony Conte, who heads up many of the specialty site work projects, says that the interchangeability of Cat attachments increases versatility for his entire fleet. They can now do more with less and that’s huge when it comes to foundation work.

“We’re always working in rock or poor soil conditions. So having equipment with versatile attachments—whether it be a hammer, a pile driver, an auger, or a different style bucket—it helps us perform our work that much faster and more effectively.”

Matt and Anthony also admire the sheer power of their Cat machines, which are really handy for lifting heavy equipment and boring large diameter piles.

“The smaller equipment is stronger and it can lift a bigger pile driver. We can now use a three-ton, where maybe with another brand we would have to use a four-ton pile driver—and there’s a big difference between those two size-wise when you’re going underneath a building or going inside a garage or a basement. This makes it a lot easier for mobilization, and it’s a much smaller piece of equipment to bring on the job site, and that’s why Caterpillar has been great for us.”

Earth Anchoring Suppliers: Always there for anything we need

Conte Company has been working with EAS for years. As exclusive distributors for Chance Helical Pile in the Northeast, their team has an extensive knowledge and understanding of deep foundations and helical pier products, that goes well beyond their competitors.

“They really do have some of the best prices in the industry, and they’re always willing to work with us on the cost. Of course we’re one of their best customers, but they always treat us like the only one they have.”

When your business consists of installing helical piles, it’s really important to have a good relationship with your pile supplier. EAS always gets back to us fast with material quotes, they almost always have exactly what we need in-stock.

“EAS brings the piles where and when we need it… We barely even have to think about delivery anymore.”

It’s no coincidence that Conte Company shares a similar service area with Earth Anchoring Suppliers. We have a common interest in developing long term relationships with our customers and we both understand that providing a superior product, at a great price, is the best way to do that. Once you can provide that consistently, everything else… the mutual respect and the loyalty fall in line. EAS has been an incredibly valuable partner over the years, and we expect many more to come.

H.O. Penn: Conte Company’s exclusive distributor for Caterpillar machinery

Patriarch, Jim Conte, made his first purchase of Cat equipment for his small construction company in 1990 when he was starting a new project that required more powerful machinery. “At that point, it seemed like a good idea to start fresh with new equipment and we gave it a shot,” he says. “And we haven’t left since.”

“Whether it’s a rental we have from H.O. Penn or a piece of equipment that we own, we never have a problem with Cat machines.”

It’s true that if you take care of ’em, Cat machines will last a long, long time. But none of that matters without sheer power. By renting a Cat machine as opposed to another brand, Conte is able to lift a 400-pound pile driver with a two-ton machine, with plenty of power left over to drive the piles. “To have that ability with a smaller machine is a real advantage for us.”

H.O. Penn has been an incredible partner over the years. Even when a small construction company like Conte isn’t quite ready to purchase, they will always offer a temporary solution.

“They’ve always worked with us to come up with a solution, and 99 percent of the time, we end up purchasing the equipment anyway.”

Adds Anthony, “You’re not going to beat the relationship that we have with H.O. Penn. They really stay on an even keel, whether it involves purchasing equipment, service, parts—there’s never an issue, and they are always there for us no matter what we need.”

From a Small Construction COmpany, To all of our Valued partners

Conte Company wouldn’t be where it is today without our strategic partners like Chance, Caterpillar, H.O. Penn, and the dozens of other companies we work with every single day. Every single one helps us create a better product, which leads to happy customers.

“So to all of our incredible partners, Thank You!”

– The Conte Family

In case you missed it, Conte Company was featured in Caterpillar’s Industry Magazine…

Read the Article

Want to join the Conte Company Team? We’re always looking for great new strategic partners.

Contact us today!

Driving Piles Next to Jets: Behind the Scenes at Logan International Airport

August 15, 2017August 14, 2017 Updated August 15, 2017by Nate Kruska

At Conte Company, we do construction work in all sorts of places, driving piles and building foundations for boardwalks, schools, houses, shopping malls, industrial plants and some other really cool sites. Once in a while we land a job that’s loaded with logistical obstacles which could easily lead to delays and complications.

We’re always up for a good challenge, and the trick is to make sure our customers are happy and relaxed from beginning to end. We do this with meticulous planning and foresight. Not only for the work that needs to get done, but to anticipate all those little things that can add up to big headaches if preparations and contingencies are not in place. We bend over backward for our clients!

When the Airport Authority is the Client

A traveler running to catch a flight will rarely have time to notice the complicated infrastructure of departure airports. But, if he did take a good look around, he might notice that the tarmacs, runways, hangers, passenger gates and terminals are in a perpetual state of upgrade or repair.

Recently, Conte Company was awarded a construction contract from Logan International Airport, a very busy hub just outside metropolitan Boston, MA. Logan covers 2,384 acres, has six runways and four passenger terminals. It employs an estimated 16,000 people and is the largest airport in the New England with 36 million total passengers passing through the terminals annually.

From a general contractor’s perspective, driving piles for this job might not seem particularly challenging. Conte was hired to simply install helical piles for an airport expansion; specifically to enlarge gated terminals and add a few new gangways, used for boarding passengers.

As it turned out, this job was extremely challenging from a logistical, and a customer service point of view. Why? Precisely because of where the job was located; at an international airport with reams of security and safety regulations! Not to mention the timing and precision requirements of an airport open for business 24/7, with activity both on the ground and in the air. It’s a busy place!

Security and Safety

Before we were even allowed to step foot onto the tarmac, each and every one of our crew had to clear thorough background checks and fingerprinting to satisfy Massport (The Massachusetts Port Authority) and MA State Troopers. Then we all had to go through a rigorous safety training program, anti-terrorism certification and a personal screening process just to be allowed to work on the premises. It took a full month before the certifications and checks were completed, and no work could begin until everyone had been cleared.

“Every time we entered the gates, everything had to be checked. Every toolbox had to be opened, engines, undercarriage, materials and people were scanned. Once inside, we could not leave the airport at will because we had to be searched each and every time. But, we are a company that enjoys a good challenge — and being flexible and adhering to our customer’s requirements is one of the things we do better than everyone else.”

Equipment Transport

When our guys were finally cleared to work, it was time for Conte Company to transport all of the necessary equipment for driving piles: trucks, trailers, excavators and pile materials onto the site. Imagine driving oddly shaped equipment out onto tarmacs while huge commercial jets are taxiing back and forth between gates and runways. Fortunately, as Conte Company specializes in helical pile technology, the transport was relatively seamless. Only small trucks were necessary to move all the installation equipment into place.

An unexpected problem did arise when Conte Company learned we would not be allowed to transport pre-mixed concrete to the site. The airport authority did not want concrete trucks coming in-and-out, or idling near the terminal, for security and logistical reasons. As a result, we had to mix all of the concrete on-site, by hand.

Work Space Limitations

On an airport tarmac, wing lines are drawn on the pavement to show where planes with various wing spans are allowed to taxi. As contractors, we could not place any equipment within these lines because it would block planes from taxiing to-and-from the gates to the runways. The very limited space between these wing lines is the only path allotted for all other types of tarmac traffic and construction equipment.

Again, as we were employing a helical pile system for the foundation of the terminal expansion, we only needed small installation equipment. We employed a 4-ton excavator, a 14-ton ex and a 15 ton rubber tire ex in order to meet certain access limitations for different parts of the project. Each of these have the ability to rotate within its own footprint without hitting or blocking any jets.

“We were working in such a tight space that the arm of our excavator could have swung around and hit the plane behind us! Needless to say, we were EXTREMELY careful… And no, we never hit anything.”

Working in such close quarters could have been catastrophic with larger equipment. If another piling method was used for the building foundations, the Airport Authority would have likely needed to shut down the nearby gates, creating delays for passengers around the world.

Safety of Passengers and Workers

Installing piles for the terminals, gates and gangways of a working airport means that people are everywhere! Imagine the responsibility of drilling very close to where passengers are boarding planes. But, because our team is trained to put the safety of people first, there was never a problem. The passengers barely noticed we were there and the Airport Authority was delighted with the seamless process.

The Soil Conditions

As geotechnical contractors, the soil conditions influencing this job were fascinating to us. Boston is a city basically built on marshland. To complicate things, Logan Airport itself, sits atop a man-made landfill and 15 feet of dense compacted gravel. Below that was anywhere from 60-140 feet of infamous Boston Clay. And below that was a layer very dense till… oh, and by the way, it’s all capped off by 2 feet of solid asphalt!

It was a serious challenge, to say the least. It was determined that we needed to drill our piles somewhere between 70-140 feet deep to assure stability and anchor into the till far below the asphalt. It was up to us to figure out how to do that.

The top 10-15 feet of the gravel was incredibly hard and much too dense for standard helical equipment to get through. Ultimately, we decided to pre-drill to break up the gravel which prevented the piles from buckling or breaking. Once we hit the clay the helical piles could screw in easily and take it from there. We built custom, reinforced digger-plates which we used to pull grout down through the gravel to encase the entire piles in a concrete column.

In the end, it all worked out nicely. We hit a couple obstructions and had to re-drill once or twice, but ultimately, the plan succeeded! At Conte Company, creativity runs deep and everything we customized for this project worked just as we designed it.

In case you’re curious about driving piles, we installed CHANCE® SS225 Helical Piles with 7″ grout shafts, load tested for 140 kips (or 70 tons).

Complicated logistics and damage control

As a contractor that specializes in foundation work, Conte Co always performs our work with precision. Even so, a minimum $10M insurance umbrella was mandatory to win the contract (obviously, it’s very expensive to repair a damaged jet).

With Conte’s helical pile technology, there is no pounding and little chance of debris shooting away and hitting planes, terminal windows, passengers or workers. Alternate methods of foundation work could have made a real mess of the surroundings and an injury hazard for the airport’s customers.

The Logan Airport job was completed in just a few weeks over the course of a full year. It was a great experience for us, and a successful install, because Conte Company knows how to plan for contingencies. And even when we don’t anticipate something strange, we bend over backwards to meet our clients’ needs.

Bulkhead Repair: Overcoming the Challenges of a Failing Boardwalk

June 1, 2017November 16, 2017 Updated June 1, 2017by Conte Company

Norwalk, CT is our home and the place where Conte Company was started in 1948. The town was founded in 1640 on the southern shoreline of CT known as the Long Island Sound. Norwalk is less than 50 miles from downtown Manhattan, but light years away in attitude and economic history.

Well known for its oystering industry, the town grew and prospered, attracting new residents who want to live on or near salt water while still in commutable distance from NYC. Charles Cove is a man-made tidal inlet, a quarter mile cut in from Long Island Sound, surrounded by a boardwalk, boasting luxury boat marinas and high-end condos. The Charles Cove Condos, which wrap cozily around the end of the cove, were built in 2004 and are highly popular for their location near beaches and shopping. Recent sales have them priced at just under a million dollars each.

Rotting Bulkheads in Need of Maintenance

Last year, the board of directors of the Charles Cove Condominium complex were informed that the wooden bulkheads holding up their complex were rotting and in serious danger of collapse. Apparently, the salt water tides running in and out of Charles Cove twice each day had taken a serious toll on the foundational structures. The residents, who strolled peacefully along the water on the complex’s walkways probably had no idea they were right on top of a disintegrating bulkhead.

Fortunately, someone did notice the rot and a marine contractor was quickly hired. But, instead of attempting a bulkhead repair by replacing the old bulkhead, the engineers proposed building a new bulkhead directly over the old one using new bulkhead sheeting, secured with piled tiebacks. This was going to be challenging, considering the natural elements in play, so the marine contractor wisely placed a phone call to Conte Company. (We are well known as the folks who love a good challenge and this one was going to be a doozy!)

Let’s talk about your project’s foundation challenges

Barging-In and Timing the Tides

We are well known for our helical pile technology expertise, which turned out to be the perfect solution to create tiebacks for this precariously threatened bulkhead.

We determined that our helical pile tiebacks would have to be securely drilled into the old timber retaining wall, a structure directly perpendicular to the salty waters of Charles Cove — and right below that 8-foot walkway. The new, poly-coated composite wall could then be attached to our secure helical piles. And, because this very tight working space was not accessible from land, we also planned to bring in a small barge to hold and transport our drilling equipment and crew for the bulkhead repair.

However, being raised in a shoreline town, we were aware in advance of a bigger challenge. Each 12.5 high tide was going to raise our working barge at least a few feet and once raised, we knew that our drilling boom would not always fit under the walkway. We would only be able to work from low-tide until just before mid-tide. Providing this critical timing information to the marine contractor in advance enabled them to plan ahead for other aspects of the project and helped to keep the project on schedule.

(we bend over backward to work efficiently)

Men Overboard (with Extensions)!

With the tidal problems addressed, our crack team anticipated, and solved, another watery problem before we began our bulkhead repair work. The barge, small as it was, still needed to be anchored 10 feet away from the bulkhead. The vertical piers that hold up the boardwalk kept the barge and our machines from getting up close and personal with our work. We were not going to get it close enough for our boom to reach where the piles needed to be drilled.

Our plan was simple, yet effective. We used standard pile extensions to lengthen our reach from the barge. Two crew members on the barge would load the extensions onto the helical piles. Two other Conte workers worked off a small floating dock where they could jump into the shallow waters, close to shore, and bolt the ends of the shaft extensions onto each helical pile as it was drilled into the wall.

At Conte Company we are team players and will to jump through hoops, or off barges, to get the job done right!

Ask us what we can do for your next foundation job

A few weeks later the job was done! Our men dried themselves off, the barge was floated out of Charles Cove and the residents began to stroll the walkways again. The customer, in this case, the condo’s board of directors, was confident that the bulkhead repair was completed according to the highest standards, as it passed all required inspections. Their residents were safe to once again stroll the walkways along Charles Cove and watch the sunsets —which are absolutely gorgeous over the waters of historic Norwalk, CT.

Why Helical Piles?

December 14, 2016July 11, 2017 Updated December 14, 2016by Matt Conte

During these modern times of engineering and construction, there are many different ways to do just about anything. This includes the selection of a helical pile foundation. Pile foundations have been used for years to support structures that bear on unsuitable soils. As equipment and methods progressed, so did the applications and installation of each type of pile. All of these options still exist because each site and project requirement is different. We have to weigh our options to decide what the safest, most cost effective approach to providing a pile foundation is going to be.

Helical Piles have been around for many years, even though most people still haven’t heard of them. They are screwed into the soil using a motorized auger torque driver, which is attached to a piece of construction equipment. The screwing method eliminates the need for vibration and aggressive impact to advance the pile into the soil. The Helical Pile simply screws into the ground. With the torque motor creating the force needed to install the pile, relatively small equipment can be used for helical pile installation.

The benefits of using small equipment can change the project in many ways. Some projects would otherwise be impossible, if not for the use of small equipment. Going inside buildings, basements, through landscaping, beneath lifted houses, high voltage, tight locations, etc. are all possible because helical piles require such small equipment to install. The reduced vibration and noise allow for businesses and daily activities to continue during installation, and the low emissions of smaller equipment help minimize any environmental impacts. Some older structures are so unstable, that any vibration will compromise their state. Helical piles can be used to underpin these structures without harming the current conditions.