Introduction

"Helical pile foundations are fine for small or light projects, but you can't use them to support commercial construction!"
That's a line our team at Postech Moncton has heard quite a few times over the years. The idea that helical piles are a good foundation - as long as you don't use it for anything too heavy.
We think this idea comes from the fact that helical foundations are extremely popular for decks, sunrooms, home additions, and other residential-focused work. That means they have a lot of representation in that space, which makes it seem like that's what they're designed for.
Today, we’re here to set the record straight.
While we do install many helical piles for lighter residential construction, that doesn't mean they're not well-suited for more demanding projects. In fact, using helical piles for commercial projects is a great way to expedite timelines and reduce risks!
But, we don't expect you to take our word for it. 
That's why in today's post, we're breaking down exactly why helical piles are a great option for commercial construction - and how they can transform the way you build this season.

Beyond Decks: Debunking the "Residential-Only" Myth

If you take a look throughout Canada and the United States, you'll see helical piles being used under all kinds of large-scale projects. From high rise buildings to massive utility infrastructure, this humble foundation solution bears some incredibly heavy loads.
So, why do so many commercial projects in New Brunswick opt for "traditional" options like poured concrete instead?
We think it's because of the perception many people have about helical piles. Because they're so popular for residential work, there's an assumption that's all they're good for.
In reality, helical foundations are more than capable of tackling tough loads and demanding structures. The "residential-only" idea here in New Brunswick is a result of misconceptions, not technical limitations.
Yes, helical piles are a great choice for residential work. 
That doesn't mean they aren't good for commercial work.
You see, helical piles are able to scale up or down to meet the exact load capacity demands of your project. By adjusting their size, configuration, and design, we can hone-in on the precise performance you need.

How Helical Piles "Scale-Up" for Tough Projects

The core design of a helical pile is simple:

Whether you're supporting a basic backyard deck or a massive steel frame building, the essential layout of a helical pile doesn't change.
What does change is the helical pile's scale.
In the same way you wouldn't use a trim nail to frame a house, we don't use the same size or configuration of helical pile for every structural load.
Here's the four primary ways a helical pile scales to meet the demands of your project:

1: Increase Pile Shaft Diameter

Helical piles can be installed in two main ways: to refusal and floating.

In this method, the pile tip sits directly on bedrock or glacial till which prevents it from moving downwards. It results in the greatest load capacity, as the limiting factor becomes the strength of the pile shaft itself.

Instead, they're installed into firm soil layers with solid bearing capacity. Their load capacity comes primarily from soil pressure pushing on the helix plate - which serves to lock the pile in-place.
Using a larger shaft boosts a helical pile's physical strength and ability to resist compression loads when installed to bedrock or till. 
It also allows us to exert more installation torque on the pile, which results in greater strength (more about install torque shortly).

A larger pile shaft presents more surface area for skin friction to create resistance between the steel and soil. That means the pile is more resistant to being "pushed over" in the ground. This, in turn, increases its resistance to lateral forces.
Of course, that's not the only way to increase lateral pile capacity! However, we'll loop-back to that in a moment. Let's keep focusing on axial capacity for now.

2: Use a Larger Helix Plate

The helix plate is responsible for creating most of a helical pile's structural load capacity. It's created by cutting a doughnut from a steel plate, then pressing it into a helical shape. The plate is then welded to the pile. Fun fact, this plate is where a helical pile gets its name from!
When the helical pile is rotated into the ground, soil pressure will push on the helix plate. It's this pressure which serves to anchor the pile in place and prevent it from moving. 
Since the helix plate is wider than the pile shaft, it creates a comparatively large bearing surface. If we make the helix bigger, the increased surface area will result in a greater load capacity.
There is, of course, limits to how large the helix can be in relation to the pile shaft. 
For example, a 3-1/2" pile shaft with a 36" helix plate would likely run into issues with breakage during installation. 
When a helix plate is too large for the pile shaft, it creates significant strain on the welds that connect them together. That means the forces of torque during installation could cause the welds to fail.
That's why it's important to engage an experienced foundation contractor who understands how to properly design a helical foundation - and knows where the limits are.

3: Add More Helix Plates

As we mentioned earlier, helical piles can have more than one helix plate. Double or even triple helix configurations are not uncommon in the industry when higher load resistances are required.
There's a couple different ways that a multi-helix pile will react with the soil. 
If the plates are spaced far enough apart, each one will act independently once installed. This is called the "individual bearing method". In this configuration, the bearing surface is essentially multiplied across the helices. 
When the helices are closer together, a column of soil in-between the plates can be formed. Load calculations are made by assessing factors like the shear strength of the created soil column. This is known as the "cylindrical shear method".
In either case, using a pile with more than one helix plate will (generally) result in more load capacity. It can also be useful if soil conditions are loose and more bearing surface area is required to overcome them.

4: Install Angled Piles

Okay, this one doesn't necessarily have anything to do with the physical design of a helical pile. It does, however, have an affect on a helical foundation's lateral load capacity.
Since helical piles have a relatively narrow pile shaft compared to the helix plate, they don't quite provide the same lateral performance as other solutions. While we can increase lateral performance by up-sizing the pile shaft, there's another option!
We're able to install helical piles on an angle (known as "battered piles") to overcome constant or cyclical lateral loads. Thanks to the fact they rotate into the ground, it doesn't matter whether that's a 90° angle or a 30° angle. 
In fact, we can even install piles horizontally to act as tie-backs for retaining walls. This ability to set helical piles at any angle makes them highly adaptable to different construction situations and demands.

No Guesswork: Why Torque Equals Peace of Mind

We mentioned earlier that one reason to increase a pile's shaft size is that it allows us to apply more torque during installation. But, why would that even matter? Let's take a brief side-bar to talk about torque! 
Helical piles rotate into the ground, which means it takes torque to advance them downwards. As the pile reaches firmer soil, it takes more torque to continue the installation. Larger pile shafts or helices will also demand increased torque.
Here's the thing - the amount of torque we exert on a helical pile has a direct correlation to that pile's load capacity. In general, more torque equals more load capacity.
So, by continually monitoring torque throughout the installation process, we're able to determine when each pile has been properly installed. 
How? 
Because during the foundation design we can establish required torques for all the piles. That lets our crews know exactly what they have to achieve in the field.
Another benefit of torque monitoring is the ability to respond quickly to unexpected conditions. For example, we've had situations where the geotech indicated firm soils at a certain depth - but we couldn't hit torque. The solution? Simply continue advancing the pile until we do obtain the correct torque readings.
We record installation depth and final torque readings on all our projects, leaving you with a report that proves the performance of your foundation. In the world of commercial construction, that brings total peace-of-mind to all stakeholders.

Why New Brunswick Contractors are Switching to Helical Piles

Alright, so maybe at this point you're getting convinced that helical piles are a valid foundation for tough projects. But why would you even want to use a helical foundation instead of something familiar like concrete?
We could cover a ton of reasons here - but in our experience there's three key factors that cause contractors, engineers, and project owners, to choose a helical solution.

Adaptable, Customizable, Precise

Commercial structures vary widely; from pipelines and stationary equipment to warehouses and retail spaces. That means you're rarely dealing with "standard" needs and requirements. 
This is an area where helical piles really shine, as they're highly adaptable and customizable to suit your exact project.

Custom Pile Caps

Some people say (and we'd agree) that one of the most important parts of a helical foundation are the inches between the pile top and your structure. Getting this transition right is key, and thankfully you have a lot of options!
Standard pile caps include configurations like saddle brackets, L brackets, flat plates, and poured concrete adapters. We even have caps designed to support heavy pipes, EV chargers, and light standards. 
While these cover a wide range of typical use-cases, what if your project isn't so typical?
In those instances, we can help you create a custom pile cap or termination. Grillages, frames, plates, adapters, whatever it takes to get the job done.

Simplifies Construction on Tricky Sites

Building on a slope? In the woods? Near the water? On a tight urban site? Muddy soils? Loose sand? Dense clay? A helical pile will happily install into all those areas without a fuss.
Because helical piles "screw" into the ground, they're far easier to use on difficult job sites. We don't need to bring multiple pieces of heavy equipment or figure out the logistics of concrete deliveries. In fact, the only machine we typically need is a simple excavator.
In addition, a helical foundation uses much less raw material than concrete. That makes them easier to transport and allows us to access sites that would be virtually impossible with other options. Plus, it could even reduce the embodied carbon associated with your foundation! 
Basically, helical piles are ready to go wherever you need to build.

Quick, Easy, Clean

Time is money in the commercial construction world. Every day you can shave off your schedule leads directly to savings - and we're not only talking about cash.
If you can expedite your foundation timeline, you'll be able to get follow-on trades started sooner. Which means you'll ultimately be able to finish sooner. 
And what does that do for you? 
Frees your schedule to do more work with the same resources.
But, how much faster are helical piles compared to concrete? Let's break it down by comparing their installation processes...

Foundation Installation: Helical Piles vs. Poured Concrete

As you can see - helical piles eliminate a significant amount of time, effort, and mess. You don't need to worry about dealing with soil spoils or open excavations, keeping your site cleaner and safer. And with zero cure time, you can start work the second our team is done. 
In fact, depending on how many piles you need, we can have your foundation installed and ready to use in as little as a single day.

Low Land Impact

New Brunswick is home to some of Canada's most beautiful natural scenery. Woodlands, coastlines, marshes, rivers, hills, and valleys, we're practically spoiled around here. 
However, these places are also highly sensitive to construction activity and disruption.
Traditional concrete foundations require a large amount of excavation, which disturbs the soil and can impact local environments. Beyond the potential ecological impacts it can also be extremely tricky to dig in wet, sandy, or coastal regions.
Think of a boardwalk in the marshland or a utility structure in a remote location. Not only is getting to these places a challenge, we need to make sure we're not damaging or negatively affecting the area. 
Helical piles allow us to do that! Because we don't need to perform any excavation, there's no disturbance or disruption to the ground. 
Our compact excavators and ground mats protect the surface, ensuring we don't leave a torn-up mess behind. When it comes to future remediation, helical piles can be easily removed and re-used or recycled. 

Frequently Asked Questions About Commercial Helical Pile Foundations

Conclusion: Yes, Helical Piles Are Good for Commercial Construction

Alright, so now you know that helical piles are much more than simply a "deck foundation". 
They're a...

...technology that's capable of meeting the demands of commercial construction.
Now, is a helical foundation the right answer for every project? Of course not. 
There's no such thing as a "silver bullet" in the construction industry.
However! 
A helical foundation can be the right answer for a lot more projects than you may think. Their adaptability, customization, strength, durability, and flexibility of design, makes them an ideal alternative to other options.
So, what do you do with this information now?
Not to sound self-serving, but if you have upcoming projects we recommend you look into using a helical pile foundation to support them. That's the best way to understand the specific benefits you could enjoy - and whether helical piles are a good fit for your needs.
Our team at Postech Moncton is ready to help you design a firm helical support for your next build, no matter what that might be. And if our solution isn't a good fit for your project? We'll be honest about it.
Get in touch with us today to learn more and get a free foundation estimate started.