The Flint Creek Civil Package included drilled shaft foundations for 14 structures utilizing 400 – 30” drilled shafts varying in depth, all requiring rock sockets into competent limestone with strengths ranging from 5,180 psi to 23,240 psi. The erratic nature of the bedrock and the presence of karst limestone at the site posed difficulty where sinkholes, caves, weak seams, and enlarged cavities where encountered. To assure drill shaft integrity, A. H. Beck utilized temporary sectional casings to stabilize the upper layers of fill and clay gravel. AFT performed 5 High Strain Dynamic Integrity Tests and 21 Low Strain Dynamic Integrity Tests - all of which confirmed the integrity of the drilled shafts to be satisfactory. To meet strict new EPA regulations, the schedule was extremely aggressive but A. H. Beck supplied three drill rigs and completed the project on time.
OWNER: American Electric Power
ENGINEERING: Sargent And Lundy, LLC
CONTRACTOR: Brasfield & Gorrie, LLC
INSPECTION: GTS, Inc.
INTERGRITY TESTING: Applied Foundation Testing
A. H. Beck delivered 1,310 steel-reinforced grouted augercast piles for the expansion of Exelon Generation’s Colorado Bend facility. The 18” diameter, 65’ deep piles were installed, supporting an additional 1,000 megawatts of generation capacity using low-carbon combined-cycle gas turbine generation. Prior to production pile installation, an elaborate pile load test program was conducted. The program consisted of axial compression, tension and laterally loaded 18” and 24” piles in three separate areas across the vast site. A. H. Beck utilized their 500 ton load frame and staff of professional engineers to perform the testing program. The results of the tests were evaluated by the owners engineers and allowed the 24” diameter piles to be redesigned to 18” piles across the site resulting in a significant cost savings.
NAG OR Project scope consisted of installing a total of 78 auger cast piles 24 inches in diameter to depths ranging from 61 to 69 feet long to support expansions to two existing pipe racks. Working within and adjacent to active units within the refinery provided a logistical challenge to meet required milestones but the schedule was met. The project required extensive communication, cooperation and planning with other subcontractors, owner operations and safety personnel. Non-destructive testing was performed under our scope of work including: 9 single hole sonic logging tests, 8 thermal integrity profiling tests and 78 low strain impact integrity tests were completed.
The Sandow Unit 4 Environmental Retrofit Program required a tight schedule to comply with various governmental regulations. A. H. Beck was contracted to design and build a shoring wall to protect sensitive ID fans and perform substructure work to install 308 drilled caissons. The shoring wall designed by A. H. Beck included 118 - 18” diameter tangent piles 26 feet deep constructed with only 11’ of head room. The main SCR foundations required 308 – 24” drilled shafts, some 65 feet deep. The engineers required Type V Cement so A. H. Beck produced all of it onsite with volumetric mixers.
The Whiting Refinery FGR Project included the installation of 150 Auger Cast in Place Piles and 69 Pile Caps to support new piping systems from all of the existing Flare Stacks to the new Flare Gas Recovery Unit. This complex OSBL project required extensive communication, cooperation and coordination with six of the existing continuously operating units within the refinery. The project demanded limited access equipment with capabilities of working adjacent to operating equipment, live power systems and other processes. This included the installation of 90 foot deep ACIP piles under live power lines and live piping systems with only 25 feet of head room.
The Whiting Refinery Modernization Project included the installation of 37 SynchroPiles™ underneath live, operational pipe racks in BP’s 12 Pipe Still Unit. These 35’ deep SynchroPiles™ were constructed with only 13 feet of head room. A test pile extending 8 feet above ground and 6 drilled shafts, including a shaft requiring concrete coring were also constructed. A. H. Beck maintained an exceptional safety record of zero incidents and performed in adherence to the contractor’s demanding schedule. A. H. Beck’s installation methods proved to be successful in minimizing risks associated with constructing foundation elements in areas with high LEL counts. A. H. Beck’s SynchroPile™ installation within the live unit minimized the unit’s down time required to change out the existing pipe racks, saving the owner time and money. A. H. Beck’s exceptional performance in safety, budget, quality, and schedule is what made this project a big success for both the contractor and owner.
This project consisted of 119 auger cast-in-place piles (ACIP) for a new pipe rack supporting large diameter pipe sections as well as multiple specific unit expansions. All work was performed and completed inside an operating plant facility utilizing a combination of restricted access, low head clearance and conventional hydraulic ACIP piling equipment. The soil conditions at the project site consisted of layered very dense sand and soft clays which required special installation procedures and quality control during production piling. The strict environmental restrictions present at the facility required that all spoils, grout and water be contained in roll-off boxes to prevent possible contaminated materials to be dispersed across the working area and to nearby drainage ditches. A total of 2 drilling rigs worked continuously at the site to meet the project schedule. A. H. Beck was given extra work beyond the original scope including drilled shafts and pump can foundations installed using low clearance drilling equipment.
This project consisted of twelve (12) drilled shafts to function as wells (to inject storm water back into the local aquifer); plus one (1) dedicated as a vent shaft. All wells were installed inside a pit several feet below ground level where storm water was collected from overflowing holding ponds. Shafts, 30 inches in diameter and with depths of up to 130 feet, were drilled dry. A slotted PVC pipe was installed and encapsulated in pea gravel to allow water flow. The top was covered with several layers of gravel and a geo-synthetic fabric to prevent fines from reaching injection wells.
The project consisted of more than 60,000 liner feet of drilled shaft up to 60” in diameter and 95 feet in depth. More than 30,000 cubic yards of drilled shaft concrete was placed in the 1000 plus shafts on the project. The “fast track” “design as you go” nature of the project required detailed coordination between engineers, the owner, contractors onsite, and suppliers to ensure that the overall project remained on schedule and stayed within budget. The drilled shaft portion of the project was completed on schedule in under 9 months. The Balcones Fault geologic formation underneath the site provided for a wide array of subsurface conditions. Casings up to 40’ in length, bentonite slurry, and underwater concrete placement methods and equipment were all utilized to install the shafts in a timely fashion. “Low overhead” drilling and concrete pumping equipment was also used to install shafts inside existing materials storage buildings to help reduce the cost of the plant expansion.
The retrofit for Olin’s McIntosh plant required SynchroPile™ Post Grouted Drilled Shafts. 31 SynchroPile 36” Post Grouted shafts 185’ deep were designed with 90 feet of steel casing. After installation of reinforcing cages, distribution plates were installed to facilitate grouting the shafts after installation. O-Cell load testing verified shaft capacity and the post grouting criteria. All of the shafts for the retrofit program were installed in areas as narrow as 14’ within operating areas of the facility.
This project consisted of installing 4 wells to house sump pumps that collect condensate from steam powered generator turbines. These wells were installed inside an existing power generation facility with a 5 foot thick reinforced concrete slab. This section of the facility was constructed below sea level so the 5’ concrete slab was the only thing keeping the plant from flooding. A. H. Beck designed a method to create an artificial water head at each sump location so the 5’ thick slab could be penetrated and the sumps could be excavated down to -40.0 in elevation. Once the sumps were excavated, a pump casing had to be installed and concreted into place. Limited access drilling equipment and all materials had to be flown in with an overhead crane to reach the locations inside the building to prevent flooding of the facility basement.
The project required 382 drilled shafts 3 feet in diameter and 70 to 100 feet deep for an unloading dock for the Voestalpine HBI facility being built in Corpus Christi Texas. Crews worked 24 hours a day, 6 days a week to complete the work which also included two additional test shafts which were Statnamically tested. The schedule required a continuous work sequence which made access crucial to the success of the project; A.H. Beck was capable of completing its work ahead of schedule.
A. H. Beck Foundation Company worked with Starcon International to install a total of 143 – 14” x 30’ augercast piles for a variety of pipe racks needed for the ConocoPhillips – Gulf Coast Fractionators plant expansion. These piles were all installed in an operational plant under a variety of work conditions. Some areas had overhead racks or structures and required the use of low overhead specialty equipment which required A. H. Beck to install the piles in as little as 15 feet of overhead clearance. Most all of the piles had some limitations to access which necessitated some innovative approaches in the construction process. Even in the low overhead, restricted work conditions, A. H. Beck was able to produce multiple piles per day using two types of drill rigs.
This project originally required 1,100 drilled shafts, 48 to 72 inches in diameter, 50 feet deep, for a connecting pipe rack 4.4 miles long between two new facilities of the “Petroleos de Venezuela” (PDVSA) Cardon Refinery in Venezuela. The soil conditions varied considerably, ranging from very soft to hard and abrasive coquina. The 72 inch diameter shafts were drilled to install several vertical oil pumps throughout the refinery. A. H. Beck teamed with a local contractor who provided labor, support equipment, and materials for the project. A. H. Beck completed the original scope of the contract in six months. Consequently, A. H. Beck’s contract was amended to include additional work directly resulting from the speed of the original construction. The final scope of A. H. Beck’s contribution to the project included over 2,500 drilled shafts, and the entire job was completed in only nine months