Wednesday, June 5, 2013

Understanding the differences of helical pile systems

I would like to address the issue of our procedures here at Arizona Repair Masons. Recently a competitor forwarded pictures of a couple of our piles that were uncovered by accident during one of their projects. The email left the impression that this work was a result of our piles failing. This is false. In fact the foundation at the location of the old piles was not lifted at all. The pictures along with the message give the impression that our piles have failed. This is false also.

Most of the issues are a result in understanding how the 2 systems differ from each other. The Ram Jack pile has a very rigid cross section in the shaft as well as very rigid connections between extensions. This helps in bending moment in the upper 5’ as required in the 2009 IBC. I will discuss the ESR 1854 in more detail at a later post. Because a square bar system has loose connections and a cross section that is more susceptible to bending moment, the system attempts to compensate by bolting to the footing and grouting the plate. The Ram Jack system does not require bolting as evidenced in the ESR issued to Ram Jack for its piling.

The Square bar system uses a bracket that reaches under the footing 6 ½ inches. The Ramjack system has a bracket that reaches underneath the footing 9 inches. If the square bar installers leave a 2” gap between the back of the bracket and the face of the footing, they would be in serious trouble with only 4 1/2”of contact. However with the Ram Jack system, there would still be 7” remaining, still 1” more than the square bar system in its entirety. Because of this fact the seat of the square bar system is very important to grout and have full contact with the footing. Because of the larger contact area, the grouting of the seat is not required of the Ram Jack System.

The moment of inertia for a 1 ½” square bar is .442 in4 as opposed to 5.043 in4 for a 2 7/8” pipe with a 3 ½” sleeve that comes standard at 4’ long in the Ram Jack system. The reason Ram Jack has such a bracket with a 9” reach as opposed to a 6 ½” reach is the fact that the shaft is very rigid and is difficult to push laterally. The Square bar system with its loose single pin connections and less rigid shaft is very easy to move laterally and because of that lateral looseness, is super critical to bolt up to counter this weakness. As a result of the Ram Jack System rigidity, the system is not required in the ESR1854 to be bolted to the footing.

Because of the familiarity of the requirements of the square bar system, and the perception that goes with it, we decided several years ago that we would bolt the system to the footing. Unfortunately there are still older installations out there that when discovered can give the wrong perception if people are not familiar with the requirements of the Ram Jack System.

We are continually looking for ways to improve our service. Our artisan installers are hardworking and conscientious, but like most contractors it is possible to have isolated breaks in protocol. To insure that the installations are continuing to be installed with the highest quality, we have implemented a quality assurance program that requires photos of each bracket installation to be kept in the job file, in addition to the post lifting manometer already being performed on each job.

Feel free to respond to this and discuss any of the items discussed here.

By the way perhaps you are aware that the only ICC recognized ESR for the AC358 is the Ram Jack System. I’ll discuss that in a later post.

Foundation Repair – Do I need to have the foundation of my home repaired?

Is it good enough to have a contractor do a visual inspection or do I need to have a more thorough inspection performed?
Do I have an expansive soil problem or do I have a settlement problem?

The cost of a residential foundation repair is usually very expensive. So it will always make sense to have a more detailed inspection.

The results of repairing a foundation with the wrong diagnosis is usually a big waste of money and can have catastrophic consequences.

Arizona Ram Jack’s approach is to perform a manometer survey. The manometer survey will provide elevation readings throughout the interior of the home. These elevation readings will then be referenced to the existing signs of stress such as wall, floor and ceiling cracks. Also any improper drainage and any ponding water areas next to the foundation of the home will also be evaluated around the exterior of the home. This information will then be imported into a mapping software program and will generate an easy to understand contour map.

After reviewing the contour mapping together with the signs of stress we will then design a detailed repair plan and will also provide an estimate to complete the repairs.

If the results of the manometer survey show that a structural foundation repair is not needed then we will provide you with some options such as adding gutters and improving the drainage around your home.

Be very careful of the contractor who wants to suggest an expensive structural foundation repair with just a visual inspection.

If you would like to have the foundation of your home thoroughly inspected by a certified foundation repair specialist give us a call.

Foundation Repairs: Arizona Home on the Edge Part 5 – Results

With this Arizona hillside home, the foundation repairs were complex and challenging. This story starts with construction errors discovered in Part 1, and involved geotechnical and structural engineering firms in Part 2 to design a workable solution to stabilize this $2,000,000+ home. Site preparation was necessary as the home backed to a preserve and temporary access required a plan in Part 3. Arizona Ram Jack artisans worked diligently to perform all tasks in Part 4 so here we arrive today with our final chapter…

In addition to special inspections by both Gervasio & Copper State Engineering, Arizona Ram Jack supplied and built schematics with logs to report the torque of the permanent helical piles, the grout takes and depths of the grout injection holes and the grout takes of the soil nails.

This Foundation Repair project on the Gogte Residence lasted a total of 5 months and was completed $45,000 under budget. Those funds were credited back to the customer on the final bill. The wall and house were restored to a safe condition and it stands today. The preserve was returned to pristine condition with no evidence of all of the work that took place.

Cost of the project: $121,500
Project Start Date: August 2008
Project Finish Date: January 2009
Repair Contractor: Arizona Ram Jack
Structural Engineer: Gervasio & Associates
Geotechnical Engineer: Copper State Engineering

This project was submitted to the International Concrete Repair Institute (ICRI) Arizona Chapter and won 1st place in the Arizona Chapter Residential category, Arizona Chapter Project of the Year Award and…

Here’s a letter from Bob to everyone involved on the project:

From: robert brown
Date: January 24, 2011 11:55:17 PM EST
Subject: 1st blog AZRJ Recieves Award from ICRI
I am honored to accept the international Concrete Repair Institute Award of Excellence for the work done at the Gogte Residence. This was truly a remarkable project that also garnered the Stuctural Engineers Association Award.

I have included a copy of the details of the project on the attached document. I would like to thank the talented artisans and team here at Arizona Ram Jack LLC and the designing engineers who made this project possible.

This was a groundbreaking job from both an engineering standpoint as wells as a construction standpoint. Unbelievable challenges were encountered on this job with access to preserving the pristine natural wilderness adjacent to the work.
AZRJ helped the engineers with construct-ability and design assist. This included, micro pile tie backs, temporary and permanent helical piles, carbon fiber reinforcement and cement pressure grouting. Once that was completed the artisans at AZRJ developed an innovative access plan that provided access over a steep terrain for a skidsteer. This access plan had to be able to be dismantled at the conclusion of the job with no loss of materials over the steep terrain.
Thanks to all who helped make this a unique innovative project.
Bob Brown
Arizona Ram Jack President
Every project is a team effort that involves numerous people, not just the workers, but the clients, engineers and the community. We listen and when called upon, perform our work professionally with attention to details. Have a home that has problems? We can help. Give us a call.

Does your building have settlement issues?

As a building owner or owner’s representative it’s often difficult to tell if you have a foundation problem. Let’s assume that while on a property walk, you notice multiple cracks forming along an exterior building wall. Obviously, you want to take care of this issue ASAP as it does not look aesthetically pleasing. You decide to paint the wall and patch the cracks and assume everything is fine. While this may be the case and it may only be normal thermal movement, you may have foundation movement, which is a serious issue and needs to be addressed for the integrity of the building.

Exterior Wall Cracking

How do you distinguish a potential foundation repair problem? Some of the most common problem signs along the exterior of the building may include cracks in the stucco, cracks in the foundation, stair step cracking in block buildings or shifting in the walls (rotating in or out). Along the interior of the building some of the most common problem signs are doors and windows that stick, cracks in brick or sheetrock, and floors that slope or are cracked.

Just like any problem, the more symptoms you have, the greater the chance of having a foundation repair related issue. To some extent, all buildings have some of these problems as seen as normal settlement. What you should be looking for is differential settlement. This occurs when one area of the building has settled more than the rest of the building.

In some cases, differential settlement occurs due to inexpensively designed construction, however most of the time differential settlement occurs because of an excess or absence of water. Moisture beneath the center of a foundation remains consistent unless aggravated by the introduction of excess moisture, such as plumbing leaks, landscaping and irrigation lines, or sub-surface water movement. As evaporation and transpiration cause the soils to dry and shrink around the perimeter of the foundation, the structure begins to move. Uneven moisture causes uneven movement; it’s this that can cause both structural and cosmetic damage to your building.

If you have already patched a crack and it comes back or expands, it is a good idea to have it checked out as soon as possible. It will be well worth your investment to hire a qualified expert for a nominal fee to perform a detailed and thorough evaluation of your foundation. In addition to his/her evaluation, you should make sure that they provide you with a detailed report on the current status of your foundation.

This report should include a footprint of the building that includes measurements taken from a monometer (floor level survey) that shows where the building is settling or heaving up, locations of problem zones and a plan of action. A manometer is a device used to take elevation readings (+/-) throughout the building showing where there is settlement or expansion that is excessive. This data used in conjunction with the visual problem signs is what a quality foundation contractor will use to diagnose a foundation settlement issue. Armed with this information you will be able to make an informed decision on whether cosmetic or structural repairs are needed.

70 foot deep Caisson Repaired by Pressure Grouting

Earlier this month we had the opportunity to engage in a very unusual job. Voids were discovered in an existing caisson shortly after it was constructed. This was a 70’ by 6’ diameter caisson that will support the 1-17 Freeway overpass at Munds Park. ADOT officials and engineering consultants were tightly overseeing the process to ensure the final product would be a safe and solid structure.

Voids were discovered at the 14’ depth and at the bottom of the caisson at the 70’ depth. Both areas were contaminated with soil and debris that needed to be cleaned out before any actual repair could be undertaken. To complicate matters the caisson was located in an area with a high water table that allowed water to seep in to the void areas bringing soil contaminants with it.

Several core holes were drilled to both the 14’ and 70’ level. One of the PVC inspection tubes was used and the core holes to inject water and air in various sequences including simultaneously to clean the voids. The return water was carefully monitored to measure the amount of silt, and concrete in it. Cameras were lowered into the core holes to examine the void areas, locate the rebar, and ascertain the surface condition of the voids and rebar.

Packers were installed on the various core hole tops to control the return flow of water. By shutting off holes in various sequences, communication could be forced between the voids to clear them out. In addition directional devices were developed to jet water and air to various locations in the voids after determining the need from camera examinations. Care was needed to avoid washing out too much soil on the outside of the shaft.

Once the voids were clean to everyone’s satisfaction, then the grouting sequences were started. The bottom of the caisson was grouted first. Because the caisson was below the water table a grout material requirement was that it needed to include an anti washout material that would not allow the grout to separate when coming into contact with standing water in the voids. In addition the grout still needed to be high strength, non shrink and flowable. Euco Tremie Grout was chosen.

As the grout was injected, the packers again were shut off and on to control communication within the void chambers. The water was the first to flow out of the various ports as it was displaced by the grout. Once the grout started to flow out of the ports, it was then checked for communication and then eventually all of the ports closed and pressured up to a minimum 200psi and closed off.
At that point, the middle void was filled using the same procedures. At the middle void, a thinner mix was first injected to penetrate the smaller voids and cracks, followed by the thicker grout with the similar sequencing as the lower void.

Timing of the injection grout was critical. Because the Euco Tremie Grout was Thixotrophic, stopping grout pumping for longer than a few minutes at a time could run the risk of having the grout thickening up in the ports or injection equipment. Several times the pressure needed to be spiked to clear lines.

The project was completed in 3 days including a Saturday because of the critical nature of the schedule. The project is moving forward and is back on track to be completed by fall of 2011.

Does your floor slab have heave?

Have you ever had a tenant call about ‘trip hazards’ in their floor slab? Or has a tenant called you about ‘stuck’ doors that won’t open, or windows that are out of level? In most cases, all of these issues can be related to floor movement. Floor movement happens all the time in buildings. While most people automatically assume that movement is settlement, in many cases it’s actually heave.
When a floor slab heaves upwards, many people jump to the conclusion that the only way to fix it is to either grind the slab back down to level, or remove and replace the slab. Neither of these solutions deal with the soil underneath, so therefore, neither will be a long term repair.

With grinding, you are not treating the source of your heave (the soil), so you are not guaranteed any long term success. You are also thinning your slab, therefore reducing its strength. Reducing your slabs strength is probably not a big issue if all you have is foot traffic, but in a warehouse where you have heavy forklift traffic, for instance, your slab will start to deteriorate very fast if ground down too much.

With removing and replace, you are not treating the soils issue. Even if you dig up a bit of soil below, unless you excavate down to the problem soil (which can be anywhere from right below your slab to 50 feet below or greater), you will not fix the problem and will experience heave with this new slab as well.

A correct long term repair that many people do not investigate is the use of ‘void forms’. Void forms are corrugated cardboard sheets that are placed underneath the floor slab and allow for soil heave without moving your floor slab back up.

To install a void form, you remove the heaved portion of your slab, excavate the depth of your void form (usually anywhere from 4 to 8 inches), set your void form and pour back your new slab. When your underlying soil heaves again in the future, it will push up into your void form, which will in turn deteriorate, allowing your soil to expand the width of the void form without causing stress on your slab.

Grouting Smoke and Mirrors Part III, Compaction Grouting

In one of my recent posts I discussed the various types of grouting with the applications for them, advantages and optimal uses each for each type of grouting for the various applications usually having to do with foundation repair and concrete leveling. For an overview see my previous blog.

In this post I am going to discuss compaction grouting.

Compaction grouting is one of the most useful types of pressure grouting. It is usually done to densify soil that usually is not able support infrastructure above it. If done properly is a very cost effective technique that builds columns of grout deep in the soil that not only densifies the soil but provides support through the columns.

Compaction Grouting in order to be effective needs to be done with Low Mobility Grout. This is a stiff cement and aggregate grout having a slump of 0-2 inches. This means if you deposit the grout in a standard slump cone and rod it with a dowel the required number of times and pull the cone up, it will slump 0 to 2 inches down. Many people erroneously feel that if you have a stiff enough mix that it is the only requirement. In order to be effective, the mix must have sufficient internal coefficient of friction to resist fracturing the soil and traveling. Toothpaste is zero slump, however it is too slippery and when it encounters weakness in soil would follow it fracturing the soil and traveling. This fracturing not only fails to densify the soil but results in actual weakening of the bearing capacity.
The ADSC has published a consensus guide using the best experts in the field backed by hundreds of field tests to identify the optimal gradation and mix to achieve a pump-able mix that still compacts the soil. The gradation curve is published and basically includes 10% pea gravel at the top end and 90% passing the 200 sieve, meaning that 10% is a silt or smaller particle.

Compaction grout since it is a low mobility grout has almost not chance of traveling to places where you don’t want it to such as electrical conduits, plumbing, soil weakness that goes near retaining walls or other structure that could be at risk of being damaged. There are lots of interesting stories of grout coming up in peoples toilets at in opportune times. These types of risks are drastically reduced if not eliminated with low mobility grout.

At the same time because the grout is low mobility, the chance of costs spiraling out of control is almost eliminated because the geometry is fairly defined and there is almost no chance of it traveling to a void area where it could rack up huge grout takes at the owners expense.

Many contractors seem to think that any cement grout is equal to a compaction grout. This is simply not true. I have seen projects bid out as a compaction grout , only to see the contractor show up with a 1 ½” pipe to grout through. Although this pipe is easier to drive through hard soils it cannot pump the low mobility grout with out plugging up the grout delivery system with out either adding water or lubricants resulting in mobile grout that will travel and fracture soils.

Your inspecting engineer should understand these points and insist on the proper equipment to achieve low mobility grouting. If your inspecting engineer is leaving the details of the grouting process to the contractor’s discretion, then your engineer is not qualified to be inspecting.

Foundation Repair – How much should it cost?

Foundation Repair – How much will it cost?


So you have come to the conclusion that you probably do have a foundation problem. You now just want to know how much this foundation problem is going to cost. The answer to that is, it depends. It depends on, what type of foundation problem you have, how severe your foundation problem is, and also depends on the size of the area of the foundation which will need to be repaired.

First you need to make sure that the foundation problem has been diagnosed correctly. Then you need to know, what are the different options which are available to repair your foundation problem.
A couple of possible foundation problems are foundation settlement and foundation heaving. Both of these problems are very different from each other and both of these foundation problems require different repair approaches.

Some of the different repair options for settlement are; helical piers, push piers, micropiles, compaction grouting, slab jacking, and a combination of all of these or some of these options.
Some of the different repair options for heaving , due to expansive soils, are: gutters, improve the drainage around the home, add a drainage system, helical piers, remove and replace the area of the foundation which has heaved up and a combination of these repair options can be used.

So, as you can see, there really isn’t a simple, straight forward answer as to how much a foundation repair should cost. It depends on which type of foundation problem you have, the size and the area of the foundation which needs to be repaired and which repair options would be best as a repair solution.

If you are not confident that your foundation repair contractor has diagnosed your foundation problem correctly and in turn you are not confident that your foundation repair contractor is applying the correct repair option or the correct combination of possible repair options then I would advise you to hire a structural engineer or a soils engineer who specializes in foundation problems and foundation repairs. For the more severe foundation problems I would advise that you hire both a structural and also a soils engineer.

You should focus more on getting an honest and objective foundation repair diagnosis before you worry about the cost of the repair.

I will be discussing the different foundation diagnosis options in my future blogs.

Pool Repair and Soil Remediation achieved by Pressure Grouting In Arizonia

An indoor swimming pool settled, broke some lines and was threatening other lines.  Significant voids were discovered under the pool. The pool and surrounding area were built on backfill adjacient to a retaining wall. Arizona Ram Jack was Called to develop a grouting plan in conjuction with local a local soil engineering firm, Alpha Geotech.

Arizona Ram Jack was a key component of a difficult pool repair. An indoor swimming pool settled, broke some lines and was threatening other lines which if broken could then inundate the soil more causing more settlement. Significant voids were discovered under the pool. The pool and surrounding area were built on back fill with insufficient soil compaction adjacent to a retaining wall. Arizona Ram Jack was called to help with the pool repair and soil remediation by developing a pressure grouting plan together with local a local soil engineering firm, Alpha Geotechnical .

The grout plan on this particular project involve some challenges that added to the complexity of the project. The first issue involved densifying the soil with out moving the wall laterally. Adjacient to the wall were rock drains that could not be filled with grout. This required careful control of the grout slump in order to be stiff enough to not flow into the crushed rock but not too stiff to move the wall while grouting.


Another challenge was to avoid the plumbing lines under and around the pool. The lines were located and in come instances removed where possible. Once the lines were located, the grout pattern was adjusted to avoid the infrastructure.

The depth of the fill was approximately 10’ below the top of the pool deck. The cut fill line was verified through driving of the grout casing. The holes closest to retaining wall were monitored for movement and pressure grouted first at lower pressures to provide protection as holes further away were grouted with higher pressures. The primary holes were pressure grouted first with the holes between grouted after the primary holes were finished.

The pool repair was done by raising it approximately 1/2” with the cracks at the grout line closing up during the compaction grouting. The soil compaction was improved using a low slump compaction grout with out added lubricants. The Project was finished in about 2 weeks, the holes patched in the pool area and new decking installed around the pool.

+Arizonia Ram Jack Foundation Repair