Clarios planned an expansion at its Tampa facility that included new lead air scrubbing stacks. Because these stacks impose concentrated, long-term loads, the owner wanted the new support slabs to be anchored to competent bearing soils before any concrete was placed. Helicon was brought in during pre-construction to design and install a deep foundation solution beneath the planned slab areas so the stacks could be set on a stable, settlement-resistant platform from day one.

Working closely with the owner and structural team, we developed a pile layout that aligned with the slab reinforcement and stack anchorage points. The plan focused on uniform support, predictable load transfer, and minimal disruption to site operations—key outcomes for a busy manufacturing facility where uptime matters.

We regularly deliver similar scopes across Tampa Bay, St. Petersburg, Clearwater, Brandon, Lakeland, Sarasota/Bradenton, Orlando, Fort Myers, and Naples.

Three issues defined success on this project:

1. Concentrated Loads & Load Paths
   Air scrubbing stacks produce significant vertical loads and require tight control of differential movement. The foundation system had to channel those forces efficiently from the stack anchorage through the slab and into deeper, stronger soils without over-designing or adding unnecessary cost.
2. Florida Subsurface Variability
    Gulf Coast and Central Florida soils can change quickly over short distances. A solution that could adapt in real time—verifying actual capacity at depth and extending piles to competent strata as needed—was essential.

Schedule & Operational Continuity
 The facility needed a fast, clean installation with minimal spoils and no long curing delays, so the expansion could stay on schedule while regular plant operations continued nearby.

Helicon installed 158 galvanized steel helical piles across the slab footprint to create a deep, uniform bearing system for the future stacks. Because the piles were installed before the slabs were poured, the slab design could “lock onto” known, verified capacities. This approach gave the owner and engineer confidence that the finished slabs would resist settlement over the long term.

Why Helical Piles Were the Right Choice

• Immediate Capacity Verification
  With helicals, installation torque correlates to pile capacity. Our crews monitor torque continuously and advance each pile until the engineered capacity is reached. That means every pile is verified in the ground—no guesswork.
• Speed & Cleanliness
  Helical piles install quickly with minimal spoils. There’s no need to wait for concrete cure times typical of drilled solutions, which keeps pre-construction timelines tight and predictable.
• Flexibility at Depth
  If soils vary, we simply continue to competent strata and confirm the required torque. This on-the-fly adaptability is ideal for Florida sites where localized changes are common.
• Durability
  Galvanized steel provides long-term corrosion resistance in humid, chloride-influenced environments, adding peace of mind for industrial owners.

How We Delivered

1. Pre-Construction Planning
   We started with the structural drawings, stack load data, and slab reinforcement intent. Our engineers coordinated with the structural team to finalize pile spacing, lead/extension lengths, and helix configurations that matched the anticipated loads and soil profile.
2. Layout & Survey Control
   Precision matters with concentrated equipment loads. We laid out pile locations to align with stack anchorage and slab load paths so that each pile contributes as designed and the slab behaves as a single, unified system.
3. Installation & Real-Time QA
   Our crews advanced each helical pile while monitoring torque and depth. When torque thresholds indicated competent bearing, piles were locked off at the designed elevations. We maintained detailed logs for each location, documenting torque, depth, and any site-specific notes.
4. Coordination With the Concrete Team
   Because helicals can be loaded immediately, the concrete team was able to mobilize without delay. Sleeves, caps, and connection hardware were coordinated so the slab reinforcement and anchor assemblies tied seamlessly into the deep foundation system.

Results & Value

• Assured Structural Performance
  The helical system delivers high, verified load capacity directly under the stack bases. By engaging competent soils below the variable surface layers, the slab and equipment benefit from robust, predictable support.
• Controlled Settlement and Ground Improvement
  With piles acting as load “columns” beneath key points, the system reduces differential movement that can compromise heavy, sensitive industrial equipment.
• Schedule Confidence
  Fast, clean installation meant the GC could keep the expansion on track. No curing delays, minimal spoils, and tight integration with the slab pour saved time and jobsite friction.
• Lower Long-Term Risk
  By engineering settlement resistance before the stacks were set, the project mitigates the risk of future slab movement, re-leveling, or alignment issues that could impact operations.

Where This Approach Excels in Florida

Helical piles are a proven solution for commercial and industrial slab support across Tampa Bay, Orlando, Sarasota/Bradenton, Lakeland, and Southwest Florida (Fort Myers to Naples). Typical applications include:

• Equipment and stack bases

• Pump pads, compressor pads, and generator slabs
• Tank foundations and pipe racks
• HVAC platforms and chiller pads
• Mezzanine and conveyor supports
• Machine foundations requiring tight tolerances

Use helicals when you need a speedy, low-disruption install with verified capacity—especially in variable soils, limited-access areas, or on projects with compressed schedules.

Why Helicon

• Florida Industrial Expertise
  Our teams regularly deliver deep foundation systems for heavy equipment pads and slab-on-grade supports across the markets we serve. We understand the local soils and how to attend to them.
• Precision & Proof
  We pair practical field experience with rigorous QA—torque monitoring, as-built logs, and load documentation—so owners and engineers get traceable proof of performance.
• Turnkey Coordination
  From pre-construction planning to pour day, we coordinate layout, embed details, and elevation controls so your structure and equipment set once and stay put.

FAQs

What makes helical piles ideal under new slabs?
They install quickly, create minimal waste, and can be capacity-verified in real-time via torque. Because they can be loaded immediately, the concrete team can pour without waiting days for drilled elements to cure.

How do you know each pile will perform?
During installation, we monitor torque and depth against engineered thresholds. If a location hasn’t reached target capacity, we continue to competent strata or adjust the helix configuration as needed. Each pile is documented so the engineer and owner have a clear performance record.

Do helicals help prevent future settlement?

Yes. Helical piles bypass weaker surface soils and transfer load to deeper, stronger layers. That significantly reduces long-term settlement and differential movement beneath concentrated loads like stacks, tanks, and heavy equipment.

Where in Florida do you offer this service?

We serve Tampa Bay, St. Petersburg, Clearwater, Brandon, Lakeland, Orlando, Sarasota/Bradenton, Fort Myers, and Naples, and surrounding communities within roughly a 2½-hour radius of Tampa and Orlando.

Call 844-Helicon today for your free inspection!