Desktop guide to aggregate pier

ground improvement
Table of Contents
Intro................................................................................................................. 01

Ground improvement 101................................................................................ 02

A deep dive into aggregate pier ground improvement...................................... 03

Feasibility and cost discussion of aggregate piers............................................ 05

What geotechnical engineers should know about ground improvement........... 07

What structural engineers should know about ground improvement................ 09

What general contractors should know about ground improvement..................12

Whether it’s a new building, a storage tank, a retaining wall or some

other structure, a stable foundation is at the core of every successful

construction project. But most construction sites fail to start on a firm

footing. Often, some sort of ground improvement or deep foundation is

necessary to get a project out of the ground and moving forward.

In this white paper, we explain the nuances of ground improvement,

particularly aggregate piers, and why those nuances should always be

primary considerations for any construction project in soft soils.

If you have any questions as you read this guide, please don’t hesitate

to contact us at 866-421-2460. Ground improvement is something we

take seriously, and we want to help you any way we can.

Ground improvement 101
Ground improvement is typically defined as using mechanical means to
improve the ground’s ability to support a structure. Although there are several
different ground improvement techniques, this white paper focuses primarily
on what are referred to as aggregate piers.

Stretching back more than a decade, aggregate piers have become a popular
construction technique in the U.S. But they’re still a relatively new option
to consider. So engineers, contractors and owners often don’t have a full
understanding of how their project can be designed, bid and built to best use
aggregate pier ground improvement.

There are three primary options that geotechnical engineers consider when
making recommendations for building on native and fill soils that are soft or
loose:

1. Removing the soil and replacing it with engineered fill

2. Using deep foundations, such as drilled shafts, auger cast piles or

micropiles

3. Using ground improvement, such as aggregate piers, to improve the

bearing pressure to support shallow foundations

Ground improvement is often the most economical and efficient of the three
options, assuming the soil conditions and structural loads are suited for it.

THE FIELD GUIDE TO FOUNDATION CONSTRUCTION

866-421-2460 | subsurfaceconstructors.com 02
A deep dive into aggregate pier ground
improvement
Before ground improvement methods like aggregate piers became prevalent,
shallow foundations could only be used if marginal soils were removed and
replaced with engineered fill. If the structural loads were still too high to
warrant the use of shallow footings, the only option for the building site was
to use deep foundations — a much more costly method. Today, aggregate
piers provide a way to construct shallow foundations in marginal soils, which
is often more cost-effective than removing and replacing fill or using deep
foundations.

Aggregate piers may also be referred to as vibro stone columns, vibropiers®

or geopiers®. Rammed Aggregate Piers® are a proprietary system developed
by the Geopier® company. They’re made up of 20-to-36-inch diameter
columns of highly compacted stone, constructed in groups within a footing.
The stone replaces or displaces the existing soft soil, resulting in a footing
area with both stone columns and existing soils. That combination can
produce bearing pressures up to three or four times the bearing pressures of
the in situ (previously present on-site) soils. The high modulus columns also
help significantly reduce the anticipated settlement of the loaded area.

There are two primary types of aggregate piers: Rammed Aggregate Piers®
and vibrated aggregate piers (or vibro stone columns). The primary difference
between the two is the way they’re constructed. Rammed Aggregate Piers®
are constructed by pre-drilling a hole, putting aggregate into lifts, and then
tamping or ramming the lifts down into the hole. The process is repeated until
the pre-drilled hole is filled with highly compacted aggregate.

THE FIELD GUIDE TO FOUNDATION CONSTRUCTION

866-421-2460 | subsurfaceconstructors.com 03
Vibrated aggregate piers use large vibratory probes that vibrate at a high
frequency to compact granular material. The probes can be inserted in a pre-
drilled hole, or using some unique rigs, crowded into the ground to laterally
displace the soft soil and create an open column. The stone can then be
poured into the hole and compacted in lifts with the vibratory probes. At
Subsurface Constructors, we use several such rigs to install stone columns
without pre-drilling. As a result, we are able to minimize or even eliminate the
generation of spoils. Because this technique eliminates a substantial part of
the ground improvement process, vibrated piers that are installed without
pre-drilling are often the most cost-effective approach. Of course, in some
soil types, it’s necessary to pre-drill. This is usually the case with extremely
hard soils and some fill soils.

When the stone for aggregate piers is dumped from the ground surface,
the process is called “top-feed installation,” especially when referring to
vibro installation methods. The top-feed technique is used when the soils
are relatively stable, and a pre-drilled or probed hole will stay open during
the stone placement and compaction process. But when the existing soils
are unstable, such as in silty or granular soils, a bottom-feed installation
technique can be used. In this case, the stone is tremied to the bottom of the
hole through the compaction device, and the tool is not removed from the
hole until the aggregate pier is complete.

Rammed Aggregate Piers® typically require a graded stone to reach

maximum compaction, while vibrated piers use clean stone — stone that
is all roughly the same size. Both rammed and vibrated piers can provide
bearing pressures in the range of 4,000 pounds per square foot (psf) to 6,000
psf or higher, depending on the soil makeup. The main concerns owners have
regarding different types of aggregate piers are one, that they provide the
structure with the necessary support, and two, choosing the least expensive
option.

THE FIELD GUIDE TO FOUNDATION CONSTRUCTION

866-421-2460 | subsurfaceconstructors.com 04
Feasibility and cost discussion of aggregate
piers
Before the development of aggregate piers, if a shallow foundation could not
be supported by the in situ soil, builders had to use deep foundations, such
as drilled shafts or driven piles. Deep foundations consist of piers or piles
made from timber, steel, reinforced concrete or pre-stressed concrete. These
piers or piles are often reinforced with rebar and can either be driven into the
ground or drilled. Implementing deep foundations is typically more expensive
than using aggregate piers or removing and replacing the marginal soils. If
it’s determined that deep foundation work is necessary for a specific building
project, the costs associated with deep foundations can actually prevent that
building project from being constructed.

Aggregate piers are often the most economical option for constructing in
soft soils because of the materials used (stone is cheaper than concrete),
the speed of construction (specialty contractors can often install 40 to 60
aggregate piers per day) and the treatment depth. The average depth of an
aggregate pier is in the 15-to-20-foot range. Although most companies have
the equipment to treat down to 30 feet, and in some cases much deeper,
ground improvement becomes much more expensive at greater depths.

Since starting our ground improvement division in 2005, Subsurface

Constructors has also designed and built custom vibro equipment that
allows for more flexibility and efficiency in the mobilization and installation
processes. By building our own equipment and parts, we are able to
increase our capacity to do work in most areas of the country. At Subsurface
Constructors, we pride ourselves on being innovators in construction process
improvements and the implementation of emerging technologies.

THE FIELD GUIDE TO FOUNDATION CONSTRUCTION

866-421-2460 | subsurfaceconstructors.com 05
It’s important to note that aggregate piers can only sustain a certain load,
depending on the soil type. In some cases, such as high-rise buildings and
other heavily-loaded structures, deep foundation work may be the only
option. Few ground improvement contractors perform both aggregate pier
work and deep foundation work. A company with knowledge and experience
in the design and construction of both can provide engineering support in the
early stages of a project to help determine the most feasible and economical
foundation solution.

THE FIELD GUIDE TO FOUNDATION CONSTRUCTION

866-421-2460 | subsurfaceconstructors.com 06
What geotechnical engineers should know
about ground improvement
The geotechnical engineer’s recommendation is typically the start of the
ground improvement process, and most geotechs have significant experience
with different types of ground improvement. The geotechnical engineer’s
borings logs and report recommendations help identify the best way to
support a new structure.

An experienced geotechnical specialty contractor can help the geotechnical

engineer determine the most feasible and cost-effective type of ground
improvement to use or help geotechs determine if deep foundations are the
most cost-effective option. A contractor who designs and installs both ground
improvement and deep foundations is best suited for this task.

When the geotechnical report is written, there’s often only limited structural
information available, such as column loads. As a result, geotechs are often
unable to provide specific information regarding the achievable bearing
pressures using aggregate piers. Usually, the specialty contractor with the
winning bid designs the aggregate piers, not the geotechnical consultant. But
geotechs should be able to provide a reasonable range of bearing pressures
(i.e. 4,000psf to 6,000psf) that are typical for aggregate piers and state that
range in their report. A ground improvement contractor should also weigh
in at this point and help determine this bearing pressure range by using
available boring information, general column loading and some assumed
footing sizes.

When recommending aggregate piers, the specific language in a geotechnical

report can greatly impact how a project is specified and bid. Before vibrated
pier technology became an economical type of aggregate pier in the U.S.,
Rammed Aggregate Piers® were by far the most-used option. Geotechnical
reports and construction specifications often referred specifically to Rammed

THE FIELD GUIDE TO FOUNDATION CONSTRUCTION

866-421-2460 | subsurfaceconstructors.com 07
Aggregate Piers® — a proprietary product that only licensed installers can
implement. There’s typically only one licensed installer per geographical
territory, significantly limiting the bid activity for this type of work. When this is
the case, owners don’t receive nearly the value they should when aggregate
piers are the chosen foundation type.

In order to get the best bid on the project, it’s important to use the correct
language in the geotechnical report and the construction specifications.
Using the phrases “aggregate piers” and “vibro stone columns” opens the
bidding process up to any company that installs aggregate piers of any kind.
While they’re both fully suitable for most ground improvement jobs today,
there’s enough of a difference between the two installation techniques that
the language of the specifications can exclude one of the processes from
being an acceptable foundation type on a project. To prevent this from
happening, many engineers and specifiers have made it commonplace to use
the phrase “aggregate piers” in reports. Then, they further define aggregate
piers as either a rammed or vibrated pier.

Specialty ground improvement contractors and geotechnical organizations,

such as the Deep Foundations Institute (DFI) and the ASCE Geo-Institute,
have guidance documents and actual specifications examples you can
modify for your project. It’s always a good idea to contact more than one
specialty contractor when developing your project specifications.

THE FIELD GUIDE TO FOUNDATION CONSTRUCTION

866-421-2460 | subsurfaceconstructors.com 08
What structural engineers should know about
ground improvement
Structural engineers probably play the biggest role in a project that will
ultimately require the use of ground improvement, and aggregate piers in
particular. A structural engineer must use the geotechnical report to decide
which type of foundation to design, understanding that if the structure can be
designed with shallow foundations, the overall construction costs will be less
than if deep foundations are used. This decision is less straightforward when
the soil conditions are poor and structural engineers are trying to optimize
footing size given the recommended bearing pressure. In these marginal
soils, aggregate piers provide a significantly greater bearing pressure than
just the existing soils, allowing the structure to be supported by shallow
foundations.

An experienced ground improvement contractor can work with structural

engineers to make sure aggregate piers can provide the required bearing
pressure for the optimal footing size. In many cases, the ground improvement
contractor can also start to put some reasonable cost estimates together
based off of the information provided by structural engineers. With specialty
expertise, ground improvement contractors can help determine whether
ground improvement or deep foundations are the most economical option.

For a structural engineer, it’s important to acknowledge consistent and

comprehensive specifications for ground improvement as a key part of the
construction process. Well-written specifications actually reduce the costs
of a construction project. They should be inclusive to every company who
should be able to bid on the project, allowing for a wider selection of bids
but also assuring that only experienced and reputable specialty contractors
are approved to bid the work. Carelessly written specs can exclude qualified
specialty contractors from the bidding process, and that can significantly
raise the price of the project. In the case of aggregate piers, the design is

THE FIELD GUIDE TO FOUNDATION CONSTRUCTION

866-421-2460 | subsurfaceconstructors.com 09
often provided by the specialty contractor, introducing even more risk to their
work. To ensure you’re working with an experienced specialty contractor,
select one who has licensed, professional engineers on staff and a long list of
completed projects under their belt.

In order to hire the best company for the job, specifications must
allow maximum flexibility in potential technologies and explicitly define
performance requirements. Discussing the project with the geotechnical
engineer, the owner and a specialty ground improvement contractor allows
you to identify this terminology before specifications and requirements are
finalized and the bidding process begins.

When writing the specifications, it’s important to consider the following:

Terminology

Subtle phrases in the text that seem general could represent a proprietary
technique. Make sure to consult more than one ground improvement
contractor when writing specifications so you can use general terminology
and ensure you don’t exclude any reputable companies from bidding.

Relationships and responsibilities

During the ground improvement process, boundaries of responsibility

between the involved parties can sometimes become blurred. Avoid
this whenever possible. Well-written specifications establish where the
boundaries are and who is responsible for what. That ensures accountability,
and accountability is what makes a job site successful.

Operation constraints

Communicating the constraints of each project site and its environment is

essential for enabling contractors to provide realistic proposals. Include all
agreements, covenants and any other situations that can restrict a contractor.

THE FIELD GUIDE TO FOUNDATION CONSTRUCTION

866-421-2460 | subsurfaceconstructors.com 10
Performance requirements

Performance requirements are extremely important and should be taken

seriously. Specifications should address the following:

• Settlement
• Bearing pressure
• Seismic considerations
• Slope stabilization
• Groundwater control application
• Confirmation/testing

The means and methods of confirmation are also an important part of the
project, and specifications should identify them. The specification should also
indicate who is responsible for the confirmation and testing procedures.

If you’re concerned about writing specifications without being exclusionary,

simply reach out to consult ground improvement contractors during the
creation of your specs. Expertly written specs will yield more and better
results during bidding.

THE FIELD GUIDE TO FOUNDATION CONSTRUCTION

866-421-2460 | subsurfaceconstructors.com 11
What general contractors should know about
ground improvement
General contractors need a good price on bid day from a company that’s well
respected in the ground improvement industry. Knowing and understanding
the process of ground improvement helps general contractors during all
phases of a project — from concept to construction. If you’re negotiating
your work on a project, then a basic understanding of ground improvement,
specifically aggregate piers, may allow you to provide value-added solutions
that the owner or engineer has not considered. If you’re competitively bidding
a project that requires aggregate piers, the same basic understanding can
help you sort through the aggregate pier bids and know what questions to
ask of your bidders. You’ll also be able to tell if the bids are accurate and can
then feel confident when it comes time to choose a ground improvement
company.

So what are some of the important aspects of aggregate pier construction

that general contractors should know when pursuing or bidding projects? The
list below addresses several.

1. Have a basic understanding of the different types of installation techniques

and the equipment that would be used on-site. Know the difference
between rammed and vibrated piers. Learn if this is a top-feed or bottom-
feed project. See how many pieces of equipment the process requires.
These elements are project-specific and are ultimately determined by
the specialty contractor, but knowing them will help you in planning and
managing the project.

THE FIELD GUIDE TO FOUNDATION CONSTRUCTION

866-421-2460 | subsurfaceconstructors.com 12
2. Learn how much spoil is generated during the aggregate pier construction
and who is responsible for removing spoils. Some aggregate pier
contractors have unique rigs that allow them to install the piers without
having to pre-drill — if soil conditions allow. When possible, this technique
could save a considerable amount of money by reducing or eliminating
spoils on a project. Ask your specialty contractors how they plan to
create the aggregate pier hole. If spoils are anticipated, make sure to plan
accordingly for spoil removal.

3. Learn whether or not your specialty contractor plans to pre-drill the

aggregate piers. Some contractors may approach the project assuming
that they could install the aggregate piers without having to pre-drill,
resulting in a lower price on bid day. However, if they ultimately decide
they need to pre-drill once on-site, they may come back to you and ask
for more money. Address this question when reviewing the bids and get
comfortable with the approach that the specialty contractor plans to take,
assessing their track record for sticking to their plan.

4. Understand the need that some installers have for temporary casing. Some
installers of aggregate piers are not well-equipped to install aggregate piers
in unstable soils, and therefore have to use temporary casing to keep the
hole open during installation. General Contractors need to know that this
expense can sometimes be “buried” in a bid. General Contractors should
educate themselves on the application of temporary casing, know whether
it’s included or excluded in the installer’s bid, and understand what it will
cost if it has to be implemented on a project.

5. Develop a level of comfort with your specialty contractor for aggregate pier
design and installation. A good geotechnical contractor communicates
openly with general contractors and other project team members, so
everyone looks good to the owner and the seeds for a successful project
are planted.

THE FIELD GUIDE TO FOUNDATION CONSTRUCTION

866-421-2460 | subsurfaceconstructors.com 13
When reviewing bids for aggregate pier work, general contractors will
naturally consider price but should also consider reputation. It’s usually
instinct to go with the lowest price, but if the lowest bidder doesn’t have a
solid reputation, it’s worth considering other companies. Look over the bid
proposals closely and ask questions if you have any. Ground improvement
is an extremely important part of any construction process, and you need to
work with a partner you trust.

THE FIELD GUIDE TO FOUNDATION CONSTRUCTION

866-421-2460 | subsurfaceconstructors.com 14
Subsurface Constructors:
your full-service geotechnical contractor
Successful ground improvement is rooted in collaboration and
communication at all steps in the process. Here at Subsurface Constructors,
we’re committed to making ground improvement as affordable and easy as
possible. At Subsurface, we:

• Are among the nation’s leading, full-service foundation contractors

• Work with engineers and contractors every step of the way

• Have a long history of technical competence and practical experience

• Believe that a safe job site is a productive job site

• Work with you to find the most practical and cost-effective means for your
foundation, shoring and ground improvement projects

From drilled shafts and driven pile to auger cast pile and vibro stone columns,
Subsurface has evolved through a century from a traditional foundation
contractor to a full-service geotechnical contractor.

If you have questions or concerns or would simply like an expert in the field
to review your project specifications, please contact us. We’ll make sure you
start your project on a solid foundation.

Call us at 866-421-2460

Subsurface Constructors Corporate Headquarters

101 Angelica Street
St. Louis, Missouri 63147

subsurfaceconstructors.com