Dairy Industrial Complex in Porto Alegre

Dairy factory and industrial complex suffering of partial subsidence. The sinking of the existing foundation slab was affecting the substructure and the existing equipment. To stop it and assure a robust support to the complex, a campaign of ARCOS driven and grouted micropiles was executed.

Project Detail

Micropiles installation for Dairy Industrial Complex foundation reinforcement.

Client

G3 Construções, Lacticínios Porto Alegre

Date

2023

Estimate Budget

Industries

LOCATION

Rio Novo do Sul – Espírito Santo (Brazil)

A newly build industrial complex (2021), with a total of 9000m2, has suffered differential subsidence creating cracks on the floor and building walls, also affecting industrial substructures and equipment. The existing foundation reinforcement had to be done using a system that could work inside the complex without affecting much its industrial operation.

The selection of ARCOS micropiles was made as simple and effective method, that could be implement in tight spaces. The rig could access all the identified subsiding areas (indoor or outdoor) and without the need of moving or dismantling existing structures/equipment. ARCOS was responsible to install the shaft-grouted micropiles.

The installation of the ARCOS shaft-grouted steel micropiles involves the injection of cement grout that will fill up the inner and outer (annulus) space of the pile, that provides improved skin friction to the element.

Challenges

Operating industrial complex with installed equipment and tight areas, besides the low head room. The areas that have been intervened were all having space limitations. It was also important to keep the operation as clean as possible and causing minimal disruption to the factory operation.

Pile installation required the mobilization and demobilization for different areas in the complex (indoors & outdoors) and having the most various uses.

Solution

ARCOS Shaft-grouted steel micropiles have been installed to consolidate the exiting foundation, stopping subsidence and offering better bearing capacity to the industrial equipment. ARCOS micropiles are cost effective and can be installed in any type of environment and space restrictions.

The pile driving rig is lightweight and could be easily mobilized and demobilized to the various locations. It could also be configured and oriented according to the available space. Being possible to assemble the rig’s support legs on top of existing industrial equipment and with different individual lengths.

Pile steel pipe is drive dry, to the design depth or by achieving refusal criteria. After it will be injected using cement grout, mixed on site.

Key Figures

Scope:

A total of 507 driven and grouted ARCOS piles with steel pipe and Ø15cm, reaching up an average 27m in depth: 12620.71m total length.

Achievements:

Daily production between 100m to 150m per day. All pile project completed from 9th august 2022 to 23rd march 2023. Two static load tests were performed to prove pile bearing capacity of 40Tf.

Geology:

The site soil profile is basically composed by silty sand, and a base of compact silty Sand (NSPT 48-60) at an average depth of 28m.

Technologies Used

G3® System

The G3® Soil Stabilization System is a next-generation polymer technology designed to transform non-cohesive soils into stable, predictable environments for excavation and ground engineering. By forming a strong cross-linked network within the soil, the G3® system improves soil cohesion, minimizes fluid loss, and enhances operational efficiency, making it ideal for challenging soil conditions.

G Line

The G Line is a versatile polymer-based soil stabilization system used in geotechnical excavations to support soil structures. It is designed for use in various soil types and conditions, offering efficient mixing, rapid hydration, and compatibility with both fresh and salt water. The G Line components (GMud, GNet, G+) work together to enhance soil cohesion, reduce fluid loss, and promote particle suspension, making it ideal for applications in deep foundation projects.

XG Series

The XG Series, developed by GEO, is a range of innovative products based on a natural polymer for use in drilling and soil stabilization. Designed for high solubility and viscosity control, Cross-Gel XG serves as an efficient drilling fluid with long-lasting stability, effective sediment transport, and continuous reuse capability. The series includes complementary products—XG Break, XG Clean, and XG Shield—to optimize performance, manage fluid viscosity, and maintain polymer structure over extended operations.

Bentonite Suspension

A bentonite suspension system is a mixture of bentonite clay and water, forming a gel-like fluid that exhibits thixotropic properties, meaning it thickens when at rest and becomes more fluid when agitated. This suspension is used primarily in industries like construction, drilling, and geotechnical applications for its ability to provide stability and lubrication.

GelPro

GelPro is a highly soluble anionic polymer that forms a high-viscosity slurry when mixed with water. It hydrates quickly and requires minimal equipment for use, offering immediate application for soil stabilization. GelPro is ideal for stabilizing various geological formations, offering ease of hydration and consistent slurry formation. It can be mixed directly in the excavation or slurry batching plant without the need for pH adjustment or specialized mixers.

GMud Ultra

GMud Ultra is an anionic polymer that creates a high-viscosity slurry upon mixing with water. It hydrates quickly and requires no special equipment, offering fast application in less demanding soil profiles. Designed for use in less complex geological conditions, GMud Ultra simplifies soil stabilization with minimal equipment. For more difficult formations, additional G3 System products are recommended for enhanced performance.

PolyGel

PolyGel is an acrylic anionic polymer, available in dry granular form, known for its excellent hydration and solubility rates. It provides a balanced price-quality solution for soil stabilization. PolyGel is effective in soil stabilization and can be used in conjunction with other G3 System products to meet specific project requirements. It is also environmentally friendly, ensuring reliable results.

Fluid Loss Blockers

GEO’s fluid loss blocker system includes two products, GFiber and GBlock, designed to prevent fluid loss during soil stabilization. Fluid loss can compromise excavation stability, particularly in permeable or fractured soils. GFiber, made from natural mineral fibers, and GBlock, a fast-swelling synthetic polymer, create barriers in the soil to control seepage effectively. This system is compatible with support fluids such as the G3 System, Gline, XG series, Bentonite, and standalone slurries.

Micropile

Micropiles are small-diameter piles made from high-strength materials like carbon steel or ductile cast iron, driven into the ground to provide additional load-bearing capacity for structures. They are ideal for both new construction and foundation reinforcement in existing buildings, especially in areas with weak soil or limited access. Micropiles are often used where traditional foundation methods are impractical, offering a flexible, cost-effective solution with minimal disruption. Their installation requires minimal equipment, making them suitable for tight spaces or urban environments where heavy machinery is not feasible.

Bi-Directional Static Load Test

Bidirectional Static Load Testing (BDLT) is an advanced and efficient method for evaluating the load-bearing capacity of deep foundation piles and barrettes. This innovative testing technique is crucial for projects that require precise measurement of both skin friction and end bearing capacity in high-capacity foundations. The method involves performing full-scale static loading tests that evaluate the load performance of piles under axial compressive loads, which is essential for ensuring the stability and integrity of any foundation system.

Water / Wastewater Treatment

Our comprehensive array of specialized polymers is designed for water, wastewater, and sludge treatment, and all our products meet NSF certification, Halal certification, and applicable local certifications. We take on the challenges of water treatment across multiple sectors, including municipal, industrial, mining, agriculture, construction, civil engineering, and dredging, to ensure water is preserved and reused for the benefit of future generations.