Case Study: Large Diameter Helical Pile Foundation for High Voltage Transmission Towers in Soft Glacial Deposits

"This paper presents the results of a static load testing program completed on helical pile foundations for the replacement of high voltage transmission line tower structures. The foundations were part of the Northeast Grid Reliability Project (NGRP) for the Public Service Electric & Gas Company (PSE&G) near Newark, New Jersey. Structure foundations “anchor bolts down” was a design build contract model with the superstructure as bid-build.The soil stratigraphy along the alignment generally consisted of fill over about 10 ft of organic deposits underlain by up to 260 ft of normally consolidated glacial lake clays and silts. Additional project challenges included working under/adjacent the existing live high voltage lines, narrow site access due to environmental permits, foundations in a tidally influenced area, and pile projections in the order of 10 feet to meet the 10 year flood level requirements.The helical piles were constructed of 12.75 inch diameter open ended pipe piles with 36 to 40 inch diameter helices. A total of seven static load tests (compression and tension) were completed on 60 ft and 90 ft long piles, using both welded and mechanical pile splices. To evaluate pile-soil setup in the sensitive fine grained soil and determine representative longer term installation torque factors (Kt) for the production piles, the static load tests were performed 7 to 49 days after pile installation.Helical piles were found to be the most cost effective foundation alternative for this project. The required length of helical piles was less than other alternatives for similar allowable axial capacity. Helical piles with mechanical splices were installed for the varying structure foundations including tangent and heavy deadend, to a deadend monopole. Installation of 448 production piles (34,320 linear ft) was completed in three months. The installation timeline was critical to meeting the semi-annual PSEG outage for switching the old and new structures. Helical piles employing a mechanical splice resulted in an efficient and effective foundation solution for the conditions encountered on the project."