Shore Systems Group, LLC was proud to collaborate with JH Green & Son Construction on a critical foundation upgrade project for Barry Callebaut USA. This project involved enhancing the foundation of an active warehouse to support new equipment and constructing a new interior foundation system for a mezzanine and office space in Eddystone, PA.

Project Overview

What

This project involved foundation upgrades for an active warehouse, ensuring structural integrity for new equipment and the installation of a new interior foundation system for a mezzanine and office space.

Where

Barry Callebaut USA LLC 903 Industrial Highway Eddystone, PA 19022

When

Shore Systems Group began work in November 2023 and successfully completed the project by January 2024.

Methodology

How

To meet the project’s structural requirements, Shore utilized a micropile system consisting of:

5.5” diameter .415 wall steel casing
#10 center bar with PVC centralizer
5000 psi grout
Termination with 10”x10”x1” A50 steel plate
Installation equipment: Commachio MC400, Sullair 1150 CFM compressor, Penndrill PC1110 grout plant, and Numa SuperJaws overburden system

Why

The project was originally designed for helical piles using (39) Chance SS175 8/10 helix square shaft leads transitioned to RS3500 round shaft extensions at an anticipated depth of 26 feet below grade. However, as installation progressed, Shore encountered obstructions including abandoned footings and pile refusal at several locations.

Foundation Upgrades for Barry Callebaut USA

Overcoming Challenges

Problems and Solutions

To address these issues, Shore relied on its extensive geotechnical expertise and acquired as-built plans from prior projects at the site. It was determined that a previously abandoned slab was buried approximately 6 to 8 feet below the current concrete elevation, with compacted gravels and fractured sandstone at depths of 22 to 30 feet.

As a solution, the foundation plan was re-engineered to include micro-piles drilled into the sandstone layer. Shore employed limited-access equipment to successfully complete the installation within the site’s constraints, ensuring a stable and secure foundation for the new warehouse upgrades.

Conclusion

Through strategic problem-solving, real-time engineering adaptations, and the use of advanced drilling techniques, Shore Systems Group successfully delivered a robust foundation solution for Barry Callebaut USA. This project underscores Shore's ability to tackle complex foundation challenges and adapt to evolving site conditions, reinforcing its expertise in deep foundation installations.