Ram Jack Completes Two Large Solar Projects

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Ram Jack Completes Two Large Solar Projects

Ram Jack Systems Distribution, LLC www.ramjack.com was contacted by Abengoa Solar, INC. www.abengoasolar.com seeking an alternate to concrete foundations for their solar array fields. Ram Jack’s research and development team, along with Darin Willis, P.E., director of engineering for Ram Jack, answered the call, designing micro pile and helical foundations as well as a variety of custom pile caps that could be used in either foundation scenario.

Once the foundation design and project logistics were complete, Ram Jack called on Tim Davis Jr., of Straight Line Construction, www.straightlinepier.com a premier Ram Jack installer and highly renowned micro pile installation company. Once mobilized, Mr. Davis and his crew were able to complete both projects ahead of schedule.

The strictest of tolerances were placed on both the fabrication and installation of the foundations. Ram Jack exceeded all specification facets of both projects, (Solana and Mojave) specifications.

The most recent project was near Hinkley, CA and was called the Mojave Project. The deep foundations on this project consisted of both Helical Piles and Micro Piles. Below is information about the project.

Mojave Project - Hinkley, CA

39,000 Helical Piles and 11,000 Micro Piles
Minimum torque requirement for helical piles was 4,000 ft-lbs
4000 PSI compressive strength concrete was specified for the micro piles
Custom pile cap
13 month project duration - November 2011 - December 2012
(4) helical pile crews and (4) drill and cap setting crews - up to 450 piles installed per day
Installation equipment included - (4) John Deere 200 series track hoes, (4) 17K ft-lbs PRO-DIG torque motors, (4) PRO-DIG Intelli -Tork wireless torque measuring systems, (1) Beretta T57 drill, (4) Terex ASV Excavators with TEI Rock Drills with 15’ mast
Blow counts ranged from 7 - 50 blows per foot
Compression, tension and lateral pre-production pile load tests were specified
0.5% of all piles were required to be proof tested – total of 191 helical piles and 59 micro piles
4mm (0.158 in.) total deflection criteria (during load), 1.2mm (0.047 in.) net deflection criteria (after load release)
Average net deflection of 0.250 mm (0.010 in.) on all 250 proof pile tests
Helical piles and caps manufactured at Ram Jack facilities in Ada, OK
Straight Line Construction, Pueblo West, CO installed the piles. Tim Davis Jr. and Don Krake managed the installation.

Additional Custom Dynamic Lateral Test Required for Helical Piles

Nearing project completion, the customer added a significant lateral load test requirement as there was concern about desert winds compromising the lateral stability of the loaded helical piles. Consequently, project engineers developed a cyclical load test criteria designed to simulate the effect of wind loads over time. A summary of the cyclical lateral load tests includes:

The first project was near Gila Bend, Arizona and was called the Solana Project. The deep foundations specified on this project were Micro Piles. Below is information about the project:

Solana Project – Near Gila Bend, AR

70,000 Micro Piles
4,000 PSI compressive strength concrete, varying pile diameters and depth
Custom pile caps
12 month project duration - December 2010 to December 2011
(3) drilling and cap setting crews installing up to 600 piles per day
(4) Terex ASV excavators with TEI rock drills with a 15 foot mast
Soils - cemented sands, up to 80 blow count
Pre-production pile load tests - compression, tension and lateral
0.5% of all piles were required to be tested - 354 total proof pile tests
4mm (0.158 in.) total deflection criteria (during load), 1.2mm (0.047 in.) net deflection criteria (after load release)
Average net deflection of .250mm (0.010 in.) on all 354 proof pile tests
Pile Caps manufactured at Ram Jack facilities in Ada, OK
Straight Line Construction, Pueblo West, CO installed the piles. Tim Davis Jr. and Tim Davis Sr. managed the installation.