Helical Pier Installation - Fiber Network Utility Building Fallon, Nevada
Challenge
Madole Construction was contracted to install a deep foundation system for an 846-square-foot precast concrete utility building supporting a Fiber Network facility in Fallon, Nevada. The structure required dependable load-bearing support in an area known for soft subsurface soils.
The primary challenge was the depth to competent bearing material. Surface soils could not adequately support the structure using conventional shallow footings. The foundation system needed to extend to stable soil layers while maintaining project schedule efficiency.
Site Conditions
Geotechnical conditions at the site presented significant challenges. The groundwater table was encountered at approximately 18 inches below grade, and soils consisted primarily of fine-grained silts and clays extending to approximately 75 feet. These conditions created a liquefiable soil profile, meaning the soil could lose strength under load or seismic activity.
Because of the shallow groundwater and soft, fine-grained soils, traditional shallow concrete foundations were not feasible without extensive over-excavation and soil replacement. Ground improvement methods such as geopiers were considered; however, the depth of unsuitable soils and high groundwater conditions would have required substantial excavation and staging, increasing cost and installation time.
The precast utility building weighed approximately 280,000 pounds, requiring a foundation system capable of transferring significant structural loads to deeper, stable soil layers.
Solution
Madole Construction installed a helical pier foundation system consisting of 16 production piers. Each pier was advanced to approximately 75 feet below grade to achieve competent bearing.
Helical piers were selected for their ability to provide immediate load-bearing capacity without excavation or cure time. Installed in a single operation, the system allows structural loads to be transferred directly to stable soil layers as soon as installation is complete. This approach provided a clear time advantage over alternative foundation methods while delivering verified performance.
Load Testing and Verification
Before proceeding with full production installation, Madole Construction conducted a pre-production load test to confirm design capacity.
Four Model 287 reaction piers were installed for testing purposes. Each reaction pier was rated at 50 kips, providing a combined 200 kips of reaction resistance. This arrangement allowed controlled loading of a production pier to verify performance under load.
The tested pier achieved an ultimate capacity of 106 kips, confirming the design assumptions and validating the performance of the helical pier system prior to full installation.
Installation
Load testing and installation of the 16 production piers were completed over approximately five days. Installation was performed using an Eskridge D600 Series hydraulic digger drive, capable of delivering up to 54,000 ft-lbs of torque. This high-torque drive system allowed the crew to advance the helical piers through soft soils and into competent bearing material at approximately 75 feet below grade.
Installation torque was continuously monitored and documented to verify capacity for each pier. The combination of high-capacity equipment and torque verification ensured consistent performance across all installations.
Because helical piers do not require excavation or concrete curing, foundation installation progressed efficiently while maintaining structural reliability.
Project Outcome
The helical pier system delivered a stable and verified deep foundation solution in challenging soil conditions.
The project achieved:
- Competent bearing at approximately 75 feet
- Verified 106-kip load capacity through testing
- Immediate structural support without cure time
- Reduced site disturbance compared to excavation-based alternatives
- Maintained overall project schedule
The Fallon Fiber Network project demonstrates the effectiveness of helical piers in deep bearing applications where traditional shallow foundations are not feasible. Through load verification and controlled installation, the system delivered measurable performance and long-term structural reliability.
Madole Construction continues to provide engineered deep foundation solutions designed to manage risk, protect project timelines, and ensure structural integrity.
For more information about Madole Construction’s helical pier services, contact us today.
