Helical Piles for Oil & Gas Projects: Meeting Industry Standards

Introduction

The oil and gas industry demands robust, reliable, and cost-effective foundation solutions to support infrastructure in some of the harshest environments. From drilling sites and refineries to pipelines and offshore platforms, stability is a critical concern. Helical piles, also known as screw piles or helical anchors, have emerged as a preferred deep foundation solution due to their versatility, efficiency, and ability to meet industry standards.

This article explores how helical piles are used in oil and gas projects, highlighting their advantages over traditional foundations.

The Role of Helical Piles in Oil & Gas Infrastructure

1. Pipe Racks & Pipe Supports

Helical piles are an ideal foundation solution for pipe racks, pipe supports and sleeper racks due to their ability to provide strong, vibration-resistant support in a wide range of soil conditions. Their fast, low-impact installation minimizes disturbance around sensitive infrastructure, and their precise load capacity ensures long-term stability for elevated piping systems, even in remote or constrained job sites.

2. Skidded Equipment

Helical piles are an excellent foundation choice for skidded equipment because they offer precise load support exactly where it’s needed, matching the concentrated points of skid-mounted systems. Their fast, low-impact installation is ideal for greenfield or brownfield sites, with no need for curing time, allowing equipment to be set immediately. Helical piles also perform reliably in a wide range of soil conditions, making them especially well-suited for remote or variable locations where traditional foundations may not be practical. The most common skidded equipment supported by helicals are vertical vessels like scrubbers, VRT, flares and horizontal vessels like separators, pumps, metering skids and launchers/receivers.

3. Control Buildings 

Helical piles are a great foundation solution for buildings in oil and gas facilities, such as MCC buildings. These structures often require stable, vibration-resistant foundations in challenging or remote soil conditions which is exactly where helicals excel. Their quick, low-footprint installation minimizes disruption to active sites and allows for immediate loading, which keeps fast-paced projects on schedule. Additionally, helical piles are ideal for modular or pre-fabricated buildings, as they can be precisely aligned with design loads and installed year-round with minimal crew and equipment.

4. Tank Foundations 

Above-ground storage tanks used for crude oil, natural gas, and refined products require strong foundation support to prevent settlement and structural failure. Helical piles help distribute weight evenly, ensuring stability in challenging soil conditions. Due to the minimal soil disturbance during installation, they are also ideal for supporting structures that are located on top of soils with contamination, minimizing negative environmental impacts.

5. Temporary Support Structures

Helical piles offer exceptional reusability for temporary structures, as they can be easily uninstalled and redeployed.This ability to remove and reuse the piles maximizes cost-efficiency and contributes to a more sustainable construction process. In contrast to traditional concrete pier foundations, which require extensive new materials for each installation, helical piles significantly reduce environmental impact.

Advantages of Helical Piles in Oil & Gas Applications

1. Rapid Installation and Immediate Load-Bearing Capacity

Unlike traditional concrete deep foundation methods such as drilled shafts, helical piles do not require extensive excavation or curing time. They can be installed quickly using hydraulic drive motors, reducing project timelines.

2. Minimal Environmental Impact

Helical piles have one of the smallest environmental impacts compared to other foundations. The installation process generates minimal soil disturbance, reduces the need for excavation, and eliminates the use of concrete, which has a high carbon footprint. This makes them ideal for sensitive environments such as wetlands, permafrost, and protected ecosystems. Helicals can also be reused, further reducing their environmental footprint.

3. Safety

Helical pile foundations are a safer alternative to drilled concrete foundations due to their streamlined installation process. They require significantly less equipment and smaller crew sizes, which reduces the risk of accidents associated with heavy machinery and large-scale operations. Their speed of installation also means less time on site, minimizing exposure to potential jobsite hazards. By lowering manpower needs and shortening project durations, helical piles create a safer, more controlled work environment.

4. High Load Capacity and Stability

Helical piles are engineered to withstand heavy axial and lateral loads, making them suitable for oil and gas infrastructure that requires high stability. Their unique ability to resist uplift forces ensures long-term durability in highly variable soil conditions, even in seismic and high-wind environments.

5. Adaptability to Challenging Soil Conditions

Oil and gas projects often take place in geotechnically challenging locations. Helical piles can be installed in a variety of soil types, including loose sands, soft clays, expansive soils, and frozen ground, where traditional foundation solutions may struggle.

6. Cost-Effective Alternative to Traditional Foundations

By reducing labor, material costs, and construction time, helical piles offer a cost-effective solution compared to traditional deep foundation methods. Their reusability also makes them an attractive option for temporary structures and modular facilities.

Helical Pile Installation Process for Oil & Gas Projects

1. Site Assessment and Soil Testing: Engineers conduct geotechnical evaluations to determine the appropriate pile design and installation depth.
2. Pile Selection and Engineering Design: Helical piles are selected based on load requirements, soil conditions, and environmental factors.
3. Installation Using Hydraulic Equipment: Helical piles are rotated into the ground using torque-driven hydraulic motors, ensuring proper embedment.
4. Load Testing and Verification: Torque monitors are used during the installation process to confirm each pile meets the required load-bearing specifications.
5. Integration with structure: Once verified, helical piles are capped and then connected to the infrastructure, either through a bolted, welded or concrete cap connection.

Conclusion

Helical piles have become an indispensable foundation solution for oil and gas projects due to their efficiency, cost-effectiveness, and superior performance in highly variable soil conditions. Regardless of the equipment being supported, they offer unparalleled stability and adaptability to challenging environments.

By leveraging helical pile technology, oil and gas companies can enhance the durability and safety of their infrastructure while minimizing environmental impact and reducing project costs. As the industry continues to evolve, helical piles will continue to gain acceptance as a preferred foundation choice for energy infrastructure.