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MAPEI Cementitous Mixing & Bagging Plant

Swedesboro, NJ

DESCRIPTION

MAPEI, headquartered in Italy, manufactures and distributes adhesives, sealants, and chemicals for the construction industry related to flooring and cementious surfaces throughout the world and has been increasing their United States presence since the early 2000’s. The products manufactured, stored in, and shipped from their facility in Swedesboro, NJ are primarily cement-based, requiring exterior storage silos and processing stacks. This project is an additional expansion of work previously completed and involves the installation of additional silos for materials storage adjacent to the existing warehouse and the recently constructed silo/processing facility.

CHALLENGES

The design of the foundation for the new silo structure needed to consider heavy loading of the new silo as well as  heavy surcharge loads associated with the recently constructed adjacent existing silos and processing structures in conjunction with minimizing possible surcharge impacts to the adjacent warehouse structure. Challenging soils included the presence of undocumented fill over 10 to 15-feet of compressible organic deposits (PEAT)  in the upper 20 feet of the soil profile immediately below the silo foundations.  In addition, site access was limited with the existing warehouse on one side and the existing processing stack on another side, 30 feet in height. Both facilities were required to remain in full operation for the duration of the construction activities, therefore minimizing size and amount of equipment was important for safety.

Figure 1 – Raft foundation stress diagram with pile locations (grey boxes).

SOLUTIONS

Due to the tight quarters for construction, heavy silo loads, adjacent preexisting silo loads, and the poor soil profile, Ductile Iron Piles (DIPs) provided the best solution.  The DIPs transferred the heavy silo loads through the PEAT while addressing the 2.7 kip per sf average contact pressure of the silo mat foundation (See figure 1).  DIPs made it possible to install deep foundations with conventional sized equipment, thereby not impacting current operations and maintaining maximum safety considerations. The finally installed solution utilized 54 DIP sections in 16, 65 feet long, 80-kip capacity piles distributed evenly over the footprint of the raft foundation. Due to the modular design of the DIPs solution, additional pile length was added to achieve set while minimizing waste and excess pile length. This solution saved time and money when compared to helical piles, while simplifying the structural design.

Figure 2 – Generalize soil profile

Owner

MAPEI - Chicago, IL

General Contractor

MAPEI - Fort Lauderdale, FL

Structural Engineer

BMH Systems - Quebec, Canada

Geotechnical Engineer

Earth Engineering Inc. - West Berlin, NJ

Product

Ductile Iron Pipe Piles (DIP’s)

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