Using Continuous Flight Auger Pile Execution Energy to Enhance Reliability and Reduce Costs in Foundation Construction
Continuous flight auger piles (CFAPs) are highly versatile and productive deep foundation elements. Known for their execution speed, low noise, and minimal vibration, they are extensively used in Brazil, particularly for urban projects or environmentally sensitive areas. Technologically, they employ...
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| Main Authors: | , , , , , , |
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| Format: | Article |
| Language: | English |
| Published: |
MDPI AG
2025-06-01
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| Series: | Automation |
| Subjects: | |
| Online Access: | https://www.mdpi.com/2673-4052/6/2/24 |
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| Summary: | Continuous flight auger piles (CFAPs) are highly versatile and productive deep foundation elements. Known for their execution speed, low noise, and minimal vibration, they are extensively used in Brazil, particularly for urban projects or environmentally sensitive areas. Technologically, they employ a Real-Time Operation System (RTOS) to control the execution energy for each drilled pile. When used effectively, this energy-based monitoring system can provide information that replaces or correlates with other challenging-to-measure variables, accommodating the impact of various exogenous variables on a pile’s execution and performance. Foundation designers often define one or more characteristic lengths for different pile groups, considered representative for each group despite uncertainties and morphological changes along the terrain. Hence, considering an energy-based control, which enables an individual assessment for each pile, is beneficial given soil’s complexity, which can vary significantly even within a small area. By determining the optimal execution energy, individualized stopping criteria for piles can be established, directly influencing costs and productivity and enhancing reliability. The present paper proposes a methodological workflow to automate the necessary calculations for execution energies, correlate them with bearing capacities measured by load tests or estimated from standard soil surveys, and predict the execution energy and corresponding stopping criteria for the drilling depth of each pile. This study presents a case study to illustrate the methodology proposed, accounting for a real construction site with multiple piles. It shows that considering fixed-length piles may not favor safety, as the energy-based analysis revealed that some piles needed longer shafts. This study also shows that for the 316 CFAPs analyzed with depths ranging from 8 to 14 m, a total of 564 m of pile shafts was unnecessary (which accounted for more than 110 m<sup>3</sup> of concrete), indicating that cost optimization is possible. Overall, these analyses improve design safety and reliability while reducing execution costs. The results demonstrate that execution energy can serve as a proxy for subsurface resistance, correlating well with NSPT values and bearing capacity estimations. The methodology enables the individualized assessment of pile performance and reveal the potential for improving the reliability and cost-effectiveness of the geotechnical design process. |
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| ISSN: | 2673-4052 |