Reinforcing the Future of DC
December 17, 2024
Berkel & Company Contractors (Berkel) is spearheading the renovation and expansion of two historic buildings in Washington, D.C. The renovations aim to address a backlog of upgrades, comply with modern building codes, enhance security, and improve energy efficiency. As part of a broader effort to consolidate the agency's staff into a more efficient and modern workspace, the renovations began in 2021 and are expected to take several years to complete.
For this project, Berkel is focusing on several key aspects particularly the deep foundation work. This involves installing piles and other structural supports necessary for the new additions and underground levels. Utilizing a Comacchio MC8D and Comacchio MC4D articulated drill rigs rented from International Construction Equipment, Inc. (ICE®), Berkel's drilling experts installed 1,018 micropiles, with an average pile length of approximately 42' (Ft), totaling more than 33,000 linear feet of casing. Achieving an impressive average of 4-5 piles per day per rig. These micropiles are both temporary for shoring and part of the permanent foundation system.
The micropiles were drilled using 10.75" (in) O.D. casing with a 0.500" (in) wall thickness, all in 5-foot threaded sections of 80 ksi. Installation through overburden using rotary-percussion duplex drilling with internal air flush (Mincon spiral flush bit) was completed, as the casing and drill rod were advanced simultaneously to the rock refusal elevation while pumping air through the inner drill rod. Each pile had a 10-foot rock socket below the bottom of the casing, with threaded casing joints assembled by the rotary head of the drill rig.
Berkel's expertise in foundation and structural work is crucial for the successful completion of this complex renovation. Initially chosen to handle low headroom drilling conditions, most piles drilled had more headroom than anticipated. However, the equipment still needed to maneuver around very tight spaces, such as existing braces, columns, and building walls, and in some cases, had to be flown in and out of the excavation by the tower crane. The MC8D was used in most areas, while the MC4D was utilized where access was especially tight, as its power pack could be removed.
According to the Berkel project manager, drilling has been the easiest part of this job, with access and site logistics posing the biggest challenges, citing that the kinematics of both rigs were key, as they were versatile and powerful enough to maintain and exceed target production rates despite the project's challenging conditions. Throughout this undertaking, Berkel has been working closely with other contractors and architects to ensure that the structural components integrate seamlessly with the overall design and construction plans. This commitment to maintaining high safety and quality standards while ensuring compliance with federal regulations and building codes is something that Berkel is known for. Additionally, the entire Berkel team is focused on completing their portion of the project on schedule to avoid delays in the overall timeline.
ICE® is proud to have provided the equipment that played a crucial role in overcoming these challenges, providing time and cost savings. Excellent work, Berkel and Company, your skill and expertise to ensure the strength of this new foundation is indisputable. Bravo!
Learn more about Comacchio Drill Rigs or contact the ICE® Drilling Team
Media Contact-
Pollyanna Cunningham, MA, MBA
Vice President Marketing, Brand and Media Relations
Vice President IT and IT Comm
ICE® - International Construction Equipment, Inc
Office - 704-821-8200 Email - marketing@iceusa.com