Henny Penny Expansion

This project presented some compounding challenges, mainly supporting high column loads (up to 1600 kips) and slab loads on a site with extensive soft undocumented fill and native soils. Additionally, the foundation sizes were large due to the heavy loads and relatively low bearing capacity. Portions of the expansion also necessitated supporting semi-truck vehicular traffic for interior loading/unloading.

The subsurface conditions generally consisted of undocumented mixed fill containing silt, clay, sand, gravel, and concrete debris from a demolished building that previously existed at the site to approximate depths of 4 to 8 ft below the existing grade.  The undocumented fill was underlain by soft to stiff native brown silty clay with SPT blow counts varying from 2 to 23.  The above materials were underlain by silty sand and stiffer gray till to the depths of the borings.

Due to high demand for their products, Henny Penny needed to expand their engineering and production facilities as quickly as possible which meant constructing foundations during the winter season.  The earthwork option was eliminated due to the high cost and inability to meet the project schedule.  Drilled concrete piers were evaluated, but ultimately eliminated due to high costs.  Geopier installations took place from mid-December through the end of January, with over 1,400 GP3® piers installed during 15 working days.