Beneath the Build: Ground Improvement Solution Beats the Clock on a Massive Distribution Center Project

When a major e-commerce retailer selected a nearly one-million-square-foot warehouse site in Little Rock, Arkansas, time was of the essence. The site was not the best and had very challenging soil conditions that need to be addressed quickly to keep the general contractor on schedule. In this episode of Beneath the Build, we show how ground improvement experts Geopier and Peterson Contractors stepped in with a solution that would ultimately beat the timeline and deliver long-term performance benefits.


The Challenge: Problematic Soils and a Tight Timeline
The selected site had three key geotechnical challenges:

1. Liquefaction Risk – Due to its location near the New Madrid Seismic Zone, the site faced seismic-induced settlement risks.
2. Excessive Settlement – The design called for 4 to 15 feet of new fill, raising concerns about differential and total settlement.
3. Building Loads – The massive footprint would introduce significant loads that the native soils couldn’t support without remediation.

To complicate matters, wetland permitting delays had already pushed construction back, forcing the building footprint to shift and design work to restart. Geopier was re-engaged to provide a reliable solution and fast.

The Solution: Geopier Impact® System
Geopier used its Impact® System, a rammed aggregate pier method tailored for sites with loose sands and soft clays. Compared to stone columns, another common ground improvement option, the Geopier solution required fewer elements due to its stiffer, more efficient design. That meant faster installation, reduced materials, and ultimately, lower cost.

In a design-build process, the Geopier team worked closely with Peterson Contractors and the general contractor Alston Construction to revise the layout, address the new seismic and settlement conditions and prepare for accelerated execution.

The Result: A Record-Setting Installation
Despite one of the wettest Arkansas summers on record, the team installed over 12,000 piers in just 53 days, a full week ahead of schedule. With up to four crews working simultaneously, the project hit peak production rates of 300–500 piers per day, setting internal records for Geopier and Peterson Contractors. Most importantly, the solution allowed other trades to begin work on time, keeping the overall construction timeline intact, which is no small feat for a build of this scale.


Why It Matters for Contractors

• Proven Performance: Geopier systems are rarely associated with post-construction settlement issues.
• Speed & Savings: Fewer elements and faster install times mean minimized project delays.
• Flexible Design: When schedules shift, the design-build model allows for quick pivots.

Whether it’s seismic risk, tight tolerances or schedule crunches, ground improvement isn’t just about what's beneath the surface, it’s about who you trust to solve the problem below. Learn more about all of Geopier solutions at geopier.com.

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