Secant Pile Solution

Project Overview

Stalworth Underground faced a complex challenge in the construction of secant piles for a project near Stoney Creek, a natural waterway in the southside Chicago suburbs. This excavation required a solution that combined precision and adaptability to achieve specific construction goals. The need for a slower early strength gain in concrete (critical for excavation flexibility) while maintaining traditional 28-day strength standards presented unique technical demands.

Ozinga provided the answer with CarbonSense® Cement, a specially developed solution that allowed Stalworth to gain the control and efficiency essential for success. Supported by Ozinga’s Product Implementation Specialists and research and development lab, the mix designs were carefully customized to meet the excavation timeline demands for primary and secondary secant piles.

About Secant Piles

Secant pile walls, a vital technique in excavation and construction, create overlapping concrete piles to provide strong lateral support while reducing groundwater infiltration. These walls are commonly used in projects requiring earth retention and water control, especially in urban environments or near significant water bodies like the Des Plaines River.

The construction process typically involves three steps:

1. Guide Wall Construction – Maintains the alignment and spacing of piles.
2. Drilling Primary Piles – Non-reinforced concrete piles are installed in alternating spaces.
3. Drilling Secondary Piles – These overlap with the primary piles while being reinforced for greater structural stability.

Solution Provided

To align with the project’s demands, Ozinga engineered a custom solution with CarbonSense® Cement. This advanced cement technology provided a delayed early strength gain, allowing Stalworth to excavate the site within 1-3 days after concrete placement.

By slowing strength development in the early days, CarbonSense® Cement gave Stalworth the flexibility to alternate between drilling primary and secondary piles according to the project’s timeline. This strategic delay not only met structural requirements but also optimized workflow, reducing unnecessary downtime between excavation phases.

Ozinga’s Product Implementation Specialists tailored the mix designs for the different types of secant piles. This customization ensured that material performance matched the unique needs of both the primary piles (designed for unreinforced use) and the secondary piles (requiring precise overlap and reinforcement for stability).

Key Features of the Solution

• Custom Strength Gain Profile: The concrete achieved slower initial strength gain, enabling excavation versatility without compromising long-term durability.
• Expert Mix Design Customization: Ozinga adjusted mix designs for primary and secondary piles to suit their specific roles in the secant wall.
• Efficient Workflow: Enhanced timing flexibility significantly reduced delays during installation.
• Sustainability: CarbonSense® Cement incorporates environmentally conscious materials, aligning with Ozinga’s commitment to sustainability.

Results and Benefits

1. Enhanced Construction Flexibility

The delayed strength gain of CarbonSense® Cement allowed Stalworth to pour and return to excavate within a flexible 1-3 day window. This provided a seamless workflow, saving time and reducing the risk of project delays.

2. Reliable Performance

Despite slower early strength development, the concrete reached the required 28-day strength, meeting industry standards for durability and structural integrity.

3. Streamlined Operations

By customizing the mix designs for primary and secondary piles, Stalworth was able to optimize daily operations and proceed with greater efficiency and confidence.

4. Positive Environmental Impact

CarbonSense® Cement’s sustainable formulation contributed to reduced environmental impact, an important consideration for both Ozinga and project stakeholders here.

Customer Testimonial

The success of the project drew high praise from Stalworth Underground. Mike Wallace, a project superintendent, expressed his satisfaction with both the innovative solution and its results.

“It would give us enough time to where we could pour a shaft, come back even a few days later, and the mix design did exactly what you guys said it was going to do,” said Mike Wallace. “This was a game changer for us on how we could handle this job. We felt so in control because of what the concrete could do.”

The confidence and control provided by this design featuring CarbonSense® Cement transformed the way Stalworth approached its secant pile projects, setting a new benchmark for efficiency and reliability.

Why Ozinga?

Ozinga’s expertise in designing innovative, sustainable material designs for different construction challenges makes them a trusted partner for high-stakes projects. With CarbonSense® Cement and a commitment to customized solutions, Ozinga demonstrates its focus on customer success, environmental responsibility, and technological advancement.

This successful project highlights how Ozinga’s innovative approach to concrete mixing, aided by CarbonSense® Cement, empowered Stalworth Underground to meet unique and challenging requirements. Through R&D expertise and a commitment to innovation and service, Ozinga not only provided a solution but also delivered a significant competitive advantage.

For more information on how Ozinga’s materials and expertise can enhance your next project, contact us today.