Essroc Facility

Location: Martinsburg, WV
Owner: ESSROC Cement Corp.
General Contractor: Brayman Construction Corp.
Value: $13.0 Million
Date Complete: September 2008

The ESSROC project is an example of the use of non-traditional applications and techniques designed and implemented for the effective installation of micropiles by combining low mobility grouting to achieve the desired design loads. Specifically, this project included the installation of over 1,600 micropiles (totaling over 93,000lf) through highly karstic limestone for the expansion of the existing cement plant. The micropiles were designed for 350-tons axial compression, 125-tons axial tension, and 15-tons lateral load capacity.

Throughout the course of the project, process adaptations to the normal installation of micropiles were necessary. Significant voids were encountered that required a grouting program to fill the voids and stabilize the free length of the micropiles. Numerous load tests were performed to verify the capacity of the micropiles in the rock and grouted zones of the project. Similarly, multiple drill rigs were used during the course of the work in order to facilitate the installation of the necessary micropiles and low mobility grouting.