1. Lower Carbon Emissions
Concrete production is one of the largest sources of industrial CO2 emissions, responsible for 7-8% of global CO2 emissions annually. Much of this comes from the cement manufacturing process, which releases around 900 kg of CO2 per ton of cement.
In contrast, screw piles use no wet trades. By fabricating and installing screw piles, the overall carbon footprint of a foundation can be reduced by up to 70%, particularly when paired with in-house manufacturing and minimal transportation requirements.
2. Reduced Soil Disruption
Installing concrete foundations typically requires extensive excavation and soil removal, leading to disrupted soil ecosystems, increased erosion, and a heavy reliance on dump trucks to haul soil away. Each dump truck trip adds to emissions, with a single truck releasing about 1.2 kg of CO2 per mile travelled.
Screw piles (also known as helical piles), however, are installed directly into the ground with minimal soil disturbance and no cart away. They preserve the natural environment, maintain soil stability, and eliminate the need for extensive excavation or soil transport. This makes them ideal for environmentally sensitive and protected areas.
3. Energy-Efficient Installation
Concrete foundations often require heavy machinery, multiple labour-intensive processes, and long curing times. These processes increase both the energy use, and the time needed for construction. The production and curing of a single cubic meter of concrete consume about 2,775 MJ of energy.
In comparison, screw piles are quicker to install, requiring only lightweight machinery and no curing time. This reduces energy consumption during construction by up to 50%.
4. Customisability and Strength
Concrete foundations are poured into pre-set forms, limiting flexibility in design and adaptability should there be fit issues or modifications. Screw piles, on the other hand, can be customised and adapted to match the exact load requirements of your steel structure.
With FLI’s in-house fabrication capabilities, each screw pile can be designed to optimise strength while minimising material waste. Screw piles can handle substantial loads, with individual piles supporting typically 200 KN or more in tension or compression, depending on soil conditions.
5. Reusability and Waste Reduction
Concrete foundations are permanent and typically demolished at the end of a structure’s life, generating construction waste. Globally, the construction industry produces over 2 billion tons of waste annually, much of which comes from concrete. Concrete cannot be used in the same form. Even repurposing by crushing for aggregate takes significant energy.
Screw piles, however, are fully reusable. They can be removed and reinstalled in future projects or recycled as steel scrap, drastically reducing waste and promoting a circular construction process.
6. Adaptability to Site Conditions
Concrete foundations are often unsuitable or impractical in challenging soil or environmental conditions.
Screw piles excel in diverse conditions, including soft soils, high water tables, and uneven terrain. This adaptability reduces the need for additional materials, excavation, or site alterations, making them a more sustainable choice.
7. Cost Efficiency Over Time
While concrete foundations might seem cost-effective upfront, but the extra time on site increases the cost of prelims and the associated risk can also increase cost. Generally, most the risk is in the ground.
Also,their environmental and logistical challenges often lead to higher long-term costs. Concrete cracks and degrades over time, requiring repairs or replacements, which add to material waste and emissions.
Screw piles, however, offer long-term durability with minimal maintenance. Their reusability and adaptability ensure they remain cost-efficient and environmentally responsible throughout their lifecycle.
