Screw Pile Design

FLI is the largest UK manufacturer of high-capacity screw piles, with all design, manufacturing, installation and training capabilities in-house. 

Common pile specifications are available off-the-shelf and through our webstore, while bespoke solutions for anything from transmission pylons to domestic construction are developed for you by our engineers.

We stock standard Ø114mm and Ø193mm screw pile sections for rapid dispatch, with a wider range of diameters and bespoke options available to meet specific project demands. Single piles typically support overturning moments of around 100 kNm, while grouped configurations can be designed to carry much higher loads, exceeding 9000kNm, making them suitable for everything from small installations to critical national infrastructure.

FLI is the only UK company that can offer steel superstructure and screw piled foundation solutions on a turnkey basis and design them as a combined system.

Standard Screw Pile Range

*TM number refers to the nominal capacity of the motors in kNm. TM210, TM90 & some TM60 motors have dual torque modes, e.g. TM90 = 90kNm or 75kNm.

Smaller diameter piles can be installed with higher capacity motors if pressure is limited. FLI should be consulted in the event.
Larger diameter piles can be installed with smaller capacity motors if ground conditions are appropriate.
Adaptor plates can be used on DHAs for non-standard PCDs.

All our piles are compatible with FLI's Patent Pending 'Pile Cap Fixing' solution.
Secondary fixings give additional capacity and safety to the crucial Pile to Structure interface whilst maintaining piling tolerances.

FLI Interface Grillages

Steel interface grillages connect the top of the pile to the base of the structure.  They can also support associated infrastructure, such as cabinets or staging.

FLI has a range of standard grillage designs to support lattice towers, monopoles, railway and highways signals and platforms.  FLI’s steel grillages are narrower than their equivalent in mass concrete, so foundations can usually be accommodated within tight spaces or existing site boundaries.

• Steel interface grillages for lattice towers, monopoles, and gantries.
• Bespoke base plates for modular cabins, REBs, and platforms.
• Integrated cable management options.
• Adjustable grillages to bridge buried services.
• Grillages are designed to accept the standard piling tolerance of ±75mm, so there is seldom a need to survey positions and modify the superstructure to suit the as-built locations.

Whether you need a single lightweight pile or a large-diameter group foundation, our range offers versatility and proven performance.

FLI Fabrication

All our manufacturing is in-house, with the production lines for foundations next to the production lines for the structures they will carry. FLI’s 3500m2 fabrication facility is on the same site as the design engineers and project managers. This shortens the supply chain, reducing delivery times and enabling fast and efficient responses to variations arising during programme delivery.

Quality

FLI’s welding personnel are all fully qualified to ISO 9606 and work according to weld procedures ISO 15614, with welder management certified and audited by Lloyds to BS EN 3834. FLI is a Fit 4 Nuclear certified steelwork fabricator, approved to BS EN 1090, Execution Class 4.

Screw Pile Installation: Fast, Low-Impact, and Reliable

Our screw piles are designed for rapid deployment with minimal ground disturbance. The foundations are installed using a crew of four. A torque motor is mounted to standard wheeled or tracked excavators or Road-Rail Vehicles, or to hand-held equipment for smaller applications. No piling mats or heavy plant are required, reducing cost and site disruption.

There is no excavation, cart away, steel fixing, concrete pouring or waiting for cube test results. The environmental impact of the installation is low, with minimal ground disturbance, noise or vibration and no chemicals. The superstructure can be fitted immediately after the piles are installed. Each screw pile is typically installed in less than half an hour (depth dependent), so often the piles and a superstructure can be installed in a single shift.

Piles can be installed between protected tree roots, rather than removing them. They offer an ideal foundation solution for installations close to historic structures, green spaces or forests. The solution can bridge existing services or infrastructure to avoid relocation or diversion costs and disruption.

Screw piles give torque readings during the installation process, validating the design torques whilst they are being installed. Simple testing is also possible for added assurance.

Installation Teams

FLI has in-house teams of installers, ensuring every foundation is installed correctly. We also work with a partner company trained to FLI standards, providing additional capacity and flexibility on larger projects. All teams are experienced in sensitive environments and adhere to best practice safety and quality protocols.

Testing & Validation

• Real-time torque monitoring during installation ensures correct load capacity
• Tension, compression, and lateral load tests available on site
• Sacrificial piles can be tested to failure for additional assurance
• Pile-by-pile records provide full QA traceability

Screw Pile Training Courses

FLI provide Screw Pile training courses to upskill your workforce, enabling you to install yourselves. Training courses are typically held at FLI’s facility in Gloucester.  Training at your location is also possible.  The syllabus includes theory and practical sessions, ending with a test of understanding. After achieving the pass mark, FLI will issue a certificate which is valid for 2 years and can be extended with onsite audits or refreshers of your site teams during an actual installation.

Torque Motor Hire

FLI has a wide range of torque motors, used by in-house installers and available to hire.

Talk to our Project Managers

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