The SFO Terminal 1C project was directed to meet the ambitious goals of enhancing guest experience. Foundation's scope in particular required supreme logistics management, large amounts of heavy equipment, and collaboration among all stakeholders.

The Project:

Foundation worked with the SFO Airport to install nearly 2,500 Tubex Grout Injection Piles ranging in length from 80’ to 120’.  Foundation managed all scopes, including deep foundations, shoring, excavation, waterproofing, and structural concrete.  From the beginning, Foundation was involved throughout the long lead time of two years, providing expertise in design through indicator and physical load testing.

  • 2,500 Tubex Grout Injection Piles
  • Up to 5 Drill Rig Operations

Aggressive Schedule:

Foundation performed two separate contracts simultaneously within Terminal 1 involving separate schedules.  In order to ensure productivity was met logistics management was critical, which included the delivery of steel and concrete.   As a result of the limited amount of space and time allocated and planned for each location on the site, it added more complexity.  Because of this, the team worked an accelerated schedule and completed a difficult sequence of work in each construction phase.  At one point, Foundation operated 5 drill rigs and 1 ABI rig running concurrently to meet the needs of the project schedule.

Managing Multiple Stakeholders:

The project involved coordinating with authorities with jurisdiction, as well as working around TSA and Homeland Security to the location within the terminal.  Foundation field supervision developed a channel of open communication to maintain instant accessibility and responsiveness to other trades working on-site.

Challenging Soil Conditions:

Like other sites in the Bay Area, the undocumented fill, bay mud, and a varying competent layer created the need for flexible installation techniques.  For example, the team encountered different footings approximately 50 feet apart due to undulating bedrock levels.  For this reason, the team retained a close relationship with Geotechnical and Structural Engineers.

Because of the inconsistency in pile lengths, length of pipe, rebar cages, and splices to maximize material, planning grout volumes all became a complex moving puzzle.  As a result, it required tremendous flexibility and creativity to balance production rates and cost impacts to find the best value.