Thank you for getting in touch!
Our team will review your message and respond promptly. If you need to get in touch immediately, please call our office at (281) 825-2221
Helical Piers for BESS: The Modern Foundation Solution for Battery Energy Storage Systems
This unique foundation solution can be installed over 75% faster than concrete, uses over 90% less raw material, and could slash construction-related emissions by more than 95%. Here's what you need to know.
Table of Contents
1) Introduction
2) Five Key Challenges in Energy Storage Construction
3) What Are Helical Piers? (A Brief Explanation)
4) How Does a Helical Foundation Work?
5) Proving Helical Pier Capacity: The Torque-to-Capacity Correlation
6) How to Install a Helical Pier Foundation
6.1) Design, Engineering, Planning
6.2) Helical Pier Installation (Step-by-Step)
7) Why Use Helical Foundations for Energy Storage? (Key Benefits)
8) Commonly Asked Questions About Helical Piers & BESS Construction
9) Conclusion: The Best Foundation for Your BESS Units
Introduction
Despite some of the recent uncertainty regarding the renewable energy industry here in the United States, it's still safe to say this market is only set to grow.
According to the U.S. Energy Information Administration, utility-scale energy storage is expected to reach 65 GW by 2027. That's more than double the current capacity of 28 GW at the end of Q1 2025. Clearly, despite some headwinds over the past year, the market is thriving and demand remains high.
In the midst of this rush to build-more utility-scale battery capacity, there's a problem that's become increasingly evident:
Building all this infrastructure at such a fast pace is... pretty darn difficult.
So, one of the critical questions the industry needs to answer right now is this...
How can we build BESS capacity faster?
One of the key places that's ripe for improving timelines and de-risking project is in the foundation phase. Traditionally, foundation construction has been one of the primary sources of cost overruns, delays, and frustrations for contractors.
But - what if you could eliminate those challenges and have your foundation installed in a fraction of the time?
Helical pier foundations have grown rapidly in the energy storage industry over the past few years. This nearly 200 year-old technology has emerged as an extremely rapid and sturdy support - even in weak or challenging soils.
Unfortunately, there's many who aren't aware of the potential helical foundations offer for their projects. Which is why we wanted to write this comprehensive guide that takes a complete look at:
By the end, you’ll have a clear understanding of why this foundation solution is gaining rapid ground in renewable energy projects - and how it can transform the way you build.
Five Key Challenges in Energy Storage Construction
Before we get into explaining what helical piers are and how they work for BESS construction, it's worth covering some of the primary challenges the industry faces. No doubt you're aware of these, and maybe feel them on a daily basis, but it sets the stage for understanding the benefits of helical foundations.
1: Extreme Static Loads
BESS containers are densely packed with batteries, making them extremely dense and heavy structures. Take this 5 mWh unit from the company e-Storage, for example. Manufactured in a 20ft. container it weighs in at a hefty 94,800 lbs., a demanding load that requires a supremely strong foundation.
2: Aggressive Project Timelines
Going from bare-ground to grid-connected as quick as possible is crucial in the time-crunched energy storage construction industry. The sector is moving fast, and builders are expected to keep up. Traditional concrete installation and curing can be a major bottleneck.
3: Challenging Site Conditions
Many energy storage sites are co-located with wind and solar farms. These are typically located in relatively remote locations and can suffer from weak, non-cohesive, or expansive soils. While poor soils can be overcome with concrete foundations, they will negatively impact timelines and costs.
4: Environmental & Site Impact
Performing large-scale excavation and drilling for concrete foundations is highly disruptive and creates soil spoils, while increasing carbon footprints due to the large number of machines. Concrete production is also associated with high emissions.
5: Scalability & Future-Proofing
As energy demands grow, BESS sites need to expand alongside them. It's likely that in the future there will be a need to build additional energy storage units to boost capacity. A poured concrete foundation can be difficult to build around, making future expansion more complex and costly.
What Are Helical Piers? (A Brief Explanation)
For a technology that's gaining big popularity in many American construction sectors, there's still many who aren't familiar with it yet. That's not a dig at anyone, the reality is engineering courses and schools have been slow to incorporate them into textbooks.
Thankfully this is beginning to change, but if you're only aware of helical foundations on a surface level, what follows is a more detailed introduction to the technology.
Heck, even if you do know about helical piers you may still find some interesting (and useful) nuggets. Skip this section if you want, but we think it's worth a read.
To start with, let's give a quick run-down on exactly how helical piers function.
How Does a Helical Foundation Work?
A helical pier foundation is comprised of a central steel shaft, with one (or more) helical-shaped plates (helix plates) welded towards the bottom. The pier shaft is typically round pipe, but solid square shafts are also available depending on the application.
This design allows a helical pier to be "screwed" into the ground, hence their original name of 'screw pile'. In fact, some places (particularly Canada and the U.K.) still call them by that name. Here in America, the terms helical pier or helical pile are generally more common.
Helical piers are a type of deep end-bearing displacement foundation. As they rotate into the ground, surrounding soil is displaced and compacted. That means very little, if any, spoils are generated by a helical pier installation.
Like any deep foundation, the idea is to reach firm and supportive soil layers. Unlike other deep foundations however, the unique installation method of a helical pier allows us to do some very cool things with torque.
As a helical pier advances through the soil, it experiences pressure from surrounding material - particularly on the helix plates. The force of this soil pressure helps anchor a helical pier in the ground.
Because we install helical piers by rotating them into the ground, we can read that rotational force as torque. This torque, in turn, can both provide real-time quality control and also indicate ultimate pile capacity. Here's how it works...
Proving Helical Pier Capacity: The Torque-to-Capacity Correlation
By monitoring the torque we're exerting on a helical pier, we can assess how the installation is going. Not only that, but we can use torque to calculate how much ultimate load capacity the pier should have.
Thanks to an empirical relationship discovered by several different researchers over many years of study, we can use the following equation to correlate torque to capacity:
Qu = Kt * T
Where:
Torque factors are generally established by helical pier manufacturers and will change along with their design. For the sake of example, let's say you have a helical pier with a Kt of 8 ft-1, and it's been installed to 10,000 ft-lbs of torque. Your equation would look like this:
Qu = 8 * 10000 = 80,000 lbs (80 kips)
Don't forget a 2.0 safety factor:
80000 / 2 = 40,000 lbs (40 kips)
So, our example pier would be able to hold an ultimate capacity of 40 kips based on that calculation. Since we determine the correct torque figures in advance, we can monitor this figure and determine when each pier has been installed to specification.
Now, there is a caveat here. This calculation does not replace a full-scale load test when it comes to 100% confirming the performance of a helical pier.
What it does do, however, is allow us to monitor a pier installation and identify if we're running into unexpected soil conditions. It also enables our field crews to assess when a given pier has been installed correctly.
It's also worth noting that this calculation is not the only torque-to-capacity correlation which exists. But, since it's the most straightforward, we thought it was the best one to highlight. Point is, helical piers can do something that virtually no other foundation can: provide immediate confidence in the install.
Speaking of installing helical piers, what does the actual foundation process look like? Let's break it down.
How to Install a Helical Pier Foundation
Installing a helical pier foundation is a straightforward process with surprisingly few steps involved compared to other options. For the purposes of explanation, we'll break it down into two main phases: design and installation.
1: Design, Engineering, Planning
Before we start putting steel in the ground, like any foundation, there needs to be a solid design and plan. The first step is to perform a thorough soil investigation at your build site. A quality geotechnical report is hugely important for our team to determine the best approach for your project.
For instance, if your geotech indicates generally dense soils to 40 feet, we'd use a different approach than if you had loose soils to the same depth. Considering that BESS units can be extremely heavy, it's worth taking the time to do this phase right.
This is also where we'll figure out how many piers you'll need, again using that soil investigation as the base. And of course, the type of battery storage units you're building will also play a key role in foundation design.
In any case, once there's an efficient and engineered plan, we can can move on to mobilization and installation.
2: Helical Pier Installation (Step-by-Step)
Mobilization
This is an easy and smooth process with helical piers, as we don't need large numbers of machines or equipment. In most cases, we'll use an excavator for installation and a skidsteer to move piers around the site.
Since helical foundations require significantly less raw material than concrete, there's no need for extensive lay-down and staging space. This expedites and simplifies mobilization, while keeping your jobsite free of extra equipment and materials.Site Prep
Generally speaking, there's not much site prep required for a helical pier install. As there's no excavation of formwork required, odds are the prep you've already done for the BESS units will be more than enough to get the piers installed as well. Of course the pier locations must be properly marked and visible, but beyond that there isn't a whole lot to worry about.
Installation
Using purpose-built hydraulic gear motors (helical anchor drives), we rotate each pier into the ground at a specific RPM. Depending on the foundation specifications, we may "float" the piers in the soil or install them all the way to bedrock. Constant torque monitoring ensures a quality result and allows for quick responses to surprise conditions.
Pier Caps
After the piers are in the ground, caps can be placed on-top for an easy transition to the BESS units. There's a wide range of cap designs and configurations, but when it comes to energy storage a straightforward flat plate is a common solution. These can either be bolted or welded to the pier, per your preference or requirement.
Load Testing
You may also choose to have a certain number of your piers load-tested to 100% confirm their performance. This does add a bit of time to the foundation phase, but overall it's a fairly quick and simple process. Plus, you get the peace-of-mind that comes with complete confidence in your project's support.
By slashing time, equipment, and labor, a helical foundation streamlines projects and expedites timelines - an important consideration in the high-demand world of BESS construction.
Why Use Helical Foundations for Energy Storage? (Key Benefits)
Fast Install, Immediate Loading
You can have your helical foundation installed and be setting units on it in the same day - no cure time required. In one project our S&B Helical team worked on, we were installed piers at a rate of 90 to 100 per day. By properly staging the installation, the electrical contractors were able to wire units while we set up piers for the next step.
Oh, and we'd be remiss if we didn't mention the weather. Concrete is dependant on having good weather conditions, things like heavy rains or cold temperatures can cause complications and delays. Helical piers? They don't care about the weather. Wet, dry, hot, cold, there's very little that can slow them down.Verified Capacity
For the most part, concrete foundations are assessed on an assumed capacity. Yes, you can load test them, but there's no way to verify if each concrete foundation element has been installed correctly. You, essentially, have to base it on faith.
As we've seen in this article, helical piers don't require any faith. Thanks to our torque correlations, we can provide real-time quality control and performance verification during the install. If a pier hasn't reached the appropriate specifications, we'll be able to respond immediately. It's a data-driven foundation.High Performance in Poor Soils
There's no shortage of challenging soil conditions in the United States. Depending on your site, you may face anything from firm clay to weak organic material. Uncompacted fill can also be a problem, as it will be prone to settlement which can negatively impact other foundation solutions.
Helical piers can simply by-pass these aggravating soils to anchor in quality stratum that will provide the best support. Thanks to their unique helix-plate design, they can deliver surprising load capacities even when they anchor in less-than-desirable soil layers. This makes them ideal for locations with high water tables, flood zones, or expansive soils.Minimal Site Impact
Think of a helical pier like a scalpel - it's a surgical approach to your foundation. Because they're a displacement foundation, you won't have any need for disruptive excavation or costly spoils management. In fact, besides the installed helical piers we leave behind, it might even be hard to notice we were even on your site.
Environmentally Friendly
It's no secret that concrete production has a big impact on the environment. The more you use on your project, the higher the emissions cost. In a world where the pressure to reduce emissions is immense, switching to helical piles can actually cut your project's CO2 emissions by more than 90%.
The reason for this is because helical piers use far less raw material to provide the same support as concrete. While there is, of course, a CO2 cost to steel production. But the fact we're using comparatively little steel helps control the environmental impact. Plus, helical piers can even be removed and 100% recycled someday - making remediation more cost-effective.Less Risk
In any construction project, there's inherent risks to your budget and schedule. If your foundation install is delayed by a week, for example, it will cause knock-on affects that impact every other phase. Not only is this a headache, it can lead to even more delays if you have to re-jig subcontractor schedules.
Beyond the time implications, there's also cost-related risks to consider as well. Generally speaking, unless the project scope undergoes revisions, helical piers are much less prone to change orders. This increased cost certainty isn't just better for your budget - it keeps the project owner happy too.
Helical pier address a wide range of challenges that are inherent to the foundation phase. Quick installs, high performance, verifiable capacity, increased cost certainty, less environmental impact... they represent an entirely different way to support your project.
Commonly Asked Questions About Helical Piers & BESS Construction
Can helical pier foundations really support heavy battery units?
As you can probably guess at this point, the answer is absolutely. Helical piers are more than capable of handling heavy loads. In fact, depending on their design and the soil conditions, a single pier can support over 100,000 lbs. More than enough for even the most demanding BESS units. The best proof of their performance is the fact that large-scale BESS installation across America are sitting on them right now.
What sorts of soil conditions can helical piers be used in?
Helical piers can be used in a wide range of soil conditions, from dense clay to silty sand. So, an easier way to answer this question is to note the soils where helical piers may not be the best fit. These are:● Extremely dense soils which the piers cannot advance through● Densely cobbled soils or those with numerous large rocks● Soils with shallow bedrock that would prevent appropriate pier embedment
Essentially, any soil that prevents the pier from advancing to an appropriate depth will likely not be suitable. In those cases, another foundation solution will be required. Outside of those soils, the odds are good a helical pier foundation will work.Are helical piers more expensive than other foundation options?
While the "face-value" cost of helical piers can be more than other solutions, it's important to look beyond that factor. Like you've seen in this article, helical piers offer a significantly faster and more streamlined installation process. They minimize site prep, require no excavation, and be installed in remote or challenging locations. These factors help de-risk your project and allow you to start build much sooner (i.e. immediately after install).
So, if you consider the cost of a helical foundation on the whole, you'll find they're a more economical option overall when compared to typical options like concrete. Plus, their long lifespan and zero-maintenance nature add up to cost savings over the lifespan of the BESS installation.Are helical piers approved by building codes, and is it hard to get them approved?
Yes, helical piers are approved by national building codes. They're recognized as a valid, safe, and effective, foundation solution. As long as your have the correct documentation and engineering stamps, there should be no significant hurdles to clear in securing permits.
However, this is one area where an experienced helical foundation contractor can make a big difference. They'll have a deep understanding of how to navigate the permitting process, and be able to produce all the paperwork required.
Not only that, but a good helical contractor should also have engineering partners who understand the unique nature of the foundation. These factors go a long way to streamlining the permitting and approval process.How long can I expect a helical pier foundation to last under my project?
The longevity of your helical foundation will be, in part, determined by the nature of your soil conditions. In general, however, you can expect to achieve a minimum 75-year lifespan for galvanized helical piers in moderate soil conditions. That said, helical piers could last well over 100 years if installed in mild soils with low rates of corrosion.
In any case, the lifespan of your helical foundation will far outlast the expected service life of the BESS facility.
Conclusion: The Best Foundation for Your BESS Units
Helical foundations have proven themselves to be a game-changer for battery energy storage construction here in America. Their adaptability, speed of installation, cost efficiency, reduced environmental impact, and longevity, are making this technology a go-to solution for countless contractors.
But, are they the best foundation solution for your project?
You might expect us to say an unequivocal "yes" to that question - but reality is more nuanced.
Yes, helical foundations are an excellent solution for BESS projects. The benefits they offer can dramatically transform your entire construction process and change how you build.
However, that doesn't necessarily mean that a helical foundation is the best choice for every single BESS project. Whether or not it's the right choice for you comes down to factors like:
That's why it's important that you connect with a qualified and experienced helical foundation contractor early in your planning process. They can assess all those factors, and more, to help you determine the most efficient and effective approach. A good contractor will act as your foundation partner, helping you identify if helical piers truly are the most sound solution for your specific scenario.
So, we'll end this article with an invitation.
If you'd like to learn more about helical piers, and uncover what they could do for your project, get in touch with our team at S&B Helical. We've installed tens of thousands of helical piers across the United States - including for projects like large-scale BESS facilities.
We offer a complete suite of services that cover everything from design and engineering to procurement and installation. Think of us as your true foundation partner, here to help you achieve success and start building sooner on a lasting support.
And hey, if a helical foundation isn't the right fit for your project, we'll be honest about it.
Send a message or give us a call today using the contact information below - we look forward to hearing from you.
Contact The S&B Helical Team
Need a foundation estimate for your project? Looking for helical foundation design and engineering? Have a question about helical piers? We're here to help, get in touch.
Connect with us on LinkedIn