foundation – piers

At about a week forms for the grade beams were stripped and the excavator came to fill around and over them. We ended up putting down about 40 tons of stone over the grade beams to provide a base for a cement slab for the garage/storage area.

The plans called for 19 12″x12″ concrete piers to support the main floor of the home. The concrete crew tied reinforcement to the dowels coming up from the grade beams, erected forms, and then we poured concrete again.

Pier reinforcement in process
Pier forms in process

Drawings showed 4 each 16″ long 3/4″ bolts at the top of each pier, at the corners of a square with 5″ sides. It was not clear to me how they were going to place these bolts, seemed like the plan was to just stick them in by hand after the concrete had been poured to the required elevation. That did not need like a great plan to me, so I did some poking around and found some adjustable anchor bolt jigs called AJ Speedsets. Concrete crew probably thought I was nuts, but I ordered these jigs and got the bolts (and nuts and washers) from Portland Bolt. I assembled the jigs and the crew tied them in to the pier reinforcement. Unfortunately they did not really keep an eye on centering as they poured the piers, but turned out that alignment of the bolts between piers was not super critical. Nuts were threaded on to the bolts and used to adjust 1/2″x11″x11″ steel plates on which the steel beams would rest (with an additional bearing plate that fit between the bolts). Then the space below the plates was filled with non-shrink grout. So after everything was together the bolts were no longer supporting anything, the steel beams were on plates that were on grout that was on the top of concrete piers.

AJ Speedset ready for installation, bolts 5″ apart, roughly 7″ bolt circle
Bolt assemblies embedded in tops of piers (made some plastic/tape covers to slow down corrosion)
Typical bearing plate with nuts below to adjust, W10x22 beam welded to plate
Forms at pier tops for non-shrink grout to fill space below steel plates
Grouted pier top, W10x30 on bearing plates

I am sure they are strong, but the piers came out a little rough. The sub offered to let me pay for rental and deposit of new forms, in hindsight perhaps should have done that. At some point will clean the piers up a bit, maybe grind them a bit and/or apply some stucco.

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