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To cite this article: Amy B. Cerato & Rory Victor (2008) Effects of Helical Anchor Geometry
on Long-Term Performance of Small Wind Tower Foundations Subject to Dynamic Loads, DFI
Journal - The Journal of the Deep Foundations Institute, 2:1, 30-41, DOI: 10.1179/dfi.2008.004
Article views: 26
The application of this study is to use helical anchors as a foundation system for small wind
tower (1 – 10 kW) guyed cables. Helical anchors are currently used to anchor guyed cables of
telecommunication and electric towers. However, the increased dynamic vibrations a wind turbine
adds to the tower and foundation system under working loads, as well as extreme environmental
conditions (e.g., straight line winds, ice load or sudden furling shocks), require additional knowledge
about the behavior of helical anchors. These field conditions were simulated in this study by
instrumenting a working tower with load cells and 3-axis accelerometers to gather data on wind speed
and tower response. These tower responses were then transmitted to the helical anchors through an
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extensive, large-scale testing program that included monitoring the performance of the helical anchor
foundation under dynamic loads, subject to natural variations in both wind regimes, precipitation
(water level) and variations in helical anchor geometry. This paper specifically discusses the effects of
helical anchor geometry on helical anchor performance under long-term dynamic loads.
predict the uplift capacity, which can be time the trailing helix bears on the soil affected by
consuming and expensive. Even with some prior the installation of both the lead and trailing
knowledge of soil properties, site conditions helices (Hargrave and Thorsten 1992). Torque
may be highly variable and one soil boring measurements taken during installation
within the tower construction site may not indicate soil strength (Perko 2000). However,
capture all of the subsurface heterogeneity. For the torque versus capacity relationship may not
uplift capacity in sand, the friction angle and be valid where the lead plate encounters hard
uplift coefficient of lateral earth pressure are material, which is known as refusal condition.
needed. For clay, the required parameters are Most manufacturers agree that torque/uplift
undrained shear strength and adhesion (Mitsch capacity correlations are not valid where the top
and Clemence 1985; Mooney et al. 1985). helix is less than 5 diameters below the surface
A less intensive empirical method that relates (Pack 2000). The torque correlation method
the installation torque to a predicted load was developed empirically, and even though
capacity in both tension and compression could it is widely used, it lacks explicit definition in
supply a “quick and clean” method to predict geotechnical concepts.
uplift capacity of helical anchors. Hoyt and Hoyt and Clemence (1989) concluded that all
Clemence (1989) analyzed 91 uplift load tests at three methods, cylindrical shear, individual
24 different sites within various soil types (i.e. bearing and torque correlation, exhibit over-
sand, silt, and clay soils) in short term loading predictions and a factor of safety should be
conditions. Their findings demonstrated that the used. The torque correlation method yielded
consistency of the torque correlation modeling more consistent results for uplift capacity,
fared better when compared to the load capacity which may be due to the elimination of several
models of cylindrical shear and individual variables including soil test data, spatial
bearing. This is probably due to the fact that variation in the soil properties between anchor
torque is taken at every anchor location, but and soil boring locations, or changes in soil
the analytical models rely on location specific properties over a testing period that play a
data (bore holes), of which there are fewer. The major factor in the cylindrical and individual
proposed formula from Hoyt and Clemence bearing method. Hoyt and Clemence (1989)
relates the ultimate uplift capacity of the helical suggest that the torque correlation be used as a
anchor to its installation torque: boundary check for the other two methods.
Qult = Kt x T (1)
Tower Monitoring
Where:
Qult = Ultimate uplift capacity [kN (lb)] A 30.5 m (100 ft) pole tower with a 10-kW
Kt = Empirical torque factor [m-1 (ft-1)] turbine located at Bergey Windpower Inc.,
T = Average installation torque [kN-m (lb-ft)] Norman, OK, was instrumented to determine
100 Hz triaxial accelerometer attached on a The anchor test site was located directly
harness (Fig. 1c). Each guy cable is pre-loaded east of the University of Oklahoma–Norman
to 10% of the minimum breaking strength with Campus Fears Structural Engineering Lab,
a come-along and re-tensioned as necessary on south campus. Anchors were installed
as the tower and foundation adjust to wind about 4.6 m (15 ft) on-center to eliminate
loads and site-specific soil conditions. The data any possibility of soil interaction between
collector was a SOMAT eDAQ system, which is adjacent anchors. The typical default
a robust system that collects a wide range of minimum spacing between adjacent anchors
signal types. The eDAQ system was housed in a is 5D of the largest helix, but not less than
waterproof gang box on a 1.2 X 1.8 m (4 X 6 ft) 1.5 m (5 ft). The soil profile of the site was
metal trailer and powered by two, deep cycle determined using several hand auger borings,
marine 12-V batteries connected in parallel. existing soil maps, and previous explorations
These batteries have diodes attached allowing of the site. Table 1 presents a summary of
the power to only flow one way and keeping the soil properties which are displayed as a
each battery from “sloshing” power back and generalized cross section in Fig. 2. It should
forth. These batteries are continually recharged be noted that the subsurface was more variable
by one 80-Watt Siemens solar panel. This data than what is shown here based in the torque
acquisition system is completely “off-grid” and readings at each anchor location, however it
works as a wireless network hub so that data was difficult to display the pockets of soil that
can be accessed and downloaded remotely over did not extend longitudinally and latitudinally
the internet (Fig. 1d). throughout the profile.
a) b) c) d)
[FIG. 1: a: 24.4 m 10 kW BWC Tilt-Up Pole Tower and Turbine, b. 4 Strain Gauges Configured as a Full-Bridge Load Cell, c. 3-Axis
Accelerometer on Upper Guy Cable, d. Solar Powered Data Acquisition Rig shown Collecting Data.
Friction Angle
Depth Layer Specific USCS / Undrained
(m) # PL LL PI Activity Gravity Symbol Shear Strengh Group Name
0 – .91 1 20.0 49.0 29.0 0.9 2.7 CL 57.9 kPa Lean Clay with Sand
0.91-2.1 2 17.0 33.3 16.3 0.7 2.7 CL 57.9 kPa Sandy Lean Clay
2.1-4.6 3 NP NP NP NP 2.7 SM 35° Poorly Graded Sand
4.6-6.7 4 20.0 26.0 6.0 0.4 2.7 CL-ML - Silty Clay with Sand
6.7-7.6 5 NP NP NP NP - - - Weathered Shale
Fig. 2 also shows the helical anchor locations screwed into the earth with a high-torque
in relationship to each other and the soil hydraulic torque motor which was mounted on
profile. The water table depth was taken from a, Bobcat®, skid steer loader equipped with an
a previously installed well near the testing in-line torque-monitoring device (Fig. 3).
site. The average depth of the water table The helical anchors installed were 4.44 cm
from March 16, 2007 to March 24, 2008 was (1.75 in) square shaft anchors supplied by
approximately 2.1 m (6.9 ft). The lowest and Hubbell Power Systems/Chance. The torque
highest water table recorded at the site during rating for this particular series of helical
the same time period was 4.48 m (14.7 ft) anchors is 14.9 kN-m (11,000 ft-lb) and the
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(March 16, 2007) and 0.61 m (2 ft) (July 16, ultimate tension capacity limit (using the Q
2007), respectively. = KtT with Kt = 33 m-1 or 10 ft-1) is 489.5 kN
(110 kip). However, the
ultimate mechanical tensile
strength is limited by
the coupling to 444.8 kN
(100 kip). Fig. 4 displays
the 4-helix anchor
plate spacing and plate
diameters installed. The
helical plate spacing and
diameters decrease from
top to bottom and the
pitch remains constant at
each plate. The 3-helix and
2-helix configurations are
[Fig. 2] Foundation Soil Cross Section with Installed Anchors
identical to the 4-helix,
by just removing the top 1 and top 2 helices,
Anchor Installation respectively.
The six anchors were installed on August 8, Each anchor was installed to a depth that met
2007 when the water table was at 2.0 m (6.7 ft) the two-part criteria: (1) the top helix had to
below the ground surface. Each anchor was be at least 5D (D= diameter of top helix) below
b)
the ground surface and (2) the average torque
a)
in the final 1 m (3 ft) of installation must meet
or exceed the designated torque value for the
small wind tower application (4.33 kN-m or
3,200 ft-lb). Fig. 5 shows the installation torque
values with depth and Table 2 summarizes the
final depth of installation, average final torque,
depth to top helix and embedment (H/D or
depth of top plate/diameter of top plate) ratios.
The average final torque signifies the mean
value of the last three torque measurements.
[Fig. 3] (a) Installing anchor extension and recording torque
every foot with the in-line Hubbell Power Systems/Chance Installing anchors to the same depth was
Torque Indicator Device, (b) Installing lead-helix section with preferable for a more direct comparison,
the first helix already underground.
DFI JOURNAL Vol. 2 No. 1 November 2008 [33]
however, as can shafts experienced shaft twist. Hubbell Power
be seen in Fig. 2, Systems/Chance representatives noted that
paired anchors their anchor shafts can rotate 1.0 to 1.5 times
were not installed in a 1.5 m (5 ft) section with no compromise in
to the same depth, the rated strength of the shaft material.
within the same The data shown, generally, indicate as
soil layer. The installation depth increases torque increases
reason for this is due to the fact that densification and stresses
that the subsurface (horizontal/vertical) increase at greater
was variable depths, and there are more friction surfaces
enough across the as the anchor advances through the soil. The
site that target torque installation results show a relatively
torque values were homogeneous layer across the site to a
not achieved at the depth of approximately 2.1 m (6.9 ft) and a
same depths, even variable subsurface to the termination of the
with anchors of the installation (~7-7.6 m or 23-25 ft). A major
same geometry. indication bedrock was approaching at depths
[Fig. 4] 4-Helix Helical Anchor Limitations were of 7-7.6m (23-25 ft), are the noticeable peaks
Geometry
met in the field in the torque measurements. Anchors V3, V4,
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with anchors V3, V4, V7, and V8. Due to a and V7 experienced significant peaks as they
weak pocket in the subsurface, anchors V7 approached bedrock or the residual soils.
and V8 could not meet the target torque of The significant increase in torque at the final
4.33 kN-m (3200 ft-lb). Even after advancing depth was probably caused by the 0.2 m (8-in)
the anchors to 7.6 m (25 ft) and 7.0 m (23 ft) helix penetrating into the weathered shale.
(where shaft extension material availability This helix penetration was minimal, however,
became an issue), the anchors
only reached average torques
of 3.39 kN-m (2,500 ft-lb)
and 4.07 kN-m (3,000 ft-lb),
respectively. Although this
would be inadequate for use
as a foundation element for
a small wind turbine, the
capacities were still sufficient
for this study on anchor
performance. Anchors
V3 and V4 (both 3-helix)
encountered a hard/dense
layer during installation,
which is known as the refusal
condition. A drawback for
helical anchors in deep [Fig. 5] Installation Torque Plot, a. 2-Helix, b. 3-Helix and c. 4-Helix
foundation applications could
be the inability to penetrate hard layers (i.e., at 0.1-0.15 m (4-6 in), and the recommended
cobbles, dense glacial till, and gravels) due to minimum depth of penetration into a bearing
steel strength limitations (Robinson and Taylor layer to use for design is 3D. Therefore, the
1969; Adams and Klym 1971). Newer, larger final torque values of Anchors V3, V4 and V7
rigs and torque motors, however, can install were discarded, and the previous three torques
anchors in soils with Standard Penetration were used to calculate the effective average
Test (SPT) blow counts (N) of up to 80. An installation torque.
anchor’s ability to penetrate hard layers is site The geometry of helical anchors is considered
specific. Strengths calculated from torque an important factor in the uplift capacity of
correlation methods can be exaggerated when helical anchors; the shaft being square or
dense layers are encountered (Pack 2000). In round, the number of helical plates, pitch size,
the process of installing V3 and V4, the anchor diameter of plates, and spacing of plates has
[34] DFI JOURNAL Vol. 2 No. 1 November 2008
[Table 2] Anchor Installation Information
been considered by many researchers such depth for 2 consecutive readings below 4.3 m
as Ghaly et al. (1991), Mooney et al. (1985), (14 ft). It is standard practice that torques
and Rao and Prasad (1993) to predict uplift should remain constant or increase with depth
capacity. Hubbell Power Systems/Chance over the last 1 m (3 ft) of installation. Anchor
also has geometry stipulations that govern V5 should either have been stopped at 4.3 m
torque correlation factor, Kt, decisions. For (14 ft), or advanced to where there was 1 m
this project, all geometry parameters were (3 ft) of increasing torque readings in order
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identical, except for the number of helical to meet the installation standards of industry.
plates. In that way, the number of helices 4-helix anchors, like 3-helix anchors, were less
could be isolated from the other parameters sensitive to soil stratigraphy changes than the
that may affect performance. The 2-helix 2-helix anchors. A typical practice utilized
anchors (V6 and V7) show that the foundation in the field before anchors are installed for a
soil was variable and installation torque particular application is to use a single, twin or
measurements differed significantly from triple-helix anchor to probe the site to not only
2.1 to 3.0 m (6.9 to 9.8 ft). At 4.1 m (13.5 ft), determine stratigraphy based on the torque
the torques were relatively similar, but then profile, but to determine an adequate helical
Anchor V7 was advanced to a greater depth anchor configuration for that particular site.
and encountered a weak soil pocket at depth
Anchor uplift capacity depends on the soil
4.6 m (15 ft). Unfortunately, the torque
strength above each helix. If the top most helix
never recovered to the design specifications.
is located in a weaker bearing capacity layer
Only at 7.6 m (25 ft) did the torque jump
than the other helices, its contribution to the
to approximately 5.42 kN-m (4,000 ft-lb),
indicating that the lead helix had entered total uplift capacity could be significantly less
the weathered shale. However, this was not than the other helices. Referring to the torque
enough to increase the final three torque profiles, Fig. 5, it can be seen that anchors V4,
readings to meet the 4.33 kN-m (3,200 ft-lb) V5, V6, and V8 top helix was in the thick sand
requirement for the small wind tower. Anchor layer, V3 top helix rested in a weak silt layer
V7 should have been stopped at 4.6 m (15 ft) (shown by torque measurements), and V7 top
after the design torque had been met. helix was located directly above the weathered
shale (as shown in plot). Due to a variable cross
The 3-helix anchors experienced similar
section and weathering, the residual or silty soil
installation torques at consecutive installation
layer above the top helix may or may not have
depths, which shows that the soil profile
was relatively consistent laterally within the significantly contributed to the uplift capacity
4.6 meters (15.1 ft) of separation distance of the anchor.
between the two anchors. The 4-helix anchors
behaved similarly to about 3.0 m (9.8 ft) and Dynamic Testing
then diverged. A noticeable observation from Five anchors (V3, V4, V5, V6 and V8) were
V8’s installation was the constant torque dynamically loaded for 2 to 4 weeks, followed
measurements as the anchor advanced past by a post-dynamic static test. V7 was only
3.0 m (9.8 ft). This observation may signify that statically tested to have a comparison anchor to
this particular anchor hit a very large, soft soil V6 to show the effects of dynamic loading on
layer. It should also be noted that anchor V5 long-term uplift capacity, which is discussed in
experienced decreasing recorded torques with a companion paper (Cerato and Victor 2009).
displays the basic setup for the dynamic test. and extreme weather conditions (i.e. tornadoes,
wind gust, etc). Fig. 7 through Fig. 9 summarize
the dynamic test hourly over the testing period.
They also indicate the maximum design load
(FS = 2) of the guyed cables. The cyclic loading
was applied between 3 and 5 hertz in a
sustained-repeated loading (anchor was always
in tension of at least 4.45 kN or 1,000 lbs) and
data was acquired at a 50 hertz frequency.
Sustained-repeated loading was an important
[Fig. 6] Dynamic Loading Set-up principle in this research. Keeping the anchor
from going into compression was imperative for
Seating loads were applied to the anchor maintaining safety on-site and preserving the
ranging between 10 and 20% of its predicted cribbing configuration. Also, helical anchors
ultimate static uplift capacity based on the used for guyed cable foundation would never
torque correlation method. Once the cribbing experience compression loading. Due to the
and anchor displacement was sustained at immense data sets, hourly summarization was
an equilibrium bearing pressure (minimal used to adequately analyze the data.
settlement), testing loads were applied. A general behavior experienced by all anchors
All dynamic loads were applied in a sustained- was the significant movement during the
repeated loading condition (Clemence and seating load. The movement of most anchors
Smithling 1985). Testing procedures followed was about 1.3 to 2.5 cm (0.5 to 1 in), when a
the sustained-repeated loading pattern, seating loading was applied in a cyclic load
where the anchor remained in tension (8.89 kN arrangement from 8.89 to 17.79 kN (2,000
or 2000 lbs) throughout the entire testing to 4,000 lb) or less. This seating movement
period to simulate operating wind loads may have been the result of excessive soil
as experienced from a guyed wire anchor disturbance during installation, shaft alignment
foundation. Previous investigations at Bergey issues, et. al. Since all guy tower cables are
Windpower (Norman, OK) estimated that pre-loaded to 10% of the mean breaking
guyed wires connected to wind towers were cable strength, this seating movement can be
under constant tension of about 4.45 kN overcome. Also, if the wind were to die down,
(1,000 lbs), with vibrations in the 3 to 5 hertz or switch directions, the anchor could return
range depending on the wind intensity. Regular to its original position (settling ~2.5 cm or
operating loads on the anchor during testing 1 in) unless soil filled in the cavities below the
oscillated between 4.45 to 35.6 kN (1000 and helices. It was seen in the displacement versus
8000 lbs). Extreme wind-shock loadings were load results of both static unload-reload cycles
this point and then could not maintain the high was installed to a depth of 7.0 m (23 ft), but
loads, so started displacing. It is possible that a that had a consistent torque profile around
3- or 4- helix anchor at the same position in the 4.07 kN-m (3,000 ft-lb) for the last 3 m (10 ft) of
subsurface would not have broken through due installation, performed slightly worse than its
to spanning a wider bearing stratum, although 4-helix counterpart, V5 (6.51 kN-m or 4,800 ft-lb
this cannot be stated with certainty. installation torque) in terms of magnitude of
Another explanation may be that 2-helix displacement under similar loads. Again, V5
anchors do not have enough surface area torque readings decreased over the final 0.66 m
to dissipate the dynamic loads and are (2 ft), which does not conform to conventional
more susceptible to creep then 3- or 4-helix installation standards. The majority of the
anchors. More tests, however, would have anchor was located in the poorly graded sand
to be performed to confirm this, as only one, layer, with low soil strength above the top
2-helix dynamic test was performed in this helix. The leading helix did not encounter the
testing program. It also may be possible that weathered shale, but sat above in an extremely
dynamic loading applications require the use weak soil layer. If this type of geology was
of larger size helices, rather than additional encountered in an actual installation, the
helical plates, to minimize creep. For example, anchor would have had to be removed and a
instead of using a 31 to 39 mm
(8 to 10-in) double helix, a 47 to 55 mm
(12 to 14-in) helix may be needed to
minimize creep, which would be in
effect a “dynamic factor” added to the
existing design criterion for helical
anchors. However, installers prefer
to use an anchor where the lead helix
is small to help pull the anchor into
the ground, and a 0.3 m (1 ft) lead
helix is not a preferred lead helix size.
Therefore, it may be advisable to add
a third helix to the 31 to 39 mm (8
to 10-in) configuration to act as the
“dynamic factor,” instead of making
the double helix diameter larger. This
research program only worked with
anchors having various numbers
of helical plates, all at the same [Fig. 10] Summary of Upward Creep Performance under Dynamic Loading
then a 2-helix anchor may not be adequate is subjected to sustained dynamic loads. All
in preventing long term creep, even if it anchors showed movement during seating
is installed to the design torque with a loads which may necessitate a pre-loading cycle
FS = 2. 3- or 4- helix anchors installed to to seat the anchors and maximize anchor life
the design torque, below a fluctuating water and minimize long-term creep before guyed
table would help to minimize creep. cables are attached, however, movement of
this magnitude is not typical, and may indicate
Conclusions either a poor installation or slightly inclined
anchor. Additional anchors installed on the
An extensive field testing program was devised
same site and recently tested showed very little
to investigate the effects of helical anchor
movement under a seating load.
geometry on anchor performance subjected to
long-term dynamic loading for 1 – 10 kW wind
Acknowledgements
tower guyed cable foundations. A pre-existing
well was used to monitor water table levels This research project was funded by the
over the course of the testing program and 3 Oklahoma Center for the Advancement of
different geometries (e.g., 2-helix, 3-helix, and Science and Technology (OCAST), Proj. #
4-helix) were tested to observe the effects on AR062.007, and is a joint venture with Bergey
the uplift performance. From the results of this Windpower Company, Inc. The authors are
field case study, the optimum anchor geometry grateful for the time, support and material
to be used for dynamically loaded guyed cable donations from Hubbell Power Systems/Chance
foundations is the 3-helix geometry. The 4-helix Civil Construction. We would also like to thank
anchors did perform well, showing minimal our installers from Atlas Systems of Oklahoma,
creep under working and extreme loading Sam Lowry and Mike Schweighardt, and Michael
events. During installation, however, the Schmitz, Fears Structural Lab Supervisor and
addition of an extra helix did not proportionally Russell Buhler, Geotechnical Engineering
increase strength with increasing torque (site Undergraduate Researcher, for their technical
specific observation), which was probably due to assistance with this project.
the differences in soil bearing strengths at the
specific anchor locations. One would think that References
if the soil strengths had been consistent at each 1. Adams, J.I. and Klym, T.W. (1972). “A
anchor location, a torque increase would be Study of Anchors for Transmission Tower
expected when using a 4-helix anchor versus a Foundations,” Canadian Geotechnical
3- helix anchor. Therefore, the 3-helix geometry Journal, Vol. 9, No. 1, 89-104.
is the economical choice, since less material 2. Cerato, A.B. and Victor, R. (2009).
needs to be used for manufacturing and a “Effects of Long-Term Dynamic Loading
similar performance can be expected. and Fluctuating Water Table on Helical
[40] DFI JOURNAL Vol. 2 No. 1 November 2008
Anchor Performance for Small Wind 13. Rao, S. and Prasad, Y.V.S.N. (1993).
Tower Foundations”. paper accepted for “Estimation of Uplift Capacity of Helical
publication, ASCE Journal of Performance Anchors in Clays,” J. Geotechnical
for Constructed Facilities. Engineering, ASCE, Vol. 119, No. 2, 352-357.
3. Clemence, S.P. and Smithling, A.P. (1984).
“Dynamic Uplift Capacity of Helical Anchors
in Sand,” Proc., 4th Australia-New Zealand
Conference, Geomechanics, Vol. 1, 88-93.
4. Ghaly, A., Hanna, A., and Hanna, M. (1991).
“Installation Torque of Screw Anchors in
Dry Sand,” Soils and Foundations, Vol. 31,
No. 2, 77-92.
5. Hanna, T.H. and Moswae, M.J. (1981).
“Performance of Prestressed Anchors under
Slow Repeated Loadings,” Soil Mechanics
and Foundation Engineering, Vol. 2, 127–
133.
6. Hargrave, R.L. and Thorsten, R.E. (1992).
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