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Energy piles in underpinning projects – through holes in load transfer

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Article in DFI Journal The Journal of the Deep Foundations Institute · March 2014
DOI: 10.1179/1937525514Y.0000000002

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Energy piles in underpinning projects – through
holes in load transfer structures
R. Lautkankare1, V. Sarola2 and H. Kanerva-Lehto*1
Energy piles are fairly new solutions and have gained significant traction around the globe. Since the
twenty-first century, geothermal energy collector pipes are being frequently installed, finding its most
common implementation in newly constructed buildings. Much less studied is the application of energy
piles in existing buildings and older constructions. The biggest challenge in the utilization of energy
micropiles in underpinning projects is related to the through holes for geothermal energy collector pipes in
the load transfer structures. In the FIN-C2M project (Case 2 Micropile Research Project in ISM
collaboration), several technical solutions were investigated to identify the most suitable options to
accommodate the utilization of energy micropiles with minimum interference of the load transfer
structures. At the moment there are 13 known load transfer structure cases and energy micropiles can be
used with nine of them. In general, they cannot be used with jet grouting. In five of the studied cases, the
through holes for the collector pipes can be constructed as found in new buildings. In the other four
cases, where pretensioning is achieved by jacking directly above the micropile, the construction of
through holes requires further development, for which limited suggestions exist, however; the challenge is
to bypass the jack. This paper will present all nine cases along with construction details and
recommendations for the utilization of energy micropiles in existing buildings.
Keywords: Energy pile, Underpinning, Load transfer structure

Introduction completed soon. These include shopping mall Puuvilla

Thermo-active foundations are foundations that also
work as heat exchangers. The principle advantage of
energy foundations such as energy piles, energy tunnels,
energy wells or basement walls is that the ground heat
exchanger is already required for structural purposes
(Brandl, 2006).
The use of deep foundations for ground heat recovery is
relatively new. The first projects where openings in the pile
casing were used for heat exchange piping are from the early
twenty-first century. Research on energy piles was not
started until the late 1990s either. (Bourne-Webb et al., 2009;
Ma and Grabe, 2009) So far all the projects have been large
new constructions where the load-bearing soil layer lies
several meters beneath the surface. These projects include
Zurich Airport terminal E and Main Tower in Frankfurt
(Pahud and Hubbuch, 2007; Ebnöther, 2008).
Several projects utilizing energy piles have been
completed during the past few years or are about to be
1
Turku University of Applied Sciences, Finland
2
Retired senior consultant. glapas@pp.inet.fi
*Corresponding author, email heli.kanerva-lehto@turkuamk.fi
(Vuorio, 2009) in Pori and Technopolis Innova 2, an office
building in Jyväskylä (Ruukki, 2013). In these projects,
energy piles have been installed into new buildings. So far
there are no known cases in the world where energy piles
have been used in renovation projects.
The use of renewable energy should be increased
significantly in Finland and in the rest of the European
Union to meet both the obligations concerning the
reduction of greenhouse gas emissions laid out in the
Kyoto Protocol (National Energy and Climate Strategy
Government Report to Parliament on 20 March 2013,
2013) and the short and long term targets of European
Union energy policy (The EU climate and energy package,
2008). Ground heat is a renewable and local energy source
with plenty of growth potential. When compared with
Finland, Sweden, for instance, boasts 10 times as many
ground heat pumps. However, ground heat is currently the
most popular new heating system in Finland. In 2011
ground heat was chosen in almost half of all new single-
family houses (The Finnish Heat Pump Association
SULPU, 2013).
In this article the recovery of ground heat in under-
pinning projects is studied. The focus of the study is on
load transfer structures transferring the load from old to

ß 2014 Deep Foundations Institute

Received 25 February 2014; accepted 5 March 2014
DOI 10.1179/1937525514Y.0000000002 The Journal of the Deep Foundations Institute 2014 VOL 8 NO 1 3
Lautkankare et al. Energy piles in underpinning projects
new deep foundations and on the through holes for
ground heat collector piping and technical implementation
of such piping in these load transfer structures. The term
‘through hole’ means a penetration or an inlet going
through the (super)structure above the pile. Openings,
pipe passages and holes that accommodate the heat
collector pipes as they pass through the load transfer
structure are referred to ‘through holes’ hereafter. This
study is part of the FIN-C2M project. The FIN-C2M
project is part of the Case 2 Micropile Research Project
in collaboration with the International Society for
Micropiles.
From pile to energy pile
Current know-how and technology make the use of energy
piles possible in certain projects. There are some specific
limitations and possibilities related to energy piles that
need to be taken into account when estimating the energy
production investments and life cycle of buildings. Two
such limitations are namely the mean distance between the
piles and the length of the piles. This is vital for obtaining
sufficient ground heat for the building and for ensuring the
temperature balance in the ground (Juvonen, 2009).
The ground thermal balance also needs to be taken into
account when designing the energy pile field. That was
also researched in the FIN-C2M project. The balance is
relatively easy to achieve in buildings having both heating
and cooling. Furthermore, energy pile systems maximize
their efficiency when they operate seasonally. The ground
thermal balance explains why energy piles need a certain
minimum distance between each others. In Nordic
countries where heating needs are higher than cooling, it
is necessary to study the ground thermal response case-by-
case. This is the case especially in buildings using energy
only for heating. To keep the thermal balance it is
important to avoid ground freezing due to the massive
heat extraction (Pérez Cervera, 2013). It is recommended
that at least 70% of the heating energy needs to be
recharged during the summer time (Uotinen et al., 2012).
Four or five meters have been sufficient distance between
the energy piles in new buildings in Finland and over 15 m
sufficient length of the piles (Vesamäki, 2011).
If the construction is to be fitted with a deep foundation
in any case, it might be reasonable to consider energy piles.
Any piles large enough for the ground heat collector
piping are suitable as energy piles. These include at least
steel pipe piles and concrete piles with holes. Of these two
only steel pipe piles have been used in underpinning
projects. There is also some experience of using concrete
piles with holes in new constructions (Tompuri, 2010;
Vuorio, 2009).
Almost all common steel pile sizes are suitable for
energy piles. Only the smallest piles are too narrow for the
heat collector piping. On the other hand, they are not
commonly used in underpinning projects due to their low
load-bearing capacity. In larger piles the distance between
the heat collector pipes and the heat source, namely the
ground, may become an issue. Optimization of the
primary circuit system requires more studying because
there are many factors affecting efficiency. Such factors
4 The Journal of the Deep Foundations Institute 2014 VOL
include, among others, at least the diameter and material
thickness of the piles and pipes, the distance of the pipes
from each other and from the ground, the filling material
inside the pile, and the soil properties.
When designing the piles, the increased corrosion has to
be taken into account. The corrosion risk exists in the
layers where the space between soil particles is not
completely filled with water and oxygen is present.
Typically this is the case just under the foundations where
gravel or sand has been used as a filling material to form a
capillarity layer and the upper part of the pile is in contact
with that moist filling material. This corrosion problem
has recently been countered by installing a centrally
positioned steel pin. In most cases a rebar with a length
of 3 m and a width of 32 mm was placed in the center of
the pile leaving about half a meter of the bar above the pile
cap (Fig. 1). The space required by the pin(s) must be
taken into account when designing the heat collector
piping. Another possibilities are to use stainless steel
quality in upper parts of the piles or cover the upper part
with grout.
A traditional pile is transformed into an energy pile by
installing inside the pile a plastic ground heat collector
pipe filled with a heat carrier fluid. The plastic used in
these pipes is usually polyethene (PE). The most common
types of PE used are medium-density MDPE, high-density
HDPE, and cross-linked PEX. The service life of these
plastic pipes is usually between fifty and a hundred years
(ISO/TR 9080, 1992). The plastic pipes are kept separately
by using plastic divider. A sufficient distance between
pipes is required for avoiding thermal short circuit and
having a good efficiency in system. In small diameter
energy piles with outer diameter between 100 and 300 mm
the typical pipe configuration inside the piles is simple
U-tube.
The liquid circulating in the collector pipes in Finland is
most commonly bioethanol. The freezing point of a 30%
ethanol mixture is 217uC. Depending on the application
ethanol can be replaced with another antifreeze agent
such as propylene glycol in groundwater areas, betaine
or potassium formate. As potassium formate is more
corrosive than other heat transfer agents, corrosion
inhibitors must be used. The freezing point of heat
transfer agents varies between products which might
affect the selection of the solution. In addition to lowering
the freezing point, a heat transfer agent has other
important qualities such as low viscosity, high thermal
conductivity, and high specific heat capacity (Juvonen and
Lampinlampi, 2013).
Nowadays constructions are generally designed to have
a 100–200 year service life; and thus, the heat collector
pipes may well need replacement during that period. Pipes
may also break due to other reasons than age-related
weakening. During transportation, storage or installation
and when handled at the construction site, precision is
important as plastic pipes scratch easily and are then
unusable. As pipe installations performed alongside
underpinning projects are usually performed in cramped
basements, the risk of breaking the pipes is much higher
than that of breaking with the usual piping of heat wells
outside the actual building (Uskali, 2013).
8 NO 1

1 Steel pin for increased corrosion resistance (Narmaplan Oy)
Energy piles and load transfer structures
The common load transfer structures comprise reinforced
concrete beams, steel beams, walls, pilasters and tension
anchors. One of the challenges of using energy piles in
underpinning projects has to do with the load transfer
structures, specifically the through holes for ground heat
collector pipes. Through holes make it possible for ground
heat collector pipes to traverse the load transfer structures.
In the FIN-C2M project this is studied on the basis of load
transfer cases by examining which types of load transfer
structures are suitable for energy piles. There are 13
recognized load transfer cases which are presented in
sequence charts (Lehtonen, 2011). According to the studies
nine of these cases are suitable for use with energy piles. In
The Journal of the Deep Foundations Institute
Lautkankare et al. Energy piles in underpinning projects
this study the energy collector pipes are added to the
sequence charts to show their installation phase on the
process (Figs. 2–5). As a rule, energy piles cannot be used
with jet grouted columns. In Figs. 2–5 all such load transfer
cases are depicted that are immediately compatible with
energy piles. All things considered the through holes for
ground heat collector pipes need to be designed for each
individual case even when using types of load transfer
structures that are immediately compatible with energy
piles. However, some general principles can be presented.
In five of the load transfer cases the ground heat
collector pipes can be led directly through the pile cap.
With reinforced concrete beams or encasings it is enough
to encase the pipes. Solutions in new constructions are
based on this technique.
2014 VOL 8 NO 1 5
Lautkankare et al. Energy piles in underpinning projects

2 Load transfer cases where ground heat collector pipes can be led directly through pile cap. Cases 2, 3 and 5 (Lehtonen,
2011. Edited by Heli Kanerva-Lehto)

6 The Journal of the Deep Foundations Institute 2014 VOL 8 NO 1


3 Load transfer cases where ground heat collector pipes can be led directly through pile cap. Cases 7 and 8 (Lehtonen,
2011. Edited by Heli Kanerva-Lehto)
In load transfer structures where a steel beam is centered
right on top of the pile cap, one possibility is to lead the
collector pipes from the pile through the load transfer
structure by using a double-web steel beam (Fig. 6) and
leading the pipes through the hole(s) in the flange or by
using two or more steel beams so that the pipes are taken
out through a gap left directly on top of the pile (Fig. 7).
Where a solution with a steel beam right on top of the
pile is desired, the pipes can be led out through the side of
the pile before the pile cap (Figs. 8 and 9). The through
hole can be made to the desired spot on site when the pile
is at its final depth and cut to its final elevation. This
structure is practically untested and has been devised
specifically for underpinning projects. With 90u angle
joints, the through holes can be relatively small (Fig. 8). If
the pipes are led through by bending them to an acute
The Journal of the Deep Foundations Institute
Lautkankare et al. Energy piles in underpinning projects
angle, the through hole needs to be vertically larger
(Fig. 9). When the pipes are led out of the pile, they are
insulated. An insulated pipe is subject to less condensa-
tion. Pipes are led to manifolds and onwards to a utility
room. With longer pipes, larger diameters or grooves can
be used to compensate for pressure loss.
The width and height of the through holes are
dependent on the diameter of the pipes and their bending
radius or the space required by angle joints. At its smallest
the through hole can have the width of two pipe diameters
and the height of one pipe diameter, in cases where 90u
angle joints are used. The most common pipe diameter is
32 mm, resulting in a 32664 mm through hole. In
practice some margin is required during installation. If a
base weight is used during installation, the space required
by it also needs to be taken into account. Modern cast iron
2014 VOL 8 NO 1 7
Lautkankare et al. Energy piles in underpinning projects

4 Load transfer cases where pipes need to be led out through side of pile before pile cap, alternatively using special jack
system depicted in Fig. 10. Cases 9, 10 and 11 (Lehtonen, 2011. Edited by Heli Kanerva-Lehto)

8 The Journal of the Deep Foundations Institute 2014 VOL 8 NO 1

 Lautkankare et al. Energy piles in underpinning projects

5 Load transfer cases where pipes need to be led out through side of pile before pile cap, alternatively using special jack
system depicted in Fig. 10. Case 12 (Lehtonen, 2011. Edited by Heli Kanerva-Lehto)

base weights are often 400 mm long, therefore, getting one
through a hole in the side of the pile requires a larger
through hole if the pile diameter is small.
The same principle can be applied in structures where
pile pretension is achieved by jacking directly on top of the
pile cap (Figs. 4 and 5). A through hole may weaken the
load bearing capacity of the pile, and thus the pile might
need reinforcement around it.
In load transfer structures where tension anchors are
used and pile pretension is achieved by jacking directly on
top of the pile cap and where cutting holes for the pipes is
not possible, a new solution (Fig. 10) has been found. It is
possible to lead the collector pipes out of the pile through
the pile cap with a special jack system and by using steel
structures so that an angle joint can be installed.
Hybrid energy piles
A hybrid energy micropile solves two issues in under-
pinning projects: transferring the load of the building and
collecting the geothermal energy from boreholes under the
piles. Thus, heat wells are here not located next to the
building, instead, they are under the building. Compared
with energy piles hybrid energy piles allow the harvesting
of energy at a greater depth of up to hundreds of meters.

6 Double-web steel beam and pipes led through hole in 7 Two steel beams and pipes led through gap between
flange beams

The Journal of the Deep Foundations Institute 2014 VOL 8 NO 1 9

Lautkankare et al. Energy piles in underpinning projects
8 Collector pipes taken out before pile cap. Small cutting
hole and 90u angle joint
The installation of the hybrid energy pile starts by
installing a traditional load-bearing pile suited for the
existing building. The dimensions of the pile (diameter
usually 170 to 220 mm) stay the same because energy use
of the pile does not affect the load-bearing capacity.
After the pile has been drilled into the load-bearing
ground, there are two options for installing the borehole
heat exchangers (here: collector pipes) to the required
depth. The easiest, quickest and cost-effective way is to
continue drilling to the required depth with a smaller drill
bit (diameter 100 to 150 mm). The borehole is filled with
9 Collector pipes led out before pile cap. Reinforced
through hole in side of pile
10 The Journal of the Deep Foundations Institute 2014 VOL 8 NO
water and is then ready for the installation of the collector
pipes. The collector pipes are installed into an open
borehole which is filled by natural groundwater flow. If
groundwater flow to the borehole is minimal water can be
added to the borehole manually. Typically in Finland the
borehole fills with water because drilling allows pressur-
ized groundwater to flow into the borehole. The ground-
water level stabilizes at its piezometric level which typically
is a few meters below ground level (Juvonen and
Lapinlampi, 2013). There may also be artesian ground-
water. Hence, it is essential to study the site specific
groundwater conditions when planning geothermal sys-
tems. Due to the crystalline bedrock, boreholes with only
groundwater fill, known as open boreholes, are widely
used in scandinavia (Banks, 2008). Water as a filling
material enables the replacement of collector pipes in case
they leak or are damaged during their life span.
If energy piles are filled with water after the installation
of borehole heat exchangers, there is a risk that hydro-
static pressure inside the filled pile is greater than natural
groundwater pressure, which makes the water flow to the
bedrock leaving an open space inside the pile (Arola,
2014). This unwanted situation can be avoided by site
studies and using other filling material instead of water.
In Finland the load-bearing capacity of a pile is
typically determined by the tip of the pile. The tip lies
on solid bedrock. Consequently the piles are mainly end-
bearing in Finland. The water filling at the bottom and the
energy use of the pile do not affect the load-bearing
capacity of the pile.
If extra load bearing capacity or corrosion margin is
needed, a smaller steel pile (diameter 115 to 140 mm) can
be installed inside the first load bearing pile, whereafter
drilling is continued to the required depth. The space
between the two piles is filled with concrete so a composite
structure is formed (Fig. 11).
The number of hybrid energy micropiles and the depth
of the boreholes are determined by the energy consump-
tion of the property. The number is also restricted by the
size of the property: the recommended mean distance
between the hybrid energy piles according to Finnish
national regulations is at least 15 m (Juvonen and
Lapinlampi, 2013). It applies the same distance as heat
wells generally. As compared the earlier regulations 2009
the distance was reduced five meters. This was due to the
consensus among the group of Finnish experts which were
composing the new regulations (Juvonen, 2014). Suitable
mean distance depends on the angle of the borehole,
groundwater flow and soil properties (Juvonen and
Lapinlampi, 2013).
Installation of ground heat collector pipes
into pile
For each energy pile, one coil of pipe is required. The
length of the coiled pipe can be adjusted as required. If
angle joints are used, the pipe can come in two coils. If the
pile is 30 m long, the length of the pipe has to be 60 m plus
the distance from manifold to pile and back. An empty
plastic pipe pair would not weigh much, but as the heat
transfer agent is often already in the pipe the total weight
1
 Lautkankare et al. Energy piles in underpinning projects

10 Collector pipes led through pile cap and passed by special jack system. (Original drawing by Vesa Sarola, edited by
Rauli Lautkankare)

could increase as much as to 1?5 kg m–1, making a 30 m
long pipe weigh 45 kg with an additional weight of 15 kg
for the base weight.
When the heat collector pipes are fed into the pile, the
center of the pile must be filled with water. Water creates
lift inside the pipe and facilitate installation. The base
weight helps the pipe settle into place and prevents the
pipes from rubbing against the pile walls. If the pile is not
full of water but the pipe is, the weight of the pipes
imposes an ever increasing load on the installation crew
and the pipes themselves. The pile could even collapse
from the strain. In an opposite situation where the pile is
filled with water but the pipes are empty, the sinking of
pipes is difficult due to flotation. The water used during
the installation may be left inside the pile if the pile is
designed to be water filled. In Finland piles are typically
filled with concrete. The use of concrete is supported by its
good thermal conductivity and the way it bonds with a

The Journal of the Deep Foundations Institute 2014 VOL 8 NO 1 11

Lautkankare et al. Energy piles in underpinning projects

11 Hybrid energy pile. Extra load bearing capacity and corrosion resistance is gained with smaller micropile inside load
bearing pile (Original drawing by Vesa Sarola, edited by Rauli Lautkankare)

12 The Journal of the Deep Foundations Institute 2014 VOL 8 NO 1


steel pile to form a load-bearing composite structure. The
selection of filling material has a great significance in the
long run as the increased thermal conductivity affects
the energy gain positively throughout the life cycle of the
structure. Then why is concrete not always used even
though it has better thermal conductivity than water?
Water filling has its own advantages as the pipes can be
replaced more easily if they break or reach the end of their
life cycle.
Before the pipes are installed inside the pile, they should
be tested while filled with liquid at 3 bar pressure for
over an hour to detect any leaks (Juvonen, 2009). At the
beginning of the installation, the sharp edged top of the
steel pile should be covered with a round edged plastic
ring, for example. This prevents pipes from scratching.
When the base weight reaches the tip of the pile, the pipes
are installed. If the pile is to be filled with concrete, the
filling is performed as underwater casting.
Conclusions
As a result of this study technical solutions were found for
combining energy micropiles and ground heat collector
pipes with nine load transfer structure cases. In five cases
the work can be done as in a new building. There is also a
special solution if steel beams need to be used. In four
cases the pipes must be led out through the side of the pile
before the pile cap or alternatively, a special jack system
needs to be used. This system allows collector pipe
installation right after the piling phase and jacking after
piping without breaking the pipes.
The geological features in Finland allow utilization of
energy and hybrid energy piles. There are some regulations
and recommendations which need to be considered. The
length of the energy piles should be at least 15 m and the
distance between the energy piles at least four or five
meters. A minimum distance of 15 m between hybrid
energy piles is required, as is usually the case with heat
wells in Finland. This distance is a recommendation and it
depends on the angle of the borehole and the properties of
the soil. The diameter or the material thickness of the steel
micropiles needs not be altered when the piles are in
energy use. In addition, the load-bearing capacity is not
reduced either by the borehole under the hybrid energy
pile or the energy use of the pile. In Finland, The bedrock
is solid and the piles are mainly end-bearing.
Both energy pile types are usually filled with bentonite
or concrete but even water may be used as a filling
material. Materials which have good thermal conductivity
have an advantage over time because of the improved
efficiency ratio. Water as a filling material is possible and
makes the collector pipes replaceable.
The risk of corrosion in the upper parts of the steel piles
can be dealt with in several ways: by using stainless steel
parts, by covering the piles with grout, by using extra steel
bars inside the piles, or by using thicker material. The
hybrid energy piles may also contain a smaller inner pile
inside the load-bearing pile and thus forming a composite
structure.
There are still challenges and questions to be tackled
and answered concerning the installation, for example in
The Journal of the Deep Foundations Institute
Lautkankare et al. Energy piles in underpinning projects
the steel beam cases and the special jack system cases. The
sequence charts depict the theoretical installation phases
but every underpinning project to be implemented with
energy piles should be studied individually.
Beside technical feasibility, the project economy must be
considered. On the basis of studies and models which
take into account climate conditions, soil properties and
heating and cooling solutions in buildings, energy piles are
economically feasible in Finland. Energy micropiles in
underpinning projects are one solution for extracting heat
from the ground and thereby for reducing the greenhouse
gas emissions of energy production.
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14 The Journal of the Deep Foundations Institute 2014 VOL 8 NO 1

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