Three percent is the swell figure that turns a foundation problem from cosmetic to damaging. The Colorado Geological Survey states that volume increases of 3 percent or more are considered potentially damaging and generally require specially designed foundations, and that most homes, schools and roads in Colorado are in areas of potentially expansive clay. For an industrial building with a slab that has to stay flat, a column grid that has to stay plumb and a crane runway that has to stay level, the foundation decision happens before the steel is ordered.
Deep foundations take the building load below the active zone, to soil or rock that does not swell and shrink with moisture. The choice among drilled piers, driven piles, helical piers and micropiles depends on the soil profile, the groundwater, the loads and the site's access. We help owners and engineers make that choice early, with a clear comparison of cost, schedule and risk, because the wrong system is expensive to correct after the first rig is mobilized.
The work does not end at the pier. Void forms under grade beams, slab isolation, drainage and the sequence of backfill all determine whether the foundation performs as designed. We build the entire system, not just the holes.
Why Front Range soils drive the decision
Much of the Front Range sits on clay and claystone that swell when wetted and shrink when dry. Parker and Castle Rock are examples of fast-growing industrial corridors where the same Geological Survey statement applies. The Denver area sits in the South Platte River valley where Cherry Creek meets the South Platte, and valley sites bring alluvial soils and shallower groundwater alongside the claystone that lies under higher ground.
Moving west and south, other jurisdictions state the requirement directly. La Plata County, around Durango, requires a soils report and/or engineered foundation design where county GIS mapping shows expansive clay soils, and its minimum foundation details cannot be used in expansive soils without an engineer stamp. The message across the state is consistent: the foundation must be designed for the soil under the building, and the soil must be investigated first.
Matching the foundation system to the building
Drilled piers are the common choice for heavy industrial buildings on expansive soils, because they reach stable bearing and resist uplift from swelling. Driven piles suit sites with deep soft soils or a high water table, where displacement and vibration are acceptable. Helical piers are fast and quiet, useful for light loads, retrofits and tight access. Micropiles handle limited-access additions and difficult obstructions. We lay out the options against the loads from your structural engineer.
Building function matters. A tilt-wall warehouse has line loads along the panels and column loads at interior points. An automotive and EV plant can have heavy presses and conveyors in addition to the structure, and metals and heavy industry sites add furnaces, rolling equipment and crane bays. Crane runways add vertical and lateral loads and tight tolerances. We compare how each foundation system serves these loads, and how it affects the slab and walls above.
Geotechnical reports, engineer stamps and local rules
Unincorporated Weld County adopted the 2024 International Building Code effective June 15, 2026, with engineered foundation designs required for most new structures. That kind of local rule makes the geotechnical investigation and the stamped design the starting point for permits. Deep foundations typically require a geotechnical report with recommendations for bearing, depth and construction, a structural design for the piers and grade beams, and special inspection during installation.
We bring the geotechnical engineer into preconstruction and make sure the number and depth of borings match the footprint. A building with a long footprint can see very different soils across its length, and one boring per corner is rarely enough. We also coordinate special inspection so the inspector is on site when the rig drills, not after the concrete is placed.
What the installation work includes
The sequence is survey layout, rig mobilization on a prepared working surface, installation, inspection, and then grade beam and slab preparation. We prepare the working pad so the rig can travel without rutting, and we keep spoils managed on site or hauled to an approved location. Installation records capture depth, material and any variation from the design so the engineer can accept the foundation.
Above the piers, we form grade beams with void forms that leave a gap under the beams, so swelling soil cannot lift them. The slab is isolated or designed to float depending on the design. Our drilled pier foundation page covers the drilled method in detail, and the foundation tie-in to equipment is covered under equipment pads and foundations.
Rig operations, utilities and open excavations
Drill rigs and pile drivers are heavy and tall. Overhead power lines, buried utilities and unstable working surfaces cause most of the incidents associated with them. We locate and mark utilities before mobilization, set exclusion zones around the rig, and require clear communication between the operator and ground crew. Open pier holes are covered or barricaded at the end of each shift.
Vibration and noise from driven piles can affect neighbors and sensitive equipment on an adjacent operating plant. When a project is next to an active facility, we measure vibration at the property line and agree on limits with the plant manager before work begins. Tilt panels cast on a slab are another place where foundation planning matters, so deep foundations are coordinated with tilt-wall industrial buildings and the crane access they need.
Settle the foundation system before ordering steel
Send us the geotechnical report and preliminary loads, and we will return a comparison of foundation systems with cost and schedule. Contact Industrial Contractors of Colorado to schedule it.
Common Questions
How deep do piers need to be on the Front Range?
The depth is set by the geotechnical engineer from the soil profile, groundwater and the loads. Piers generally extend through the expansive layer into more stable material or bedrock. A report with proper borings gives the depth, and we do not guess. We review the report before pricing.
Are driven piles ever better than drilled piers?
They can be, particularly when soils are soft, groundwater is high or temporary casing would be costly. Vibration, noise and access limitations can rule them out near sensitive neighbors. The engineer compares them with the same loads, and we price both.
What does a void form do?
A void form is a degradable carton placed under a grade beam or slab to create a gap between concrete and soil. If the soil swells later, the gap absorbs the movement instead of the structure. It is a standard detail on expansive sites and it needs to be installed carefully.
Can we start foundations before the permit is final?
Sometimes. Some jurisdictions issue early foundation permits or allow site work under a separate permit. That requires a stamped foundation design and agreement with the building department. We check the options early.
What happens if we hit rock or water?
Differing site conditions are handled through the contract and the geotechnical report. Our approach is to put the boring data in front of everyone during bidding and to agree on a method for unit prices. Unexpected conditions are documented and resolved through change control.