I have designed and observed a large number of driven pipe piling for end bearing conditions. Many of our soils are very soft (SPT <2/12) under the water table and the bearing formation is a hard shale (SPT >100/12). For light to medium loads (up to 100 tons) we usually use 10" or 12", closed ended pipe piling. The wall thickness are 0.25" or thicker if driving into cobbles, large loads and/or if the piles are long (over 90'). The piling are concrete filled after driving. I deals with large amounts of sulfate salts.

The pipe piling are normally designed with little or no contributions from the surrounding soil (similar to coastal conditions of docks). The concrete filling is not used to determine the ultimate pile capacity. The pipe are designed similar to columns and extra thickness may be added if excessive corrosion is anticiapted. As our soils are usually basic, instead of acidic, the high sulfates are not as much of a problem.

Visitor mentioned the problem of 'breaking'. I have experienced some buckling, usually when the hammer is too 'heavy'. Proper selection of the driving equipment proper selection of the final drive or 'set' will usually minimize damage to the piling.
The first question is do you intend to use the steel shell to carry any of the load. If you do, you should be concerned about corrosion. At .08mm/yr, the shell would be reduced to .25 inches of shell thickness in approx. 40 years, which may be the limit of the design life. However if you figure just the concrete, the 75 tons applies psi stress to the concrete. (P/Ag). Note that a load test to 2x Design will impose a higher stress, although the shell could participate, so that the load in the concrete would be less than psi.

The next consideration is the pile driving. Driving pipes closed end is not a problem, however I have not driven pipes less than 12" There is not a big difference between driving open or closed pipes. Usually the pipe will plug tightly and act as a closed end. If you plan to fill the piles, the really should be closed end as you will never do a good job of cleaning out the pipe prior to placing the concrete. Often a flat plate is welded to the bottom of the pile, although conical points are available. I would strongly recomend a WEAP analysis in the design phase for your project due the unusual soil conditions in your project. I would use a Vulcan 01 air hammer with an aluminum mcarta cushion and see what the driving stresses and final blow count look like.

Which segways into my third consideration, the soil/rock profile. The soft soil deposits may not sufficantly brace the piles. To have a rod sink 2 feet in one blow is pretty soft. Also since the soil is so soft pile alignment will be a problem. You should expect significant out of location on these piles. Also these piles may not have good lateral stability. If that is an issue, you may want to consider batter piles. The limestone can have soft zones underlying competent rock. If this is the case, then you could have serious questions abut the bearing capacity of the rock.

Depending on the field conditions, you could get 10 inch piles to work, although I would consider 12 to lower the stress. I would not figure the cpacity of the shell into the capacity of the pile. I would be concerned about lateral support and unbraced length. I would also be concerned about pile alignment and driving stresses. I would also closely look at the bearing capacity of the limestone. As a final thought, I would consider 10 inch drilled in mini-piles that were socketed at least 5 feet into the rock. This could solve a lot of problems, including the alignment, the bearing and the driving stresses. A conversation with a local pile driver and a local mini pile installer could give you a wealth of information.
Good luck and let us know how you make out!

Uses for Steel Pipe Piles

In general, steel pipe piles are required in situations where the shallow soils are not strong enough to support loads from a new structure. Steel pipe piles are therefore used to transfer heavy loads from a building or structure to the stronger rock formations or solid soil layers that exist deep underground. Steel pipe piles are commonly used when building structures such as bridges, buildings, or docks on soft soils or near lake, river, or ocean shores.

There are a number of types of pipe piling available including those that are made to be used as dock pilings. Additionally, there are a number of methods and techniques that can be used when installing steel pipe piles in a variety of situations.

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Primary Uses for Steel Pipe Piles

Steel pipe piles are commonly used to create deep foundations for buildings, bridges, and other construction projects. Using steel pipe plies is recommended in a variety of types of situations in order to strengthen a foundation and improve the structural support of new construction. Steel pipe piles will transfer the structure load to rock formations or stronger soil deep below the surface. This creates a sound foundation for large structures and even in difficult building situations.

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The main uses for steel pipe piles include to create deep foundations for:

• Building Construction
• Offshore Construction
• Marine Construction
• Dock Construction
• Bridge Construction
• Road and Highway Construction

• Rail Road Transportation Structure Construction
• Structural Support Construction
• Column Construction
• Oil Field Construction Services
• Communication Tower Construction

Special Situations Requiring Steel Pipe Pile Use

There are a number of special building situations during which deep foundations using steel pipe piles are recommended over shallow foundations. One such reason is during situations where a building or structure will have a very large design or heavy load. Additionally, steel pipe piles are important when a construction project will take place where there exists very poor soil at shallow depths. Finally, site constraints, such as property line restrictions may also make the use of steel pipe piles necessary. In any of these situations, or any combination of these situations, construction teams may find it necessary to utilize steel pipe piles in order to create a deep and sturdy foundation.