--- title: NYC - STELCOR Piles For The DHL Warehouse At JFK Airport - IDEAL Foundation Systems description: "  OVERVIEW: Global shipping delivery provider DHL needed to add a mezzanine level to its existing warehouse at John F. Kennedy International Airport in Queens, New York, to expand its package handling and sorting center.  The warehouse needed to remain clean and fully functional during the duration of the project. CHALLENGE: The engineer of record, […]" image: https://www.idealfoundationsystems.com/hubfs/Imported_Blog_Media/web-thumbnail-dhl-jfk-stelcor-1024x664.jpg --- [Skip to main content](https://www.idealfoundationsystems.com/blog/dhl_jfk_nyc_stelcor#maincontent) [ «  View All Posts ](https://www.idealfoundationsystems.com/learning-center/) # NYC – STELCOR Piles For The DHL Warehouse At JFK Airport February 12th, 2019 1 min read By [Bruce Stroyer](https://www.idealfoundationsystems.com/blog/author/bruce-stroyer) ![](https://www.idealfoundationsystems.com/hs-fs/hubfs/Imported_Blog_Media/web-thumbnail-dhl-jfk-stelcor-1024x664.jpg?width=1024&height=664&name=web-thumbnail-dhl-jfk-stelcor-1024x664.jpg) **OVERVIEW:** Global shipping delivery provider DHL needed to add a mezzanine level to its existing warehouse at John F. Kennedy International Airport in Queens, New York, to expand its package handling and sorting center. The warehouse needed to remain clean and fully functional during the duration of the project. ![for web 1](https://www.idealfoundationsystems.com/hs-fs/hubfs/Imported_Blog_Media/for-web-1-1024x768-1.jpg?width=1000&height=750&name=for-web-1-1024x768-1.jpg) **CHALLENGE:** The engineer of record, Mueser Rutledge Consulting Engineers (MRCE), was concerned about weak and unstable soils with risk of liquiefaction so a 48-hour load test to verify that STELCOR® could support the load in a suspect soil environment. Two piles were installed to a depth of 67 feet with a net settlement of less than one-eighth inch. Other challenges included limited access, mobilization, demobilization, and overhead clearance. Conditions of the contract stated that the DHL facility remain operational during the duration of the project. This meant that construction would be confined to a strict Tuesday to Friday schedule from 9 a.m.- 3:30 p.m. Additionally, the DHL package sorting tables on site would need to removed to perform the work; then put back into place at the end of every work day. Mobilization and demobilization would need to be repeated every day, and cleanliness was paramount. **SOLUTION:** The new design specified 42 STECOR® Drilled-In Displacement micropiles to support the new columns for the mezzanine. Piles were installed in groups of 3 to accomodate 14 pile caps, . The piles were driven 67 feet to support the 201-ton ultimate load in compression. The piles also had to resist a 5-ton lateral load. A Kobelco 270 excavator with a 70,000-foot-pound Digga drive head was used to access the very tight site through an overhead door. Fifteen-foot leads and extensions were utilized to deal with overhead limitations. The grout mixer was kept outside of building and grout was pumped in via a long hose. “Between daily remobilization, evening demobilization, and site prep that includes table shuffling, we only have about four hours to work,” said Audubon project manager Chuck Tauscher. “Nonetheless, we were installing three piles per day, which is great considering the depth and the fact that this was our first STELCOR® job.” [![web thumbnail dhl jfk stelcor](https://www.idealfoundationsystems.com/hs-fs/hubfs/Imported_Blog_Media/web-thumbnail-dhl-jfk-stelcor-1024x664.jpg?width=1000&height=648&name=web-thumbnail-dhl-jfk-stelcor-1024x664.jpg)](https://www.idealfoundationsystems.com/hubfs/Imported_Blog_Media/web-thumbnail-dhl-jfk-stelcor.jpg) **LOADS:** 402 kips ultimate compression 11.2 kips ultimate lateral **PILE DETAIL:** STELCOR 1600 18” tip or drive plate 16” corrugated grout column 13” solid grout column 11” reverse auger 7.00” O.D. X 0.408” W.T. – 80 ksi central shaft **SOILS + EMBEDMENT DEPTH:** Weak unstable sands with risk of liquefaction. Piles installed to 67’. **INSTALLER:** [Audubon Environmental ](https://www.audubonenvironmental.com/) Topics: [ Limited Access ](https://www.idealfoundationsystems.com/blog/topic/limited-access) [ Low Headroom ](https://www.idealfoundationsystems.com/blog/topic/low-headroom) [ Drilled-In Displacement Piles (DDM) ](https://www.idealfoundationsystems.com/blog/topic/drilled-in-displacement-piles-ddm) Don't forget to share this post: ## Related Articles [![](https://www.idealfoundationsystems.com/hs-fs/hubfs/Baltic%20St_.png?width=713&height=401&name=Baltic%20St_.png) ### STELCOR Supports a Complex Development Site in Brooklyn’s Gowanus Neighborhood May 18th, 2026|1 min read ](https://www.idealfoundationsystems.com/blog/stelcor-supports-a-complex-development-site-in-brooklyns-gowanus-neighborhood) [![](https://www.idealfoundationsystems.com/hs-fs/hubfs/86%20DELANCEY%20web(16)--jpg.jpeg?width=720&height=471&name=86%20DELANCEY%20web(16)--jpg.jpeg) ### NYC - 112 STELCOR® Piles to 30' for a 12-Story Mixed-Use Rental Building June 23rd, 2025|1 min read ](https://www.idealfoundationsystems.com/blog/nyc-112-stelcor-piles-to-30-for-a-12-story-mixed-use-rental-building) [![](https://www.idealfoundationsystems.com/hs-fs/hubfs/Imported_Blog_Media/brokk_drillingserviceco_1.jpg?width=1267&height=950&name=brokk_drillingserviceco_1.jpg) ### REMOTE-CONTROLLED DEMOLITION EQUIPMENT SOLVES CHALLENGING HELICAL PIER INSTALLATION March 10th, 2023|1 min read ](https://www.idealfoundationsystems.com/blog/remote-controlled-demolition-equipment-solves-challenging-helical-pier-installation) [![STELCOR® DDMS TOUCHING DOWN AT JFK AIRPORT](https://www.idealfoundationsystems.com/hs-fs/hubfs/Imported_Blog_Media/20220617_140517-WEB-scaled.jpg?width=2560&height=1920&name=20220617_140517-WEB-scaled.jpg) ### STELCOR® DDMS TOUCHING DOWN AT JFK AIRPORT October 31st, 2022|1 min read ](https://www.idealfoundationsystems.com/blog/stelcor-at-jfk) [![](https://www.idealfoundationsystems.com/hs-fs/hubfs/Imported_Blog_Media/FNC-rendering-web-150x150-1.png?width=150&height=150&name=FNC-rendering-web-150x150-1.png) ### STELCOR For The First National Center August 10th, 2020|1 min read ](https://www.idealfoundationsystems.com/blog/stelcor-for-the-first-national-center) [![](https://www.idealfoundationsystems.com/hs-fs/hubfs/Imported_Blog_Media/malt-house-new-rendering.jpg?width=736&height=552&name=malt-house-new-rendering.jpg) ### NYC – Stelcor® in the Manhattanville Factory District for the Malt House Building May 29th, 2020|1 min read ](https://www.idealfoundationsystems.com/blog/nyc-stelcor-manhattanville-factory-district-malt-house-building) [![](https://www.idealfoundationsystems.com/hs-fs/hubfs/Imported_Blog_Media/5299F445-web.jpg?width=864&height=648&name=5299F445-web.jpg) ### STELCOR Seals of Approval – 150,000-Gallon Harbor Seal Exhibit in Norwalk, CT April 2nd, 2020|1 min read ](https://www.idealfoundationsystems.com/blog/seals-of-approval) [![](https://www.idealfoundationsystems.com/hs-fs/hubfs/Imported_Blog_Media/NYHC-awards_DraperHall_image4-910x1024-910x1024-1.jpg?width=910&height=1024&name=NYHC-awards_DraperHall_image4-910x1024-910x1024-1.jpg) ### 295 STELCOR® DDM for the new 16-Story Gilbert in NYC March 9th, 2019|1 min read ](https://www.idealfoundationsystems.com/blog/its-gonna-be-a-gilbert) [![](https://www.idealfoundationsystems.com/hs-fs/hubfs/Imported_Blog_Media/86-DELANCEY-5.jpg?width=600&height=800&name=86-DELANCEY-5.jpg) ### A Boring Story – How to Save 6 Weeks, 50 Foot, and $500,000.00 August 3rd, 2018|1 min read ](https://www.idealfoundationsystems.com/blog/1972-2) [![](https://www.idealfoundationsystems.com/hs-fs/hubfs/Imported_Blog_Media/DSC01761-web.jpg?width=872&height=583&name=DSC01761-web.jpg) ### Cornell University – STELCOR® DDM for Increased Column Loading In The Historic Rand Hall March 21st, 2018|1 min read ](https://www.idealfoundationsystems.com/blog/cornell-university-stelcor-ddm-increased-column-loading-historic-rand-hall) [![](https://www.idealfoundationsystems.com/hs-fs/hubfs/Imported_Blog_Media/DC-SEWER-2-1024x576-2.jpg?width=1024&height=576&name=DC-SEWER-2-1024x576-2.jpg) ### Keeping it Clean in Washington D.C. With STELCOR February 2nd, 2018|1 min read ](https://www.idealfoundationsystems.com/blog/keeping-it-clean-washington-d-c-stelcor) ```json { "@context" : "https://schema.org", "@type" : "BlogPosting", "author" : { "@type" : "Person", "name" : "Bruce Stroyer", "url" : "https://www.idealfoundationsystems.com/blog/author/bruce-stroyer" }, "dateModified" : "2024-11-20T17:11:24.723Z", "datePublished" : "2019-02-12T08:27:48.000Z", "headline" : "NYC - STELCOR Piles For The DHL Warehouse At JFK Airport - IDEAL Foundation Systems", "image" : [ "https://www.idealfoundationsystems.com/hubfs/Imported_Blog_Media/web-thumbnail-dhl-jfk-stelcor-1024x664.jpg" ], "mainEntityOfPage" : { "@id" : "https://www.idealfoundationsystems.com/blog/dhl_jfk_nyc_stelcor", "@type" : "WebPage" }, "publisher" : { "@type" : "Organization", "logo" : { "@type" : "ImageObject", "url" : "https://www.idealfoundationsystems.com/hubfs/ASSETS/logos/Ideal-Logo.png" } } } ```