How The Dwyer Company Stabilized Mason Fire Annex with Precision Underpinning and Shoring Solutions
- Project Type: Commercial
- Project Services: Earth Retention, Push Piers, Shoring/Underpinning
When Mason Fire Annex required new staircases so the lower level of the Mason Fire Annex could connect to the upper level of the structure, the project presented a unique engineering challenge: excavation near an existing building, if not properly addressed the building would settle and slope. In close collaboration with Haglage Construction, Inc., The Dwyer Company installed push piers to support the existing building when excavating and provided a wood lagging solution attached to the new push piers to prevent soils from being undermined from underneath the footer. Because the soil conditions were both sandy and water logged we also used sump pumps to remove excess water and used smaller excavation cuts to limit the amount of soil exposure to the water and sandy conditions, proving that even the tightest access points, poorest soil conditions and structural lacking projects can achieve structural integrity with the right expertise and approach.
Quick Facts
- Location: Mason, Ohio
- Project Type: Retrofit
- Key Metric: Push piers installed to support existing building during excavation with integrated wood lagging system
- Key Metric: Sump pump deployment and controlled excavation to manage waterlogged, sandy soil conditions
- Key Metric: Underpinning and shoring for 10-foot wide section with 6-foot excavation below existing footer elevation
- Key Metric: Zero structural settlement despite challenging soil and access conditions
- Timeline: Completed within aggressive construction schedule with no delays to subsequent phases
- Partners: Haglage Construction, Inc.
The Challenge:
The primary challenge was excavating 6 feet below the existing footer elevation for staircase installation while maintaining structural integrity of the Mason Fire Annex building. The project required our team to carefully navigate sandy, waterlogged soil conditions and establish stable working conditions in a confined 10-foot wide section. Conventional excavation couldn’t achieve the required depth without extensive and costly temporary shoring systems—and risked significant settlement or structural failure given the poor soil bearing capacity and constant groundwater infiltration.
The Solution: Integrated Push Pier and Wood Lagging System
The Dwyer Company designed and installed a push pier underpinning system that transferred building loads to stable soil strata below the excavation zone. The solution required detailed pre-installation planning, precise pier spacing calculations, and careful coordination with active excavation operations.
The installation process involved establishing load-bearing push piers adjacent to existing footers, executing controlled excavation to 6-foot depths below footer elevation, and implementing wood lagging panels attached directly to the pier system to retain soil and prevent undermining. To manage groundwater and sandy conditions, we deployed continuous sump pumping and utilized smaller excavation cuts to minimize soil exposure and maintain stability throughout the operation.
The entire installation maintained the project’s aggressive construction timeline, providing Mason Fire Annex with a permanently stabilized foundation system and eliminating the risk of structural settlement or soil undermining during and after construction.
Key Project Details
Underpinning Scope
wide structural support section requiring full foundation transfer
Excavation Depth
below existing footer elevation in challenging soil conditions
Load Transfer System
Push pier array engineered to support building loads during and after excavation
Soil Retention
Custom wood lagging solution integrated with pier system to prevent undermining
Groundwater Management
Continuous sump pumping with staged excavation to control sandy, saturated conditions
Project Coordination
Seamless collaboration with Haglage Construction to maintain construction schedule
Why Push Piers?
Push pier systems are essential for commercial properties experiencing foundation issues that threaten structural safety, operational continuity, or property value. Common scenarios include:
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Settling Foundations in Commercial Buildings
When facilities show signs of settlement—cracked walls, uneven floors, misaligned doors—push piers provide permanent stabilization, especially critical in areas with expansive clay soils common in Ohio and Kentucky. -
Foundation Cracks or Slab Issues in Industrial Facilities
Essential for addressing cracked concrete slabs or foundation walls in warehouses, manufacturing plants, or distribution centers caused by soil settlement, hydrostatic pressure, or heavy equipment loads. -
Properties on Unstable Soils
Critical for commercial buildings on expansive clay, loose fill, or poorly compacted soils, where push piers anchor structures to deeper, stable layers capable of supporting substantial loads. -
Foundation Underpinning for Renovations or Expansions
Necessary for retrofitting or reinforcing existing foundations during commercial renovations, vertical expansions, or equipment upgrades—ensuring stability without major excavation that disrupts operations. -
Urban Commercial Sites with Restricted Access
Ideal for properties in dense commercial districts where minimal disruption is critical, site access is limited, and deep foundation support is needed without impacting neighboring structures or daily operations. -
Multi-Tenant or Investment Properties
Essential for maintaining structural integrity and property value in commercial real estate portfolios, preventing costly repairs and tenant disruptions from progressive foundation settlement.
The Impact: On-Time Delivery with Zero Structural Compromise
Cost-Effective Solution
The integrated push pier and wood lagging system eliminated expensive temporary shoring structures and reduced engineering complexity, delivering budget optimization without compromising structural performance.
Schedule Preservation
Completing the underpinning and excavation work within the construction timeline prevented delays that would have cascaded through subsequent construction phases.
Zero Structural Settlement
Most critically, the system achieved zero structural settlement in challenging soil conditions, providing Mason Fire Annex with permanent foundation stability for their new staircase structure—even in sandy, waterlogged conditions where conventional methods would have failed.
Why Choose The Dwyer Company for Structural Integrity?
Deep History • Solid Choice
The Dwyer Company’s proven track record in commercial and industrial foundation systems made us the trusted partner for this critical infrastructure project. Our team’s technical expertise, advanced equipment, and commitment to precision execution delivered a foundation system that will support decades of heavy industrial use.