The Manufacturing of Helical Piles: A Guide

Posted on: 19 December 2023

Helical piles are becoming increasingly popular in the construction industry due to their durability and versatility. These foundation elements are used to support structures, including buildings, bridges, and solar panels. However, while many are familiar with the installation process of helical piles, the manufacturing process is often unknown.

In this post, we will provide a guide on how helical piles are manufactured, from the initial design to the final product.

Design and Material Selection

The first step in the manufacturing process of helical piles is the design phase, where engineers determine the structural requirements and specifications needed for the pile. This includes the dimensions required for the helical plates and shaft, as well as any additional supports or brackets needed. Once the design has been approved, the materials are selected for the manufacturing process. Typically, helical piles are made from steel due to its high strength and durability.

Manufacturing Process

After the design phase, production of the helical pile begins. The first step involves cutting steel plates and bending them into the required shapes for the helical plates. The steel plates are then welded to the shaft to create the helix shape. The shaft is typically made up of multiple steel tubes welded together, with one end sharpened to allow for penetration into the ground. The helical plates are then carefully welded to the shaft to ensure stability and strength.

Quality Control

Once the manufacturing process is complete, each helical pile is subject to strict quality control measures to ensure that each pile meets the necessary standards and specifications. This includes checking the dimensions, weld quality, and any additional supports or brackets that were added. If any deficiencies or issues are found, the pile is rejected and sent back for reworking.

Coating and Finishing

After quality control, the helical pile is coated with a corrosion-resistant finish, typically a layer of hot-dipped galvanized steel or a powder-coated finish. This coating ensures that the pile can withstand the elements and prevents rust or corrosion from developing. Finally, each pile is marked with a unique identification number for tracking purposes during installation.


After the manufacturing process and quality control are complete, the helical piles are shipped to the construction site and installed. Once on-site, a machine with hydraulic power drills the helical pile into the ground, rotating the shaft to create a screw-like motion. The helical plates of the pile then transfer the load of the structure to the surrounding soil, providing a secure foundation.

Contact a helical pile manufacturer to learn more.