AGRU America Expansion in Georgetown, SC

Using Advanced Analysis and Rigid Inclusions to Optimize Cost Savings, Reliability, and Project Schedule

How Claycor delivered performance, reliability, and constructability on a challenging site.

Project Type: Industrial

Client: AGRU America

Location: Georgetown, SC

Timeline: 4Q 2025

System Used: Ground Improvement using Fuller

                        Pile Rigid Inclusions

Project overview

AGRU America

The AGRU America Expansion in Georgetown, South Carolina is a large industrial warehouse project constructed in a challenging coastal environment with seismic and subsurface constraints. When escalating foundation costs and schedule risks became apparent under the original design approach, the general contractor retained Claycor Contractors to redesign and execute a new foundation design approach using advanced analysis. The Fuller Pile delegated design delivered a data-driven foundation solution using Fuller Pile Rigid Inclusions and advanced analysis that allowed the project to move forward rapidly while reducing cost, complexity, and long-term risk.

Grout Volume During Placement version 2a 1-22
The challenge

These inclusions optimize constructability, verification, seismic performance, and efficiency. By functioning as structural elements within a composite ground system, they remove many inefficiencies associated with conventional methods. Projects benefit from reduced risk and greater design flexibility. Regular attention to correct rigid inclusion installation helps achieve the full potential of this value-engineered approach.

High production rates and schedule compression

Installation rates of up to 50 inclusions per day per rig allow large foundation areas to be improved quickly. This significantly reduces foundation duration compared to stone columns or soil mixing systems. Faster installation keeps project timelines on track, and consistent, rigid inclusion installation practices ensure productivity is maintained across multiple rigs. This helps keep projects on schedule and resources optimized.

Flexible, small-footprint equipment

Installation uses small CAT-class rigs with auger attachments, enabling work in confined or urban sites. Multiple rigs can operate simultaneously, scaling production efficiently and adapting to fast-track schedules. This flexibility minimizes equipment congestion and site disruption, while maintaining best practices in rigid inclusion. This ensures work proceeds efficiently, safely, and on schedule across every project.

Reduced vibration and seismic suitability

Unlike vibro-replacement or grout systems that induce vibration and rely on soil confinement, these inclusions install with minimal disturbance and perform predictably under seismic loads. Correct rigid inclusion installation ensures ductile, reliable performance even in earthquake-prone regions. This gives engineers and contractors confidence that foundations will maintain integrity and stability under all seismic conditions.

No Spoils, no soil disposal, no contamination risk

Because the system generates no spoil, there are no disposal costs or environmental concerns. This simplifies overall site logistics, reduces regulatory hurdles, and ensures each rigid inclusion is environmentally compliant. It also helps construction projects stay on schedule while promoting sustainable practices, enhancing site efficiency, and supporting safe, cost-effective, and highly reliable construction outcomes.

Project confidence starts with the right foundation

Every project presents its own challenges, from complex ground conditions to demanding structural requirements. This case study demonstrates how Claycor combines engineering expertise, proven systems, and practical construction knowledge to deliver reliable foundation and ground improvement solutions.

If you’re facing similar site constraints or need a constructable solution tailored to your project,
Claycor is ready to help. Speak with our team to explore the right approach for your next project and move forward with confidence.