Piles are indispensable elements in modern construction, especially when it comes to erecting buildings in difficult ground or realizing large-scale projects. Their ability to absorb high loads and transfer them safely into deeper, load-bearing soil layers makes them a preferred foundation type in many construction projects worldwide. Here you can find out more about piles – from their definition and the various areas of application to the different production methods and types. Finally, we look at the processing of piles, a crucial step for their integration into structures.

Content
What are piles?
Piles are cylindrical concrete or reinforced concrete piles that are sunk deep into the ground and serve as load-bearing elements in construction. They are mainly used where the ground is not sufficiently stable to bear the load of buildings or other structures directly. Piles provide stability and safety, especially for large structures such as high-rise buildings, bridges or industrial plants.
Pile can reach diameters of 30 cm to over 2 m and lengths of several dozen meters. The dimensions depend on the specific requirements of the construction project, the soil conditions and the loads to be borne. The high load-bearing capacity of piles is achieved by the friction between the pile and the surrounding soil as well as by the peak pressure on load-bearing soil layers.
What are piles used for?
Piles are used in numerous construction projects. Their versatility allows them to be used in a wide variety of structures and environments:
Deep foundations: For buildings with high load-bearing capacity if the subsoil is weak. This applies in particular to high-rise buildings, industrial plants and large residential complexes.
Bridge construction: For stabilizing piers in river or sea areas where changing water levels and soft soils place special demands on the foundations.
Slope stabilization: To prevent landslides on slopes, e.g. for road, tunnel and railroad construction projects.
Special civil engineering: For example, offshore installations, wind turbines and harbor constructions where extreme environmental conditions prevail.
Subsequent foundation reinforcements: In existing buildings when additional loads have to be absorbed or during renovation work.
Piles not only offer structural advantages, but also economic and ecological ones. They enable construction on difficult soils, reduce material consumption through targeted use and minimize interference with existing structures.
How are piles manufactured?
The production process of piles is a highly specialized process that is adapted depending on soil conditions and project requirements. However, the basic steps are similar in most cases:
1. planning and soil investigation
Before drilling can begin, a thorough soil investigation is required. Geotechnical reports provide important information about the soil type, groundwater level and load-bearing capacity. This data is crucial for the choice of drilling method and the dimensioning of the piles.
2. drilling the pile hole
The borehole is created using special drilling equipment. Various methods are used for this:
Dry drilling method: For stable soils without groundwater problems.
Support fluid method: Use of bentonite or polymer suspensions to stabilize the borehole walls.
Cased drilling: Use of steel pipes to support the borehole wall, ideal for unstable soils or high groundwater levels.
3. insertion of the reinforcement
After drilling, a steel reinforcement cage is inserted into the borehole. This ensures the necessary tensile and bending strength of the bored pile. The reinforcement is often installed in segments and fixed with spacers to ensure the correct concrete cover spacing.
4. concreting
The borehole is filled with concrete. The tremie method is often used here, in which the concrete is poured through a pipe from the bottom to the top. This prevents the concrete from segregating and ensures a homogeneous structure. In cased boreholes, the pipe is pulled step by step as the concrete is poured in.
5. curing and quality control
After concreting, the pile hardens. The curing time varies depending on the weather and type of concrete. Quality checks are then carried out, including
Ultrasonic measurements: For testing the homogeneity of the concrete.
Test loads: To check the load-bearing capacity of the pile.
Drill core extractions: To analyze the concrete structure.
What types of piles are there?
Piles can be divided into different types, depending on the construction method, area of application and load requirements.
1. by manufacturing process
In-situ concrete piles: The pile is cast directly on the construction site. This method is flexible and cost-efficient.
Prefabricated bored piles: Prefabricated concrete or steel piles are inserted into the borehole and, if necessary, set in concrete.
Cased bored piles: Stabilized with steel pipes, particularly suitable for unstable soils.
Micropiles: Small diameters (up to 300 mm), ideal for confined spaces or subsequent reinforcements.
2. according to static function
Pressure piles: Carry vertical loads and transfer them to deeper soil layers.
Tension piles: Absorb tensile forces, e.g. for offshore installations or wind turbines.
Inclined piles: Dissipate horizontal forces, e.g. for slope stabilization.
3. by material
Concrete piles: Standard in building construction and civil engineering.
Steel piles: For extreme loads or temporary constructions.
Composite piles: Combination of concrete and steel for special requirements.
Challenges when breaking piles
After piles have been installed, they often have to be cut to the desired height. Regardless of the diameter of the bored piles. This is necessary to create a level bearing surface for the subsequent construction. Capping bored piles using conventional methods can be time-consuming and cost-intensive, as it involves manual work and heavy equipment.
Brextor® offers a particularly efficient, safe and economical solution for breaking piles. With this innovative method, both individual piles and all types of bored pile wall can be machined – regardless of the weather conditions.
In the following section, you will learn more about the advantages and functionality of the Brextor® method for capping bored piles:
🏗 Increased construction quality
Perfect pile breaking without cracks in the pile body or spalling on the pile outer skin, no bent or torn reinforcements and a height accuracy of +/- 1cm.
💵 Reduced construction costs
The demolition material consists of 80% gravel 0-30mm and can therefore be reused directly on the construction site. In addition, Brextor® requires less working space than conventional mining methods. This means that not only expenses for transportation and disposal incl. fees are saved, but the purchase and supply of replacement material is also eliminated. Furthermore, the preparatory work eliminates the need for a separating diamand cut at the final extraction level and the cleaning effort is massively lower than with conventional extraction methods.
⏱ Shortened processing time
For example, a pile with a diameter of 1 m and a height of 1 m can be processed within 40 minutes. A daily output of up to 16 piles is possible. In addition, Brextor® provides reliable performance and therefore increased planning security.
♻️ Environmentally friendly
With Brextor®, the demolition material (80% gravel 0-30mm) can be reused directly on the construction site. Brextor® also requires less working space. This saves excavation and replacement material. By reusing the demolition material directly on the construction site and saving on excavation and replacement material, transportation can be saved. In addition, landfills are less polluted.
👷 Increased health & safety at work
No heavy physical labor is required for pile processing, which massively reduces the risk of health hazards such as HAVS syndrome. Brextor® also avoids working in danger zones.
Find out more about Brextor® here:
Contact us for more information and find out how you can benefit from this revolutionary pile breaking method.
Call us on +41 41 495 05 20 or send an e-mail to info@brc.swiss. We look forward to working with you and taking your projects to the next level.