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case study Piling Work type Working Platform/Piling Customer Roger Bullivant Limited (RBL) Design Engineer Rodgers Leask Key issues/ requirements T The early establishment of a stabilised all-weather working platform on construction sites provides a safe and sufficiently durable working surface at all times of year for trucks and construction plant, such as piling rigs, to operate safely. Ground Stabilisation Contractor T Piling is specified in many cases as the engineered foundation solution because the existing soils and substrata is considered weak or prone to settlement. The creation of an easily accessed, safe piling mat is therefore essential to the piling operation. DNS (Midlands) Ltd Main Contractor MWH Treatment Ltd Project Brief The installation of a safe working platform before commencing a complex pre-cast driven piling contract to support new structures at Clay Mills Sewage Treatment Works, Burton on Trent. The £42m upgrade of the sewage works was a major project for Severn Trent Water resulting in one of the largest treatment works in Europe. T The contract was for the design, manufacture, delivery and installation of 1,381 no. permanent pre-cast piles to support new structures at the sewage treatment works. Large areas of the existing site had been filled or built-up with spoil from previous excavations, and was unsuitable for the proposed structures. ROGER BULLIVANT LIMITED T. 0845 838 1801 www.roger-bullivant.co.uk T In many cases, large quantities of stone have to be imported to create piling mats and unsuitable soil removed to landfill, so soil stabilisation was the ideal solution. T Utilising on-site materials, treated with RoadCem and cement, a working platform was created. The resulting mat allowed very accurate placement of piles. It was strong enough to hold the piling rig safely, but flexible enough to allow the precast piles to be driven right through. This not only ensured the safety of operatives and plant equipment, but also eliminated the need for over 2000 lorry movements from site across a busy rail crossing resulting in £70k savings on project costs. T The use of site-won material, not only leads to significant reductions in lorry movements, but also significantly reduces the environmental damage and overall carbon footprint of the project. And because the platform is built from existing site material and not imported stone, there is no additional weight to the construction during the piling programme. R Piling Solution RoadCem is a cement modifier which improves soil stabilisation for road and construction platforms. It is a fine grain-sized additive produced from alkali earth metals with synthetic zeolites and a complex activator to alter and improve the way cement cures and binds soils. RoadCem enhances and increases the flexibility and tensile strength of stabilised soils and significantly improves the overall performance of cement bound materials used in construction. The addition of RoadCem to cement stabilisation prevents problems of shrinkage and cracking and allows roads, foundations, and construction platforms to be constructed quickly even with very soft or organic soils. Photo: MWH Treatment The top 3.0m of made ground was remediated and a RoadCem stabilised 250mm platform constructed for the 38 tonne RBL Quiet Hammer driven piling rig to operate from. RBL manufactured, delivered and installed 1,381 no. permanent pre-cast concrete piles to support the new structures at the sewage treatment works. This displacement pile solution eliminates the need for spoil removal. Often low lying ground is water bearing and a pre-formed driven pile satisfies the need for absolute integrity. RBL adopted the use of the RB driven pre-cast piles utilising 250mm x 250mm, 300mm x 300mm and 350mm x 350mm square section piles driven to a depth of 8m to carry safe working loads(SWL) up to 900kN in two sections to eliminate waste. The main structures piled were: • 6 no. final settlement tanks, 36m dia (FST) and associated distribution chambers • ASP (activated sludge plant) 70m x 70m x 6.5m high concrete structure • Inter stage pump station 20 x 7 slab foundation Carlow Precast provided an innovative solution for the six large 38m diameter final settlement tank structures The modular pre-cast structures were designed & manufactured off-site ready for on-site assembly. The quality of precast product ensures the delivery of a far superior finished structure for the client and combats the challenges normally associated with an insitu build, especially during poor weather conditions. R Roger Bullivant Ltd. Head Office, Walton Road, Drakelow, Burton-on-Trent, Staffordshire DE15 9UA T. 0845 838 1801 F. 01283 517 704 E. [email protected] www.roger-bullivant.co.uk