Case Studies

CASE STUDY: RABY BAY

For more than eight years we have worked with Redland City Council on a number of projects to combat the ongoing problem of subsidence at Raby Bay. With over 20km of manmade canal slopes suffering from settlement and lateral displacement, we were engaged to design and carry out revetment wall remedial work; which principally involved repairing, propping up or entirely replacing walls across the bay precinct.
The technical difficulty of this project was augmented by the unique characteristics of the site, with all work being undertaken from a pinned down floating barge. However, with an expert design team we were able to offer the client a workable solution to their problem which has been successfully implemented through detailed planning, meticulous regulatory compliance and precise construction methods.

 

Technical Implementation

With some of the industry’s best designers and a wider product offering than most competitors, we were able to offer Redland City Council a bespoke solution that would solve their subsidence problem in a timely and effective manner.

• Armour rock and failed revetment walls were removed, with customised finned screw piles installed before reinstating the revetment wall and armour rock;
• Piles were then screwed to a depth of approximately 11 metres below sea level with two piles cast into a single headstock at approximately two metre centres along the canal bank;
• On the land side of the headstocks we cast a continuous concrete curtain wall to retain the property and constructed a new revetment wall;
• We also installed inclinometer casings into other areas where suspected land slips were occurring, using screw-in technology to depths of nine metres below armour rock levels on the embankments;
• This has enabled the council to measure movements weekly and allowed designers to design to actual recorded movement, ensuring the end result is both accurate and cost effective.

 

Managing the Access and Regulatory Challenge

The unique nature of this project posed a number of challenges from both an access and regulatory perspective. Firstly, given that the work site could only be reached by water it was necessary to ferry all equipment and material by crane from land to a dumb barge and subsequently off-loaded to the floating barge for construction to commence. Whilst access could be managed through precise scheduling and logistics, a further challenge in utilising commercial shipping vessels was that we had to comply with both Workplace Health and Safety regulations and also Maritime Law. The latter required a registered Sea Master to be on the barge at all times to maintain the safety and security of the workforce.

CASE STUDY: BONDI JUNCTION

New Space Constructions are in the process of building a residential development of 44 units, and engaged us to complete a contiguous wall pile job for the shoring of neighbouring buildings in preparation for the excavation of a five-level basement. New Space Constructions were concerned by the tolerance and verticality of the piles, with minimal basement space to lose, however we worked closely with them and their designer to devise a suitable piling solution that would be effective for all concerned.
The three-week project was completed on time and to budget, despite a number of challenges in relation to levels and site access. By providing flexibility, design expertise and a practical mind-set in tackling the site access issues we were able to ensure an excellent quality of work.

 

Why SFL Piletch?

This project highlights the versatility we bring to any construction job; working closely with the client from the outset to manage expectations, minimise risk and deliver on time and to budget.

• Design and construct expertise
• Flexibility in approach
• Problem solving in complex situations
• Robust logistics
• Excellent workmanship
• Strong work documentation
• Competitive prices
• Speed of availability

 

My experience with SFL Piletech was very good. There were a number of challenges during this project given the constrictiveness of the site, however SFL Piletech overcame them all in an experienced and knowledgeable manner. They provided expertise in the design process to advise us of what could and couldn’t be drilled and were willing to offer ideas throughout the project as complex situations arose.
I am very happy with the project outcome and would recommend SFL Piletech in the future.

George Catsaros

New Space Constructions

CASE STUDY: LEVEL CROSSINGS REMOVAL PROJECT

Working on behalf of engineering giant John Holland, we have been commissioned to fabricate, supply and install over 350 screw piles to support the removal of level crossings across the state of Victoria. Having pioneered the use of screw piles in Australia we are expertly positioned to meet the project requirements, which form part of the Victorian Government’s $2.4bn plan to remove 20 level crossings by 2018 and 50 by 2022.

 

Completion of the work, which includes removing level crossings, reconstructing local stations and making improvements to the road and public transport connections, aims to deliver a number of benefits, including improved road and rail safety, reduced pollution and lower congestion levels.

 

Managing loads of up to 100 tonne or 1000kN our screw piles are designed, manufactured and installed to meet a wide range of project requirements. Vibration free and environmentally friendly, they can reach depths of up to 48 metres and are installed many times faster than alternative piling types. For this project our 219mm outside diameter screw piles were utilised, satisfying depths of between 6.0 and 10.5 metres.

Screw Piling Expertise

 

For this project our expert team of in-house design engineers have worked closely with the client to design a tailored solution to meet their screw piling requirements. Along with the fabrication, supply and installation of the screw piles to multiple worksites, we have also undertaken proof load testing of the piles, providing a detailed report of results achieved at each site.

 

All of our screw piles are fabricated in accordance with AS4100. This requires us to guarantee the full traceability of all material components, evidence welding consumable certificates and demonstrate compliance with weld procedures for each and every weld carried out by our fabrication facility.

 

 

Client Satisfaction

 

John Holland is part of an alliance established with KBR, VicRoads, Public Transport Victoria, Metro Trains Melbourne and the Level Crossing Removal Authority to deliver the $2.4bn project for the Victorian Government.

 

When called upon to support a contractor in their project delivery, we strive to achieve the highest standards in quality of output, workmanship and communication. For this particular project we worked closely with John Holland to support the delivery of their project aims and are proud to have received the following feedback:

SFL Piletech have achieved far and beyond what was expected of a contractor put in the position of installing 389 screw piles in a single week, all whilst managing six working interfaces over three separate sites.

I would like to express my utmost gratitude for the work completed on this project; the quality, precision and leadership your team has shown while under pressure is nothing but world class.

Andrew Savva

Project Engineer, John Holland

CASE STUDY: TUGAN BYPASS

We have in-house geotechnical, civil and mechanical design capabilities and vast experience, combined with software which is specific for all types of pile design to enable us to work on a turnkey design and construct project basis, as needed.

If needed, we are more than happy to provide references of current and past infrastructure projects to support our expertise and level of commitment on large projects.

We feel it is important to highlight the Tugun (Coolangatta) bypass infrastructure project. The contract was with Pacific Alliance, a joint venture between RTA of Queensland, RTA of NSW, SMEC Corporation as Designers, and ABI Group. The Tugun project is a large infrastructure project, made up of approx 2000 piles based around our design. The piles are predominantly for uplift control on a series of tunnel approach ramps in a high water table environment for the 6 lane highway.

The tunnel designers problem was the tunnel conceptually floating out of the ground, creating many unique design challenges. The piles are 600-700mm diameter helix 32mm thick varying in installed depth up to 35m. The design life of the system is 100 years. We also installed a quantity of piles with a top connection RL of 6m below ground, allowing for future excavation using our unique customised tooling developed in Perth a few years ago for a similar project. Some of the piles were approaching an installed torque of 170000Nm.

The project installation uses excavator based rigs, drive motors, tooling equipment and infrastructure buildings, all owned by Piletech.

Why SFL Piletech?

This project highlights the versatility we bring to any construction job; working closely with the client from the outset to manage expectations, minimise risk and deliver on time and to budget.

  • Design and construct expertise
  • Flexibility in approach
  • Problem solving in complex situations
  • Robust logistics
  • Excellent workmanship
  • Strong work documentation
  • Competitive prices
  • Speed of availability