Cementation - Total foundation engineering

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Total foundation engineering

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For more than 100 years, Cementation Skanska has been an internationally recognised piling and ground engineering specialist contractor. What makes us different is the breadth of our expertise in all aspects of geotechnical engineering, from micro-piling to diaphragm walls.

Transcript of Cementation - Total foundation engineering

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Total foundation engineering

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Total foundation engineering

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For more than 100 years, Cementation Skanska has been an internationally recognised piling and ground engineering specialist contractor. What makes us different is the breadth of our expertise in all aspects of geotechnical engineering, from micro-piling to diaphragm walls.

Operating in almost every sector, we deliver projects of all sizes across the UK. We achieve this by working as a team with our clients, partners and supply chain. We have many years’ experience of this collaborative approach, sharing knowledge at every stage of the development process and making key decisions together. Alongside our supply chain, we constantly push the boundaries to develop innovative, cost-effective, safe, green solutions. As well as finding the most sustainable solutions for our clients, we apply them to our own facilities, such as our brand new £14m Bentley Works fabrication plant in Doncaster.

Innovation is a key factor in our success, and our teams use the very latest digital engineering technology to design and install piles and foundations. This saves time and improves performance. Safety is also paramount, and our Injury-Free Environment behavioural safety initiative means that we look after each other to make sure our employees, supply chain partners and stakeholders all go home safely at the end of each day.

My team and I look forward to working with you to turn your vision into a reality. We call it ‘Total foundation engineering’.

Cameron Foley Managing Director

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Leaders in our fieldOur in-house design team offers a huge range of geotechnical experience to ensure the success of your project. Our experts are at the forefront of engineering solutions, from deep-piled foundations and piled embedded retaining walls, to complex tunnel-pile interaction problems requiring innovative solutions.

Our designers have played a leading role in the implementation of Eurocodes (European Codes of Practice for the design of structures) for pile design in the UK, and have developed advanced, in-house modelling software for design optimisation. Our design team is committed to technical excellence through back-analysis of real pile performance, and through continuous research collaboration with several leading UK universities.

We are always striving to implement new ideas and techniques to advance the state of the art. A recent example of this is our innovative Energy Piles™, which use geothermal energy to assist in the heating and cooling of buildings. We have decades of experience and a worldwide reputation for delivering high-quality results, and our passion for technical excellence is second to none.

Cementation Skanska is also leading research and development in foundation reuse and smart foundation technology, as a key industry partner in the Cambridge Centre for Smart Infrastructure and Construction programme.

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A trusted partner Partnering is at the very core of Skanska’s business ethos. By working together with our clients, partners and supply chain, we can achieve amazing things. In fact, the majority of our work is delivered through partnerships, and we strongly believe that this approach offers the greatest scope to move the industry forward.

By working together, we make a positive difference to every project we undertake. A key part of this is our resolute commitment to a more sustainable world, creating innovative solutions and setting high standards in green construction, as well as helping project stakeholders to make more sustainable choices.

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RailOver the past 20 years, we have designed and built more than 35km of earth structure remediation projects across the UK’s rail network. In addition, we stabilised old coal workings to allow the Borders Railway to be reconstructed, injecting 5,000 tonnes of grout into 325m of borehole at depths of up to 70m. For the upgrade of London’s Victoria station, our geotechnical experts installed secant walls for two new ticket halls.

EducationThe piling carried out by our team at Woodlands School in Essex was integral to the success of the £26m building and the 1,500 students who now use it.

Our work was rewarded with the BIM Project of the Year prize at the British Construction Industry Awards.

Commercial propertyAt 6 Bevis Marks in London we contributed to make the 16-storey office building 80% more efficient than its predecessor. By reusing 67 existing piles, we saved over 1,000 tonnes of carbon.

Our work on 6 Bevis Marks also received Ground Engineering magazine’s sustainability award.

Expertise across many sectors

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Opened in May 2015, the new Queen Elizabeth University Hospital in Glasgow is one of the most advanced primary care facilities in the UK, and the largest design-and-construct project ever awarded in Scotland.

Cementation Skanska’s work on the project was our largest piling contract in Scotland to date. We installed approximately 2,000

Queen Elizabeth University Hospitalload-bearing piles, ranging from 600mm-1,200mm in diameter at depths of up to 30m, using rotary bored and mini-piling techniques. At its peak, we had more than 50 operatives and seven rigs deployed on the contract.

The 45-week operation was completed by our team on time and to budget.

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CrossrailAs one of the UK’s largest geotechnical specialists, Cementation Skanska delivers an unparalleled range of high-value, complex projects.

For instance, for the new Paddington station box, we installed 165 diaphragm wall panels, each 1.2m wide, to a maximum depth of 42m and to a vertical tolerance of 1:200. We also installed 30-tonne steel reinforcing cages with four levels of box-outs, to tolerances of ±50mm.

On the Plumstead Portal project, we delivered a diverse range of techniques, including diaphragm walls, cased CFA secant walls, rotary bored tension piles and standard CFA bearing piles.

Bond Street station required our engineers to research and implement new techniques to achieve the client’s exacting requirements. Pushing the boundaries of geotechnical engineering, we installed the following:

• 24-tonne reinforcement cages

• 59.5m-long reinforcement in secant walls

• Plunge columns over 34m long and 21 tonnes in weight

• Geothermal pipes for improved sustainability in both walls and piles

• Base grouting

• Permanent liners, 2.3m diameter, 20m deep

In total, we cast more than 33,000m³ of concrete and installed 6,750 tonnes of reinforcement across the Bond Street site. We also worked to cut-off levels up to 32m below ground for the bored piles.

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PublicThe £85m Brent Civic Centre, constructed in London by Skanska, has been recognised as one of the UK’s greenest buildings and is the first public facility to be awarded a BREEAM ‘Outstanding’ rating for its sustainable design.

Our team installed more than 1,000 piles on the project, 476 of which formed a contiguous bored pile wall.

RetailOur piling for the extension of St. Enoch Square, one of Glasgow’s major retail destinations, required the shopping centre to remain fully operational throughout the works. Piling up to 30m deep also had to be carried out within just 10m of the live St. Enoch subway station.

Our works included 75 mini piles, 116 rotary bored piles installed under Bentonite solution, and 85 soil displacement piles.

ResidentialThe Corniche in Vauxhall, London, is a landmark riverside development situated in the Nine Elms regeneration area offering luxury apartments.

We installed 420 interlocking secant piles to depths of up to 23m across this highly constrained site. By adopting a cased secant piling technique on the wall piles, we achieved significantly tighter verticality tolerances without sacrificing outputs.

Expertise across many sectors

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Specialist piling techniques

We offer unparalleled expertise in piling, foundations and ground engineering, and maintain a large team of in-house design and technical experts. We currently offer the following specialist techniques:

• Rotary bored piles

• Continuous flight auger piles

• Cased continuous flight auger piles

• Bored displacement piles

• Diaphragm walls

• Secant walls

• Driven cast-in-situ piles

• Under-reamed piles

• Grouting

• Soil nails

• Ground anchors

• Computer modelling

• Energy Piles®

• Pile testing

• Track level monitoring

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Continuous flight auger

We have installed countless vibration-free piles using Continuous flight auger (CFA) techniques.

Our CFA installations have included three buildings within the MediaCityUK complex in Salford, near Manchester. Boasting some of the largest production studios in Europe, the development has regenerated Salford Quays and become a northern hub for a number of high-profile organisations, including the BBC and ITV.

Cemloc©

We developed the Cemloc© system to accurately place plunged columns into bearing piles — most effective when carrying out ‘top-down’ construction.

We implemented this technique, which uses rotary bored piling techniques, on the Bulgari Hotel redevelopment project in Knightsbridge. The Cemloc© frames were used to position and embed these columns from ground level to ensure that the tight constructional tolerances could be achieved at the cut-off, six storeys below.

Rotary bored piles

Our fleet of rotary piling rigs can install piles ranging in diameter from 375mm to 3,000mm, including specially-designed drilling tools, buckets and grabs to suit all design configurations and ground conditions.

At London Bridge Place we installed 98 bearing piles, ranging from 750–2400mm in diameter. The work included permanent liners and plunge columns, together with 170m of 900mm cased CFA pile wall.

Rig loadings: 35–164 tonnesPile diameter: 375–3,000mmMaximum depth: 75mWorking load: 400–53,000 kN

Key capabilities

Pile diameter: 1,200–2,400mm

Key capabilities

Rig loadings: 28–105 tonnesPile diameter: 350–1,200mmMaximum depth: 32mWorking load: Up to 8,000 kN

Key capabilities

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Cased continuous flight auger

We were the first company in the UK to use the cased continuous flight auger process, an innovative form of piling which not only commands superior cutting power, but also reduces vibration, making it ideal for environmentally sensitive areas.

The technique was used extensively by our team when working on Ebury Square and The News Building in London Bridge.

Soil and screw displacement

The screw displacement system is quiet, vibration free and produces virtually no spoil, with a completed pile profile that resembles a screw with nominal pile core. The technique ensures optimum performance, with lower environmental impact and lower costs.

Our contribution to the new HMP Thameside, more than 1,000 piles, helped the prison achieve a world first — an ‘Outstanding’ BREEAM environmental accreditation for the design stage.

Driven cast-in-situ

Driven cast-in-situ piles are fast to install and suitable for most ground conditions. They are top-driven and installed using crawler-mounted rigs, which are fully instrumented and use efficient hydraulic hammers.

We installed almost 600 such piles to support construction of the new Riverside Museum in Glasgow.

Rig loadings: 60–105 tonnesPile diameter: 335–525mmMaximum depth: 24.5m Working load: 350–1,500kN

Key capabilities

Rig loadings: 80–90 tonnesPile diameter: 410, 510, 610mm (soil) and 300/600mm (screw)Maximum depth: 21.5mWorking load: up to 1,500kN (soil) / 1,000kN (screw)

Key capabilities

Rig loadings: 140–184 tonnesPile diameter: 600–1,000mmMaximum depth: 26mWorking load: up to 8,000kN

Key capabilities

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Pile removal

With city centre space at a premium, the pressure to build on previously developed land is increasing. This often necessitates the removal of existing piles, which we carry out using rotary bored techniques.

We used this method at Bankside 123, a three-building office development in London, where we removed over 300 piles to facilitate the installation of two secant walls.

Secant and contiguous walls

This method offers the fastest and most efficient solution when short-term soil and water retention is required. Piles are installed through guide walls using both rotary bored and continuous flight auger techniques.

At London’s Bond Street station, we installed secant wall piles with geothermal loops to support two new ticket halls. The work was carried out in preparation for Crossrail, Europe’s largest infrastructure project.

Diaphragm walls

Diaphragm walls are suited to deep retaining walls and provide a high level of leak protection.

We have carried out major diaphragm wall projects on landmark infrastructure schemes, such as Crossrail, the Amsterdam Metro and Stratford Box — the largest such operation ever completed in the UK.

Rig Loadings: 140–184 tonnesPile diameter: 600–1,200mm

Key capabilities

Rig loadings: 120 tonnesWall thickness: 600–1,800mmMaximum depth: 80m

Key capabilities

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Soil nails and ground anchors

Soil nailing is a method of slope stabilisation made possible by installing fully-bonded ties into the ground.

The process, which is both cost-effective and faster than alternative retention techniques, was used to install 900 nails on our M1 widening project.

Ground anchors can be either temporary or permanent, and are normally used for propping retaining walls.

Mini piles

Mini piles are ideally suited to challenging ground conditions, the interior of existing buildings and constricted working areas. We use a range of techniques, including Down The Hole Hammer, case-and-auger, rotary duplex and rotary percussive.

When working on the award-winning Quadrant Three in Regent Street, London, our 25 years of experience in mini piling enabled us to operate at optimum efficiency in space-restricted basements while protecting the Grade II listed structure’s heritage features.

Grouting

For 50 years we have played a key role in the development of grouting techniques, with unrivalled experience on some of the UK’s largest and most complex geotechnical projects.

On the Borders Railway reinstatement, we drilled over 325km of boreholes and injected 5,000 tonnes of grout to treat abandoned coal workings beneath the rail track.

Our techniques include bulk infill (infilling of cavities and deep old coal workings), chemical (stabilising granular materials using chemical injections), jet grouting (formation of grout columns), compaction grouting (injection into granular materials at close centres) and compensation grouting (a ground treatment that limits damage to existing structures).

Rig loadings: 1.5–14 tonnesPile diameter: 102–660mmMaximum depth: 50mWorking load: 40–1,500kN

Key capabilities

Rig loadings: 1.5–14 tonnes

Key capabilities

Rig loadings: 1.5–14 tonnesPile diameter: 50–300mm (nails) and 100–300mm (anchors)Maximum depth: 35m (nails) and 50mm (anchors)Working load: 10–500kN (nails) and 50–2,250kN (anchors)

Key capabilities

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Our piling and ground engineering fleet is one of the largest and most versatile in Europe. In fact, over 60% of our units are multi-functional. From 2-tonne to 190-tonne-class rigs, we can install piles from 150mm to more than 3m in diameter.

Rigs are maintained by our in-house specialists, both in the field and at our state-of-the-art facility in Doncaster.

Our team works in close collaboration with our suppliers, not only to ensure that we have the most up-to-date equipment, but also to develop and advance machine technologies. For instance, by using Euro Tier 3b and IV engines, together with related technologies, we have achieved a 15% reduction in fuel usage, equivalent to more than 500 tonnes of CO2 per year. To further improve sustainability, all of our rigs use biodegradable lubricants.

Our constant investment in plant and equipment translates to real benefits to our clients, as the low average age of our fleet contributes to an unprecedented average annual downtime of less than 2.5%. This allows us to offer the highest levels of reliability, availability and capability, all managed using our own in-house resources.

Our fleet and equipment

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Cementation Skanska is constantly embracing the latest technologies to make our projects as efficient as possible. Building Information Modelling (BIM) embeds key data within a three-dimensional model that effectively manages information throughout the project, from early design to construction and handover.

Always at the forefront of technogy, we have been developing BIM, its process, standards, workflow and staff training since 2010. It enables our teams to work smarter and with greater efficiency, eliminating defects and clashes before the construction phase.

The technology links up with mobile devices in the field, such as tablet computers, enabling our people on site to access the model and the latest plans. This translates into the cost savings that go hand-in-hand with a project that has fewer defects and a shorter installation period.

BIM-enabled mobile technology also speeds up the quality assurance and sign-off processes. It cuts down on paperwork and provides evidence that faults have been fixed, all at the press of a button.

Other benefits we are delivering through BIM include:

• The ability to plan and test designs in a ‘virtual world’, reducing defects, risk, time and cost

• Access to up-to-date models, drawings, spreadsheets and specifications in the field

• Immediate access to a database that links our design and construction teams together, allowing them to view and update the latest information in real time

• The ability to capture, report and track issues using digital technology

• Improved safety and communication throughout the life of the project

BIM and digital engineering

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M1 Junction 19BIM played a key role in the redesign of this major motorway interchange, where we installed over 750 piles across six of the 10 bridges under construction. Using highly detailed 3D models, BIM helped us to plan almost every aspect of the piling programme and react quickly to changes. This meant we could work safer and more efficiently, always operating to the highest quality standards.

Out in the field, our team always had the most up-to-date information at their fingertips. By making it easier to see and optimise the placement of piling rigs, cranes and other machinery, we were able to identify and resolve issues before work began, ultimately saving time and money for both ourselves and the client.

Cementation Skanska Project Manager, Kevin Burns, says: “BIM saves a huge amount of time and reduces errors, as the information does not have to be written down during the day into notebooks and then typed up at the end of the shift.”

By downloading relevant project data directly into tablet computers using Wi-Fi or 4G, our site teams always have access to the most up-to-date information.

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Founded more than a century ago, our advanced fabrication facility at Bentley Works in Yorkshire employs a multi-skilled workforce of mechanical and civil engineers. They are experts in production design, fabrication, welding, electrical engineering, hydraulics and Computer Numerical Control (CNC) machining.

Using state-of-the-art equipment, we can manufacture small and intricate components for our piling rigs, as well as bespoke structural items up to 40m in size for temporary or permanent works.

Our steelwork is CE certified to British Standard EN 1090-2, including Execution Classes one, two and three, so that our products meet all European health, safety and environmental regulations.

Bentley Works

From left to right: The Cementation Skanska Senior Leadership Team: Yvonne Lynn, Jamie Dunbar, Tyrone Fletcher, Tina Patel, Jonathan Morris and Cameron Foley.

Bentley Works is Skanska UK’s most sustainable building and is developed to the highest environmental standards. The site is extremely energy efficient, with almost no impact on the environment.

Our plant and machinery are all equipped with low-emission engines and use recycled hydraulic oils. This benefits our customers, our business, the environment and the future.

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Our experts use the latest technology, including Computer Numerical Control (CNC) machines, to produce intricate and bespoke designs.

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We’re safeOur Injury-Free Environment programme fosters a culture of care and concern for others. It encourages everyone to take responsibility for the well-being of their colleagues and themselves, and extends to our partners and supply chain. We also operate advanced safety management reporting systems and processes.

We’re greenWe are committed to contributing actively to a green society. The ultimate aim of our Journey to Deep Green™ is for all Skanska projects to have almost no impact on the environment. We use the Skanska Color Palette™ to measure how green our projects are, providing us with ever-more-challenging goals as environmental performance standards evolve.

Passionate people

We’re ethicalWe believe in treating everyone fairly. That goes for our employees and everyone we work for, and our commitment to high ethical standards runs throughout the company. Being an ethical company is good for employees, good for society and, ultimately, good for business. We also place great value on diversity, which helps us to maintain the best possible pool of innovative individuals across our business.

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If you’d like to discuss how we can help with your project, please get in touch. Our team of experts is ready to help you achieve first-class results, no matter where in the UK you’re located.

[email protected]

Our regional offices

Brandon FerreiraBusiness Development

01923 423023

[email protected]

Gordon SimsRail/Ground Engineering

0330 1050221

gordon.sims@ skanska.co.uk

Julian MansfieldPreconstruction

01923 423528

[email protected]

Steve JoynsonPlant and Fabrication

0330 1050187

steve.joynson@ skanska.co.uk

Head OfficeMaple Cross House Denham Way Maple Cross Rickmansworth Hertfordshire, WD3 9SW

Reception: 01923 423100

Bristol240 Park Avenue Aztec West Bristol, BS32 4SY

Reception: 07876 873462

DoncasterNeelands House Bentley Works Pipering Lane Doncaster South Yorkshire, DN5 9NB

Reception: 0330 105 0135

ManchesterAtlantic House Atlas Business Park Simonsway Manchester, M22 5PR

Reception: 0161 437 4316

Get in touch

MotherwellExcel House 1 Renshaw Place Eurocentral Lanarkshire, ML1 4UF

Reception: 01698 735899

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Chris Grodzicki Scotland/Ireland

01698 735872

chris.grodzicki@ skanska.co.uk

Graeme Mitchell South

01923 722122

[email protected]

Mark BodenNorth

0330 1050143

mark.boden@ skanska.co.uk

Shane Baker London

01923 423423

shane.baker@ skanska.co.uk

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Cementation Skanska

Maple Cross HouseDenham WayMaple CrossRickmansworthHertfordshireWD3 9SWTel: 01923 423100

www.skanska.co.uk/Cementation