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Capability Document 2014

The past 12 months has seen Keltbray Piling continue to go from strength to strength as we pass our 5th anniversary. We continue to build on our reputation of successful delivery, having completed the £4.8M contract for rotary bored piling and enabling works at the BSkyB Campus in Osterley as well as the double basement secant wall to exceptional tolerance at Sloane Street. We have also recently been awarded our largest ever contract for the piling works at the prestigious Chelsea Barracks project. This project involves the installation of some 1.2km of 600mm & 1200mm diameter rotary bored secant piles in collaboration with the wider Keltbray Group and the overall client, Qatari Diar. We continue to drive improvements in our safety culture through the adoption of new technologies and procedures such as our hard hat hierarchy system. Our recent capital investment extends to £2.5M in 3Nr new, multi-discipline piling rigs, fitted with the latest environmentally friendly Tier IIIB/IVi engines and associated equipment. We have developed a passion for sustainable and innovative design, working closely with our clients and in-house structural and geotechnical teams in order to focus on total enabling, piling and basement formation packages. We will consider all types of piling, in any environment, although we have developed a niche in complex, logistically challenging inner-city sites. We welcome the opportunity for early contractor involvement in order to develop the right solution for your project and look forward to working with you.

Stuart Norman Managing Director, Keltbray Piling

Our Piling Capability in 2014

Our Mission Statement

“To provide our clients with a quality foundation design and construction service by drawing on the broad range of skills and services of the Keltbray Group, Thereby delivering a reduced construction programme, safely and economically”

1-2 New Ludgate, London –

CFA & Rotary bored bearing piles

Piling Solutions Offered – Core Techniques

CFA Augers on CM50

Small & Large Diameter Piling

Deep Basement Construction

Mini & Micro Piling Rail Piling (from RRVs)

Continuous Flight Auger (CFA)

Secant Piled Walls Sectional Flight Auger (SFA)

Driven Steel Tubes

Cased Secant Piling (CSP)

Contiguous Piled Walls

Case & Auger Case & Auger

Larger Diameter Piling (LDP)

King Post Walls Self Drilled Micro Piles

Plunge Column Piles Ground Anchors

Port of Southampton – CFA bearing piles

Technical Overview - Continuous Flight Auger (CFA) Piling

Advantages of CFA Piling:

• Speed – Quicker to install than rotary bored piles

• Cost – Lower than rotary bored piles

• Low noise & vibration – Virtually vibrationless, without

large peaks and troughs in noise emissions

Our CFA Fleet Capability:

• Modern hydraulic Soilmec piling rigs including SR-30,

SR-75, R625 & CM50 models

• 350mm to 1200mm diameter up to 28m depth

• Fully computer instrumented rigs, ensuring installation

parameters are monitored and recorded for every pile

• We carry a range of equipment , including extra heavy

duty augers for deep basement construction

CFA Augers on CM50

•

“The project itself is immensely complex and at all times the Keltbray Piling representatives

have acted professionally and responsibly, particularly given the extremely sensitive location of these works”

“The construction and technical advice offered by the Keltbray Piling team has been excellent at each stage and I look forward to working with them again in the future"

JEROME BRADLEY SENIOR PROJECT MANAGER THE GLEBE GVA SECOND LONDON WALL

Technique overview - Cased Secant Piling (CSP)

Advantages of Cased Secant Piling:

• Speed – Typically as quick to install as CFA piles

• Cost – Lower than rotary bored piles

• Low noise & vibration – The system is virtually vibrationless,

without large peaks and troughs in noise emissions

• Pile Overbreak – Reduced concrete overbreak as a result of

forming piles within the temporary casing

• Increased verticality tolerance – 1:150 typically for secant

walls compared to 1:75 for CFA walls

Our CSP Capability

• Powerful Soilmec R625 rig fitted with cased CFA capability

• Fully computer instrumented, ensuring installation

parameters are monitored and recorded for every pile

• Pile diameters up to 750mm available

• Up to 19m bored length

CFA Augers on CM50

Cased CFA @The Glebe

R622 at City Road R622 at Three Quays R625 at 100 Cheapside

Three Quays, London, - Rotary bored pilesl

Technique Overview - Large Diameter Piling (LDP)

Advantages of LDP Piling:

• Depth capability – not limited as with CFA piles

• Load bearing - Longer, larger piles can carry much higher

loads than CFA piles

• Tolerances – 1:200 verticality achievable within casing

• Obstruction removal – Various tools are available to ensure

coring through a range of obstructions

• Visual inspection – Ground is excavated in short “bites” so

each layer and the base of the pile are easily inspected

Our LDP Fleet Capability:

• Modern SR-75’s, R625 & SR-30 rotary models to suit all site

& ground conditions

• Pile diameters of 450mm to 2400mm available

• Pile lengths up to 50m

• Bespoke frames for installation of plunge column piles to

1:400 verticality

• Range of pile casings, augers and cleaning buckets

Technique Overview - Mini, Micro and Restricted Access Piling

Through our network of contacts either by cross hire or sub-

contract we have the flexibility to design, manage and install

an extensive range of mini and micro piling techniques in

restricted access conditions:

• Sectional Flight Auger (SFA) 350mm to 600mm diameter

• Mini Case & Auger – 350mm to 600mm in diameter

• Self Drilled Micro Piles – Various diameters up to 250mm

• Ground anchors

Casagrande C6 in Micro Piling mode at Three Quays

Technique Overview - Rail & Trackside Piling

Liverpool to Manchester, Fambo Driving Hammer

Our Rail piling division has growing expertise and experience

having recently completed the second phase of the Liverpool

to Manchester piling works for overhead line electrification.

Keltbray Piling in conjunction with our Keltbray Rail division

are able to carry out work work via our own Principal

Contractors licence. Our current capability includes:

• Fleet of Movax vibratory and Fambo hydraulic hammers

working from Road Rail Vehicles (RRVs)

• Capable of installing up to 610mm diameter steel piles to

depths in excess of 15m

• Patented solution for reducing noise generated during

pile driving

151 City Road

259 City Road, CFA Secant

151 City Road, London –

Rotary bored secant wall

Experts in Piled Retaining Wall Construction

Our specialism as a piling company and as a group includes deep basement construction in confined inner city centres. Below is a project list of our most recent achievements:

Project Scope Max Retained Height

Technique Value

The Glebe, Chelsea 388No 750mm diameter @ 1.15m c/c & 140lm of sheet piling

12.2m Cased Secant Piling, Rotary Bored and Silent Press Sheet Piles

£5.5M

Sloane Street, London 456Nr 600mm dia secant wall piles to a maximum depth of 15m

8.2m CFA (Hard/Firm Secant) £0.59K

261 City Road, London 296No 900mm dia & 63No 880/780mm diameter

8m CFA (Hard/Firm Secant) £0.91M

Holland Green (The Parabola)

650No 900mm diameter 10m Rotary Bored (Hard/Firm Secant)

£3.3M

259 City Road, London 173No 900mm dia 10m CFA (Hard/Firm Secant) £0.85M

151 City Road, London 150No 900mm dia 12m Rotary Bored (Hard/Firm Secant)

£1.1M

W4 – Regent Street, London

200No 600mm dia 6m CFA (Hard/Firm Secant) £1.1M

7-8 St James Square, London

100No Secant wall & 30No Contiguous wall piles, 900mm dia

12m Rotary Bored £1.25M

•

"Keltbray Piling were committed to

ensuring high standards of health, safety and quality on the project. We found that not only did the people of Keltbray have a professional approach, but they were a pleasure to work with.

We would very much look forward to working with them again in the future.”

TIM WOOD PROJECT MANAGER (HOLLAND GREEN) Green) MACE

Proven Ability to Deliver: Selected Project History (2011-2014)

Most Recent

Projects

Bearing Piles Retaining Walls Coring &/or Plunge Cols

Value

Mini Piling or restricted access

CFA 350-1200 mm

LDP 750 mm or less

LDP >750 mm

Contiguous - CFA 600mm dia or less

Contiguous -CFA >600mm

Secant CFA or Cased CFA

Secant Rotary Bored

Sky Building 2 £4.80M

The Glebe £5.50M

1-2 New Ludgate £1.35M

Southampton Docks £0.72M

127-135 Sloane Street £0.51M

Silchester Garages £0.55M

Holland Green (formerly The Parabola)

£3.20M

259 City Road, London £0.85M


W4 – Regent Street, London

£1.10M

7-8 St James Sq, London £1.25M


3 Quays, London £1.10M

259 City Road, London

- CFA secant wall

In-House Technical Excellence

We work closely with our in-house geotechnical and structural engineers. Wentworth House Partnership (WHP) and are therefore able to offer a full design and construction service package for piling and temporary works. Our design team are driven to develop sustainable and innovative solutions, working in accordance with the latest Eurocodes and design standards. WHP have a dedicated Geotechnical Engineering team offering all aspects of support from practical advice through to complex finite element based design.

In-House Technical Excellence

We pride ourselves in designing value engineered alternative solutions for our clients. Our current geotechnical services include:

• Piling, temporary works and basement construction advice

• Specification , supervision and management of site investigation works

• Detailed retaining wall and bearing pile design across a multitude of techniques and disciplines

• Mini & micro-pile design

Our design capability is enhanced through the use of the latest software packages including:

• PLAXIS (2D & 3D) • Adsec • WALLAP • PIGLET • Geoslope • CADS

This is further supplemented through our extensive experience and use of in-house design programs.

One Keltbray - Specialist Support Provided by the Keltbray Group

Recent Project History

Recent Project History – Sky Building 2

Contract Profile

Location:

Client:

Main Contractor:

Quantity Surveyor:

Structural Engineer:

Value:

Programme:

Scope:

As part of a multi-million pound redevelopment of its Osterley Campus, BSkyB are building a new mixed use building comprising approximately 41,000m² of office, studio, production, research and development space.

The conforming scheme at tender stage was based on 1050mm diameter bearing piles, however several value engineering options were offered and later accepted as part of our winning bid.

The first proposed the use of 900mm rather than 1050mm diameter bearing piles which offered both programme and cost savings. Early stage preliminary and working pile load tests were undertaken to confirm design assumptions and the performance of the piles.

With Sky’s strong focus on sustainability our second proposal was the use of recycled aggregate within concrete. In this case, 50% recycled aggregate was incorporated into the concrete mix, providing a reduction in the CO2 generated by the foundation works.

Keltbray Piling used this project to trial several new pieces of technology designed to reduce the risk of accident and injury due to plant and vehicle movements. The piling rigs were fitted with cameras and the VT Overview system to provide 360 degree real time vision for the driver. In addition, all larger items of plant were fitted with Sitezone© which provides a an audible and vibratory warning when personnel enter within a set radius of the machine.

As part of an on going investment programme two new piling rigs were used on this contract. A Soilmec SR-75 (the first of its type in Europe) and SR-30 rotary piling rigs were purchased prior to works commencing and completed their first contract with flying colours.

Keltbray Piling were responsible for pile attendance and muckaway which enabled the programme to be efficiently managed. As part of these works Keltbray employed Bactec to carry out a detailed magnetometer survey of the site to ensure pile positions were clear of ordnance before piling.

Following successful completion of the works Keltbray Piling have since started work on associated schemes with the same project team.

Sky Building 2 P186

Brentford

BSkyB

Mace

Aecom

Arup

£4.7M

18 weeks

Installation of 430nr 900mm diameter bearing piles

2300m2 sheet piled wall

Pile attendance & muckaway

Recent Project History – The Glebe, Chelsea The Glebe, London – Cased secant piling

Contract Profile

Location:

Client:

Main Contractor:

Quantity Surveyor:


Value:

Programme:

Scope:

The redevelopment of Glebe Place involves retaining the existing building and converting the interior space into luxury apartments with a new two-level basement. As part of the development, two new 2-3 storey villa, with 2-3 level basements were constructed. Following on from Keltbray’s demolition works, Keltbray Piling were employed as Principle Contractor on the site to undertake the foundation piling.

Keltbray Piling’s scope was to install 456No. 750mm diameter secant piles to form the new basement box and 309No bearing piles, ranging in diameter from 750-1050mm. The bearing piles incorporated permanent and temporary plunge columns to enable the new basement to be excavated in a top down construction sequence. Both Cased Secant Piling (CSP) and rotary bored technique s were used to construct the piles. Sheet piling was also required along a 180linm length of wall.

The pile design was undertaken by our in-house structural and geotechnical engineering team, Wentworth House Partnership, and required close liaison with the client’s Structural Engineers, AKTII. The secant wall was designed as a multi-propped wall in the both the temporary, and permanent conditions. Design of the bearing piles involved a complex set of loading conditions as the piles had to support both short term temporary loads and the permanent building structure,.

Access into and around the site was extremely limited due to proximity of site boundaries and three storey retained façade. In several areas, specialist restricted access rotary piling rigs were required to install lengths of secant wall and bearing piles. Alongside Glebe Place, sheet piling was required and Keltbray successfully managed these works using a Kowan Still Walker to ensure vibration and noise was kept to a minimum.

The site was located in an exclusive area of Chelsea , with surrounding neighbours on all sides. Careful planning and execution of the works was essential to ensure disruption was kept to a minimum. Keltbray ensured residents were kept informed of the works at all times and piling works were completed successfully within a tight programme schedule.

The Glebe P175

36a Glebe Place, London

Orion Glebe Trustee Ltd.

AKT II

Gleeds

AKT II

£5.5m

28 Weeks

456 No. 750mm diameter secant piles

309No. Bearing piles 750-1050mm diameter

180linm sheet piling

Site management, piling attendance and temporary works

Recent Project History – Holland Green

Contract Profile

Location:

Client:

Main Contractor:

Quantity Surveyor:


Value:

Programme:

Scope:

Keltbray were appointed by Chelsfield Developments for the demolition, enabling works, piling and bulk excavation for a new extensive basement on the site of the former Commonwealth Institute in Kensington.

A 465lm hard/firm secant piled wall, designed by the Clients Engineer, Arup was required to be installed for a new double storey basement. The project was made all the more complex owing to the existing grade 1 listed structure of the Commonwealth Institute which was to be retained and incorporated into the new structure.

Pile installation took place in a defined sequence, adjacent to controlled demolition activities with the Keltbray works package offering the Client significant programme saving as opposed to more traditional procurement methods.

The Clients specification called for pile verticality tolerances of 1:200 determining the need for a rotary bored piling technique. In total, 653No. piles were installed up to 24m using larger 90t hydraulic piling rigs. Piles were also required around the existing structure, under the extended canopy of the signature parabolic roof. These piles were installed using specialist restricted access piling rigs, managed on site by Keltbray. At its peak, Keltbray were operating 5 piling rigs on the site.

Keltbray Piling were also responsible for the installation of the small diameter mini piles in order to support the parabolic roof in the temporary condition. These piles were designed in accordance with Eurocodes and installed in restricted headroom conditions to stringent settlement criteria.

Keltbray delivered a high quality product under the supervision of the Arup resident Engineer with the works also completed on programme.

Holland Green (Parabola) P154

High Street Kensington, London

Chelsfield Developments

MACE

Davis Langdon

Arup

£2.3m

13weeks

653No, 900mm dia Rotary Bored hard/firm secant piles

Recent Project History – 127-135 Sloane Street

“Keltbray Piling, at each step of the process, reassured us of their capability and approach to the

works”

“The scheme is on target to finish mid 2015 with Keltbray Piling making a valuable contribution in meeting this timescale. I would have no hesitation in recommending

Keltbray Piling as a key partner on construction projects” JEZ DYER,

DIRECTOR, CAPITAL & PROVINCIAL

Contract Profile

Location:

Client:

Main Contractor:

Quantity Surveyor:


Value:

Programme:

Scope:

This major development for Cadogan Estates will consist of 135,000 sq ft office and retail space over six storeys in addition to a two level basement. Mace were appointed as Main Contractor for the project with Keltbray Piling being awarded the contract for design and construction of the piled retaining wall.

A secant wall was required around a basement perimeter of 270linm to retain heights of up to 9m. Ground conditions beneath the site consisted of made ground overlying 6m of River Terrace Gravels, with London Clay extending to depth.

Keltbray Piling in conjunction with their specialist geotechnical engineers, Wentworth House Partnership, offered a value engineered design to Mace which required only a single level of temporary props. Significant cost and programme savings were made using this approach in comparison to the Engineers original scheme which required 3 levels of props in some areas. An observational method was employed to manage the risk of ground movements in proximity to existing structures with regular readings from eight inclinometers installed within the piles at critical locations around the site.

For similar retained heights it is common practice to use a rotary bored piling technique to ensure pile verticality and interlock is maintained. Upon careful review of the site investigation information Keltbray proposed a CFA technique which reduced the piling programme. An additional electronic monitoring system was installed in the piling rig which allowed the position and verticality of the pile to be recorded during construction and this information provided to the Engineer. Following excavation to the new basement formation level the position of all piles was surveyed and no significant deviations from the required tolerances were recorded.

Piling works were originally programmed to be completed in a single visit to site however this was eventually split into two separate visits due to delays in enabling work packages. Keltbray worked with Mace to resequence the piling to minimise delays and completed the piling in accordance with this revised programme.

127-135 Sloane Street P174

Sloane Street, London

Cadogan Estates

Mace

n/a

AKTII

£510,893

8 Weeks

270linm secant wall 600mm diameter retaining up to 9m

height

Recent Project History – 1 & 2 New Ludgate

“Keltbray co-ordinated the piling works in-between the existing temporary works propping arrangement and this also

involved amendments to the propping layout which Keltbray undertook.”

“The works were completed on programme, without any health and safety or quality issues. The level of interface and

commitment from the offsite management was excellent and was reflected in the overall work ethic from Keltbray Piling

operatives.”

John Crawley – Operations Director, Skanska UK

Contract Profile

Location:

Client:

Main Contractor:

Quantity Surveyor:


Value:

Programme:

Scope:

The development at 30 Old Bailey and 60 Ludgate Hill covers approximately 0.4 hectares, and will offer a mixed-use development of a new two storey building with high quality office accommodation, new restaurant and retail facilities, improved pedestrian links and new public areas for those working, visiting and living in the area.

Keltbray Piling were appointed by Skanska for the construction of over 800No. bearing piles, constructed using CFA and Rotary Bored methods. The site was split into two main areas, with 460 No. 450/600mm Bearing Piles installed at 30 Old Bailey, and a further 349 No. 450m Bearing piles at 60 Ludgate Hill.

Piles were constructed on site from multiple piling platform levels ranging from +12.50mOD to +4.50mOD. Keltbray utilised three different piling rigs, a Soilmec R312, Soilmec CM50 & Soilmec CM70, due to the different piling techniques and diameters required. Due to the complexity of the site, there was also a number of piles installed using mini piling ‘case & auger techniques’ where piles were in close proximity to raking props.

Pile designs were carried out to Eurocode 7, which although not unusual now, was uncommon in 2010 when the design work was. A preliminary test pile was installed and alpha values of 0.6, as opposed to the usual 0.5 were adopted after back analysis. The site had been previously developed and as a result, hundreds of existing piles were present. This presented a challenge regarding the positioning of new piles to avoid clashes and need to core some areas to install the piles.

As Keltbray Piling were given full access of the site, work was completed several weeks ahead of schedule and comfortably within budget, further aided by the number of different rigs on site.

30 Old Bailey & 60 Ludgate Hill P174

30 Old Bailey & 60 Ludgate Hill, London

Land Securities

Skanska

n/a

Watermans Group.

£1.4m

21 Weeks

460No. 450/600mm bearing piles at Old Bailey

349 No. 450mm Bearing Piles at Ludgate Hill

Recent Project History – 151 City Road

Contract Profile

Location:

Client:

Main Contractor:

Quantity Surveyor:


Value:

Programme:

Scope:

Located on City Road just off Old Street roundabout in London is the site of the new City Road Hotel, the proposed hotel is a 22 storey structure with a 3 level basement. The piling scope comprised the installation of guide walls, secant piled wall, load bearing piles and the removal of pile arisings from site.

Directly opposite the site is Moorfields eye hospital. During the preconstruction phase, Keltbray Piling submitted stringent proposals to ensure vibration during the construction phase was reduced to an absolute minimum. This comprised a detailed methodology together with historical data of piling adjacent to sensitive structures.

Wentworth House Partnership were responsible for the geotechnical design on behalf of Keltbray Piling. The scheme was designed in accordance with Eurocode 7 and detailed pile group analyses were carried out on the bearing piles to reduce the overall number of piles. Engineering advice was also provided to aid the understanding of the structural load transfer from the perimeter columns to the retaining wall.

The 880/780mm diameter secant piled wall was installed using the traditional rotary bored method to achieve verticality tolerances of 1 in 200. The wall comprised of 184No. Male and Female piles at nominal 1400mm centres with interlock to a level of 12 metres, and piles extending to a depth of 22m.

85 No. 880/780mm diameter bearing piles were also constructed using the rotary bored method from the high level and concrete cut off at formation level some 11 metres below ground. The piles were up to 30m long and were founded in the Lambeth Group.

A preliminary pile test was also carried out with the pile fully instrumented using strain gauges. The maximum test load of 9MN was reached without achieving full geotechnical failure. This was unusual in itself as the piles were bored dry, founding in the Lambeth Group. Such a solution was warmly welcomed by the client as the alternative would have meant the use of support fluid, likely adding significant time and cost to the project.

Piling was completed within budget and on schedule, to the satisfaction of the client.

151 City Road P137

151 – 157 City Road, London

Montcalm Hotel Ltd

SGP Contracts

n/a

Curtins Consulting

£1,300 000

16 weeks

85No. 780/880mm diameter rotary bored Bearing piles

184No. 780/880mm dia. male and female secant wall piles

Recent Project History – 7-8 St James Square

Contract Profile

Location:

Client:

Main Contractor:

Quantity Surveyor:


Value:

Programme:

Scope:

Keltbray were appointed by main contractor, Galliford Try Construction for the demolition, temporary works (design and installation) and piling works at 7-8 St James Square, London. These works were required in order to deepen the existing double storey basement by a further 6m and subsequently permit the construction of a new mixed use residential and office development. The grade 2 listed building, No. 7 St James Square, was required to be retained with the new basement formed underneath.

The original scope of works comprised a temporary propped 750mm diameter rotary bored contiguous pile wall, and 600, 750 & 900mm diameter rotary bored bearing piles. Mini piling was also utilised for the temporary works needle piles, to permit the extension of the basement to Nr. 7 St James Sq.

The first phase of the piling works were undertaken during the demolition phase. The piling rig worked from street level, installing the new contiguous piled wall outside of the line of the existing basement. During this phase the rig worked off a two storey, back-propped slab in order to allow demolition work to continue in the southern end of the site.

During the construction of these early piles, it became apparent that the London Clay level dipped significantly. This change in the expected ground conditions was later proven (through extensive additional site investigation works co-ordinated by Wentworth House Partnership) to be a result of the erosion caused by a former tributary of the lost River Tyburn.

This variation lead to a change in the second phase piling works (installed from the existing basement level) from a contiguous to a secant wall around the perimeter. Equally as significant was the subsequent knock-on effect of a major increase in the temporary propping forces.

St. James Square (1 of 2) P145


Green Properties Ltd.

Galliford Try

n/a

Price & Myers

£1.2M

16 weeks

50 No. 900mm Rotary contiguous wall piles

132 No. 900 & 750mm secant wall piles

80 No. 750mm bearing piles (temporary & permanent)

8 No. 750mm tower crane piles

22 No. 340mm restricted headroom mini piles

Recent Project History – 7-8 St James Square

Contract Profile

Location:

Client:

Main Contractor:

Quantity Surveyor:


Value:

Programme:

Scope:

The second phase secant wall piles were increased in diameter to 1000/900mm, and were installed from existing basement level, working in-between the stage 1 raking props supporting the basement walls. This involved detailed sequencing together with Keltbray Demolition, in order to install the guide wall and later the piled wall.

A number of the wall piles and bearing piles had UC’s (kingposts) installed for the temporary works to support the temporary propping of the existing basement. This in itself presented a significant challenge, with the existing basement walls extending up to 7m above the lower piling platform level. This challenge was overcome by pre-stressing the kingposts in order to eliminate the excessive deflection calculated at ground level.

To further complicate the project, the existing sub-station in the centre of the site was required to be retained until the new sub-station was constructed. Therefore, in order to permit the deepening of the basement and ensure bulk excavation in accordance with the programme, a temporary works secant wall was installed using the CFA method around the basement.

Although the project presented a number of unique technical challenges, the logistical challenges were equally as complex with both demolition and piling works sharing the same entrance off St James Square. All concrete, reinforcement, platform material and muck-a-way vehicle movements were co-ordinated in-house.

All piles were designed in accordance with Eurocode 7 and Keltbray designed a scheme with all bearing piles as 880/750mm diameter to minimise the amount of equipment and tools on site.

The needle piling works, supporting the temporary works required to permit the extension of the basement of No. 7 St James, consisted of 340mm restricted headroom mini piles. Owing to the localised dip in level of the London Clay, these piles were constructed using both traditional case and auger and SFA techniques. These piles had full size, spliced UC sections installed in 1.5m sections (owing to headroom restrictions of 2.9m) to support the internal columns and walls thereby allowing the basement to be deepened at a later date.

These works were co-ordinated around the on-going underpinning shafts along the party wall with No 5 St James Square.

Contract Profile P145


Green Properties Ltd.

Galliford Try

n/a

Price & Myers

£1.2M

16 weeks

50 No. 900mm Rotary contiguous wall piles

132 No. 900 & 750mm secant wall piles

80 No. 750mm bearing piles (temporary & permanent)

8 No. 750mm tower crane piles

22 No. 340mm restricted headroom mini piles

St. James Square (2 of 2)

Recent Project History – 100 Cheapside

Contract Profile

Location:

Client:

Main Contractor:

Quantity Surveyor:


Value:

Programme:

Scope:

Skanska chose Keltbray Piling for the piling works at 100 Cheapside after a competitive tendering process. The development involved the demolition of the existing single storey basement building and the subsequent construction of a 10 storey building.

The scope of works for Keltbray Piling was the design and installation of 46No. 600mm diameter, 17No. 750mm diameter and 11No. 1200mm diameter Rotary Bored bearing piles. Pile design was completed by our in house Structural and Geotechnical Engineering team Wentworth House Partnership (WHP), based on Eurocodes 2 & 7. A maximum pile length of 37m was needed to carry the vertical loads.

The site constraints provided a challenge for the works. Not far from the River Thames, the site was L-shaped with maximum dimensions of 21m by 15m, with limited access by surrounding streets. Careful planning, and the selection of the most suitable plant was essential for the project as piling was undertaken from two different piling levels. The site was also of significant archaeological interest, and considerate piling works ensured the successful completion to the satisfaction of the client.

100 Cheapside P168

100 Cheapside, London

Ten Times Ten Developments Limited

Skanska

Quantem

Waterman Structures

£330,000

5 weeks

74No. 600-1200mm diameter Rotary bearing piles

Recent Project History – 261 City Road

Contract Profile

Location:

Client:

Main Contractor:

Quantity Surveyor:


Value:

Programme:

Scope:

AJ Morrisoe & Sons (AJM) appointed Keltbray for the piling works at 261 City Road, London. The scope of works comprised the design and construction of 333 No. 900mm Hard/Firm CFA secant wall pile for the construction of a luxury 36 storey landmark building. In addition to this, Keltbray Piling was responsible for the design and installation of 59 No. 780/880 mm diameter Rotary Bored bearing piles, to depths of 26m below ground level.

The CFA secant wall piles were installed from multiple piling platforms to facilitate the construction of an additional level basement across the entire site. The existing basement was extended by 5.5m using 900mm diameter CFA male and female piles at nominal 1450mm centres, using conventional CFA boring techniques. The secant pile wall acted in cantilever for the temporary condition around the basement.

As the project progressed numerous obstructions along the line of the secant wall were found. A range of options were considered together with AJM, these consisted of both CFA and Rotary Boring techniques in order to clear.

Pile couplers were also incorporated within the CFA pile cages in order to provide a shear connection between the new basement slab and the piled wall. The pile design was completed in house by our structural and geotechnical engineers Wentworth House Partnership in accordance with Eurocodes.

Keltbray piled using the knowledge gained from immediately adjacent sites at 259 and 151 City Road in order to design the bearing piles to a lower factor of safety, without the requirement for static load testing. This involved careful negotiation with both WSP and building control.

The project was completed in 2 separate phases in 2013 in accordance with the Engineers, WSP, requirements and to the satisfaction of our client. Through careful planning and co-ordination, the overall piling programme was completed on time and to budget.

261 City Road P162

261 City Road, London

Mount Anvil Ltd.

AJ Morrisroe & Sons Ltd.

n/a

WSP

£953,000

13 Weeks

217lm of retaining wall in the form 333No. 600-900mm CFA Secant Piles to depths of 23m below ground level. 59 No. 880 mm dia Rotary Bored bearing piles to depths 26m below ground level.

Developer:

Recent Project History – Port of Southampton

“One of the main concerns was the

piling work, so I am relieved

everything has gone smoothly.”

STEVEN GARRIGAN,

PROJECT MANAGER,

VOLKER STEVIN

Contract Profile

Location:

Client:

Main Contractor:

Quantity Surveyor:


Value:

Programme:

Scope:

Berths 201 & 202 of the Container Terminal at the Port of Southampton are to undergo a major redevelopment which will facilitate the accommodation and turnaround of some of the largest container ships around the world. The project involved the installation of a new sheet pile combi-wall to allow the deepening of the adjacent berths by approximately 7m, as well as a new seaward and rear crane rail some 550m along the lengths of the berths.

Keltbray Piling competitively tendered and won the contract to install 298No. 750mm diameter bearing piles to support the new crane rail. During the tender process, Keltbray proposed several value engineering proposals that reduced both cost and programme. These proposals were further developed with the project team during the detailed design process.

Piles beneath the crane rail were subject to a complex combination of loadings. In addition to the temporary and permanent loadings from operation of the crane, a dead man anchor sheet piled wall imposed horizontal loads on the piles. Keltbray undertook the detailed geotechnical and structural pile design in accordance with Eurocode 7.

Ground conditions varied along the length of the crane rail and were characterised using two different design sections. Piles were installed through approximately 10m of made ground, placed during historic ground raising to construct the port. Dense sands and stiff laminated clays of the Bracklesham Beds were found to dip beneath the site and were underlain by the Marsh Farm Formation.

The project was completed in the summer of 2013 in accordance with the Main Contractor’s programme. Through strategic planning and effective implantation of the programme, all works were completed within budget and on schedule to put in place the first steps of a major integrated project.

Berths 201-202 Port of Southampton P170

Berths 201-202, Port of Southampton

Associated British Ports

VolkerStevin

n/a

Mott McDonald

£700,000

10 Weeks

298 No. 750mm diameter bearing piles

Keltbray Piling in the Press

CFA Augers on CM50

Piling & temporary works at 1-2 New Ludgate - Ground Engineering

(November 2013)

Piling & temporary works at 7-8 St James Square - Ground

Engineering (June 2013)

Keltbray Piling in the Press

CFA Augers on CM50

Piling at Port of Southampton - Ground Engineering (April 2013) Piling at 151 City Road - Ground Engineering (August 2012)

David Roy

Proposals Manager

Team Structure

John Price

Keltbray Group

Managing Director

Stuart Norman

Managing Director

(Piling)

Lee Cain

Operations Director

(Piling)

Stuart Marchand

Wentworth House

Director

Jan Jones

Business Development

Leader

Wentworth House

Structural &

Geotechnical Design

Engineers

Keith Stableford

HSEQ

Keltbray Group

Neil Grace

Senior Construction

Manager

Our Team Structure

Keltbray Piling

Keltbray Group

Wentworth House

Greg Haynes

Commercial Manager

Design, Estimating &

Administration

Jason Light

Senior Piling Supervisor

Contract Engineers &

Site Delivery Teams

Stuart Norman – BEng (Hons) CEng MICE

Managing Director (Piling)

Stuart joined Keltbray in 2010 and is a professionally qualified Civil

Engineer with 15 years experience at industry leading contracting

companies. He manages the day-to-day running of the piling division

using his excellent communication and technical skills to bring out the

best in his senior management staff.

Stuart is both dynamic and an innovator, always looking to bring a

unique edge to the projects that we work on for the benefit of our clients

and the overall Keltbray business. He has extensive experience in the

design and estimating of a full range of piling and foundation systems

with a particular interest in bored displacement piling.

Responsibilities

Key

Competencies &

Qualifications

• Chartered Civil Engineer

• Excellent communication & leadership skills

• Management of complex piling, groundworks and rail projects

• Adaption & compliance with processes & procedures

• Proactive problem solving approach

• Management of relationships including 3rd

party

• The day to day management of the Keltbray Piling business.

• Lead the development of new products, systems and procedures.

• Ensure that the content of our systems and procedures are

rigorous and fully communicated.

• Ensure safe handover of projects to the operations teams and

assessment of key project risks.

• Help Keltbray learn from completed projects on site and to

communicate good and bad experiences.

• Attend technical meetings such as ICE, FPS, seminars and

conferences.

• Prepare and present articles and papers ensuring publication.

• Undertake safety & technical audits.

• Identify areas for training of design staff. Undertake performance

reviews.

• Perform role as Delegated Civil Engineer assisting in the training

of graduate Civil Engineers.

• Mentor young engineers

Keltbray were appointed for the demolition, temporary works (design and installation) and piling works at 7-8 St

James Square, London. These works were required in order to deepen the existing double storey basement

by a further 6m and subsequently permit the construction of a new mixed use residential and office

development. The grade 2 listed building, No. 7 St James Square, was required to be retained with the new

basement formed underneath.

Keltbray Piling were appointed by Skanska for the construction of over 800No. Bearing piles to be constructed

through CFA and Rotary Bored method using a heavy duty piling rig. 460 No. 50/600mm Bearing Piles were

installed at the location of 30 Old Bailey, and a further 349 No. 450m Bearing piles at 60 Ludgate Hill.

Design Co-ordinator and later Diaphragm Wall Station Manager for Rokin Station. Responsible for the

supervision and organisation of all construction activities associated with the installation of diaphragm wall panels

to depths of 45m as part of the foundations for the new Metro Station. Development of steering system for

hydraulic grabs to allow panels to be constructed to verticality tolerances of up to 1:400.

Challenging Projects require Innovative Solutions

Location: Metro Station Rokin, Amsterdam

Client: Amsterdam City Council

Main Contractor: Max Bogl

Consulting Engineer: Witteveen & Bos

Value: £40M

Programme: 36 months

Scope: 450no diaphragm wall panels, 1200mm

wide with depths up to 45m including glass

fibre panels for soft eye

Location: 30 Old Bailey & 60 Ludgate Hill

Client: British Land

Main Contractor: Skanska

Consulting Engineer: Watermans

Value: £1.4M

Programme: 21 weeks

Scope: 809 No. 450/600mm Bearing Piles

Location: 7-8 St James Square

Client: Green Properties Ltd

Main Contractor: Galliford Try

Consulting Engineer: Price & Myers

Value: £1.2M

Programme: 16 weeks

Scope: 182no secant & contiguous wall piles

80 No. 750mm bearing piles

22 No. restricted headroom mini piles

Rokin Metro Station - Amsterdam

1-2 New Ludgate

7-8 St James

Lee Cain

Operations Director (Piling)

Lee has over fifteen years experience in the construction industry

gained in piling, ground works and rail works. Lee has worked with

Keltbray for more than 5 years as a Contracts Manager and more

recently taking on board additional responsibilities as Operations

Director.

Having managed projects in both the UK and the Gulf region he enjoys

the continued daily challenges offered by the multi-disciplinary projects

Keltbray undertake.

Responsibilities

Key

Competencies &

Qualifications

• Construction site Management NVQ Level 6, SMSTS, SSSTS,

Appointed Person

• Excellent Communication and leadership skills

• Management of complex piling, groundwork's and rail projects

• Adaption and compliance with processes and procedures

• Proactive problem solving approach

• Management of relationships including third party

• Ensuring the successful delivery of the project and that the defined

scope is delivered to cost and programme.

• Provide safe working conditions for all site operatives, visitors and

third parties

• Understand and implement the project and specific specifications

and deliverables

• Ensure that the projects, as well as Keltbray’s procedures/systems

are adhered to

• Oversee administration and record keeping for the duration of the

project

• Report to operations director

Adjacent to the Tower of London, has been developed for both retail and residential purposes. Installed 128no

bearing piles ranging from 600-1500mm and to depths of 32m. Existing piles made the project challenging and

had to be cored out beforehand. Keltbray Piling competed the works 2 weeks ahead of contract completion

date.

Holland Green (formerly The Parabola)

The Glebe, Chelsea

Three Quays

Our scope was to install a 465lm hard/firm secant piled wall whilst retaining the existing grade 1 listed

structure. Keltbray also installed mini piles in order to support the Parabolic roof in temporary condition. Up to

5 piling rigs were working on site at any one time. Pile installation took place in a defined sequence , adjacent

to controlled demolition activites.


Location: Kensington High Street

Client: Chelsfield

Main Contractor: Mace

Consulting Engineer: Arup

Value: £3.1M

Programme: 13 weeks

Scope: 653no. 900mm diameter rotary bored

hard/firm secant piled wall

Location: Lower Thames Street, London

Client: Cheval Group

Main Contractor: Mace

Consulting Engineer: Ramboll

Value: £1.6M

Programme: 10 weeks

Scope: Installation of 128no rotary piles from 600mm-1500mm dia

Location: Glebe Place, Chelsea

Client: Orion

Main Contractor: Keltbray

Consulting Engineer: AKTII

Value: £5.5M

Programme: 28 weeks

Scope: Basement wall consisting 223linm secant

and 140linm sheet piling, 250 bearing

piles including 87 plunge columns

Working in an extremely sensitive environment with a large retained façade, this project was the largest ever

secured by Keltbray Piling. Scheme consisted of rotary bored piles for both secant wall and bearing

elements, sheet piling and restricted access piling to provide a new 3 storey basement for this prestigious

residential development.

David Roy (MSc, FGS)

Proposals Manager for Keltbray Piling

David is a Geotechnical Engineer with 10 years experience within the

construction and ground engineering industry. Initially working as part

of a busy regional estimating team, David has built up a wide

experience of a range of ground improvement and piling techniques.

His technical knowledge, particularly in the design of deep foundations

and retaining structures, was further developed after working for several

as a Design Engineer, leading the design development and detailing of

several major projects in London.

More recently, David has focused on maintaining and expanding

Keltbray’s client base, while developing internal estimating and

management systems.

Responsibilities

Key

Competencies • Extensive knowledge of ground improvement and piling techniques

• Ability to organise and communicate within a project team

• Producing high quality bid and supporting technical documentation

• Review of pre qualification documents and tender enquiries

• Producing competitive bids for bearing pile and retaining wall

schemes

• Assist design engineers in producing efficient, value engineered

foundation designs

• Advise clients on value engineering options for foundation

schemes

• Manage graduate design engineers and estimators

• Regularly attend meetings with Clients and Engineers to discuss

and develop schemes

• Carry out and check tender pile and retaining wall designs to

latest standards

• Attend industry events and keep up to date with new products and

techniques

• Maintain current customer base and ensure high quality of service

to key clients.

• Develop industry presence and market visibility

• Develop internal estimating systems to increase efficiency

Responsible for the design of deep foundations and retaining walls to Eurocode 7. Bearing piles up to 2.4m

diameter, 65m deep, constructed under bentonite support fluid were required to support structural loads of up

to 40MN. Plunge columns of 750mm sq were installed to allow a top down methodology to be adopted.

Secant wall up to 1200mm diameter was designed to retain 15m deep basement excavation in a single span.

The Glebe, Chelsea

Bid Manager for piling and ground improvement package for this landmark bridge on the London Olympic site.

The scope of work changed dramatically during construction, requiring detailed redesign and on-going design

development. Design had to integrate both Olympic and legacy mode uses for the bridge.

Central Park Bridge, London Olympic Site

100 Bishopsgate, City of London

Responsible for commercial submission to secure largest contract to date for Keltbray Piling. Working in an

extremely sensitive environment with a large retained façade, the scheme consisted of rotary bored piles for

both secant wall and bearing elements, sheet piling and restricted access piling to provide a new 3 storey

basement for this prestigious residential development.



Client: Orion



Value: £5.5M

Programme: 28 weeks


and 140linm sheet piling, 250 bearing piles

including 57 plunge columns

Location: Queen Elizabeth Park

Client: Olympic Delivery Authority

Main Contractor: Lagan Construction

Consulting Engineer: AKTII / Mott MacDonald

Value: £1.2M

Programme: 20 weeks

Scope: CFA bearing piles at bridge abutments,

vibro concrete columns supporting

approach embankments & reinforced earth

retaining walls

X

Location: Bishopsgate, City of London

Client: Brookfield / Great Portland Estates

Main Contractor: Brookfield Multiplex

Consulting Engineer: Robert Bird Group

Value: £10M

Programme: 34 weeks

Scope: 338linm secant wall and 152 bearing piles


X

Neil Grace

Construction Manager for Keltbray Piling

With 18 years experience in the construction industry, Neil has

managed piling projects up to £20M in value. Initially working as a Site

Engineer and progressing to Foreman, Neil was responsible for

managing piling works on a day to day basis using CFA, rotary bored

and sheet piling techniques. Moving in to major projects, Neil has

managed some of the largest piling contracts in the UK, including The

Shard, Heathrow T2B and more recently several major Crossrail

infrastructure contracts involving a range of piling techniques.

A committed and knowledgeable individual, Neil’s ability to manage

plant and labour resources to meet challenging deadlines is invaluable.

Responsibilities

Key

Competencies • NVQ Level 3, Civil Engineering Site Supervision

• HNC Civil Engineering

• CSCS Site Manager Safety Training Scheme (SMSTS) IOSH

• CSCS Gold Skilled Card.

• CPCS Crawler Crane Operator

• CPCS Slinger Signaller

• Management of plant and labour resources to ensure project

deadlines are met or bettered.

• Liaison with principle contractor and client.

• Financial and programme contractual reporting both internally and

to project team.

• Performance against budget and on site efficiency.

• Supporting bid team with sequencing and planning of projects at

tender stage.

• Review of site processes, systems, standards and training to

improve business efficiency.

Over 700 rotary bearing piles 1.2-1.8m in diameter were required to support the new terminal building on this

project. Top down construction was chosen in some areas, requiring 163nr piles to be constructed with plunge

columns. Up to 6nr. Piling rigs were worked 24 hours a day to meet programme. Works were carried out to

the highest levels of health and safety due to the proximity of live airport operations.

Crossrail – Whitechapel Station

Working on a site measuring just 40x35m, detailed 3D models were needed to ensure the piling works could be

completed safely. The diaphragm wall shaft was constructed up to 60m depth, requiring reinforcement cages to

be joined in a dummy diaphragm wall panel before installation. Surrounded on all sides by existing buildings or

roads and with two underground lines running beneath the site, site logistics proved a major challenge.

Crossrail – Liverpool St Station (Moorgate Shaft)

Heathrow T2B

This project involved the installation of two diaphragm walls for ventilation and access shafts to the new

Whitechapel Crossrail station. Diaphragm walls were sunk to depths of up to 30m to form the new 28m

diameter Durwood Street shaft and the 57x21m box structure.


Location: Whitechapel, London

Client: Crossrail

Main Contractor: BBMV

Consulting Engineer: Hyder

Value: £13.5M

Programme: 7 months

Scope: 28m dia diaphragm wall shaft

57x21m diaphragm wall box

Location: Liverpool Street, London

Client: Crossrail

Main Contractor: BFK

Consulting Engineer: Mott MacDonald

Value: £12M


Scope: 6165m2 diaphragm wall to 53m

1714m2 strutting diaphragm wall to 42m

Location: Heathrow Airport

Client: BAA

Main Contractor: Balfour Beatty


Value: £30M


Scope: 2,000linm diaphragm wall

705nr. bearing piles

163 plunge column piles

Greg Haynes (BSc Hons)

Commercial Manager

Greg is a professional and skilled Commercial Manager with vast

experience in main contracting, sub-contracting and the chartered

surveying side of the business; together with knowledge from numerous

sectors within the construction industry and the communications

market.

A determined individual with good interpersonal and negotiation skills

and a strong drive to improve processes and functions with an

organisation.

Responsibilities

Key

Competencies

• Knowledge of complex structures,

• Excellent presentation skills & IT abilities

• Provision of ‘usable’ commercial advice

• Objective approach, focused on achieving a successful contract

• Sound commercial understanding of the contract

• To participate in the management of each contract by providing

commercial and financial advice to the contract team at all stages

of a contract

• Production of interim applications throughout the contract through

to agreement of the Final Account

• Successful appointment following procedural selection, of

subcontractors that may be required for the contract

• Administer all sub-contracts through to Final Account

• Produce realistic evaluation of variations

Keltbray Piling competitively tendered and won the contract to install 298No. 750mm diameter bearing piles to

support the new crane rail. During the tender process, Keltbray proposed several value engineering proposals

that reduced both cost and programme. These proposals were further developed with the project team during

the detailed design process.

100 Cheapside

Assisted with commercial submission to secure largest contract to date for Keltbray Piling. Working in an

extremely sensitive environment with a large retained façade, the scheme consisted of rotary bored piles for

both secant wall and bearing elements, sheet piling and restricted access piling to provide a new 3 storey

basement for this prestigious residential development.

The Glebe

Berths 201-202 Port of Southampton

The site constraints provided a challenge for the works. Not far from the River Thames, the site was L-shaped

with maximum dimensions of 21m by 15m, with limited access by surrounding streets. Careful planning, and

the selection of the most suitable plant was essential for the project as piling was undertaken from two

different piling levels.


Location: 100 Cheapside, London

Client: Ten Times Ten Developments Ltd

Main Contractor: Skanska

Consulting Engineer: Waterman Structures

Value: £339,947

Programme: 4.5 weeks

Scope: 79nr Piles 600-1200mm diameter


Client: Orion Glebe Trustee Ltd



Value: £5.5M

Programme: 28 weeks


and 140linm sheet piling, 250 bearing piles


Location: Southampton

Client: Associated British Ports

Main Contractor: VolkerStevin


Value: £698,753

Programme: 10 weeks

Scope: 300no 750mm diameter CFA piles

Keltbray Ltd St Andrew’s House Portsmouth Road Esher KT10 9TA | T 020 7643 1000 | F 020 7643 1001 | E

Stuart Norman, Managing Director, M 07793 650 514 E [email protected]

David Roy, Proposals Manager, M 07827 351 495 E [email protected]

Lynsey Bratton, Administrator, D 0207 643 1000 E [email protected]

www.keltbray.com

mailto:[email protected]



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