Innovation in Engineering
PILING SERVICES CAPABILITIES OVERVIEW 2023
Keltbray is a specialist construction engineering and infrastructure solutions group
Our purpose is to redefine the way sustainable development is delivered. Based on our collective experience, we collaborate at the earliest stage to design and self-deliver innovative customer solutions across technically demanding built environment and infrastructure sectors. Working in partnership with our stakeholders, we are actively contributing to economic growth, social advancement and environmental protection.
Contents Group overview 2 Introduction 6 Piling capabilities 8 Piling innovation 10 Sustainability framework 16 HIPER® Pile and EFC 18 Contact 20 1 Keltbray | Piling Services capabilities overview | 2023
Group overview
A SUSTAINABLE BUSINESS MODEL
We are focusing our integrated services on solving customers’ engineering challenges in a rapidly changing world.
The resilience of the Keltbray model and the commitment of everyone in the business has shown the resourcefulness, agility and above all else, the dedication to the customers we serve and the communities in which we operate.
WHO WE ARE
Keltbray is a UK-leading specialist construction engineering and infrastructure services business, offering a range of self-delivered solutions for blue-chip public and private sector customers.
WHAT WE DO
Operating in highly-regulated ans safety-critical sectors, we are a key player in developing and maintaining Britain’s economic infrastructure and built environment, and in selective overseas markets.
Our customers trust us to deliver certainty on their projects – to specification, safely, on programme, within budget and with care for the environment and the communities that host us.
Our integrated delivery approach is underpinned by the significant investments we are making in the development of our people, our specialist delivery capabilities and our research and development agenda. It focuses our business on engineering innovation and delivery excellence to provide greater value for all our stakeholders.
WHY WE DO IT
Our purpose is to redefine the way sustainable development is delivered. Our long established expertise means that we offer standalone and holistic services, to meet our clients’ complex and changing engineering demands to enhance, upgrade and decarbonise their capital assets.
HOW WE DO IT
Keltbray’s distinctive delivery model is based around a set of complementary capabilities that together constitute the way we go to work to deliver certainty through the smart solutions we provide for our customers.
SCAN TO WATCH OUR FILM
Watch our corporate film to find out what we do and how we are redefining the way sustainable development is delivered
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Our progressive approach seeks to break down the barriers to success inherent in traditional contracting models. Clients need to feel confident entrusting their investments with a delivery partner capable of turning vision into reality. They need to be certain the end result will meet their expectations – and will be completed to the agreed programme, budget and specifications.
We believe that our delivery model has the potential to address these challenges – and the key to unlocking its benefits lies in deep and trusting client relationships that allow us to engage early on projects as a prerequisite to delivering greater value. It is only when clients and delivery partners – along with designers and others with vested interests – collaborate from the outset, as part of an integrated team, that opportunities for innovation in engineering can be fully exploited.
STRATEGIC CUSTOMER RELATIONSHIP MANAGEMENT
Inherent in the way we go to work is a different kind of client/delivery partner relationship management approach – one based on establishing and maintaining long-term strategic relationships where both parties’ interests are aligned to deliver mutual benefit.
INNOVATIVE ENGINEERING EXCELLENCE
We work collaboratively with our clients, supply chain and industry partners to de-risk project delivery and engineer solutions with a high degree of outcome certainty. Our multi-disciplined network of professional engineers can design, contract and supervise sustainable, high performance engineering and construction services in the public and private sectors.
INTEGRATED SELF-DELIVERY MODEL
By drawing on our specialist in-house delivery businesses and directly employed workforce, we have greater control over quality and productivity. It enables us to be more responsive, rectify issues and interface clashes quicker and achieve greater integration across the project phases. This brings an operational focus and intensity to project delivery that is very different to the traditional subcontracting model.
“Our sustainable business model provides progressive, long-term environmental, social and economic value to the stakeholders we serve”
CLIENTS COMMUNITIES EMPLOYEES INVESTORS / I N S U R E R S S U P P L Y C HA I N PARTNERS Strategic customer relationship management Innovative engineering excellence Integrated self-delivery model Talented people Future-proofed digital technologies, processes and equipment Financial resilience HOW WE C R E ATE VALUE OUR KEY E NABLERS Delivery certainty 3 Keltbray | Piling Services capabilities overview | 2023
Our services and sectors
STRONG OPPORTUNITY PIPELINE
Keltbray is positioned strongly in its chosen markets to take advantage of the visible opportunities and deliver stakeholder value.
MACRO-TRENDS
Built Environment
Growth in building activity is forecast to pick up in 2023 and beyond, despite tighter monetary policy putting pressure on borrowing rates. The large backlog of work will help to mitigate the impact on building construction work done over 2023 and 2024. Supply-side constraints will subside and construction costs will re-base at a higher level. This correction in the mismatch between supply and demand will ease the pressures driving construction cost growth. Less carbon-intensive demand will also push investment levels and ramp-up activity over the next decade in the UK building and refurbishment market where Keltbray is well positioned.
Infrastructure Outlook is positive and has been boosted by the government’s £650 billion National Infrastructure strategy, providing the highest levels of economic investment in our industry for decades. This has been further boosted by the Government's commitments to nuclear and renewable energy infrastructure investment to decarbonise the UK generation fleet and increase security of supply in an increasingly uncertain world. This will see civil engineering be the fastest-growing sector in the construction market.
Industry-leading business services
Keltbray operates an integrated construction engineering and infrastructure services business model. This is proving highly effective in diversifying our income streams across targeted sectors, locations and different phases of the value chain, helping to deliver a sustainable performance over the longer term.
SPECIALIST ENGINEERING AND ENVIRONMENTAL SERVICES
Demolition and remodelling
Geotechnical engineering and deconstruction
Environment
– Contaminated soil / ground water
– Asbestos removal
– Site remediation
Decommissioning and hazardous waste management
CONSTRUCTION SERVICES
– Engineering design –Wentworth House Partnership
– Civil engineering
Piling
Sub and super structures
– Transport piling
– Transport structures
INFRASTRUCTURE SERVICES
– Rail systems design –Wentworth House Rail Systems
Rail civil engineering
Rail overhead line electrification and distribution
– Power transmission
– Energy network distribution
– Renewables
Highways civil engineering
Energy storage
– Primary and distribution substations and telemetry
SUPPORT SERVICES
Preconstruction and commercial management
BIM and digital engineering
– Civil engineering plant, lifting and haulage equipment
– Project delivery support services:
– Recruitment
Operational safety training
Occupational health and wellbeing
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Dynamic growth sectors
Through our UK business network, Keltbray has a strong and growing presence in built environment and infrastructure sectors. Our business activities are shaped by the product innovation and delivery certainty of the services we provide to meet clients’ sustainable development challenges.
Building – Residential/ Commercial – Manufacturing – Industrial Energy – Civil Nuclear – Power Networks and storage – Renewables Rail – UK Network – Urban Transit – High Speed 2 Transport – Highways – Aviation – Marine Government infrastructure – Defence – Health – Law and Order Public Utilities – Telecoms Networks – Urban realm and regeneration – Flood alleviation environmental services Specialist engineering and Constructionengineeringservices engineering servicesInfrastructure services Logistical support Integrated self-delivery 5 Keltbray | Piling Services capabilities overview | 2023
Innovation in foundation engineering
Our Piling Services business plays a fundamental role in this regard, through the comprehensive coverage of all geotechnical and foundation engineering phases of complex sub-structure building and infrastructure projects.
Keltbray delivers an end-to-end solution from the early stages of major projects, backed by a central technical design and engineering resource to deliver bespoke engineering solutions on site.
We provide this service typically for market leading clients and contractors within the built environment and infrastructure sectors.
Introduction 6 Keltbray | Piling Services capabilities overview | 2023
Through close collaboration with our customers and the supply chain, we are continually seeking innovative ways to mitigate environmental impacts and decarbonise the built environment and infrastructure assets for future generations.
Our specialist piling services team brings a wealth of technical design and delivery knowledge and practical experience gathered over many years. We understand projects can be complex, carry risk, whether technical, environmental, contractual or financial and can be extremely challenging for stakeholders involved in or affected by the project. We offer practical, innovative, and cost-effective piling solutions for customers looking for reassurance from experts that deliver geotechnical
projects of all sizes and complexities. Recognising that each foundation project has differing engineering needs and utilising our experience, knowledge, technical ability and meticulous approach, we gain the best result for customers and the communities where we work.
With a rich history of geotechnical experience and knowledge, the Keltbray piling services business uses a range of piling techniques, using the latest plant, technology and equipment with market leading emissions performance to provide clients with a ‘onestop' foundation solution, across the UK.
We also offer an industry leading temporary works consultancy capability, Wentworth House Partnership, specialising in materials technologies,
geotechnical design, land surveying specialisms, and reinforcement detailing. We use the latest digital technologies to implement a state of the art digital build before any manufacture or construction commences to ensure absolute certainty during project delivery. Above all else, we are a peopleorientated business, which is open and collaborative in its approach. We work continuously to build trusted relationships with our customers, working in partnership from the earliest conceptual stages of a project to develop mutually beneficial solutions.
Our greatest strength is our people, and their willingness to identify and overcome challenges and deliver geotechnical and piling foundation projects to the highest possible standard.
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Piling capabilities
Rotary-bored piling
One of the main advantages of our fleet is its ability to interchange between our main piling techniques, CFA and rotary bored. Key aspects of our Rotary bored piling fleet include:
– Pile depths of up to 80m
– Pile diameters of up to 2.4m
Enhanced load bearing capacity over CFA piles due to increased depth capability
Thin wall and segmental pile casings, with associated digging tools and equipment
Existing pile and obstruction removal using coring barrels and tools to enable piles of up to 1.2m in diameter to be removed
– Plunge Columns up to 600mm SHS
Why choose rotary-bored piling?
– Rotary bored piles offer enhanced load bearing capacity over CFA piles due to their increased depth and diameter capability
Rotary bored piles are less wasteful than CFA
– Rotary bored piles offer the ability to overcome heavy obstructions in the ground through a combination of different coring barrels and augers
CFA piling
We have a range of piling rigs, mast sizes and extension poles to suit the needs of your project. Early engagement with us will ensure that we can allocate the most effective and efficient piling rig to suit the geotechnical ground conditions and site constraints.
The key aspects of our CFA rig fleet are as follows:
Maximum diameter – 1200mm
Maximum Depth – 34m
– All rigs – euro stage V compliant engines
– All rigs are modern, hydraulically powered <7 years old
– All our CFA piling rigs are fully instrumented and automated with the manufactures instrumentation and pile monitoring systems (either the Soilmec DMS system or the Bauer B-Tronic system)
Extra heavy-duty augers for piled retaining wall construction and hard drilling conditions
CFA piles are generally quicker and cheaper to install than rotary
Why choose CFA piling?
– CFA piles are generally quicker to install than rotary bored piles
– In light to medium loaded structures generally CFA piles are less expensive to install than rotary bored
Cased CFA
Piling through unstable and water bearing soils can be best served with a cased CFA piling methodology which realises the following benefits for our clients:
– Improved wall verticality enabling interlock to greater depths, typically at 1:150 verticality
– Casing installation improves bore stability in more challenging ground conditions
– Improved production rates when compared with a drilling rotary bored piles under support fluid alternative
Reduced concrete overbreak particularly in poor soils
Improved wall finish
– Max depth 1m upto 21m diameter is achievable
Why choose cased CFA piling?
Our cased CFA piling capability gives us the option to provide deeper basements in challenging and water bearing soils. Improved wall tolerance and quality can reduce the cost of follow-on structural works which ensures the most efficient solution across multiple packages of work.
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Plunge columns
We have a range of temporary plunge column frames to suit individual project requirements.
A list of our most recent projects where plunge columns were designed and installed is as follows:
150 Bishopsgate
Camden Lock
10 Fenchurch Avenue
The Glebe
10 Albert Embankment
60 Curzon Street
Why choose plunge columns?
Splice details are typically designed in-house by Wentworth House Partnership and we have a range of 1:400 verticality up to 1:1000 with mechanical and hydraulic frames.
Piling under polymer and bentonite support fluid
After completing several successful projects utilising bentonite support fluid, at our ‘Nova East’ project in 2020, we undertook piling using polymer support fluid for the boring of 80m deep piles, while at Silvertown Tunnel, excavations reached 500m³.
Operational benefits of polymer fluids over bentonite include:
Smaller site footprint
– Quicker plant mobilisation/demobilisation
– Drier excavated materials
– Lower fluid disposal costs
Usable in environmentally sensitive areas
Higher shaft resistances
The key aspects of our capability are as follows:
– Tools and equipment to allow pile diameters up to 2.4m to be constructed
– Support from key supply chain partners for fluid storage and mixing silos
Project support from our suppliers to design bespoke fluid support systems for each project
We are able to bring site specific benefits to each project, particularly when using polymer support fluid, please contact our team for further details.
Keltbray piling is committed to further investment in our support fluid plant and resources to ensure our capabilities are industry leading and keep pace with the latest technology.
Deep basement retaining walls
The following pages detail the most notable, deep basement construction projects that Keltbray Piling have undertaken to date. Our modern fleet of plant and equipment coupled with our extensive technical experience means we are able to we are able to construct deep piled basements of up to 24m in retained height. The choice of technique (either rotary bored or CFA) is ground condition and specification dependent. A unique selling point of the Keltbray Group is our ability to manage combined basement construction and piling packages. Through the coordination of our business units as ‘one Keltbray’, we are able to offer our client best value, minimal potential delay and disruption, and maximising of the programme saving benefits. Additionally, using the support of our in-house temporary works engineers (Wentworth House and the wider Keltbray Group), we are able to optimise both the temporary and permanent works design to give value to the client for the overall basement scheme.
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Piling innovation
Design
We have a wide experience in the design of embedded retaining walls and deep piled foundations, providing bespoke design and build solutions for the majority of the projects we work on. Keltbray’s in-house piling design team are focussed in providing robust, efficient and above all buildable foundation solutions. Our team has expanded to support the growth of Keltbray's Piling business and now includes four Chartered Engineers. Our design team are also able to draw on the specialist structural and geotechnical in-house expertise provided by Wentworth House Partnership, in particular for the design of temporary retaining structures and propping systems. We also maintain a strong relationship with external design consultancies such as A-squared Studio, Arup and Robert Bird Group for both detailed design and independent checking. We are committed to utilising the latest technologies to improve our technical delivery and are able to offer our clients BIM Level 2 compliant information. State of the art software is used to assist with our designs including:
– OASYS – Pile, Adsec, ALP
PLAXIS – 2D and 3D
Geosolve – Wallap and Geoslope
REPUTE
– Autodesk – Revit and Civils 3D
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Innovation in ground engineering
Headline figures:
– Greater than £2.5m in tax rebate in 2022 from Innovation spend
– Four patents secured, with one further pending
– Three formalised industry partnerships
One government funded Knowledge Transfer Partnership (KTP)
A full-time dedicated R&D Manager
Innovation is embedded within our business. From the alternative foundation and construction solutions that we develop on a daily basis to our drive to embrace, develop and adopt new technology.
Our core purpose and values embrace innovation to drive us as a business to lead significant change and technological development in piling and foundation engineering.
In 2021, Keltbray announced the proprietary development of the groundbreaking innovation, HIPER® Pile, that has been designed, developed and tested over the last two years following a UKRI grant, as part of the wider transforming construction challenge.
INNOVATIVE ENGINEERING EXCELLENCE
We have an active innovation department within Keltbray which consistently pushes the boundaries of new technology to ensure we can deliver the best solutions for our clients. Our team have most recently focused on:
The trial and implementation of EFC (a cement free concrete) into both temporary and permanent works piles cross our sites.
The development and implementation of a new pile type, the HIPER® Pile
Reducing embodied carbon in design through the use of our design expertise and new innovations such as the HIPER® Pile
More on our innovation development can be found within our HIPER® Pile brochure on our website: keltbray.com/sectorsservices/piling/
KIPS
Embracing technology to improve productivity, efficiency and quality
Over the past seven years, Keltbray have worked in collaboration with software developers, Blueberry, to develop a bespoke software system which has significantly improved the accuracy of our record keeping with data shared to and directly from the workface. KIPS stands for Keltbray Integrated Piling Software and the system records key aspects of safety, quality and performance. We have recently completed the Customer Portal module allowing complete transparency between Keltbray and the client. At any point the client can log in through a bespoke portal and view live as built progress in terms of health, safety and productivity.
The KIPS system offers the following significant benefits:
Improvement in quality and quantity of data capture
Elimination of miscommunication of construction requirements
Analysis tools automatically flagging up poor performance
An accurate record of actions raised and their close out
Automatic updates of as-built construction schedule and drawings
BIM Level 3 compatibility
– A ‘Big data’ system storing and recording all aspects of construction
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Case studies
£35m
Silvertown Tunnel
The Silvertown Tunnel (STT) project involves the construction of a twinbore road tunnel providing a new connection between the A102 Blackwall Tunnel Approach on Greenwich Peninsula and the Tidal Basin roundabout junction on the A1020 Lower Lea Crossing / Silvertown Way.
STT will be approximately 1.4km long and able to accommodate large vehicles including double-decker buses. It includes a dedicated bus, coach and goods vehicle lane, enabling Transport for London (TfL) to provide additional cross-river bus routes.
As part of the STT project, there are a series of underground structures that are required to allow the TBM to be launched and then later received on the Silvertown side of the River. Additional structures make up a cut-andcover section of the tunnel as well as an entrance portal.
Keltbray were contracted in January 2021 to complete the piling work for the Silvertown side of the STT. The piling scope included some very technically challenging aspects along with the requirement for a lot of very large plant and equipment. The key structure, required to allow the tunnelling to commence, was the Launch Chamber. This is made up of four interconnected circular shafts. At the intersection of each shaft, there is a large structural element referred to as a counterfort. These were built using a unique method where 6No. 2200mm piles are dug under polymer and overlap to create a large single ‘T’ shape excavation of approximate 515m³ volume. Within this excavation a large ‘T’ cage was installed with a combined weight of circa 95tn. The counterforts required a number of bespoke temporary works and equipment for the project, including a large tilt bed to assist lifting of the cages and custom made concreting platforms to deal with the unique shape of the excavation.
VALUE
Scope
– Secant Wall piles up to 1300mm and 30m deep.
– Counterfort piles (6No 2200mm stitched together in a single excavation)
– Reinforced primary and secondary secant wall (Hard-Hard)
– Large complex cages of 95tn +
– Low Head Room piles
Working in close proximity (and underneath) of DLR assets
Polymer support fluid (new product due to EA restrictions)
Ground improvement
Pile trimming
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40 Leadenhall
Keltbray were contracted by Mace to install the pile foundations for the construction of 40 Leadenhall Street, a new twin-tower office building with a total height of 38 stories above ground and two stories below ground. The works package included: Existing pile removal, secant piled wall construction, polymer 1500 dia bearing piles, dry 880 and 1500 dia bearing piles, plunge column installation and extensions, sheet piled cofferdams, RC capping beam, RC retaining wall, pile caps, retaining wall propping, existing prop alterations, tower crane base construction, tower crane grillage fabrication, L Block wall and site access ramp installation.
Keltbray started on site in January 2020 with existing pile removal in the North Core before beginning construction of the wet bearing piles and secant wall piles in April 2020. The capping beam and other RC works began in June 2020 following just behind the installation of the secant wall piles. Works continued until September 2020 after which A J Morrisroe took over the site to deliver the substructure and basement dig. Keltbray successfully completed one of their largest projects to date, maintaining a very high standard in H&S and quality while also completing works within programme.
£15m
VALUE
Scope
– Rotary piling and under polymer support fluid
– Secant piled wall
– 1500mm diameter bearing piles
– Capping beam installation
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Keltbray
Capital House
Keltbray were appointed by Mace to carry out the piling works for a new development consisting of a forty five storey building and a single-storey basement with partial mezzanine. The basement excavation was approximately 8m deep and was supported by a piled secant wall. The foundation system is a hybrid raft assisted pile group designed based on a performance specification. Keltbray Piling carried out the construction of a Cased 880mm CFA secant wall, designed to Cantilever to 3m to allow bearing pile construction from lower level piling mat and propped at ground level for the basement excavation.
Following Capping Beam construction a two-stage excavation took place. The first to 3m below street level to allow MOLA search of site and local deeper excavations utilising temporary props to 5m in the SE and NW corners of site. Following the MOLA excavation a piling mat for bearing piles was constructed at 2.5m below street level.
The construction of 64No 1200mm rotary bearing piles which all had full length reinforcement of these 28No were drilled under polymer support fluid to 53m depth. Bearing piles were also designed to take the tower crane loading. To allow the bulk excavation, 7No temporary props (assembled on site) were installed. Keltbray also carried out bearing pile trimming and casting of basement blinding.
AKT II were instructed to provide design calculations for the proposed bearing piles for the above development. Due to the proximity of the bearing piles to the retaining wall, it was necessary to design for excavation-induced bending moments and shear forces in addition to the longterm vertical loads induced by the superstructure. Temporary Works design was carried out by Wentworth House Partnership.
£5m
VALUE
Scope
Cased CFA Secant wall
Rotary-bored Bearing piles
– Capping beam
– Bulk excavation
studies cont.
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Maria-Fidelis
The HIPER® Pile was designed as the foundation system for the Maria Fidelis Welfare Building as part of the HS2 Euston Station, Welfare Facility development. Wentworth House Partnership (WHP), appointed by MaceDragados Joint Venture (MDJV) as the Structural Engineers, provided the engineering design for the HIPER® Piled-raft foundation.
The building comprises modular units, supported by a structural steel frame, all of which is founded on a 600mm slab cast in Earth Friendly Concrete (EFC) and founded on 40No HIPER® Piles. The scheme was developed to protect a large number of sensitive existing underground services beneath the footprint of the site.
This was the first ever full scale deployment of the HIPER® Pile which uses all elements of the innovation. HIPER is an acronym and stands for Hollow, Impression, Precast, Energy-generating and Reusable pile.
A total of 35No piles were constructed as in-situ hollow piles and the remaining 5No piles were constructed as precast hollow piles. All piles were constructed
as 900mm piles, typically with a 500mm void through the centre. The hollow piles reduced the volume of concrete used by 30% compared with a conventional solid pile of equal length. All piles were impressed with Keltbray’s bespoke impression tool which increased the shaft capacity of the piles by 40% within the London Clay to provide a more efficient, sustainable solution and avoid penetrating the Lambeth Group at depth.
The hollow piles were designed to support the ground source heat pump scheme with all piles being used as heat exchangers. Four HDPE u-loops installed within were the void of each HIPER® Pile after the piles have been exposed by the groundworks team. The voids were filled with water and the loops were lowered to the toe of the piles which are then fed to the manifold underneath the raft. This method of converting a hollow pile to a thermal heat exchanger removes all risk of damage to the loops which would otherwise be present during the construction of a conventional solid cast in-situ thermal pile.
VALUE Scope – 40No 900mm HIPER® Piles – GSHP installation – Substructure design – Basement slab installation – Drainage – Groundworks 4 15 Keltbray | Piling Services capabilities overview | 2023
£1m
Sustainability framework
Sustainability runs through everything we do. From the people we support, the company we sustain, the local communities we work in, the industry we represent and the planet we live on.
The built environment and infrastructure industry is materials and resource intensive, with huge pressures exerted on the natural environment at every stage of a project’s life-cycle.
Sustainability is therefore mutually beneficial to both the natural environment and our business, aiding us to use resources efficiently to create long-term sustainable value, build resilience to environmental and social pressures, as well as minimise risks throughout our supply chain to drive economic growth.
Managing the environmental, social and economic pillars holistically is key to protecting our environment, supporting local communities, serving our customers, sustaining the economy and helping wider society thrive. The areas of focus below have been identified as being integral to Keltbray, based on a materiality assessment of their impact on our business, and they therefore set the framework for the Group’s sustainability approach and programmes of work.
Keltbray's sustainability pledge is to provide innovative building and infrastructure engineering solutions that generate value to our customers and support their own sustainability commitments, whilst playing our own part in addressing the global challenges determined by the UN Sustainable Development Goals.
Holly Price Group Sustainability Director
ENVIRONMEN T A L SUSTAINAB I L I T Y
S
Sustainable cities and communities Climate action Industry, innovation and infrastructure Decent work and economic growth Good health Quality education Gender equality Reduced inequalities 16 Keltbray | Piling Services capabilities overview | 2023
SUSTAINABILITY SOCIAL ECONOMIC
USTAINABILITY Redefining the way sustainable development is delivered
Environmental review
OBJECTIVES AND SMART KPIs
Decarbonise our operations to achieve Net Zero by 2040
Achieve an absolute reduction for Scope 1 & 2
GHG emissions by 46.2% by 2030 and reduce Scope 3 GHG emissions by
55% per £’m of GEVA by 2030Achieved PAS 2080 Accreditation
Protect environment and enhance biodiversity
– Zero environmental harm
Measure our impact on biodiversity, and identify and implement opportunities to contribute to biodiversity net gain (aim 10%)
Fully implement our PH2 strategy on all projects and in all work places
Increase environmental awareness and knowledge at all job levels
Use resources more efficiently, maximising their life cycle to drive circular economy
– Zero non-hazardous waste to landfill –championing circular economies, material passports and urban mining
– Key building materials to be sourced from responsible and certified suppliers
– Define scope of water and material usage to set reduction targets
ACTION AGENDA
Climate action
– Carbon footprint and energy efficiency
– Biodiversity
Waste and the circular economy
Water usage
Materials and responsible sourcing
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HIPER® Pile and EFC
HIPER® PILE
The HIPER® Pile is a highly innovative system comprised of individual innovations which, when combined, offer unprecedented savings in embodied carbon and a significant enhanced asset value to our clients.
The system has been developed to assist designers and developers in meeting ambitious carbon reduction targets for new-build structures as well as harnessing geothermal energy to heat and cool buildings more efficiently than traditional, energy piles.
ENERGY
REUSABLE
As a direct result of our collaboration with academia we have also exclusively licenced the City, University of London patent for the Hollow, Re-usable pile.
Up to 70% material volume reduction
Embracing off site manufacture, improving quality and productivity
A fully circular product for deep foundation use and re-use
HOLLOW
PRECAST
Improving shaft f riction, reducing pile lengths by 10-20% IMPRESSION Up to 70% increase in thermal conductivity, de-risks construction delivery over traditional thermal piles
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Case Study – UK first use of Ultralow carbon Concrete (EFC) in Permanent Works Foundations
CANADA WATER PETROL STATION PROJECT
Keltbray completed a UK first in terms of the design and integration of Earth Friendly Concrete (EFC) into permanent works piles. Essentially EFC is an ultra-low-carbon concrete which instead of using Portland cement as a binder it utilises a liquid Alkaline solution, together with other cement replacement material (PFA/GGBS) in order to bind the core materials in concrete together. Such a product has excellent strength properties and durability properties and offers advantages over traditional Portland cement based concretes.
By converting the piling mix from a traditional mix to an EFC mix a saving of approximately 45% of the embodied carbon was made compared to current best practice.
The piles themselves were designed as 600mm diameter CFA bearing piles, supporting compression loads of up to 2000kN. The piles were drilled to depths of up to 25m and extensive concrete trials were completed both before and after in order to prove that the material could comply to Eurocode 2.
Waste Assets People’s transportation Mob/demob Freight Energy Materials Piling Element Scope 3 emissions Original Scheme Keltbray EFC Scheme
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Contact
Stuart Norman Managing Director
07793 650 514 stuart.norman@keltbray.com
Stefan Smith Design Manager
07816 665 618 stefan.smith@keltbray.com
Marc Othen Pre-Construction Manager for Ground Engineering 07525 590 101 marc.othen@keltbray.com
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This report was written, designed and produced by Keltbray Group Proposals and Corporate Communications Team. No part of it may be reproduced without the prior permission of Keltbray Holdings Limited. 21 Keltbray | Piling Services capabilities overview | 2023
Redefining sustainable development St Andrew’s House Portsmouth Road Esher, Surrey KT10 9TA T: +44 (0) 20 7643 1000 E: enquiries@keltbray.com keltbray.com © This document is the copyright of Keltbray Holdings Limited. Any unauthorised reproduction or usage by any person other than the addressee is strictly prohibited.