Roger Bullivant Limited (RBL) is supporting the regeneration of South Shields’ historic waterfront by delivering a highly engineered foundation solution for Cussins (North East) Ltd at the former Holborn Docks. The long‑derelict dockland site is undergoing transformation, backed by more than £9 million of investment from the North East Local Enterprise Partnership and a further £1.85 million of Government funding. This support is enabling the creation of new homes and public space for one of the area’s most significant industrial heritage sites.
RBL’s involvement in the scheme builds on an established partnership with Cussins (North East) Ltd. Having successfully collaborated on various developments, including the first phase of Holborn Docks, RBL was appointed to engineer and deliver a foundation solution that could meet the site’s demanding technical requirements. The company’s local knowledge of this area meant the team could confidently approach the engineering challenges associated with a former dry dock.
Outside the historic graving dock, RBL encountered stiff natural clay overlying mudstone, while within the dock itself the ground comprised compacted engineered fill placed over a substantial concrete dock base. Ensuring that every pile achieved refusal on this former dock floor was essential. However, the density of the engineered fill meant that pre‑boring was required across significant areas of the site to allow piles to reach the necessary depths. This added complexity to the installation process and demanded close coordination with the design and site teams throughout.
To address the varied ground conditions and sensitive locations across the development, RBL utilised a combination of Driven Steel Tubular Piles, Continuous Flight Auger (CFA) piles, Sectional Flight Auger (SFA) piles and its in-house designed and manufactured precast RBeam system. Steel tubular piles were selected for their ability to penetrate stiff clays and to ensure a secure founding depth in the underlying bedrock, as well as for their suitability in the infilled dock where they could successfully toe into the original concrete base. CFA piles were deployed where the works were positioned close to the quay wall anchors and ties, minimising vibration and protecting critical marine infrastructure. SFA piles were installed on plots located only a few metres from already completed or occupied homes, enabling RBL to maintain low‑vibration operations and ensure minimal disruption to residents.
The RBeam system was chosen as the most efficient solution for a large residential site of this scale. Manufactured offsite under controlled conditions, RBeam reduces shortens installation time, and supports safer working methods.
The wider Holborn Docks regeneration promises long-term social and economic benefits for South Shields. As well as delivering high-quality new homes, the project will create a public riverside promenade, reconnecting the community with the River Tyne. The restored dry docks and enhanced public realm will contribute to an attractive environment for future residents and visitors. The restored dry docks will celebrate the area’s industrial heritage, while the addition of a new play area and improved public realm will support a welcoming environment for future residents and visitors.
Phil Howard, Preconstruction Manager for Roger Bullivant Limited commented: “We are pleased to continue our partnership with Cussins (North East) Ltd on this landmark regeneration scheme. Working within a former dock environment presents significant engineering challenges, but our team is delivering a robust and value engineered solution that will support the long‑term success of the development.”
