Roger Bullivant Limited (RBL) continues to demonstrate its technical expertise and adaptability in delivering foundation solutions for energy infrastructure across the UK. RBL has successfully executed piling works for several substation projects, each presenting different challenges ranging from restricted access and complex ground conditions to live utility environments.
Across projects in Willesden, Thurrock, and Amersham, RBL has deployed a range of piling techniques, including Sectional Flight Auger (SFA) and Driven Precast Concrete Piles, to suit diverse site constraints and project demands. These installations highlight not only the company’s geotechnical knowledge but also its commitment to delivering value engineered, reliable, and safe foundation systems for infrastructure projects.
Willesdon
RBL delivered a tailored foundation solution for the Willesden Substation project in London. The RBL South Central team installed Sectional Flight Auger (SFA) piles using the compact 900 Series Rig to overcome restricted access constraints on the site. The scope included the installation of 10 piles of 300mm diameter to depths of 6.0m, designed to support a substation within a live utility environment. Detailed planning, sequencing, and the rig’s compact profile were critical to navigating the restricted access and ensuring minimal disruption to the ongoing utility operations.
Given the site’s proximity to sensitive underground and overhead services, the project demanded high-precision rig positioning and continuous monitoring. A grouted piling solution was utilised due to limitations on conventional concrete deliveries, enhancing material handling in the confined workspace. Each pile position underwent pre-excavation and was sleeved with protective tubes to safeguard existing services. These protective and logistical measures, alongside strict health and safety protocols and clear team communication enabled the successful execution of the works while maintaining operational efficiency and infrastructure integrity.
Thurrock
RBL successfully delivered a Precast Foundation solution for a new 275KV AIS (Air Insulated Substation) at the Thurrock Flexible Generation Plant for Statera Energy. This development includes both power generation with gas-fired reciprocating engines (450MW) and battery storage (300MW).
The site presented variable ground conditions, with up to 2.0 meters of made ground (gravelly clay with brick and gravel fragments) underlain by very soft silty clay alluvium extending to approximately 16.0–18.0 meters below ground level. Beneath this, competent strata of the Lewis Nodular, Seaford, and Newhaven Chalk Formations provided a reliable capacity for the pile solution.
Extensive site probing and testing confirmed that piling was the most suitable method for these conditions. RBL installed 12,000 linear meters of 250 x 250 Driven Precast Concrete Piles, each capable of supporting loads up to 500kN, to support transformer bases and ancillary equipment in the new substation. All precast products were produced in-house at our Walton Park manufacturing facility using low carbon concrete mixes, incorporating a 50% Ground Granulated Blast-furnace Slag (GGBS) replacement. The pile design met the client’s specifications and was consistent with installations in other areas of the development, ensuring efficient delivery and installation.
Amersham
RBL provided piling works for a substation project in Amersham requiring the installation of 64 No. 250mm diameter Sectional Flight Auger (SFA) piles. The pile design matched the client’s original specification, with SFA selected primarily due to restricted access constraints on site. Ground conditions consisted of a shallow mantle of made ground overlying a firm clay formation, which was suitably addressed using SFA piling. This approach facilitated minimal site disruption and maintained bore stability throughout installation.
Given the site’s limited access, compact rig solutions and careful sequencing were implemented to ensure operational efficiency within spatial constraints. The choice of SFA piles allowed for effective deployment in the confined working area without compromising on load-bearing performance or productivity. With the ground profile being well-suited to SFA techniques, the project was delivered in accordance with structural and logistical requirements.
RBL’s experience in substation foundation delivery proves its role as a trusted partner for complex, high specification piling works in the energy sector. Whether addressing restricted access, challenging ground conditions, or sustainability and safety requirements, RBL’s localised geotechnical engineers continues to offer flexible, in-house solutions tailored to the needs of each site in any location across the UK. This is supported by RBL’s extensive range of piling rigs and equipment that deliver differing piling solutions including both displacement and replacement techniques. These case studies reflect RBL’s ability to meet evolving project requirements while maintaining quality, efficiency, and technical excellence across all stages of project delivery.
