Weybridge Haleon Innovation Centre

During pre-construction, we worked with the client to develop a multi-phased piling platform that enabled safe, efficient installation while minimising imported material into what would remain a somewhat constrained site. Sheet piles were installed using a TM17 leader rig with a 30VV vibro hammer, longer piles were back driven using a crane suspended CX85 impact hammer. By using our own extensive stock of sheet piles, rather than procuring new piles for the temporary works, we saved a total of 140T of CO2eq embedded carbon across 200T of steel piles. This demonstrates our commitment to providing environmentally conscious solutions.

Our in-house design team managed the complete design process from tender through to completion. Coordinating closely with operations to ensure pile sections were available across all areas, aligned with programme requirements and appropriate for ground conditions. All designs were carried out in accordance with Eurocodes and client specifications, with regular coordination meetings supporting the delivery of a compliant, efficient, and robust solution. Retained heights ranged from 1.3 m to 9.5 m, with the deeper sections requiring two levels of framing for stability. Given the site’s varying topography, frame levels were tailored to suit each individual design case. Pile lengths varied between 4.5 m and 15 m depending on the section, with both Z and U profile sheet piles specified to maintain flexibility based on stock availability.

Throughout construction, we worked with the client to address local stakeholder concerns around noise and vibration, rapidly mobilising pre augering equipment to minimise disruption to adjacent properties and businesses. With one integrated team managing both design and installation, delivery was efficient and free from conflicts between design intent and buildability.

Despite the working constraints that remained after the pre-construction planning and sequencing workshops with the client, and the environmental sensitivities, we successfully delivered the sheet piling works with a strong focus on safety, efficiency, and collaboration, demonstrating our ability to integrate design and construction expertise to meet client objectives and manage project risk.