Major iron ore export wharf infrastructure founded on large-diameter driven steel piles in highly variable coastal geology, requiring innovative pile verification and sign-off processes to maintain programme certainty during construction.
Client
Rio Tinto Iron Ore (via EPCM)
Location
Cape Lambert, Western Australia
Sector
Mining & Resources
Services Delivered
Dynamic Pile TestingPile DesignPile Driveability ReviewReal-time Pile VerificationVerification Process Development Optimisation
The challenge.
The Cape Lambert Port B expansion involved approximately 500 large-diameter steel tubular piles supporting a 1.8 km wharf and jetty structure. Ground conditions along the alignment were highly variable, comprising claystones, weathered and fresh basalt, and occasional bands of high-strength chert and siliceous calcarenite. Following challenges encountered during Phase A, the project required a more efficient and reliable approach to pile acceptance and verification that would not delay critical-path piling activities.
The approach.
FSG was engaged to undertake a geotechnical and foundation design review and develop an improved geotechnical design, pile testing and verification framework for Phase B. Dynamic pile testing data was correlated with real-time installation information to assess axial, lateral and tensile pile capacity as piles were driven. The team developed a rationalised PDA testing programme and automated verification process, enabling clear installation targets and acceptance criteria to be established before construction.
The outcome.
The verification methodology enabled the majority of piles to be assessed and signed off immediately following installation, eliminating delays associated with traditional testing and review processes. PDA testing requirements were reduced from 100% of piles on Phase A to approximately 25% on Phase B, delivering significant productivity and cost benefits while maintaining confidence in foundation performance. Piles were verified and signed off by FSG in real time as the piling works were executed, significantly streamlining construction engineering and operations.