Remediation of a major port facility founded on long driven steel tubular piles in highly variable volcanic and marine deposits, requiring specialist driveability analysis, pile testing and rapid verification processes to support construction of new wharf infrastructure.
Client
Opus / Port of Lyttelton
Location
Lyttelton, New Zealand
Sector
Ports & Marine
Services Delivered
Driveability AnalysisDynamic Pile TestingPile DesignPile VerificationSign-OffSteel Pile Procurement Advice
The challenge.
The Cashin Quay redevelopment involved approximately 250 driven steel tubular piles supporting new wharf infrastructure at the Port of Lyttelton. Located on the edge of an ancient volcanic crater, the site comprised deep fill over soft marine sediments, volcanic deposits, residual materials and steeply sloping volcanic bedrock. Expected founding levels ranged from approximately 50 m to 70 m below surface, creating significant uncertainty around pile drivability, installation performance and foundation capacity. The project required a robust design and verification framework that could provide confidence in pile procurement and performance, while maintaining construction productivity.
The approach.
Recognising the complexity of the ground conditions, FSG provided end-to-end involvement from design through to construction. The team undertook back-analysis of existing pile testing data, steel pile design and detailed driveability assessments for the proposed tubular piles. FSG provided advice on hammer selection, installation methodology, piling specifications, procurement and construction risk management. During delivery, FSG undertook PDA testing, CAPWAP analysis, PDM monitoring and pile verification services, implementing a streamlined sign-off process that enabled rapid assessment of pile capacity and installation performance. Detailed interpretation of testing results also identified site-specific pile relaxation behaviours, allowing practical driving criteria to be developed for the contractor.
The outcome.
FSG’s integrated design, testing and verification approach provided the project team with a practical and efficient framework for managing foundation risk in highly variable ground conditions. The streamlined verification process improved programme certainty, supported efficient construction and reduced the risk of installation-related delays. Close collaboration between the client, contractor and FSG enabled successful delivery of the piling works while maintaining confidence in long-term foundation performance.