DRIVEN STEEL TUBULAR PILES

The M1 to Raymond Terrace Extension is a major 15-kilometre upgrade of the Pacific Motorway, designed to enhance connectivity, improve traffic flow, and increase freight efficiency in New South Wales. This significant infrastructure project includes the construction of nine new bridges, including a 2.7-kilometre viaduct across the Hunter River, providing a vital transport link for the region.

Project Scope:

• Bored piles: 73 (1,050mm diameter), 29 (1,500mm diameter), 8 (1,800mm diameter)

• Driven steel tubular (DST) piles: 10 (900mm diameter), 95 (1,500mm diameter), 28 (1,800mm diameter)

• Sheet piling: 65 metres of sheet piling for the causeway jetty

Project Value:

• Approximately $58,000,000

Equipment:

• 2 x BG28 Piling Rigs

• M12000 Crane + Leader and M16000 Crane

• 30SB Junttan Impact Hammer

• ICE 58B and ICE 110 Vibratory Hammer

• CKE2500 Crane

Partnering with John Holland / Gamuda Joint Venture, Caporn Piling played a key role in delivering the deep foundation works for this transformational transport project, ensuring a safer, more efficient motorway network for New South Wales.

The Heatherbrae Bypass is a key component of the M1 Pacific Motorway extension, a major transport infrastructure project designed to improve travel times, safety, and freight efficiency between Sydney and Brisbane. This project will significantly enhance connectivity and reduce congestion in the Hunter region, benefiting both commuters and the freight industry.

Project Scope:

• 30 driven steel tubular piles, up to 65m deep

Project Value:

• Approximately $10,200,000

Equipment:

• BG28-H Piling Rig

• Junttan HHX350

• ICE 58B Vibrator

• LR1300 Crane

• EWP

Working in partnership with Seymour Whyte Constructions Pty Ltd, Caporn Piling delivered specialist deep foundation works, ensuring a strong and resilient base for this critical highway upgrade.

The Hexham Straight Widening (HSW) Project is a key transport infrastructure upgrade, expanding a six-kilometre section of the Pacific Highway (Maitland Road) from four lanes to six lanes. This major project aims to enhance traffic flow, improve freight efficiency, and increase road safety on one of New South Wales’ busiest transport corridors.

Project Scope:

• 13 bored piles (900mm, 1050mm, 1200mm, 1500mm diameter), up to 40m deep

• 15 driven steel tubes (900mm, 1050mm, 1500mm diameter), up to 65m deep

Project Value:

• Approximately $7,300,000

Equipment:

• BG28 Piling Rig

• Junttan HHX350

• ICE 58B Vibrator

• 300T Crawler Crane

• 14T Excavator

• EWP

Working in collaboration with Georgiou, Daracon, and SMEC Alliance, Caporn Piling provided specialist foundation works, ensuring a strong and stable base for this vital highway expansion.

The Wyaga Creek Floodway Upgrade is a key infrastructure project aimed at improving flood immunity on the Gore Highway, between Millmerran and Goondiwindi. By constructing a new, higher bridge, this upgrade will enhance road resilience and reliability, ensuring safer and more efficient travel for freight and regional communities.

Project Scope:

• 8 driven steel tubes (1,200mm diameter) installed under bridge headstocks

Project Value:

• Approximately $1,200,000

Equipment:

• BG28V Piling Rig

• CKE2500 – 250t Crawler Crane

• Junttan HHX350 Impact Hammer

• 8t Excavator

Working in partnership with Civil Mining & Construction Pty Ltd, Caporn Piling successfully delivered the foundation works for this essential transport upgrade, ensuring improved flood resilience and long-term safety on the Gore Highway.

The Centenary Bridge Upgrade is a major transport infrastructure project designed to improve traffic flow and safety in Jindalee, QLD. The new three-lane northbound bridge will provide a vital extension to the existing Centenary Bridge, reducing congestion and enhancing commuter efficiency during peak hours.

Project Scope:

• Abutment A & B (Land): 13 bored piles (1,200mm diameter, avg. 21m deep)

• Pier 1 (Land): 4 bored piles (2,100mm diameter, avg. 27m deep)

• Pier 2-5 (Marine barge): 16 bored piles (2,400mm diameter, avg. 24m deep)

• Pier 6 (Land): 4 bored piles (1,500mm diameter, avg. 10m deep)

• Southern Section Ground Improvement: 180 CFA piles (450mm diameter)

Project Value:

Approximately $17,000,000

Equipment:

Caporn Piling deployed specialised land and marine-based equipment to execute the project, including:

• 1 x BG28V Piling Rig (Marine Barge)

• 2 x BG28H Piling Rigs (Land)

• 2 x 250t Crawler Cranes (Land)

• 1 x 300t Crawler Crane (Marine Barge)

• 1 x Marine Barge (18m wide by 64m long)

• 2 x Service Modular Barges/Pontoons (12m x 9m & 12m x 15m)

Working in collaboration with GBJV (Georgiou BMD Joint Venture), Caporn Piling is proud to support this significant infrastructure upgrade, ensuring a more efficient and safer road network for Queensland commuters.

Caporn Piling is proud to have contributed to the Pacific Motorway (M1) Palm Beach to Tugun Upgrade, the final section of the Varsity Lakes to Tugun (VL2T) project. This major infrastructure upgrade, which includes the construction of 10 new bridges, improves safety, capacity, and connectivity along one of Queensland's busiest transport corridors.

Project Scope

Caporn Piling delivered extensive foundation works, including:

• 44 bored piles (900mm diameter, up to 46m deep).

• 72 bored piles (1200mm diameter, up to 43m deep).

• 24 marine bored piles (900mm diameter, up to 32m deep).

• 40 driven steel tubular piles (900mm diameter, up to 38m deep).

• 43 driven steel tubular piles (1200mm diameter, up to 41m deep).

Equipment Utilised

• Bauer BG28 Drill Rig for precision bored piling.

• Bauer BFD1500 Fly Drill for challenging ground conditions.

• Crawler Cranes:

  • Manitowoc M8500, M12000, and Kobelco CKE2500 for lifting operations.

• Pile Driving and Vibratory Equipment:

  • Juntann HHK16S Impact Hammer for driven pile installation.

  • ICE 58B Vibratory Hammer for casing and steel pile installation.

Client
Seymour Whyte

Project Highlights

• Successful delivery of marine and land-based piling works to support 10 new bridges.

• Piles installed to depths of up to 46m, requiring advanced drilling and driving techniques.

• Safe and efficient operations within a high-traffic corridor and environmentally sensitive areas.

At Caporn Piling, we bring expertise, innovation, and precision to complex infrastructure projects. Our work on the Pacific Motorway Palm Beach to Tugun Upgrade delivered the robust foundations required to support Queensland’s future transport needs.

Caporn Piling played a critical role in the duplication of the Tourle Street Bridge, a major infrastructure project addressing the increasing demands of this key corridor. Spanning 340 metres across the Hunter River with 11 spans, the bridge forms part of the 3.8km road upgrade that caters to the 33,000 vehicles traveling this busy route daily.

Project Scope

• 65 driven steel tubular piles (750mm diameter, up to 36m deep).

• 12 driven steel tubular piles (1200mm diameter, up to 37m deep).

• Total of 77 reinforced concrete steel-lined piles, constructed predominantly over water.

• Managed land-based piling on the southern bank, through highly contaminated landfill from Newcastle’s historical steel industry, ensuring zero environmental incidents.

Equipment Utilised

• Bauer BG15 drill rig for piling operations.

• Cranes: 180T and 110T crawler cranes for lifting and support.

• Marine equipment:

  • 35m barge for piling operations.

  • 55m barge with a 600T crawler crane for substructure and superstructure works, including the installation of 80T Super T Girders.

  • Service barges and workboats for river-based logistics.

• Pile driving equipment:

  • IHC S150 impact hammer.

  • Junttan HHK 16SB impact hammer.

  • PTC 50 HD Vibrator.

Project Innovations

• Construction of the substructure entirely submerged in water, requiring innovative solutions to avoid the use of traditional cofferdams.

• Seamless execution of piling and superstructure works in challenging marine and contaminated land environments, ensuring project success and environmental compliance.

Client

WBHO McIlwain Civil Engineering JV (TSJV)

Project Benefits

• Improved traffic flow and road safety through dual carriageway upgrades.

• Increased bridge capacity to meet current and future demands.

• Safe and efficient construction that preserved the environmental integrity of the Hunter River and surrounding areas.

At Caporn Piling, we pride ourselves on delivering robust and innovative foundation solutions for complex infrastructure projects. The successful duplication of the Tourle Street Bridge stands as a testament to our expertise in marine, land-based, and environmentally sensitive piling works.

Caporn Piling is proud to contribute to the transformational Inland Rail Project, a 1,700km freight rail line connecting Melbourne and Brisbane through regional Victoria, New South Wales, and Queensland. Inland Rail serves as Australia’s fast freight backbone, delivering greater efficiency, supporting economic growth, and creating lasting opportunities for regional communities.

Project Scope

• Installation of:

  • 102 driven steel tubular piles (1200mm diameter, up to 29m deep).

  • 8 driven steel tubular piles (1500mm diameter, up to 29m deep).

Equipment Utilized

• Piling Rigs: Bauer BG15 and Bauer BG28 for precision pile driving.

• Crawler Cranes:

  • 60T Sennebogen, 110T Manitowoc, and 250T Manitowoc for lifting operations.

• Pile Driving Equipment:

  • IHC S90 and IHC S150 Impact Hammers for driving steel tubular piles to depth.

Client
Trans4m Joint Venture (John Holland & See Civil JV)

Project Highlights

• Delivery of large-diameter driven steel tubular piles to support critical rail infrastructure.

• Precision execution in challenging environments to ensure foundation stability and reliability for long-term freight operations.

• A key milestone for the Inland Rail project, enabling the efficient movement of goods across Australia.

At Caporn Piling, we are proud to deliver strong, reliable foundations for projects of national significance. Our work on the Inland Rail ensures a resilient infrastructure backbone that supports Australia’s economy and connects regional communities for generations to come.