MARINE PILING

The Kingsford Smith Drive upgrade involves the widening of the road from four to six lanes. The key feature of the upgrade is the new river walk structure that supports the widened road and shared pedestrian and cyclist path.

SCOPE:

• 14 No. 1200mm bored piles upto 17m deep

• 176 No. 1500mm bored piles upto 31.5m deep

• 16 No. 1800mm bored piles upto 31.5m deep

All piles installed with permanent casing to MRTS63

EQUIPMENT:

• 3 x Drill Rig Bauer BG28

• 2 x IHC 58B Vibrator

• 1 x IHC 110C Vibrator”

CLIENT: Lend Lease Engineering

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 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.

The Isle of Capri Bridge Upgrade is a vital infrastructure project improving connectivity between Surfers Paradise and the Isle of Capri. Spanning 135 meters across the Nerang River, the new four-lane bridge will significantly ease congestion, enhancing traffic flow and access for commuters and businesses in the area.

Project Scope:

• Installation of 32 permanent lined bored piles, approximately 45 meters deep

• 12-16 piles installed via barge, 4-8 piles installed via FW (2-4 spans)

• 12 LB piles and FW load-out jetty (1-2 spans)

Project Value:

$12,000,000

Equipment:

Caporn Piling deployed industry-leading equipment to complete the works efficiently, including:

• BG28V 3514 + 4m extension

• BK28/419/4/64

• Long Auger 6m 1350

• 1 x 110t Crane

• 2 x 250t Cranes

• Junttan 16t hammer + powerpack

In collaboration with Georgiou Group, Caporn Piling is proud to contribute to this essential transport upgrade, improving access and connectivity for one of Queensland’s busiest urban corridors.

Caporn Piling is proud to have delivered specialist piling solutions for the construction of the new Clyde River Bridge in Batemans Bay, a transformative infrastructure project enhancing connectivity for the region. The 425m, six-span bridge provides improved access for motorists, freight, emergency services, pedestrians, cyclists, and river users. Importantly, the increased bridge height allows for uninterrupted access for vessels up to 12 metres.

Project Scope

Caporn Piling delivered:

• 12 permanent cased bored piles (2.1m diameter).

• 3 permanent cased bored piles (1.8m diameter).

• 9 permanent cased bored piles (1.5m diameter).

• Piles installed to depths of up to 40m.

Equipment Utilised

• Bauer BG28 drill rig for precision pile installation.

• 2 x 250T crawler cranes for lifting operations.

• Marine equipment including:

  • Main barge and service barges.

  • Workboats for marine logistics.

  • ICE 110 Vibrator for pile driving and casing operations.

Client

John Holland

Project Highlights

• Construction of a new four-lane bridge in a high-risk marine park environment, requiring careful planning to protect the thriving local oyster industry and surrounding ecosystems.

• Improved connectivity for all road users, including freight transport and emergency services.

• Enhanced river access with the bridge’s increased clearance for boats, supporting local marine activities.

• Part of the $274 million project that opened to traffic in March 2021, delivering safer, more efficient connections for the Batemans Bay community.

At Caporn Piling, we’re proud to support projects that transform local infrastructure while respecting sensitive environments. Our expertise and commitment to precision ensured the successful delivery of reliable foundations for the Clyde River Bridge, creating stronger connections for the region now and into the future.

Caporn Piling is honoured to contribute to the Nelligen Bridge Replacement project, a vital new two-lane bridge over the Clyde River designed to provide a safe and reliable crossing for generations to come. With a 100-year design life, this bridge is a testament to modern engineering and infrastructure excellence.

Project Scope:

• Installation of permanently lined bored piles, including:

  • Abutment A: 3 No. 1200mm

  • Piers 1 and 2: 2 No. 1500mm each

  • Piers 3 to 10: 4 No. 1500mm each

  • Abutment B: 16 No. 900mm

  • North Retaining Wall: 19 No. 900mm

Project Value: Approximately $18,456,954

Equipment:
To meet the project's technical demands, we deployed advanced machinery, including:

• BG45 and BG28 drill rigs

• ICE110C and ICE58 B vibratory hammers

• 8T Excavator.

Working in partnership with Seymour Whyte Constructions Pty Ltd, Caporn Piling delivered a solid foundation for this iconic infrastructure, ensuring the safety and efficiency of the Clyde River crossing for decades to come.

Caporn Piling is proud to support the construction of the Burrill Lake 290-meter-long bridge, set on a new alignment east of the existing structure. This vital infrastructure project enhances connectivity and ensures a modern, efficient crossing for the community.

Project Scope:

• Installation of 8 bored piles (1050mm diameter, 25m deep)

• Installation of 30 bored piles (1500mm diameter, 25m deep)

  • 32 piles on land and 6 piles over water

Equipment:
To execute this complex project, Caporn Piling utilized an array of advanced equipment including:

• Bauer BG28 Drill Rig

• 130tn and 110tn Crawler Cranes

• Workboat

• ICE 110C Vibrator

• 5 x 12m spans of temporary access Bridge.

In collaboration with BGC Contracting, Caporn Piling is proud to deliver precise, reliable piling solutions, laying the groundwork for this remarkable bridge that will serve the region for years to come.

Caporn Piling is proud to have delivered critical foundation solutions for the Yandhai Nepean Crossing, an iconic 258-metre-long single-span triangular truss bridge over the Nepean River. This record-breaking pedestrian bridge, the longest single clear-span footbridge in the southern hemisphere, creates a landmark that combines engineering innovation with community connectivity.

Project Scope

Caporn Piling’s contribution included:

• Installation of 20 permanent cased bored piles (900mm to 1500mm diameter, up to 25m deep) to support the bridge structure.

• Design, installation, and removal of temporary launch structures within the Nepean River to facilitate bridge assembly and installation.

Equipment Utilised

• Drill Rigs: Bauer BG28, BG30, BG20 for precision piling.

• Crawler Cranes: 2 x Manitowoc M12000 for heavy lifting.

• Marine equipment:

  • Modular barge and service barge.

  • Workboats for river-based operations.

Client

Seymour Whyte Construction

Project Highlights

• 258m total bridge length with a 200m main span, designed as a triangular steel Warren truss with curved steel-concrete composite approaches.

• Unique features include viewing platforms, balconies, and architecturally-designed feature lighting to enhance aesthetics.

• Landscaping and shared path connections (455m) integrate the bridge seamlessly into the local network.

Legacy and Benefits

• Improved community connectivity for pedestrians and cyclists, linking Penrith’s key recreational areas and pathways.

• A world-class pedestrian bridge that showcases engineering excellence and innovative construction solutions.

• Restored land use and enhanced landscaping to fit within the natural river environment.

• Recognition as an engineering benchmark, inspiring future generations.

“The Project Team has created an integrated infrastructure solution that reflects engineering excellence, creativity, and sets new benchmarks for Penrith.” – Stuart Ayres MP, Member for Penrith

At Caporn Piling, we are proud to have delivered the strong foundations and temporary structures that made the Yandhai Nepean Crossing a reality. This project demonstrates our ability to solve complex challenges through technical expertise, precision, and collaboration, leaving a lasting legacy for the people of Penrith.

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 have delivered specialist foundation solutions for the construction of the Hammond Island Marine Facility, a vital project enhancing accessibility and berthing conditions for the local community. The new facility ensures compliance with the Federal Disability Standards and significantly improves access for elderly residents, school children, commuters, and those with disabilities.

Project Scope

• Installation of 2 permanent cased bored piles (610mm diameter), socketed into extremely high-strength ignimbrite, to provide robust support for the marine structure.

Equipment Utilised

• Bauer BG20 drill rig for precision piling operations.

• 610mm diameter full-face hammer for drilling into hard rock.

• 3 x 1100 CFM compressors to support hammer operation.

• Sany 150T crawler crane for lifting and support works.

Client

Pacific Marine Group in partnership with Torres Strait Island Regional Council

Project Significance

• Improved accessibility for ferry passengers, ensuring safer and more inclusive berthing conditions.

• The facility provides reliable and compliant access to critical services on Thursday Island, including schools, hospitals, and social services.

• Enhances community connectivity for residents who rely on the ferry service as their primary mode of transportation, alongside limited helicopter and private vessel options.

Project Benefits

• Compliance with Federal Disability Standards, ensuring inclusivity for all users.

• Safer and more reliable berthing conditions for ferries, improving service efficiency.

• Supports daily access to essential services for the community, fostering economic and social well-being.

At Caporn Piling, we take pride in delivering durable, high-quality foundations for projects that improve accessibility and transform the lives of regional and remote communities. Our expertise and commitment to excellence ensure lasting infrastructure solutions where they matter most.

The upgrade of the Penneshaw and Cape Jervis ports is a vital project enhancing safety, efficiency, and connectivity for visitors, freight, and tourism on Kangaroo Island and the Fleurieu Peninsula. These upgraded ports will support quicker, safer trips while bolstering South Australia's reputation for world-class produce and travel experiences.

Project Scope:

• Installation of 39 cased bored piles (610mm and 762mm in diameter) up to 20 meters in length

• Piles installed from temporary jetty structures and a jack-up barge

Project Value: $10,500,000

Equipment:

• BG24H

• ICE 58B Vibratory Hammer

• DTH Hammer

• Flydrill

• 9t Junttan Impact Hammer.

In collaboration with McMahon Services Australia Pty Ltd, Caporn Piling is proud to contribute to this critical infrastructure project, supporting South Australia's tourism and freight industries while ensuring safe and efficient port operations for years to come.

Caporn Piling played a pivotal role in Tasmania’s largest-ever transport infrastructure project, the iconic Bridgewater Bridge, by delivering advanced piling solutions to support one of the longest road bridges over water in Australia.

Project Scope

• Test Piles - using Osterberg Load Cells (4 No.)

• Abutment A & B permanent piles (4 No. 2100mm diameter bored piles)

• Piers 1 and 2 permanent piles (4 No. 2400mm diameter bored piles)

• Piers 3 to 19 permanent piles (34 No. 2380mm diameter bored piles)

• Piers 20 and 21 permanent piles (4 No. 2400mm diameter bored piles)

• Piers 3 to 13 drilled under Polymer drilling fluid.

• Piles were up to 90m in length and typically permanently cased for half the pile length.

Project Value:

• $20,300,000

Equipment:

• Bauer BG45 (2 No.)

• Manitowoc M16000 Crawler Crane (2 No.)

• ICE 110C Vibratory Impact Hammer

• PTC 120HD Vibratory Hammer

In partnership with McConnell Dowell Constructors (Aust) Pty Ltd, Caporn Piling successfully delivered the foundation works for this forward-thinking project, demonstrating our commitment to engineering excellence and collaborative success.