BORED PILING

Located in south-west New South Wales, the Balranald project is a rutile-rich critical minerals development. To access the ore-body at depth - approximately 60 metres below the surface - Iluka Resources is pioneering an innovative, remotely operated underground mining technology method using directional drilling. This approach significantly reduces surface disturbance, minimises the project footprint and supports progressive rehabilitation.

Project Scope:

• 72 No. 1200mm segmentally cased piles across 12 locations including grout plugs at pile tops

• Detailed excavation works

• Installation off headworks and structural frames to support the mining rig platform.

Project Value:

• Approximately $2,200,000

Equipment:

• Bauer BG28V Bored Drilling Rig

• Zoomlion ZCT1000V Telescopic Crawler Crane

• 15t Excavator

Caporn Piling is extremely proud to partner with Iluka Resources on this innovative and environmentally responsible project.

As part of the Cross River Rail project, a new rail bridge over Breakfast Creek is being constructed to support Brisbane’s 10.2km underground rail expansion. This critical infrastructure will enhance public transport connectivity and capacity, improving the city’s rail network for future growth.

Project Scope:

• Breakfast Creek Rail Bridge:

  • 13 cast in place piles (1,500mm diameter)

  • 8 cast in place piles (1,800mm diameter)

  • 8 cast in place piles (1,200mm diameter)

• Temporary Jetty Construction

Project Value:

• Approximately $3,600,000

Equipment:

• BG28V Piling Rig

• M1200 Crane

• 8T Excavator

• ICE 58B Vibrator

Working with CPB Contractors Pty Limited, Caporn Piling provided specialist foundation works for the Breakfast Creek Rail Bridge, ensuring a strong and stable structure as part of this transformational rail project.

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 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.

Spanning 613 metres, the LH Ford Bridge has been a critical transport link for Dubbo since its opening in 1969. Nearing 50 years old, this reinforced concrete bridge required significant maintenance work to ensure its structural integrity and extend its design life. This upgrade plays a vital role in maintaining safe and efficient transport across the Macquarie River for the region.

Project Scope:

• 6 permanently cased bored piles (900mm diameter)

Project Value:

• Approximately $970,000

Equipment:

• Soiltek S-120

• Sennebogen 40T Crane

• PVE 16V Vibratory Hammer

• Modular Barge

• Work Boat

Working with Freyssinet Australia Pty Ltd, Caporn Piling delivered specialist piling works, ensuring the long-term stability and safety of this essential bridge infrastructure.

The Aquila Mine, located in Central Queensland’s coalfields region, is a key operation for Anglo American, requiring critical infrastructure to support its coal processing facilities. As part of the project, Caporn Piling was engaged to deliver bored piles for the ACV002 – Primary Feed Conveyor, which transports material from the pit to the ROM stockpile.

Project Scope:

• 4 bored piles (1,500mm diameter)

Project Value:

• Approximately $2,000,000

Equipment:

• Liebherr LRB23

• M12000 Crane

• ICE 58B Vibrator

• EWP

Working with Anglo Coal (Capcoal Management) Pty Limited, Caporn Piling successfully delivered these specialist foundation works, ensuring structural integrity and long-term reliability for this important mining infrastructure project.

The Tiger Brennan Drive and Berrimah Road Intersection Overpass is a crucial safety and efficiency upgrade for one of Darwin’s busiest corridors. With close to 20,000 vehicles traveling on Tiger Brennan Drive daily, this intersection has been the site of multiple crashes and fatalities. The new overpass will greatly improve road safety while reducing congestion and travel times.

Project Scope:

• 24 temporary lined bored piles (1,200mm diameter)

Project Value:

• Approximately $1,600,000

Equipment:

• BG15 Piling Rig

• 50HV Vibrator

• 120T Crawler Crane

• EWP

• 15T Excavator

In partnership with Sitzler Pty Ltd, Caporn Piling played a vital role in delivering the foundation works for this high-priority road infrastructure project, ensuring a safer and more efficient transport network for the Northern Territory.

The Rockhampton Ring Road is a transformative infrastructure project designed to enhance the Bruce Highway, delivering improved flood resilience, freight efficiencies, and road safety for Central Queensland. The North Package Stage 1 includes the construction of a six-span bridge over Limestone Creek, a key component of this major transport upgrade.

Project Scope:

• 50 permanently lined bored piles (1,200mm diameter)

• Pile depths reaching up to 32 metres

Project Value:

• Approximately $5,200,000

Equipment:

• BG24H Piling Rig

• M12000 Crane

• ICE 58B Vibrator

• 14T Excavator

In collaboration with BMD Bielby RRR JV, Caporn Piling played a crucial role in delivering the foundation works for this essential project, ensuring a safer, more efficient, and flood-resilient transport network for Queensland.

The Oaky Creek Bridge Replacement is a critical rail infrastructure project on the electrified North Coast rail line, located approximately 30 km south of Rockhampton. The project involved constructing a new eight-span concrete bridge to enhance rail safety and reliability. Given the time-sensitive planned track closure, Caporn Piling deployed four dedicated crews to enable 24/7 operations, ensuring the project was completed efficiently within the restricted timeframe.

Project Scope:

• 4 bored piles (1,200mm diameter)

• 12 bored piles (1,500mm diameter)

• Piles permanently lined and extending up to 28 metres deep

Project Value:

• Approximately $4,750,000

Equipment:

• 2 x BG28V Piling Rigs

• 2 x CKE2500 Cranes

• 1 x M12000 Crane

• Junttan 14T Hammer

• 2 x ICE58b Vibrators, 1 x PTC30HV Vibrator

• 8T Excavator & EWP

Partnering with Queensland Bridge & Civil, Caporn Piling successfully delivered this high-priority rail infrastructure upgrade, ensuring minimal disruption to one of Queensland’s busiest rail corridors.

The Waratah Super Battery Project is a landmark energy infrastructure development designed to enhance grid stability and support renewable energy integration in New South Wales. As part of this initiative, Caporn Piling was engaged to construct transmission pole foundations essential for the project’s high-capacity energy storage system.

Project Scope:

• 12 transmission pole foundations across 6 sites

• Utilisation of bored piles and anchors for structural stability

Project Value:

• Approximately $5,400,000

Equipment:

• BG24H

• BG28H

• Soilmec SM401-077A

• 12t excavator

• Crane Truck

• Skid Steer

Partnering with Zinfra Pty Ltd, Caporn Piling played a critical role in supporting this cutting-edge energy infrastructure, reinforcing the future of renewable energy storage in New South Wales.

The Sportsman’s Creek Bridge is a vital infrastructure upgrade, providing a 175-metre-long, seven-span concrete bridge with a 4.7-metre navigational clearance. As part of the Bridges for the Bush initiative, this project enhances connectivity between Grafton and Lawrence, improving transport efficiency and supporting regional growth.

Project Scope:

• 23 bored piles ranging from 750mm to 2200mm in diameter

• Pile depths reaching 36 metres

• 21 piles on land, 2 piles over water

Project Value:

• Approximately $3,500,000

Equipment:

• BG28

• 110t Crawler Crane

• Workboat

• ICE 110C Vibrator

• 3 x 12m spans of Temporary Access Bridge

Working alongside Delaney Civil, Caporn Piling played a key role in delivering this crucial transport link, ensuring improved accessibility and long-term benefits for the Northern Rivers region.

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 successfully delivered specialist foundation solutions for the 2.5km slope rehabilitation project on the Sunshine Coast, commissioned under the National Disaster Relief and Recovery Arrangements (NDRRA) following extreme weather events. This critical project restored stability and safety to the affected section, ensuring long-term resilience against future conditions.

Project Scope

• Installation of 116 cast-in-place, lined bored piles (750mm diameter, up to 10.6m deep).

• Construction of a retaining wall from a Caporn-designed temporary platform to enable safe and efficient piling works in challenging terrain.

Equipment Utilised

• Bauer BG28 drill rig for precision pile installation.

• Manitowoc M12000 crawler crane for heavy lifting and support.

• Falsework temporary structure for platform stability and safety.

Client
Seymour Whyte Constructions Pty Ltd

Project Highlights

• Delivered piling works in difficult slope conditions by utilising a temporary platform to maintain safety and efficiency.

• Stabilisation of a 2.5km section of infrastructure impacted by extreme weather.

• Ensured project completion within tight schedules to restore critical access and prevent further erosion or slope failure.

Project Benefits

• Enhanced slope stability and resilience against future extreme weather events.

• Restoration of safe and reliable access for local communities.

• Mitigation of environmental impacts through precision construction techniques.

At Caporn Piling, we pride ourselves on delivering innovative and dependable piling solutions in even the most challenging environments. Our expertise played a key role in stabilising this vital section, ensuring a safer and more resilient Sunshine Coast.

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.

The Gateway Upgrade North project was the widening of the motorway from four to six lanes from Nudgee to Deagon on the northern side of Brisbane. The project required six new bridge structures with piled foundations.

SCOPE:

• 150No. Bored Piles ranging from 750mm to 1800mm in diameter upto 50m in depth.

• 60 No. 550mm PSC Driven piles upto 31.5m in length.

EQUIPMENT:

• Drill Rig Bauer BG15, BG24, BG28, Soilmec SR40, LoDril DH20

• Driven Rig Junttan PM25, M12000 leader with 16tn hammer

• Various Crawler Cranes, 80tn upto 400tn

• IHC 58B Vibrator

CLIENT:Lend Lease Engineering

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 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.

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 played a significant role in the construction of 143km of new rail infrastructure to service Fortescue Metals Group Eliwana Site, which is approximately 90km west of the town of Tom Price in Western Australia’s Pilbara region.

SCOPE:

• 40No. 900mm diameter bored piles upto 10m deep with temporary liners.

EQUIPMENT:

• Bauer BG15

• Telescopic Crawler Crane

• Bobcat

• Misc auxiliary equipment

CLIENT: NRW Contracting

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 new Scone Bypass has removed around 500 heavy vehicles from the town centre of Scone and will improve traffic flow, travel times, and safety for all road users.
Caporn was delivered bored piles for three large bridges

Kelly Street South Loop ( 64.5 m long ) and consisted of three spans, each 21.5 m in length with central span crossing over Kelly Street.

Main Northern Railway Bridge (99.5 m long) and consisted of three spans, with the central span crossing the existing rail line.

Parson’s Gully Bridge (540m) consisting of twenty spans, each 27m in length.

SCOPE:

• 37 No. 1050mm permanently cased bored piles.

• 42 No. 1500mm permanently cased bored piles.

• CSL testing

VALUE: $7m

EQUIPMENT:

• 2No. Bauer BG28

• 3No. Crawler Cranes 100 to 150tn

• 2No. ICE 58B vibratory hammer

• Polymer plant

CLIENT:Daracon Group

As part of Australia's largest regional public infrastructure project, the Pacific Highway Woolgoolga to Ballina (W2B) Upgrade, Caporn Piling delivered specialised piling solutions for the foundations of 45 bridges. This transformative project spans 155 kilometres and includes over 170 bridges, improving safety, capacity, and connectivity along this critical transport corridor.

Project Scope

Caporn Piling’s contributions involved:

• Installation of:

  • 900mm to 1050mm steel tubular piles.

  • 900mm to 1500mm temporary and permanently cased bored piles.

• Conducted comprehensive testing, including:

  • Crosshole Sonic Logging (CSL).

  • Pile Integrity Testing (PIT).

  • PDA testing for performance assurance.

Equipment Utilised

• Piling Rigs: Bauer BG28, BG20, BG15 and Soilmec SR60.

• Crawler Cranes ranging from 100 to 250 tonnes for lifting operations.

• ICE 58B vibratory hammer and IHC Impact Hammers (S150, S200, S280) for pile installation.

Client

Multiple main contractors across the project.

Project Highlights

• Delivered critical piling solutions for 45 of the project’s 170 bridges.

• Supported one of Australia’s most significant infrastructure upgrades aimed at improving travel efficiency and safety along the Pacific Highway.

Key Benefits of the Project

• Enhanced safety by upgrading from two to four lanes.

• Reduced travel times and improved freight efficiency.

• Strengthened resilience and connectivity for regional communities.

At Caporn Piling, we are proud to have been a trusted partner in delivering robust foundations for a project of national importance, contributing to safer, more efficient transport networks that support economic growth and community development.

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 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 is proud to have delivered critical foundation solutions for the Pacific Highway Upgrade at Lisarow, a significant infrastructure project enhancing safety and capacity along this busy transport corridor. The upgrade involved transforming the existing highway into a four-lane divided arterial road and constructing a new road bridge over the Main Northern Rail Line to replace the existing structure.

Project Scope

Retaining Wall Piles:

• 66 bored piles (600mm and 750mm diameter, up to 9m deep).

Bridge Piles:

• 78 permanent cased bored piles (900mm, 1050mm, and 1200mm diameter, up to 27m deep).

Equipment Utilized

• Soiltek S60 Low Headroom rig for restricted space piling.

• Bauer BG20 and Bauer BG28 rigs for precision piling operations.

• Crawler Cranes:

  • 40T Sennebogen for lighter lifts.

  • 80T Manitowoc for larger lifting requirements.

• ICE 58B Vibrator for casing installation.

Client
Daracon Group

Caporn Piling delivered specialist foundation works for the Bolivia Hill Upgrade on the New England Highway in Northern New South Wales. The project, located 35km south of Tenterfield, included a 320-metre-long bridge and 2.1km of upgraded road to enhance safety, transport productivity, and travel efficiency on this critical route.

Project Scope

• Installation of 8 permanent cased bored piles (1050mm diameter), socketed into extremely high-strength granite, ensuring stability and durability for the new bridge structure.

Equipment Utilised

• Bauer BG15 drill rig for precision pile installation.

• 1050mm diameter cluster hammer for challenging rock penetration.

• 3 x 1100 CFM compressors for high-powered drilling support.

• Kobelco CKE1800 crawler crane for lifting and operational support.

• 8T excavator for site preparation and auxiliary works.

Client
Georgiou SRG Joint Venture

Project Highlights

• Construction of a 320m-long bridge to bypass the challenging terrain of Bolivia Hill.

• Piles installed into high-strength granite, requiring advanced drilling techniques and specialized equipment.

• Delivery of a complex project in a remote location, requiring precision and innovation to overcome geotechnical challenges.

Caporn Piling delivered advanced secant piling solutions for the Kidston Pumped Storage Hydro Project, a groundbreaking 250MW renewable energy facility designed to generate power for the national grid using a pumped hydro storage process.

Project Scope

Cable/Access Shaft:

• 32 secant piles (750mm diameter, depths ranging from 9.3m to 13.6m).

Ventilation/Exhaust Shaft:

• 34 secant piles (750mm diameter, depths ranging from 9.5m to 15.0m).

Equipment Utilised

• Bauer BG28 drill rig for precision piling operations.

• Manitowoc M12000 service crane for lifting and support.

Client

McConnell Dowell John Holland Joint Venture

Project Details

During raisebore operations, the shafts encountered extremely weathered rock in the top 20m of ground, posing risks of ground squeeze, ravelling, and instability. To mitigate these risks, Caporn Piling installed circular secant piled rings as part of an advanced presink activity.

• Secant piling forms an overlapping ring of piles that stabilises the upper shaft zone, preventing collapse during reaming operations.

• The secant piled rings enabled the raisebore machine to operate safely, providing a secure platform with negligible differential movement during operations.

Project Challenges & Innovations

• The need for presink piles arose following comprehensive geotechnical investigations, identifying areas of unstable ground not originally accounted for in the scope.

• Innovative piling solutions ensured the raisebore operations could proceed without risking shaft instability.

At Caporn Piling, we specialise in delivering innovative and dependable piling solutions for complex projects. Our work on the Kidston Pumped Storage Hydro Project ensured critical ground stability, supporting the successful delivery of one of Australia’s leading renewable energy initiatives.

Caporn Piling proudly delivered specialist piling solutions for Stage 3 of the Sydney Gateway Project, a vital infrastructure upgrade creating a new viaduct entrance to Sydney Airport's domestic terminal. Spanning from Qantas Drive to Sir Reginald Ansett Drive, the project enhances traffic flow and access to one of Australia’s busiest airports.

Project Scope

• Installation of 28 permanent cased bored piles:

  • Varying diameters, up to a maximum of 2.4m.

  • Piles installed to depths of up to 35m.

• Geotechnical site investigation works to inform detailed design, including:

  • Cone Penetrometer Testing (CPTs) for embankment and soft ground treatments.

  • Boreholes for bridge, culvert, and retaining structure foundations.

  • Installation of vibrating wire piezometers (VWP) and inclinometers for long-term monitoring.

  • Test pits, pavement cores, and geophysical seismic surveys to assess subgrade and landfill conditions.

Equipment Utilized

• BG45 and Bauer BG28 rigs for precision piling in challenging ground conditions.

• Kobelco CKE2500 crawler crane for heavy lifting and support.

• IHC 120HD Quad Jaw Vibrator for efficient casing installation.

Client
John Holland/Seymour Whyte Joint Venture

Project Highlights

• Delivered large-diameter, deep cased bored piles to support the new viaduct structure.

• Successfully navigated challenging ground conditions, including soft soils and landfill areas.

• Comprehensive geotechnical investigations ensured structural integrity and performance.
  
  At Caporn Piling, we are proud to deliver innovative piling solutions for critical transport infrastructure projects. Our expertise on Sydney Gateway Stage 3 has laid the foundations for improved connectivity and a seamless journey for millions of travellers.

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.