PROJECT ~ L2C PILE CAP DEVELOPMENT
CLIENT ~ PIPE AND PILING SUPPLIES LTD
END CLIENT ~ CARILLION POWERLINES FOR NETWORK RAIL
END DATE ~ JAN 2018

SCOPE OF WORKS
To support Pipe and Piling Supplies Ltd with the development and approval of a steel pile cap to replace the BOSS connection on driven steel piles.  The scope included the development of a cap to take Series 2 OLE equipment which would normally be founded on concrete, this enabling more equipment to be founded on 610 dia piles and reduce the concrete foundation works.  There were 7 mast baseplate types to accommodate.


DELIVERABLES

- Eurocode compliant steel design with 3D stress modelling to support hand calculations

- Provision of drawings and specification

- Network Rail civils technical approval F001/F002/F003 including DRN close out

- Overhead Line Allocation drawings

- AFC drawings for fabrication


KEY ACHIEVEMENTS

The development of installation methodology and inclusion of tolerances to give flexibility on site whilst retaining the serviceability requirements of the installed OLE masts.  This was achieved through careful review of the bolt tolerances and restriction of the rotational ability of the overall cap.

The effective use of a design decision log to capture key development decisions regarding connection to unpainted piles, corrosive limits, galvanising life overall design life, etc.


KEY CHALLENGES

The client asked if there could be a common pile to cap fixing so that pile installation could proceed without the need to reference which mast would be fitted.  This required a common pile cap sleeve and needed careful assessment of all loading conditions to give the 'worst case' for design.  3D stress modelling supported by hand calculations in Excel enabled this to be achieved and all 7 caps now sit on a common pile connection, thus driving efficiency in the fabrication and installation process.