Roger Bullivant Limited (RBL) has successfully completed a series of piling works for critical substation projects across the UK, demonstrating its technical capabilities in delivering tailored foundation solutions for energy infrastructure.

The projects, located in Willesden, Thurrock, and Amersham, each presented distinct challenges including restricted access, varied ground conditions, and live utility environments.

RBL deployed a range of piling techniques, including Sectional Flight Auger (SFA) and Driven Precast Concrete Piles, adapting its approach to suit the specific constraints and demands of each site. These installations underscore the company's geotechnical knowledge and its commitment to providing value-engineered, reliable, and safe foundation systems for infrastructure developments.

Willesden Substation, London

For the Willesden Substation project in London, RBL's South Central team implemented a tailored foundation solution. They used a compact 900 Series Rig to install ten 300mm diameter Sectional Flight Auger (SFA) piles to depths of 6.0m. The primary challenge was restricted access within a live utility environment, which was overcome through detailed planning, precise sequencing, and the rig's compact profile, ensuring minimal disruption to ongoing operations.

Due to the site's proximity to sensitive underground and overhead services, the project required high-precision rig positioning and continuous monitoring. A grouted piling solution was chosen due to limitations on conventional concrete deliveries, facilitating material handling in the confined space. Each pile position was pre-excavated and sleeved with protective tubes to safeguard existing services, ensuring successful execution while maintaining operational efficiency and infrastructure integrity.


Thurrock Flexible Generation Plant, Essex

At the Thurrock Flexible Generation Plant, RBL delivered a Precast Foundation solution for a new 275KV Air Insulated Substation (AIS) for Statera Energy. This development integrates both power generation with gas-fired reciprocating engines (450MW) and battery storage (300MW).

The site presented variable ground conditions, including up to 2.0 metres of made ground overlying very soft silty clay alluvium extending to approximately 16.0–18.0 metres below ground level. Competent strata of Chalk Formations provided reliable capacity beneath this. Following extensive site probing and testing, piling was confirmed as the most suitable method. RBL installed 12,000 linear metres of 250 x 250 Driven Precast Concrete Piles, each designed to support loads up to 500kN for transformer bases and ancillary equipment. All precast products were manufactured in-house at RBL's Walton Park facility using low-carbon concrete mixes, incorporating a 50% Ground Granulated Blast-furnace Slag (GGBS) replacement.

Amersham Substation, Buckinghamshire

In Amersham, RBL carried out piling works for a substation project, installing 64 No. 250mm diameter Sectional Flight Auger (SFA) piles. SFA was selected primarily due to restricted access constraints on site. Ground conditions, consisting of a shallow mantle of made ground overlying a firm clay formation, were well-suited to SFA piling, which facilitated minimal site disruption and maintained bore stability.

Compact rig solutions and careful sequencing were crucial for operational efficiency within the spatial constraints. The choice of SFA piles allowed for effective deployment in the confined working area without compromising load-bearing performance or productivity.

RBL's recent projects in substation foundation delivery reinforce its position as a trusted partner for complex, high-specification piling works within the energy sector. The company's localised geotechnical engineers offer flexible, in-house solutions tailored to specific site needs across the UK, supported by an extensive range of piling rigs and equipment for both displacement and replacement techniques. These case studies highlight RBL's ability to meet evolving project requirements while maintaining quality, efficiency, and technical excellence.