Foundation Selection Guide ALL TORQUE, NO CONCRETE. Screw Pile Foundations. Issue

Foundation Selection Guide Screw Pile Foundations Issue 6-2013 ALL TORQUE, NO CONCRETE

Contents About FLI...3 Our Capabilities...4 Screw Piles & Steel Grillages...5 Single Screw Pile Foundations...6 Hand Installed Screw Piles...7 RAIL PRODUCTS Straight Signal Post Foundations...8 Light-Weight Signals...9 Cantilever Gantry Foundations...10 Portal Gantry Foundations...11 OLE / OHLE Foundations...12 OLE / OHLE Structures...13 457-610mmø Driven Pile...14 Modular Platforms...15 GSMr Rapid Deployment Solution (RDS)...16 GSMr RDS Light Grillage...17 3 Legged Lattice Tower Foundation...18 4 Legged Lattice Tower Foundation...19 Principal Supply Point Cabin Foundations (PSP)...20 REB & TEH Foundations...21 Road Traffic Light Foundation (RTL)...22 Level Crossing Barrier Foundations...23 LOC & Refuge Platforms...24 Composite Foundation: Pile & Concrete...25 HIGHWAYS PRODUCTS MS3 & MS4 Foundations...26 Portal Gantry Foundations...27 Cabinet Platforms...28 Weather Station Platforms...29 Advanced Message Indicator (AMI) Foundation...30 Complete Road Sign Packages...31 FLI Combi-Pile Solution...32 Lighting Columns...33 CCTV Poles, Speed Camera Masts & Traffic Light Foundations...34 FLI Retaining Wall...35 Footbridge Abutments...36 Additional Services...37

About FLI Francis & Lewis International Ltd (FLI Structures) are part of the Haley group, the best collection of specialist companies owned & operated by engineers. Established for over 60 years and based in Gloucester, we have all of our project management, design & engineering, manufacturing and installation teams based in-house. FLI are the UK s No.1 for the design and manufacture of tower structures and screw pile foundations. This is down to our strong culture of innovation and our high quality standards. FLI have around 70 dedicated permanent staff who have the ability and knowledge to produce bespoke products to solve the needs of our clients. Our design, engineering and manufacturing teams work closely with our clients to meet their requirements. Our in-house capabilities give us an edge over our competitors and allow us to provide a better service in every way. Our designs are award winning and are produced with manufacturing and ease of installation in mind. FLI is fully certified to all relevant standards, providing good quality design, manufacture, installation and survey services. All manufacturing is carried out by Lloyd s certified welders, employing procedures to British and European standards.

Our Capabilities With over 60 years experience in steel structures, our in-house design and manufacturing capability enables us to offer you competitive prices and shorter delivery lead times. We have the ability to carry out site specific checks and design a solution from an array of standard off-the-shelf designs. We also provide bespoke solutions for difficult sites. Design (In House) FLI Structural Engineers are experienced in designing to Railway, Highways, Telecoms and MoD standards. As well as providing efficient designs, we understand the factors that add time and money to the manufacturing and installation processes, which enables us to offer competitive solutions. Services include Form 1, Site specific Form 2, CAT2 & CAT3 checks, as well as AIP s & Departures, and MoD R13 & R14. Manufacture & Stock (In House) Our in-house manufacturing ability enables us to control and maintain high quality standards and gives us flexibility to respond quickly to urgent requirements. We have state-of-the-art CNC machinery, fully qualified welders and a stock holding for quick delivery. Installation FLI have installation teams able to install our screw piles with our very own range of torque motors including the UK s biggest. FLI s installation teams operate on Railways, Highways & Construction sites. Training courses are also available (held at FLI) to enhance the skills of your workforce. Site supervision with our PTS personnel can be provided to audit your installation team.

Screw Piles & Steel Grillages FLI are the UK s No.1 for helical screw piled foundations. Made of galvanised steel, these foundation solutions are quick to install but also sustainable as they can be removed and re-used after use. FLI Helical Screw Piles will support structures in both tension and compression, providing an ideal solution where overturning moments are significant. Our piles are individually designed by our engineers to suit the separate ground conditions on each site. FLI Screw Piles have been installed all over the UK to support towers, railway signals, level crossings, road signs and managed motorway schemes. Their quick installation provides time and cost saving benefits to every client. With no concrete curing time, time on site is minimised and there is also, no excavated spoil to cart away. FLI Helical Screw Piles are a flexible, sustainable and removable solution. They are fast becoming the ideal solutions for every application in rail, highways, construction and much more. Benefits of Screw Piles Quick to install - increasing productivity, saving time and money No excavations or spoil to cart away saving money, particularly if there is contaminated ground No concrete or curing time - enables speedier commissioning of sites Small footprint - enables smaller bases in restricted areas Sustainable foundation solution - removable and re-useable Installation in low temperatures - no down time, unlike concrete Cost effective solution in soft ground, where traditional piling is more expensive and concrete is technically unsuitable Railways - reduced possession time reduces cost Highways - less traffic management and disruption to travel and safer working due to reduced time on site Less time on sites - reduces health & safety risks for those on-site

Single Screw Pile Foundations FLI have various foundation solutions to cater for horizontal loads and bending moments, suitable for supporting rail signals including Straight Signal Posts, OLE Columns and other similar structures. In conjunction with screw pile foundations, steel grillage designs are available from stock. Bespoke designs can also be supplied for sites where space is limited or to bridge buried services. Screw pile lengths and diameters vary according to ground conditions. Please send us your enquiry with the structure loads and geotechnical information for a site specific solution.

Hand Installed Screw Piles Our hand held installation solutions offer our clients an alternative which allows foundations to be installed in tight, difficult to access sites, without the need for large plant. Designed to take high tension and compression loads using a high strength solid bar. Easy to install in restricted and difficult to access sites. Enables more working in the green zone giving higher productivity outside of possessions. Power Pack Weight Torque Head Weight Factored Pile Capacity 147 Kg 56 Kg Up To 140 Kn

Straight Signal Post Foundations Straight Signal Post foundation solutions as below use a group of 3 screw piles with steel interface grillage. The W24 solution is used for sites where the ground is poor or where base forces are high. Grillages have a 10cm opening for cable management and can be installed above ground level or buried. Bespoke designs can also be supplied for sites where space is limited or to bridge buried services. Product Ref Capacity No. of Piles PCD W39 Up to 40KN 3 1.23m W24 Up to 40KN 3 2.0m Screw pile diameters and lengths vary according to ground conditions. Please send us your enquiry with the site design pack and geotechnical information for site specific designs.

Lightweight Signals FLI s single screw pile solutions are designed to cater for horizontal loads and bending moments, suitable for supporting both traditional and modular signal structures. The signal interfaces with a cap plate on the pile. Quick and easy installation increases build productivity saving time and money.

Cantilever Gantry Foundations Cantilever grillage foundations are designed to your loading requirements. These grillages are designed to accommodate the overturning moment and torsion applied by the structure. Raking piles or larger top sections can be used to resist lateral forces when required. FLI grillages are bolted for easy and safe handling. Supplied preassembled if access allows.

Portal Gantry Foundations Portal gantry grillage foundations are designed to meet the gantry span length and loadings. Typical overturning moments are up to 600kNm. Raking piles or larger top sections can be used to resist lateral forces when required. FLI grillages are bolted for easy and safe handling. Supplied pre-assembled if access allows.

OLE / OHLE Foundations Screw pile foundation designs are suitable for universal column, lattice or box beam of OLE gantry structures. Steel interface grillages are used to support the structures, with connections according to base plate design. Our focus is on innovative solutions for the design and installation of rapid deployment foundations, increasing your productivity on site. Single large piles or a group of piles with a grillage can be used to suit the site conditions. FLI can also supply the structure if required.

OLE / OHLE Structures FLI s in-house steel fabrication facility is equipped with state of the art machinery enabling efficient and competitive manufacturing for a range of OLE structures. FLI s innovative hand build-able structures for either single or twin track gantries offer a solution for green zone / mid week daytime working, giving projects higher rates of build productivity. Our solutions offer a cost effective option for soft ground conditions, where traditional piling is more expensive and concrete is technically unsuitable. Structure Solutions: OLEMI range Furrer & Frey FLI s innovative in-house solutions. Foundation solutions include: 457-610mm ø driven piles 244-610mm ø single screw pile acting like a driven pile Group of piles with steel grillage

457-610mmø Driven Pile Pile Diameter Pile Lengths Plant Design Up to 610ø According to ground and loading data Movax Vibro & Hydraulic Hammer In-House by FLI engineering team FLI provide the fabricated steel and the installation service of driven piles. Installed using side driven vibration plant with hydraulically driven drop hammers, our 610mm diameter pile offers high productivity compared with traditional concrete foundations.

Modular Platform Foundations FLI Screw Piles have proved to be a fast, efficient foundation solution for steel, FRP or concrete modular platforms. Pile and platform interfaces are designed to suit the application. Screw pile diameters and lengths vary according to the loading and ground conditions.

GSMr Rapid Deployment Solution (RDS) FLI supply combined grillages to support towers and REB cabins which are suitable for either pre-cast concrete blocks (below) or screw pile foundations. This solution reduces the foundation installation from 4 weeks to 2 days. REB Grillages Rapid deployment foundations are also available for REB cabins, sizes from Type 2 to Type 9 and weights up to 15 tonnes. Supported on 4 or 6 screw piles, this concrete free solution requires no excavation or curing time.

GSMr RDS Light Grillage FLI supply lightweight grillages for monopoles and lattice towers up to 30m in height, as shown below. Collapsible grillages allow for ease of transportation, handling and access to restricted sites. The solution separates the structure from the cabin which saves weight in the grillage. The final solution would depend on the height, load and ground conditions. FLI Ref Pole Height No. Of Piles PCD HPF 17 15m 4 325.0 HPF 19 20m 4 355.0

3 Legged Lattice Tower Foundation FLI supply foundations for 3 legged lattice towers up to 30m in height. Typical examples for various heights are shown below although the final solution would depend on structure type, load and ground conditions. FLI Ref Tower Height No. Of Piles PCD W33 10m 3 3.0m W33 15m 3 3.0m W18 20m 4 3.7m W18 25m 6 3.7m W18 29m 6 3.7m

4 Legged Lattice Tower Foundation FLI supply foundations for 4 legged lattice towers up to 30m in height. Typical examples for various heights are shown below although the final solution would depend on structure type, load and ground conditions. FLI Ref Tower Height No. Of Piles Plan Area W1 10m 4 2.3m W1 15m 4 2.3m W19 25m 8 4.3m W19 29m 8 4.3m

Principal Supply Point Cabin Foundations (PSP) FLI supply PSP foundation designs suitable for cabin weights up to 25 tonnes. The use of FLI screw piles greatly reduces the foundation construction time, compared to concrete base designs. Other foundation solutions are also available for different cabin sizes and styles. Contact FLI for a generic Form A.

REB & TEH Foundations REB Foundations With the markets leading designers, FLI has the ability to design individual, specialist frames to fit with the specified Relocatable Equipment Buildings (REB) and Temporary Equipment Housing (TEH) foundations. REB & TEH foundations are another area where FLI have experience that ensures they provide the best service in the industry. We have REB cabinet grillages suitable for weights up to 5 tonnes, supported on 4 piles. Please specify FLI/W20 when ordering this product. *FLI carry stock designs for all of Network Rail s standard REB & TEH type sizes* TEH Foundations FLI s TEH foundation is a 4 pile solution. Please specify FLI/W29 when ordering this product. Other frames and solutions are also available for different cabin sizes and styles. Contact FLI for generic Form 1.

Road Traffic Light (RTL) Foundation FLI s single screw piles for RTLs and traditional/ modular signal structures increase productivity saving time and cost. Developed for a wide range of applications the single piles are designed to cater for horizontal loads and bending moments. The structure connects directly to the pile cap through a simple 4 bolt arrangement enabling a complete foundation and structure erection in less than two hours. Where suitable, installation can be completed using hand-held light weight torque motors and power packs negating costly plant and associated, operator labour. Screw pile lengths vary according to ground conditions and base forces. Types of application Traffic light Speed signs Sign posts Emergency telephones Axle counters Low level lighting columns

Level Crossing Barrier Foundations Single screw pile foundations for Level Crossing Barriers (as shown) can be provided. Buried services or obstructions can be bridged by cantilevering off the pile cap plate. Quick installation and immediate loading of the foundation mean sites can be commissioned much quicker than concrete bases.

LOC & Refuge Platforms LOC Platforms and Safe Cess Refuge Platforms designs are available from stock. Piles are designed to interface directly to platform feet. Off the shelf designs or bespoke solutions according to the site requirements. These platforms provide a time and money saving benefit compared with traditional concrete solutions.

Composite Foundation: Pile & Concrete Vertical piles with concrete pile cap are suitable when tension resistance cannot be easily achieved, i.e. when there is poor ground overlying rock at shallow depth. This foundation solution can be used for signal posts, towers and gantries. Rectangular bases can be designed when space is limited in one direction (either in the cess or alongside a road). Lighting column foundation supported on hand installed FLI piles.

MS3 & MS4 Foundations FLI s steel grillage foundation design can be supplied either with or without cabinets. The frames can be used in conjunction with screw piles or micro piles. Our solutions are suitable for both flat or sloping sites. We can provide cladded grillage solutions in cuttings or an integrated retaining wall / grillage solution on embankments. Installation can be completed within 2 or 3 shifts, which is significantly less than traditional foundation solutions. Time savings and limited excavations can improve safety. Less traffic management improves journey time reliability for road users, and saves costs. AIPs, GDR s, Departures & CAT II checks can be provided.

Portal Gantry Foundations FLI can apply their screw piles and steel grillage foundations with or without cabinets for portal gantries used on the UK motorways. Our steel grillages can be adapted to work with many foundations including concrete and can function on sloping sites if required. Cladding and access steps can also be included in the design to provide a neat finish and easy access to all necessary equipment for maintenance. All of the above are site specific designed and supplied to all relevant Highways Agency standards.

Cabinet Platforms FLI s cabinet platform solution can be provided to suit the site requirements. Our platforms are designed with easy access for maintenance and on sloping sites are finished with timber cladding around the structure. Hand-railing completes the structure and bespoke access options are available. All are designed and supplied to relevant Highways Agency standards making our cabinet platforms safe and quick to install.

Weather Station Platforms FLI provide Highways Agency approved roadside platforms to support various structures including weather stations (as shown below). Platforms are designed specifically to suit the equipment loading. Piles are designed to interface directly with the steel grillage platform. Features include bracing and cladding for sloping sites, hand rails, access steps and extended platform areas for maintenance.

Advanced Message Indicator (AMI) Foundation AMI signs can be supported on a single FLI screw pile foundation. Large diameter screw piles work in both tension and compression and can be installed within an hour, depending on ground conditions and the pile depth. The structure can then be mounted during the same shift. FLI s in house installers can carry out the installation at night, saving money for the contractors and improving journey time reliability for UK motorists.

Complete Road Sign Packages FLI s innovative design allows single screw piles to interface directly with the sign structure. The solution is suitable for passively safe structures or standard steel columns. Quick installation and elimination of curing time results in sign structures being completed much faster. Once the piles are installed and the sign post erected, the sign face can be attached during the same shift. All this is done by FLI as a complete turnkey package.

FLI Combi-Pile Solution The FLI Combi-Pile This solution uses the top of the screw piles as the sign post and is suitable for passively safe structures or standard steel columns. FLI can provide a foundation and columns only package or a complete turnkey solution including the signage. The screw pile and CHS column combines foundation and structure into an efficient solution for signage schemes. A passively safe option is available and the solution is useful on sloping sites. Screw Pile & Steel Grillage Solution Screw piles with steel interface grillages can support a multiple of upright columns from a variety of makers including passively safe or standard steel columns. The grillage can be sloped to suit the site if necessary.

Lighting Columns Socket Pile root extensions can support a number of lighting columns with varying heights including passively safe structures or standard lighting columns. Designed and supplied to Highways Agency specifications with cable access built in, this product is quick to install reducing the times on-site for these schemes. FLI can also supply and install the lighting columns to offer a complete turnkey package if required. Foundation Technical Summary Main Application Street Lighting Columns Plant Highways Lighting Column Foundation Solution 1 x Screw Pile 244mm diameter JCB, 360 Excavator, Hi-Ab Varying Pile Sizes

CCTV Poles, Speed Cameras & Traffic Lights FLI offer steel foundation solutions and steel poles & masts for the mounting of CCTV cameras, speed cameras and traffic lights. With quick installation these foundations and mast solutions can be completed in one shift reducing the need for traffic management saving time and cost onsite. Both the foundation and pole/mast are made to Highways Agency specifications here at our own steel fabrication facility in Gloucester and are designed to all relevant standards by our Engineers.

FLI Retaining Wall The FLI Wall is a retaining wall solution incorporating a steel L frame, with FLI s screw piles taking the compression and tension load. The FLI Wall is a cost effective solution and is designed to replace reinforced concrete or sheet pile alternatives. Screw pile diameters vary according to the ground conditions and load. The system is fully galvanised with panelling made from either steel mesh, pre-cast concrete or timber sleepers. Types of application: Retaining Wall Refuges Embankments Equipment location Cess widening and walkway Lay-by / safety area Ballast retention Patent No. GB245270

FLI use a combination of screw piles & steel grillages to form abutments and can incorporate a retaining wall locally to retain the soil behind the embankment. Installation of the screw piles can be carried out with heavy plant or light weight hand held torque motors and piles. This enables access to restricted sites, where deployment of larger plant is not possible. Footbridge Abutments

Additional Services FLI can provide you with a full turnkey solution, with additional services listed below. Upon review of the borehole data, one of our Chartered Engineers will innovate a solution to your specification. Our focus on innovation has been recognised by Network Rail, with FLI winning the Innovation Award in 2009. Geotechnical Investigations Site / Ground Investigations are carried out by us in accordance with the specifications for deep pile foundations, i.e. to minimum depth using dynamic probes and window sampling rigs. Bespoke Solutions Bespoke solutions can be produced to meet the site requirements. Completed by our in-house teams the process is quick and efficient. Pile Testing Tension, compression and lateral pile load testing is available. Sacrificial piles can be installed and tested to failure if required. Steel Fabrication Our fabrication workshop contains state of the art CNC machinery for efficient & quick production. Welding is carried out by Lloyd s Certified welders and all our products carry CE certification.

SERVICES AIP, GDR & Departures CAT II & CAT III Form A & B Form 1 & Form 2 Geotechnical Installation Investigations Maintenance Structural analysis Structural surveys 3D design PRODUCTS AMI Signage Foundations Bridge Abutments Cantilever Gantry Foundations Composite Foundations Driven Piles Highways Sign Foundations Lattice Tower Foundations Level Crossing Barrier Foundations Lighting Column Foundations LOC Platform Foundations LOC Platforms Modular Platforms Foundations Modular Platforms Monopole Foundations MS3 & MS4 Foundations OLE Foundations OLE Structures Portal Gantry Foundations PSP Cabinet Foundations REB & TEH Foundations Refuge Foundations Retaining Wall Road Traffic Light Foundations Signal Post Foundations Single Pile Foundations Weather Station Platforms