Project Overview:
Ground Sun Limited was appointed by main contractor, T Vaughan Ltd, specialist groundworks and civil engineering company, to deliver the piling for a new Auxiliary Power Unit (APU) within the live operational environment of Rye House Combined Cycle Gas (CCG) Power Station in Hertfordshire which provides 715MW of electricity to London.
The works were undertaken on a constrained plot within the existing power station footprint, requiring a foundation solution that could be installed quickly, safely, and with minimal disruption to ongoing operations.
The Challenge of Working in a Live Power Station Environment:
- Live power station environment with strict safety controls
- High load capacity
- Programme-critical foundation works
- Requirement for low-noise, low-vibration installation
- Verification of changing ground conditions via AB Chance Digital Torque Monitor/logger where torque is used to determine capacity
Why Screw Piles Were Chosen for the APU Foundations:
Ground Sun proposed AB Chance helical screw pile foundations, providing an efficient, alternative to traditional piling methods which is safer and responsive to changing ground conditions.
The solution allowed foundation works to proceed without excavation, spoil removal, or impact on adjacent operational assets—ideal for a sensitive energy infrastructure site.
Depth Testing and Digital Torque Monitoring
Prior to full installation, depth test piles were installed to depths of up to 10 metres as the site had reworked ground and varying geology
- Installation torques recorded in real time
- Ground conditions verified against design assumptions
- Performance confirmed before production piling commenced
This approach reduced risk and ensured full confidence in the final foundation design.
AB Chance Helical Screw Pile Installation:
Following successful testing, Ground Sun installed:
- 101 No. SS150 AB Chance helical screw piles
- Solid steel shaft piles with 150 mm grout column
- Ultimate capacity: up to 500 kN per pile
The piles were installed using compact 5T excavator with 16000 Nm anchor drive, allowing precise positioning within the restricted site and immediate readiness for construction of the reinforced concrete raft and slab.
The project was completed safely, efficiently, and on programme. The helical screw pile solution enabled Ground Sun to deliver a robust foundation system while maintaining uninterrupted operation of critical power generation infrastructure.
Key Benefits For Power Stations:
✔ Rapid installation – 7 days
✔ Minimal site disruption – no piling mat required
✔ Proven load performance
✔ Ideal for live operational sites, low-vibration, low-noise installation
✔ Clean, sustainable foundation solution – no excavation or spoil removal
Screw Pile Foundations for Energy and Infrastructure Projects
Our team can support projects from design and testing through to supply and installation, using proven equipment and digital torque monitoring to verify performance on site. Where low-noise, low-vibration and low-disruption piling is essential, screw piles offer a practical alternative to traditional foundation methods.
Contact Ground Sun to discuss screw pile foundations for your next infrastructure or energy project.
FAQs – Rye House Power Station
Why were helical screw piles used at Rye House Power Station?
Screw piles were used because the works took place within a live operational power station environment. The system allowed foundations to be installed quickly, safely and with low noise and low vibration, helping minimise disruption to ongoing operations.
What were the foundations used for?
How many screw piles were installed?
What load capacity did the screw piles provide?
How were ground conditions verified?
Why are screw piles suitable for live operational sites?
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Certified AB CHANCE Helical Screw Pile Installations
As an experienced Piling Contractor, Ground Sun delivers technically robust screw piling solutions using AB CHANCE® Helical Screw Piles. The system is supported by established technical data and can be designed to meet relevant structural and Building Regulations requirements, subject to site-specific engineering design and approval by the appointed Building Control body.
Suitable for both residential and commercial projects, screw piling is particularly effective in urban locations, restricted-access sites and environmentally sensitive areas. Installation data, pile calculations and testing information can be provided to support the design and approval process, helping to demonstrate performance and long-term structural suitability.