Projects

London City Airport – (BAM Nuttall)

CA Drillers worked with BAM Nuttall to deliver concrete cutting and sawing services for the airport’s development project. Our job required precise operations in challenging locations, which we achieved on time and with high-quality results, earning us to be shortlisted for an award by The International Association of Concrete Drillers & Sawers.

Due to tight schedule constraints centred around the piling contractor, a daily requirement existed for cutting 80 linear metres (600 mm / 700 mm deep). To meet this demanding timeline, we had to consider installing 40 metres of track at a time with two saws operating concurrently. This was achieved while working from a barge and implementing rigorous water management measures to contain the substantial amounts of water/slurry generated, as, for environmental reasons, it was imperative to prevent contamination of the water within The King George V Dock.

Our cut line was positioned 200mm above the water level, adding significant complexity, particularly since we had to cope with the constant motion of the working barge. Another challenge we faced was that the protective measures used had to be removable daily to accommodate the arrival of the night barge, which was tasked with lifting the cut concrete sections.

Our final solution involved the installation of a 150mm steel guttering system beneath the cut line. This system was installed in 20m sections in both directions, each with a very slight incline, leading into a specially designed container. The resulting waste water/slurry was then pumped into 1000-litre IBC containers located on the barge. These were removed each evening for recycling through a silt buster

Ardmore Construction – The Old War Office

In August 2019, the CA Drillers team started restoration project at the Old War Office, an iconic site nestled in the heart of Westminster. As the project progressed, our team expanded, reaching a robust strength of 60 skilled operatives during its most demanding phase. This ambitious endeavour was brought to a successful completion in October 2023.

Our extensive scope of work showcased our versatility and expertise in a variety of challenging tasks. This included the diamond drilling of substantial sump pits in the basement areas, complemented by the advanced use of Brokk demolition robots for efficient break-out operations. In the swimming pool area, we undertook precise core drilling to accommodate lighting installations, blending functionality with aesthetic considerations.

Furthermore, our team formed builders’ work openings, employing both hand saws and track saws, coupled with stitch drilling techniques to avoid overcutting. Followed by the installation of lintels was carried out with across all levels, reinforcing the framework of the building. In adherence to stringent health and safety measures, we implemented control measures in our work areas which included full tent enclosures, chapter 8 barriers for demarcation, and dust cubes for effective extraction of any dust generated during our operations.

Our responsibilities also extended to complex tasks such as forming rainwater pipes, a challenging process that began at the roof and involved cutting and breaking through walls and slabs, down to the fourth basement level. Additionally, we were tasked with the intricate chasing of electrical conduits within the ceilings, slabs, and walls throughout the entire building.

A particularly challenging aspect of our work involved the wire saw removal of steel-plated, bomb-proof walls encircling the building. The scale and diversity of our work package not only demonstrated our technical prowess but also our dedication to preserving and enhancing a building that is a symbol of British heritage. CA Drillers takes immense pride in having played a pivotal role in the restoration of this venerable landmark, contributing to the conservation of its rich history and architectural grandeur.

Riverlinx CJV (BAM Nuttall Joint Venture) – Silvertown Tunnel

CA Drillers established site in September 2021, our first task was the deconstruction of the River Wall. This challenging task required the implementation of vertical stitch drilling from the landside to sever the wall into detachable sections and subsequently be lifted out by the aid of Riverlinx machines. To ensure the River Thames, located underneath, remained free of slurry produced by the drilling and sawing, strict water and slurry control measures were employed.

Following that, we performed a series of operations on multiple areas on site. We have carried out floor sawing activities critical for initiating the open-cut procedure of the tunnel’s construction. Wire sawing was also conducted on existing UAE structures. Furthermore, we carried out a large quantity of pile cropping, we trimmed the pile tops to the necessary height using an effective combination of track sawing and Brokk demolition. It was essential that we was to retain the rebar within and not cause any damage, therefore the track sawing and Brokk activities was carried out with due diligence as to negate affecting the integrity of the rebar.

In addition, we was awarded the scope of works to demolish the Victorian dock wall which obstructed the trajectory path of the tunnel. For this, we employed a Brokk 400 & Brokk 800, to carry out the heavy duty demolition task. More recently, we were involved in the headwall cut and carve operation. This operation was vital to prepare for the Tunnel Boring Machine (TBM)’s departure from Silvertown to Greenwich. This stage was a pivotal moment in the project, as it is when the TBM made its initial breakthrough at Greenwich after setting off from Silvertown, effectively forming the initial tunnel wall. In order to facilitate the Tunnel Boring Machine (TBM)’s successful exit, we employed a drilling and sawing approach.

This involved creating a series of drill holes around the circumference of the TBM machine and making vertical track saw cuts. The primary aim of this intricate operation was to weaken the structural stability of the wall. By doing so, we enabled the TBM to successfully penetrate and bore through the wall. This operation required meticulous planning and flawless execution, all of which were crucial in ensuring the TBM’s successful journey to Greenwich. We was provided short notice and time frame to start and complete. We received the phone call on a Friday with the intent to mobilise site on the Sunday and all works completed within the time frame of Wednesday. This achievement was a testament to our team’s dedication, expertise, and commitment to delivering high-quality work on schedule. (Please see pics below of the headwall cut and carve).

BAM Construction – Space House

At the onset, C A Drillers undertook specific assignments for the Space House project, which included making track saw cuts on 48 concrete T units within PAYE’s yard. These intricate tasks demanded heavy-duty cutting and drilling. Each unit required a 3m x 450mm deep track saw cut, a 3m x 750mm deep track saw cut, and a central stitch drill to separate the 3m x 750mm x 450mm section.

Once cut, these units were lifted by the on-site crane and redistributed. Due to certain time restrictions, PAYE made accommodations for additional T units in the yard, consequently amplifying the productivity expected from CA in order to ensure compliance with the project’s schedule. Despite these demands, the team completed the tasks within the set timeframe. Following this initial phase, CA relocated to the Space House site where they were tasked with trimming back lift shaft slabs and executing necessary concrete repairs. Considering the tasks were to be carried out within a lift shaft, operatives ensured the implementation of adequate safety measures to mitigate risk from falling debris.

Activities within the lift shaft were managed with multiple layers of corex to reduce the amount of debris. This careful breakout of the slab also allowed for efficient debris clearance. Additionally, the concrete repair works within the lift shaft were thoroughly documented by the C A site manager through quality assurance documents. These were countersigned by BAM management to verify that all repairs were conducted to their specifications.

In the subsequent stages, C A has carried out a host of diverse tasks around the site. These tasks range from prepping the floors throughout the entire building, lowering the slab level to assist the screed applicators in their work, employing our Brokk robots to chip away at the screed in B2, stitch drilling riser openings across every floor, and creating numerous openings and core holes through both the slab and wall for M&E and ductwork facilitation. Our team continues to work diligently on site, delivering high-quality results and readily accommodating the site team’s requests, irrespective of the given time constraints. For quality control and safety assurance, our contracts manager and health & safety manager conduct either weekly or bi-weekly site visits, undertaking on-site briefings and carrying out safety walkarounds with the C A site team.

Erith Group – 105 Victoria

CA Drillers commenced a significant project at 105 Victoria in November 2022, working in closely with the Erith Group to safely perform a variety of demolition tasks, including intricate cut and carve operations. This includes the stitch drilling of pile openings to a depth of 1.5 meters and the subsequent lifting of large segments using A-frames.

We also carried out track sawing to form trenches that are 1 meter deep, which were then efficiently broken out using a pair of robust Brokk 400 machines. Our expertise extended to diamond drilling, creating 600mm diameter holes to a depth of 600mm, which was then broken back to create slots for the installation of new steel wailers.

Additionally, we have undertaken tasks involving track sawing for creating corner holes and employing Brokk machines for demolishing sections of a small roof. Furthermore, the operatives used the specialised munching jaw and sheathe attachment of the Brokk machines in removing the roof, effectively reducing the risk of flying debris and limiting vibration transmission through the structure.

Our ongoing efforts include extensive track sawing and floor sawing in the basement levels’ structural slab. This range of work undertaken at the site reflects our standing as a leading specialist drilling and sawing company, particularly skilled in cut and carve techniques. This assertion is supported by our track record on this project.