Keller was selected by Kanadevia Inova as the Principal Contractor on the new waste-to-energy project, which is being built on behalf of Viridor, one of the UK’s leading waste management companies.

More than 1,000 piles have been installed by Keller at Essex's Tilbury Docks, which will be home to the Thameside Energy Recovery Facility (ERF).

A combination of continuous flight auger (CFA) and driven precast piles have been used to support the substantial loads of the facility.

Some of the CFA piles were up to 1050mm in diameter and reached depths of 36 metres, highlighting the scale and complexity of the structure.

Richard Smith, Keller’s Preconstruction Manager – Foundations, said the project required careful planning and constant monitoring throughout the works.

"Getting the foundations right from the outset for such a large and technical scheme is crucial," said Richard, "which is why we've taken a very thorough approach to testing and validation.

“It’s about giving the client confidence that the foundations will perform exactly as designed over the long term.”

Keller’s in-house design team was able to react swiftly to changing ground conditions during construction, helping to reduce risk.

Richard added: "Having design and delivery under one roof makes a real difference.#

Reliable and efficient

"It meant we could respond quickly during pre-construction stage to reduce material and improve buildability by reassessing the structural design of the piles. This value engineering is introduced where appropriate, without compromising performance.

"This approach ensured a reliable, efficient, and technically robust completion of a critical foundation package, meeting the client’s high-quality requirements and timescales."

Advanced piling rigs were used throughout the works, with real-time data tracking factors such as penetration rates, torque, and concrete volumes. This helped Keller maintain consistency and identify any issues early.

Quality assurance also played a key role, with a series of integrity and load tests carried out to confirm that the piles were performing as expected.

Alongside the piling works, Keller also delivered a full package of support activities, including classification and disposal of excavated material, maintaining piling platforms, setting out, excavator attendance, UXO surveys and overseeing traffic management.

The project demonstrates Keller’s ability to deliver full piling and attendance packages to the highest quality and health and safety standards, whilst exceeding the client’s expectation on budget and programme.

Richard added: "Installing more than 1,000 piles across a live construction site takes detailed coordination and a strong team on the ground.

"Projects like this are vital for future energy resilience. We’re proud to be contributing to infrastructure that will have a long-term impact.”

Once complete, the Thameside Energy Recovery Facility will treat 350,000 tonnes of residual waste each year and turn it into electricity, with Viridor targeting a start of commercial operation in 2028.