At an estimated cost of about $ 4 billion, the New Champlain Bridge over the St. Lawrence River is one of the largest projects under construction in eastern Canada. The new bridge project is to replace the existing bridge, built in 1962, and is designed for a service life of 125 years.
BAUER Foundations Canada was contracted by Signature on the St. Lawrence Construction (SSLC), a consortium of companies that includes SNC-LAVALIN, DRAGADOS and FLATIRON to construct 200 concrete piles for the two main bridges; the New Champlain Bridge over St. Lawrence and Nun’s Island Bridge.
All piles were permanently cased to top of competent rock. 190 piles were drilled from land or jetties and 10 piles were marine piles drilled from barges. Piles had diameters of 1,300 mm and 2,000 mm and lengths ranging from 10 to 24 m.
Two rigs were initially mobilized to the job: a BAUER BG 28 and a BG 40. The original BG 40 on site was later replaced by a new BAUER Premium Line BG 39 in January 2016.
Working from a floating barge in the middle of the St. Lawrence to install the 2,000 mm diameter piles was especially challenging. Detailed planning and coordination was undertaken with the client and all parties involved. Piling operations started at the Main Stay Tower (MST) in October 2015. The work proceeded initially with two crews on the day shift. As the MST was on the critical path of the project, BFCA added a third night shift crew during November and December 2015 to meet the client’s schedule. The last pile was constructed in July 2016, and was followed by full demobilization thereafter.
The project was completed successfully with no safety, environment, quality and schedule issues being experienced.