Lafarge originally contracted BAUER Foundations Canada for 107 piles, 880mm and 1180mm diameters, of several lengths, for the expansion of the existing plant in Exshaw, Alberta. In September 2013, a change order was issued for an additional 92 piles, bringing the total quantity to 199 piles for several structures.
With a bedrock sloping through the site, the pile lengths varied and the design opted for piles with rock socket on the West side and friction piles without socket on the East side of the site. The sandy gravel with cobbles necessitated a BG 40 drill rig to install temporary casings to the rock.
During construction, several challenges were overcome: The presence of natural boulders as well as obstructions from the previous buildings was found in the gravel area, requiring the particular set of skills from the BAUER operator to keep the casing into position. The remote area with limited concrete resources for the whole site imposed a good inter-relation with the main contractor, as well as the limited platform area.
The team managed to overcome every situation to complete the site before winter.
BFCA performed as direct contractor for Lafarge. All work was completed at the full satisfaction of the Client and on schedule.