Intel Fab 10, Waste Lift Plan

Project outline 

Murphy were commissioned to construct a waste pit by M and W Limited, Intel and Bam Building, as part of the overall expansion of Intel’s Leixlip campus in Co. Kildare. BAM Building Ltd is ranked in the top two building contractors operating nationally in Ireland and has carried some of the largest scale projects in the country. 

The site was located in a bustling manufacturing campus, which is home to Intel Ireland. Murphy International Ltd. were contracted to carry out all of the piling activities for the project. Our good working relationship with BAM on previous projects was a deciding factor in the award of the tender. We were favoured for the systems we have in place for health, safety, environment, sustainability and quality. 

Key challenges  

The project involved the installation of rotary augur bored, rock socketed piles to construct a secant pile wall. This acted as a retaining wall and provided water cut off, allowing BAM access to excavate the waste lift pit. A series of 8 load bearing piles were then installed to support stanchions for an overhead gantry crane which would eventually service the pit. In order to speed up BAM’s dig, we proposed drilling out six 900mm diameter piles inside the footprint of the pit to help break up the rock. This innovative solution helped BAM dramatically reduce their pit excavation programme. 

Our company wide, robust safety system was viewed favourably by the client and allowed us to work to maximum capacity on the site. The safety, health, environmental, sustainability and quality systems implemented by Murphy received high praise throughout the project and on completion of the works. 

Regular communications with the client, keeping them updated on our progress and proposed movements, ensured that their programme was adhered to. The skilled and dedicated team worked safely and efficiently to achieve the 10 week works programme. Once again we delivered a difficult project on time and budget, in a tough working location. 

Key facts 
  • Twenty nine 900mm and fifty one 1200mm diameter secant piles 
  • Secant piles were between 12m and 13m deep with rock sockets between 0.5m and 9.9m long 
  • Eight 900mm diameter load bearing trestle piles installed 
  • Gantry piles were between 5.5m and 7.5m deep 
  • Six rock cores drilled to a depth of 5m 
  • Eight pile integrity tests 
  • Two pile dynamic tests 

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