GVR Geo was proud to support Smulders Projects UK Ltd to lead a critical ground investigation in the development of their significant new fabrication facility on the River Tyne in Wallsend — a project at the forefront of the UK’s offshore wind manufacturing sector.

Laying the Groundwork for Offshore Wind Innovation

Our role began with a comprehensive review of historic ground investigation data for the former industrial site, which has seen over 150 years of continuous industrial activity. We followed this with a Phase 1 geoenvironmental desk study, crucial for both planning submission and informing the design of a detailed ground investigation.

From Tidal Flats to Industrial Heartland

The desk study revealed that the site was originally tidal mudflats before being reclaimed in the 1800s, the land being raised using a mix of fill materials — colliery spoil, Thames flint gravel (brought as ballast in collier boats), boulders, and Victorian demolition debris. The site had then been used as an industrial quayside, boatyard, and marine engineering works, leaving a legacy of complex made ground.

Targeted Investigation for Structural Insight

Given the scale of the proposed high-bay fabrication shed, we developed a ground investigation strategy aligned to its structural grid. This included two drilling phases to work around ongoing fabrication activity, totalling nine cable percussive boreholes to depths of 25m.

GVR Geo engaged NML Diamond Drilling Ltd and Clay Drilling Ltd to carry out the boreholes using a Dando 3000 rig. Boreholes began at 300mm diameter and were reduced to 200mm and 150mm to achieve the target depths. Both disturbed and undisturbed samples were taken and subjected to geotechnical laboratory testing to obtain parameters for pile design.

Findings Beneath the Surface

The boreholes revealed a deep and variable made ground up to 6.2m thick, overlying black organic alluvium with significant coal dust content — a nod to the Tyne’s industrial past. Beneath this, lay alternating layers of laminated clay and glacial till, a geological signature of the region’s glacial history. Although geological maps suggested shallow rockhead, and one earlier borehole within the drilling footprint indicated rock, none of our boreholes proved rockhead within the drilled depth.

This data informed a pre-bored, cast-in-situ pile design, combining friction and end-bearing to achieve the necessary load capacity.

Extreme Conditions, Uncompromising Standards

The drilling operations took place under Smulders’ stringent health and safety protocols, including mandatory full-body anti-flash overalls. While the investigation team had no issues adapting to this, the timing coincided with the 2022 heatwave — with on site temperatures hitting 42°C – encouraging buckets of iced water to keep the drilling crews fresh. This marked a personal record for GVR Geo’s Director, Grant Richardson, who led operations on the ground.

Supporting the Future of Offshore Wind

Smulders’ new facility at Wallsend is central to the UK’s push for renewable energy. Specialising in the production and assembly of steel foundations for offshore wind turbines and substations, the site spans 325,000 m² with 40,000 m² dedicated to production. It now employs 220 staff people and 200 external staff through their supply chain and subcontractors. Smulders now stands as a strategic hub for offshore wind supply.

The GVR Geo team feels extremely proud to have played a part in powering the UK’s renewable energy future — one borehole at a time.

Grant Richardson, Director at GVR Geo, reflected: “Working on the Smulders project was a rewarding challenge. The site’s rich industrial history presented complex ground conditions, but our team’s expertise and perseverance through multiple boulder obstructions ensured we obtained accurate, quality assured data for the pile design. Collaborating with Smulders on such a pivotal renewable energy project was a privilege.”

A spokesperson at Smulders Projects UK, commented: “The Wallsend facility is a cornerstone of our UK strategy and plays a vital role in supporting the offshore wind sector. Working with GVR Geo gave us the confidence that the complex ground conditions on this historic site were properly understood and addressed. Their professionalism and technical input helped lay the foundation — quite literally — for what will become a key hub for renewable energy infrastructure in the UK.”

Get in touch

If you would you like to learn more about our ground investigation capabilities, please get in touch with the team at https://gvrgeo.co.uk/. For further information on Smulders Projects UK Ltd, please visit https://www.smulders.com/.

A-frame drilling rig in action

Diamond coring of existing reinforced concrete hardstanding prior to drilling