Case Study

Greenwich Substation

Engineer: Mott MacDonald

Contractor: J Murphy

Architect: NORD Architecture

Market Sector: Piling Products

Product: Sheet Pile Infills


Due to the ongoing growth of the residential and commercial population of the Greenwich Peninsula, a new electricity substation is required. The new building has been designed to accommodate three transformers and a large switch room, and has been constructed with an underlying cable basement. Cordek were asked to supply Sheet Pile Infills to facilitate the construction of the basement.

Project Scope

Sheet piles were used to support the excavations during construction of the basement. The basement construction consists of a 300mm thick reinforced concrete wall which is cast against the sheet pile wall. Cordek were approached to supply a product to infill the pans of the sheet piles to create a flat surface to cast the wall against.

The Solution

Sheet pile infills are designed as a quick and lightweight solution to infilling the open pans in the exposed sheet pile wall. Manufactured from Filcor EPS (Expanded Polystyrene), they are profiled to the exact dimensions of the trough shaped voids. The infills come in lengths of 1.2m, making them easy to handle on site. In this instance, in addition to the infills, the contractor wanted to incorporate additional sheets of Filcor EPS at 240mm thick to provide insulation.

The Process

The contractor, J Murphy, provided 2D drawings of the infill required. Our production department used these drawings to programme our hot wire CNC cutting machine. Manufactured from Filcor 90 EPS, the profile was cut to the exact dimensions of the indents of the sheet pile panels, making them quick and simple to install.


The lightweight and easy to handle profiled sheet pile infill blocks removed the need for backfilling in a confined space and offered a quick and economical installation.

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