SPI Piling Ltd, delivered the permanent sheet pile retaining structures for the new Darlaston Station, part of the West Midlands Combined Authority’s HS2 Connectivity Programme. The station includes two single‑face platforms, a footbridge with lifts, a 300‑space car park, and flood‑mitigation works. Challenging ground conditions—Made Ground, alluvium, loose sands and gravels, and historic shallow mining—required a robust geotechnical solution to ensure long‑term stability and safe construction adjacent to the River Tame and a live railway.

SPI Piling Ltd’s package included sheet pile walls behind Platform 2 and within the raised car park area, using 9m AZ26 piles to retain up to 3.0m of fill. The team worked closely with the Principal Contractor and designers to confirm pile lengths, installation feasibility near overhead line equipment, and integration with temporary and permanent works.

Because of sensitive ground conditions and rail proximity, SPI adopted a low‑vibration two‑stage method: VDW cased‑auger pre‑drilling to loosen ground, stabilise soft strata, and control ground behaviour; followed by leader‑rig vibratory installation for accurate alignment, reduced deviation, and safer embedment into competent strata. This approach significantly reduced ground resistance and vibration near critical rail assets.

On completion, line and level checks were undertaken, and a reinforced concrete capping beam was installed to tie the wall together before controlled backfilling. The combined methodology allowed SPI to maintain tolerances, minimise vibration, and manage complex ground conditions efficiently and safely.

Safety and quality management were central due to risks including historic mining, contamination (hydrocarbons, PAHs, VOCs), UXO, ground gas potential, and the operational railway. SPI operated under detailed RAMS, controlled piling platforms, and compliance with Network Rail standards and GRIP 4 retaining structure requirements, with full depth and tolerance verification.

SPI Piling Ltd, successfully delivered a permanent retaining system that supports the new platform and car park, integrates with flood‑mitigation measures, and addresses complex ground conditions. The project demonstrates SPI’s strengths in early geotechnical engagement, constructability input, controlled rail‑adjacent piling, and delivering safe, high‑quality solutions on brownfield rail infrastructure schemes.