In mid-2024, we were commissioned to develop a lightweight screw piling system for a contractor in London.

The contactor was working on several projects with limited access to the jobsite, meaning they could not use their existing excavator mounted piling equipment. This necessitated a portable, lightweight solution that could be operated manually. Collaborating with Devon-based Gyru-Star dealer Machine Serve, who were supplying additional machinery for the project, we developed a bespoke concept tailored to these requirements.

Our team was tasked with transforming the initial design concept into a market-ready product. Thanks to our turnkey design and manufacturing capabilities, we were able to complete the entire process in-house, from initial development to final production.

The Product

The auger system consists of three main components: the auger driver and cradle, torsion bar, and hydraulic power pack. The system is designed to be broken down into these three components for ease of transport and to allow access to confined work areas.

At the centre of the system is the Digga HH-6K planetary drive, which is specially designed for confined work areas. This is powered by an external hydraulic power pack with a 13hp petrol engine. This provides a hydraulic output of 30 l/min at 140 Bar, resulting in a maximum force of 8554 NM and a rotational speed of 8 RPM.

Fitted to the auger cradle is a collapsible torsion bar, with a maximum extension of 2 metres. A fluorescent orange marker on the internal section provides a visual confirmation when the bar is properly extended.

The system has a combined weight of approximately 221 kg, with the heaviest individual component being the torsion bar at 90 kg. To make transport easier, the power pack is fitted with wheels.

Manufacturing

Our turnkey manufacturing capabilities enabled us to manufacture this product completely in-house. This includes design and development, fabrication, CNC machining, powder coating, and assembly.

Once the design and development phase was complete, our fabrication team cut the steel components using our plasma profiler before welding the cradle and torsion arm. At the same time, our CNC machinists manufactured the remaining components.

Once these processes were complete, and all the components had been powder coated, the product was passed over to our assembly team. The logistics team then arranged transport to Machine Serve’s headquarters in Devon for testing.

Compliance and Technical Documentation

Before the final product could be sold in the UK and Europe, it required UKCA and CE certificates. This is an official declaration from the manufacturer that the product is safe, and that it conforms to all of the relevant regulatory standards. A CE certificate is also a requirement for export to Europe.

As an established manufacturer and experienced exporter, our team have an in-depth knowledge of this process. We carry out every stage in-house, including creating all of the required technical documentation.

In the case of this project, this capability allowed us to deliver a bespoke, market ready solution without delay.

Real World Testing and Design Validation

Testing of the final prototype was a great success, and no major changes to the design were required. However, a carry handle was added to the reaction arm to make it easier to transport. A locking mechanism was also added to the reaction arm to lock the two telescoping sections in the collapsed position, further improving transportability.

At the time of writing, the product is still being evaluated by the customer, and we are awaiting further feedback. However, initial reports are positive.

Do You Need a Bespoke Industrial Solution?

Sometimes you’re facing a problem that doesn’t have an ‘off-the-shelf’ solution, and it’s these problems we specialise in solving. We work closely with customers across a variety of global industries, to design, manufacture and deliver innovative solutions to their biggest challenges.

If you would like to discuss a project, then you can get in touch with our team at info@wheatway.com.