Project Summary:
Commissioned in 1963, the original steel grillage tower foundations had reached the end of their service life. Due to modern environmental and safety legislation, traditional replacement methods—particularly those involving concrete—were not feasible. PCA’s patented K-LoK™ micropile system provided a highly adaptable and low-impact solution.
Challenges
- Restricted access through a protected national park
- Inaccessible tower locations, including one reachable only on foot
- Fragile fire trails and creek crossings limiting heavy machinery use
- Environmental constraints prohibiting concrete use and extensive clearing
- Proximity to live high-voltage power lines limiting aerial access
The Solution: K-LoK™ System
PCA deployed its K-LoK™ system, featuring micropiles installed parallel to each tower leg and secured with custom steel brackets. Designed using advanced finite element analysis (FEM), the system ensures:
- Zero bending stress on tower legs
- Full axial and shear load transfer
- Compact footprint with minimal site disturbance
- Installation using lightweight, hand-portable equipment
- Capability to work under live line conditions
Outcome
The K-LoK™ solution extended the life of the towers by 50 years, delivered at a fraction of the cost of conventional methods, and ensured minimal environmental impact—meeting all technical and regulatory requirements within a sensitive national park.