Abstract:
The Darlington New Nuclear Project (DNNP) introduces North America’s first grid-scale Small Modular Reactors (SMRs), a pioneering initiative set to provide clean, reliable energy to approximately 1,200,000 homes. The focus of this paper is the first of several SMRs planned for the Darlington site, marking the beginning of a new era in sustainable nuclear energy. At the heart of this groundbreaking effort is the construction of three secant pile shafts, totaling 458 piles, critical for structural stability and groundwater control of the new reactor and support structures.
Traditional pile quality verification often relies on manual data collection and limited real-time insights, increasing the risk of errors, delays, and rework. This paper highlights the transition to data-driven methodologies that bridge these gaps, showcasing advanced Quality Verification Engineering (QVE) strategies implemented to ensure the success of the DNNP’s secant pile walls.
A custom-built app was developed for this project to integrate quality control, production tracking, and real-time reporting. The app provides instant alerts on tremie/casing embedment, verticality deviations, and other critical metrics, enabling quicker and more informed decision-making on site. It further enhances project efficiency by automatically generating comprehensive QC packages. These packages compile essential documentation, including records for pile drilling, concreting, and reinforcement, ensuring all construction activities are accurately tracked and readily accessible for review. It also streamlines daily shift reporting and employee tracking, such as LEM documentation, by leveraging live progress data. This functionality reduces administrative workload and ensures real-time accountability and consistency across project teams.
The app’s transparent design fostered a collaborative environment, providing critical data to all stakeholders, including contractors and non-technical members, while aligning with industry trends for greater transparency.
Leveraging other modern tools, the QVE team applied QC techniques such as Thermal Integrity Profiling (TIP) to detect pile anomalies and rigorous monitoring of verticality and overlap tolerances to meet strict design specifications. The team also utilized collected data to create a "wall map" that visualized concrete drop levels for each pile, enabling the identification of potential anomalies and driving performance enhancements across the wall.
As the first SMR of its kind, the DNNP represents a template for future projects worldwide. The success of its secant pile walls demonstrates their potential application in similar SMR initiatives, where stringent design tolerances and complex geological conditions are expected. By addressing traditional limitations and adopting modern digital solutions, the DNNP sets a benchmark for quality control in piling. These advancements pave the way for improved efficiency, precision, and collaboration in high-stakes foundation projects across the globe.