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FTA helical screw piles help compress timelines, reduce site risk, and support modular delivery for government-backed regional housing.
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In Bundaberg East, Queensland, Saltair Modular delivered 34 modular homes for QBuild, supported by a helical screw pile foundation system from FTA. Designed to fast-track project delivery while reducing site-based risks, the system was selected to suit both the ground conditions and the tight construction timeline.
The project, which also included carports and a BBQ area, involved installing 354 three-metre hot-dip galvanised screw piles for the homes and another 84 for the ancillary structures. “We did the screw piles in two or three days per stage, and rain didn’t stop us,” said Saltair’s Operations Manager Toby Johns. “Concrete delays didn’t affect us. It just de-risks everything.”
Integrated modular delivery
Saltair Modular, based in Queensland, manages full modular project delivery across residential, commercial and government sectors. This includes design, building manufacture, installation, siteworks, civil works and landscaping.
“Over the past few years, we’ve expanded from supplying modular buildings to managing complete delivery,” said Johns. “In projects like this one, it became clear that separating the building supply from the site works wasn’t efficient. By taking on the full scope—including design, construction and installation—we’ve been able to streamline the process and improve outcomes for clients.”
That full-service approach was central to meeting QBuild’s expectations for the Bundaberg build. “We started construction of the buildings on the same day we started on-site,” Johns said. “That shaved about three months off the programme just by going modular.”
The project was one of three large government-backed housing packages in the region. “There were three packages of a similar size, and we were the first builder finished and handed over,” he added. “The feedback was very good.”
Benefits of helical screw piles for modular installation
FTA’s helical screw piles are manufactured in Australia and designed for fast, low-disruption deployment across a range of soil conditions. With high load capacity and corrosion resistance, they provide a reliable footing solution for modular projects where time, access and weather constraints can all impact programme.
“If we’d gone with bored piers, it would’ve taken us two and a half weeks per stage,” said Johns. “We did the screw piles in two or three days per stage. It saved time and reduced our exposure to wet weather and delays.”
Coordination was also simplified. “With bored piers, you’re dealing with the concrete plant, steel fixers, a pump crew, engineers. If one of them doesn’t show, you’re stuck,” he said. “With FTA, it’s one call.”
Johns highlighted the value of FTA’s internal engineering team. “If there’s an issue, they solve it. Other providers rely on external engineers, which delays things. FTA deals with it quickly.”
On-site installation and performance
Saltair staged the project in three parts, using FTA’s LevelMaster adjustable connectors and stirrup fittings throughout. These allow 100 to 150 millimetres of vertical adjustment—an important feature in modular construction, where alignment and tolerances are critical.
“You don’t have to hit exact heights with each screw,” said Johns. “It speeds up the process and allows for adjustments later if needed. We always use this system. It reduces the risk at install and gives us options if there’s settlement.”
The piles also contributed to a safer and more efficient site setup. “No bored holes for people to fall in, no concrete pumps, and you need only a third of the personnel on site,” he said.
With the piles installed, the placement of homes went according to plan. “Install day running costs can be up to $2000 per hour when you factor in cranage, trucking, labour, supervision, traffic management,” said Johns. “Everything has to run like clockwork. The screw piles helped ensure that.”
He added that better timing could streamline future installations. “We probably installed the screw piles a bit early—about two weeks before they were needed,” said Johns. “It meant a bit of extra site management and some minor safety considerations. Next time, we’ll time it closer to install.”
Planning for future use
Screw piles now feature in around half of Saltair’s modular projects. “Two years ago, it was maybe 10 percent,” said Johns. “There’s a sweet spot. On larger residential jobs with 100 to 140 footings, they’re a great fit. For smaller builds, we just weigh them up against local factors like distance and concrete availability.”
He noted their particular benefits in regional settings, where concrete supply, ground conditions, and weather delays all increase delivery risk. “They help us keep control over every part of the build,” he said. “And that control flows through to the client. With modular, if you get behind, it backs up the factory. It’s not just a site delay—it affects production, logistics, install.”
FTA’s system, Johns added, fits well with Saltair’s broader delivery model. “We’ve worked with FTA on multiple projects now. Their ability to adapt, stick to programme, and understand what’s required for modular makes them a valuable part of our approach.”
See: Saltair Modular
See: FTA
