FREY-FIL
CORPORATION
​INFRASTRUCTURE ​PROJECTS AND CASE STUDIES
Athletes’ Village – New Clark City
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Challenge:The government required a large-scale residential complex to house athletes participating in the 2019 Southeast Asian Games. The project comprised multiple 2–5 storey buildings with decks and one 2-storey structure with deck, totaling 26,500 sqm of floor area and 525 rooms. With a strict 12-month deadline for completion by November 2019—just in time for the opening of the Games—the project demanded both precision and speed.
Prefab Solution:
Frey-Fil utilized prefabricated concrete applications for walls, slabs, and structural components. Offsite production enabled simultaneous site works and manufacturing, allowing for rapid onsite installation while maintaining quality and uniformity across all buildings.
Results:
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Delivered on time within 12 months for the 2019 Southeast Asian Games
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Achieved faster construction cycles through prefabricated concrete systems
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Completed 525-room complex meeting international safety and design standards
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Provided durable, functional accommodations for thousands of athletes and officials
Ayala Bridge Rehabilitation
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Challenge:
The iconic Ayala Bridge, a vital link between Ermita and Quiapo in Manila, required urgent rehabilitation as the decades-old structure showed signs of wear and structural fatigue. The project called for a fast-track solution to ensure public safety, reduce traffic congestion, and minimize disruption for thousands of daily commuters.
Prefab Solution:
Through Frey-Fil’s extensive experience in handling prefabricated and modular construction solutions, the team implemented a hybrid precast-steel rehabilitation approach. Prefabricated structural steel components were manufactured offsite and assembled onsite, allowing simultaneous site preparation and fabrication. This method ensured precision, quality control, and accelerated project timelines.
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Results:
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30% faster completion compared to conventional methods
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15% overall cost savings through optimized labor and equipment use
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Enhanced bridge strength and durability, extending its service life by over 50 years
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Significantly improved traffic flow and commuter safety across one of Manila’s busiest crossings
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PCPC 135MW CFBC Concepcion Coal Unloading Facility
Location: Concepcion, Iloilo
Client: Palm Concepcion Power Corporation (PCPC)
Scope: Design and Construction of Civil and Electro-Mechanical Works
Project Type: Industrial / Marine Infrastructure
Completion: 2016
Challenge:
The Palm Concepcion Power Plant required a coal unloading facility capable of supporting continuous operations for its 135MW CFBC power plant. The project faced challenges typical of marine environments—strong tides, saline exposure, and the need for precision integration of civil and mechanical systems—all under a strict timeline to align with the plant’s commissioning.
Design & Precast Solution:
Frey-Fil applied its expertise in prefabricated and hybrid construction systems, combining cast-in-place and precast components for strength, speed, and corrosion resistance. The optimized design minimized on-site work and enabled seamless coordination between structural and electro-mechanical components, resulting in efficient assembly and reliable operation.
Results:
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Delivered ahead of schedule to support timely plant commissioning
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Achieved cost savings through optimized design and reduced construction duration
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Enhanced long-term durability against marine exposure
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Ensured smooth, efficient, and reliable coal unloading operations
Sustainability & Performance
Through the use of prefabrication and design optimization, the project reduced material waste, on-site emissions, and construction impact—demonstrating Frey-Fil’s commitment to efficient and sustainable industrial infrastructure.
Putatan Water Treatment Plant 2 – Advancing Water Sustainability through Engineering Excellence
Location: Muntinlupa City, Metro Manila
Client: Maynilad Water Services, Inc.
Scope: Design and Construction of Civil Works
Completion: 2019
Overview:
The Putatan Water Treatment Plant 2 (PWTP-2) strengthens Metro Manila’s water security by supplying up to 150 million liters per day of treated water sourced from Laguna de Bay. Frey-Fil was entrusted with the design and construction of major structural facilities, ensuring reliability, precision, and long-term durability under continuous operation.
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Challenge:
Building near Laguna de Bay required a structural system resilient to high moisture, variable soil conditions, and a tight project timeline. The large-scale concrete tanks and foundations demanded advanced waterproofing and stability solutions.
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Solution:
Frey-Fil pioneered the use of precast tanks and post-tensioned water-retaining structures, combining precast and cast-in-place methods to optimize strength, precision, and speed. The project’s optimized structural design minimized material waste, enhanced durability, and ensured compliance with strict environmental standards.
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Results:
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Completed on schedule to meet Maynilad’s expansion goals
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Achieved cost and time efficiency through precast and post-tension systems
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Delivered durable, water-resistant structures built for long-term performance
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Supported sustainable water access for southern Metro Manila communities
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Calumpang Bridge (3rd Calumpang Bridge), Batangas City
Project Overview:
The Calumpang Bridge, also known as the 3rd Calumpang Bridge or “Bridge of Progress”, serves as a crucial connection between Sitio Ferry in Barangay Kumintang Ibaba and Barangay Gulod Labac in Batangas City. Spanning approximately 140 meters in length and 15 meters in width, the bridge enhances connectivity, eases traffic congestion, and supports economic activity in one of Batangas’ busiest corridors.
Challenge:
After the collapse of the old Calumpang Bridge during Typhoon Glenda in 2014, Batangas City urgently needed a replacement structure that could withstand flooding, strong river currents, and heavy vehicular loads. The goal was to deliver a durable, flood-resilient bridge through fast and efficient construction, ensuring minimal disruption to local traffic and surrounding communities.
Frey-Fil’s Solution:
Frey-Fil Corporation undertook the Design and Build contract for the Calumpang Bridge, implementing a balanced cantilever segmental box girder system—a first in the city. The structure was engineered for high strength, superior durability, and construction efficiency, integrating both precision design and advanced fabrication techniques.
Key project components included:
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Balanced Cantilever Segmental Box Girder Design: Ensured structural stability, efficient load distribution, and reduced on-site formwork.
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Precast Segment Fabrication and Installation: Concrete box segments were manufactured under controlled conditions at Frey-Fil’s facility, ensuring quality and uniformity before being transported and installed using specialized equipment.
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Optimized Construction Timeline: Offsite precasting allowed simultaneous foundation works and superstructure fabrication, significantly reducing project duration.
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Flood-Resilient and Low-Maintenance Design: Elevated deck and durable concrete composition provided long-term resistance against environmental wear and river scouring.
Results:
The completed Calumpang Bridge successfully reestablished a vital transport link across Batangas City, greatly improving traffic circulation and accessibility for residents and businesses. Its balanced cantilever segmental box girder design showcased Frey-Fil’s engineering excellence in delivering complex bridge projects with speed, precision, and sustainability.
Today, the bridge stands as a testament to Frey-Fil’s design-and-build expertise, providing safe, durable, and resilient infrastructure that supports Batangas City’s continued growth and development.
Project Highlights
Client: City Government of Batangas
Location: Batangas City, Batangas
Scope: Design and Build of Balanced Cantilever Segmental Box Girder Bridge, including fabrication and installation of precast concrete box segments
Bridge Type: Segmental Box Girder Bridge
Length: ~140 meters
Completion: 2019
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Hinulugang Taktak Sewerage Treatment Plant
Antipolo City, Rizal
Project Overview:
Located near the iconic Hinulugang Taktak Falls in Antipolo City, this ₱2.2-billion project plays a vital role in restoring and protecting one of Rizal’s most historic natural landmarks. The Hinulugang Taktak Sewerage Treatment Plant (STP) is designed to treat up to 16 million liters of wastewater per day, ensuring that clean water flows back into the waterways surrounding the falls and nearby communities.
Frey-Fil Corporation was commissioned for the Design and Build of the civil and structural works of the treatment facility — a key infrastructure under Manila Water’s environmental sustainability program.
Challenge:
The site’s terrain posed significant engineering challenges:
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Uneven topography near the Hinulugang Taktak Falls required precise geotechnical and structural planning to ensure stability.
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The project demanded a compact yet durable design to fit within a limited footprint while accommodating heavy mechanical equipment and tanks.
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Strict environmental compliance was required to prevent any disturbance to nearby ecosystems and water channels during construction.
Frey-Fil’s Solution:
Leveraging its design-and-build expertise, Frey-Fil developed an efficient structural plan and executed high-quality construction that balanced functionality, safety, and sustainability.
Key project features included:
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Integrated Structural Design: Engineered foundations and superstructures were optimized for heavy plant loads and long-term resilience under wet conditions.
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Precast and Cast-In-Place Systems: Select precast elements were used to accelerate construction timelines and minimize on-site waste generation.
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Sustainable Construction Practices: Controlled material usage and efficient water management were implemented to align with the project’s environmental objectives.
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Collaborative Engineering Approach: Close coordination with Manila Water’s design and electromechanical teams ensured seamless integration of all plant components.
Results:
The completed treatment facility is one of Rizal’s largest modern sewage treatment systems, serving over 148,000 residents across key barangays in Antipolo.
Frey-Fil’s design-and-build delivery ensured:
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On-time project completion despite challenging terrain and environmental restrictions.
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Structural reliability for long-term operation of tanks, clarifiers, and other process facilities.
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Minimal ecological disruption during construction, preserving the surrounding environment of the Hinulugang Taktak area.
The Hinulugang Taktak STP now stands as a benchmark for sustainable water infrastructure, contributing to improved sanitation, cleaner waterways, and a revitalized natural ecosystem in the region.
Project Highlights
Client: Manila Water Company, Inc.
Location: Antipolo City, Rizal
Scope: Design and Build of Civil and Structural Works
Capacity: 16 MLD (million liters per day)
Completion: 2024
Significance: Enhances wastewater treatment capacity while protecting Hinulugang Taktak’s natural ecosystem.
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E.B. Magalona Port Development
Location: Negros Occidental, Philippines
Scope: Design and Build – Port Facilities
Overview:
Frey-Fil Corporation undertook the design and construction of the E.B. Magalona Port to enhance maritime transport and support regional trade in Negros Occidental. The project involved the structural design, fabrication, and installation of reinforced concrete port components, engineered for long-term performance under demanding marine conditions.
Challenges:
The team faced logistical complexities in transporting and installing large precast elements in a coastal environment, where weather and tidal changes affected scheduling. Coordination with local authorities and strict compliance with environmental and safety standards were also critical throughout the project.
Results:
The completed port now serves as a vital gateway for commerce and transport in Western Visayas. The use of durable precast systems reduced construction time while ensuring strength and resilience against coastal exposure—delivering a modern, reliable facility that supports economic activity in the region.
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Abusag Bridge, Baggao, Cagayan
​Type: Design and Build Project
Scope: Construction of a 511-meter Balanced Cantilever Segmental Box Girder Bridge
Overview:
The Abusag Bridge is a 511-meter structure designed to enhance connectivity between Tuguegarao City and Baggao, Cagayan. As part of the government’s regional infrastructure improvement initiative, the bridge was designed and constructed using balanced cantilever segmental box girder technology—ensuring superior strength, durability, and minimal environmental disruption during construction.
Challenges:
The project faced logistical and engineering challenges due to the terrain and river conditions of Baggao. Precise segmental fabrication and installation were critical to achieving structural balance and alignment while maintaining project timelines amid variable weather and site accessibility issues.
Results
Upon completion, the Abusag Bridge reduced travel time between Tuguegarao City and Baggao from two hours and thirty minutes to just one hour and thirty minutes. The bridge now serves over 15,000 commuters daily, providing safer, faster, and more efficient regional connectivity while reinforcing long-term economic growth in the province.
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