PAKISTAN DEEP WATER CONTAINER PORT PROJECT - KARACHI

Country: PAKISTAN Owner: Ministry of Ports and Shipping

Operated by Karachi Port Trust

Contractor: CHEC China Harbor Engineering Company Designer: Royal Haskoning

Construction period: 48 months

CLI’s involvement Sublicense granted to the Contractor and technical assistance provided during the

construction

Background The Karachi Port is the primary seaport of Pakistan that is aptly referred to as Gateway to Pakistan.

The capacity of the port, that was 2.5 million tonnes in 1947, recorded substantial growth and presently the throughput of cargo stands at 41 million tones and is expected to rise 100 million tonnes by the end of this century. To achieve these fundraising objectives a number of ambitious initiatives have been carried out in related with the harbour. Before the start of the extension of the surface of the harbour. Three massifs breakwaters reinforced by CORE-LOC™ blocks had been carried out in order to protect the new extended superficies against the strong waves during the monsoon.

Hydraulic conditions Length of three breakwaters:

1. Oyster breakwater- 2506 m 2. Manora breakwater-1100 m

3. Keamari breakwater- 300 m

Max. water depth (toe):- 18 m Top of the crest: +9 m Design wave Hs: 6 m Wave period Tp: 12.85 s

3D model test: HR Wallingford (UK)

CORE-LOC™ Construction aspects Up to 17 lines in the slope Placement carried out in 24 months CORE-LOC™ sizes:

2.4m3 = 21510 units 6.2m3 = 9923 units 8.5m3 = 627 units

Concrete quantity: 118 000 m3

CORE-LOC™ placement

Construction of the breakwater

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AL DUQM PORT

Country OMAN

Owner Ministry of Transport and Communication

Contractor CCC-STFA JV

Contractor Designer Royal Haskoning, UK

Construction period 2007 - 2010

CLI’s involvement Sublicense granted to the Contractor

and technical assistance provided during the construction

Background The two breakwaters have been

constructed in difficult sea conditions (important wave agitation and poor

visibility below water). The use of the POSIBLOC™ positioning

system was quickly decided in order to allow the proper positioning of the

units with poor visibility condition and without permanent divers.

CLI provided GPS referenced 3D

placing drawings to be used directly by the POSIBLOC™ system.

The rate allowed by the POSIBLOC™

system was unusually high for 8.5m3

units (about 110 units per day and per crane) allowing completing the work

ahead of schedule.

Hydraulic conditions

♦ Length of MKB (CORE-LOC™): 4020 m

♦ Length of LKB (CORE-LOC™): 3425 m

♦ Max. water depth (toe): -11.5 m ♦ Top of the crest: +8.0 m

♦ Design wave Hs: 5.8 m (cyclone)

♦ Wave period Tp: 9.4 s

♦ MHHW +2.53 m

♦ Cyclone possible

CORE-LOC™ Construction aspects

♦ 47 500 CORE-LOC™ units

♦ Up to 18 lines in the slope

♦ Placing with POSIBLOC™ system (visualisation of the units below water on a screen and recording of as-built positions)

♦ Placement rate (2 cranes): 2 x 110 units/day

♦ CORE-LOC™ sizes:

3.0m3: 26 744 units 8.5m3: 20 637 units

♦ Concrete quantity: 256 000m3

CORE-LOC™ storing yard

Placing with POSIBLOC™

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NEWBIGGIN BAY

Country United Kingdom

Owner City of Newbiggin

Contractor Westminster Dredging Company LTD

Designer Atkins

Construction period March 2007- August 2007

CLI’s involvement Sublicense granted to the Contractor

and technical assistance provided

during the construction

Background The City of Newbiggin has decided to

recharge the sandy beach along the shore

next to the bay promenade. In order to protect this newly reclaimed

beach against erosion, the hydraulic engineering office Atkins had designed an

off shore breakwater. The visual impact of the breakwater was a

predominant aspect of the project and it was crucial to have a very limited impact.

Consequently it was decided to create a low crest structure which was totally

submerged at high tide and partially visible at low tide.

This breakwater was covered of 3.9m3 units on both sides and on the top.

Furthermore, the structure had a wide crest where the blocks were laid on a flat

surface. Eventually the breakwater was

topped by a sculpture having its steel piles going through the CORE-LOC™ armouring.

The CORE-LOC™ units were transported by barges from the casting yard to the

breakwater.

Hydraulic conditions ♦ Length of CL structure: 200m

♦ Max. water depth (toe):-7m

♦ Top of the crest: +4.80m

♦ Design wave Hs: 5.7 m

♦ Wave period Tp: 12 s

♦ MHWS:+5.6

♦ 3D model test: DHI December 2004 ♦ Important tide range

CORE-LOC™ aspects ♦ Fabrication at 20km from the structure ♦ 1288 CORE-LOC™ units

♦ Placement completed in 2 months

♦ CORE-LOC™ sizes: 3.9m3

Particular aspects of the project ♦ Low and wide crest (10 lines on the berm)

♦ 6 Lines in the slope

♦ Transport of the units by barges

♦ Placement from a barge

CORE-LOC™ feeding barge

CORE-LOC™ placement

Casting yard

UMM AL – MARADEM SERVICE HARBOUR Country Kuwait

Owner Ministry pf Public Works (Special Projects Administration)

Contractor Gulf Dredging & General Construction C.O

Consultant KAMPSAX INTERNL & KEO Consultants

Construction period September 2004 – September 2005

CLI’s involvement Core Loc™ sublicense agreement including the supply of standard technical services, design review, formwork drawings, technical specifications, positioning drawings and site visits during construction.

1.4m³ Core Loc™ moulds Handling trial test

Background Umm Al Maradem island is located in the Persian Gulf, about 30 Kms off the south coast of Kuwait The one square kilometer island requires to be serviced by a new harbour for the coast guard. The 500m long breakwater exposed to the south waves required concrete armouring. The original design called for 10 000 m³ of tetrapods. The core Loc™ single layer was preferred since it saved 4 000m³ of armour concrete. The 2 000 Core Loc™ units were cast on the island using materials supplied from the main land.

Hydraulic conditions ♦ Hs: 4.3m ♦ Tp: 9.3 sec ♦ Design water level: +3.3m ♦ No physical modelling study but

unit weights were increased to the next size up.

Construction aspects ♦ Total project duration: about 12

months for the construction of the port.

♦ 15 forms of three Core Loc™ sizes were made locally: 1.4m³, 2.4m³ and 5.0m³ (roundhead).

♦ Land placement using theodolite method.

♦ 3 site visits by CLI.

IDKU LNG TERMINAL Country Egypt

Owner Egyptian LNG (ELNG)

Contractor APP consortium Arichirodon

Construction (Overseas) C.O. S.A. and Petrojet

Designer - FEED design by SOGREAH Consultants

- Final design by COWI

Laboratory DHI

Construction period May 2003 – December 2004

CLI’s involvement Sublicense granted to Petrojet and technical assistance: for the casting operations: to Petrojet for the placement: to Archirodon

View of one 11 m³Core loc™ block cast

Breakwater seaside view

Background The project is located east of Alexandria, in Abu Quir bay. The marine works package included the construction of a 900 m long offshore breakwater. Total volume of Core Loc™ concrete installed: 62 700m³.

Hydraulic conditions ♦ Max water depth: -11.5m ♦ Max water level: +1.09m ♦ Design wave Hs: 6.3m ♦ Tp: 16.6 sec.

Construction aspects ♦ Number of moulds

(locally made): 6.2m³: 30 sets 11.0m³: 40 sets.

♦ Number of Core Loc™ units 3 200 units of 6.2m³ (rear side) 3 900 units of 11m³ (seaside + roundheads).

♦ Placement with floating equipment equipped with DGPS.

♦ Nine site visits by CLI.

FUJAIRAH NAVAL BASE

Country United Arab Emirates

Owner Directorate of Military Works

Contractor Sixco Limited, Dubai

Designer Mouchel, Middle-East

Construction period Started in June 2002

CLI’s involvement Core-Loc® sublicense granted to the Contractor and technical assistance provided during design (modeling) and construction.

Background New Naval Base constructed in Fujairah, east of the UAE. The port is protected by two breakwaters

- main breakwater: 1 100 lm - lee breakwater: 550 lm

The trunks are armored with 3m³ Core-Loc® units on the seaside. Roundheads are armored with 5m³ units. Total quantity of armour concrete is about 45 000m³

Hydraulic conditions ♦ Max. waterdepth: -14m ♦ Hs= 4.7 m, T = 9 sec. ♦ Crest elevation: +8m ♦ 2D and 3D model tests at

Sogreah laboratory Construction aspects ♦ 40 Core-Loc® moulds used

during 12 months casting period

♦ Placement of 14 500 units by land crane equipped with GPS. Control by divers.

♦ 6 site visits by CLI

Casting 5m³ units

Progress on main breakwater

RAS LAFFAN COMMON COOLING WATER SYSTEM

Country Qatar

Owner Qatar Petroleum Company

Contractor Grandi Lavori Fincosit Middle East (W.L.L.)

Designer Technital, Italy

Construction period Started in September 2002

CLI’s involvement Sublicense granted to the Contractor and technical assistance provided during design (modeling) and construction.

Background Ras Laffan industrial city is located north of Qatar. The common cooling water system involves the construction of two breakwaters. Total length of breakwaters:

- western: 1 700 lm - eastern: 1 300 lm

Two sizes of Core-Loc® units have been used: 1.4m³ (trunk) and 2.4m³ (roundheads). Total volume of armour concrete placed: 14 000m³

Hydraulic conditions ♦ Max. waterdepth : -6m ♦ Design wave Hs: 4.30 m ♦ Wave period: 11s ♦ 3D model tests carried out at

ENEL and Sogreah laboratories.

Construction aspects ♦ 60 Core-Loc® moulds made in

Qatar ♦ 4 months precasting time ♦ Land-based placing with DGPS,

controlled by divers ♦ CLI technical assistance during

casting and placing of the units on the structures

♦ 5 site visits by CLI

Hauling units on trailers

Casting yard in production

HALUL HARBOUR REFURBISHMENT – PHASE 1 Country Qatar

Owner Qatar Petroleum Company

Contractor Archirodon Construction (Overseas) CO. S.A. Dubai Branch

Consultant COWI ALMOAYED GULF

Construction period November 2001- September 2002

CLI’s involvement Sublicense granted to the Contractor and technical assistance provided during design (modeling) and construction

Plan view

Background The project is on an island located on the western part of Qatar. The first works phase of the Halul harbour refurbishment works included the extension of the Western breakwater by about 600 meters. The existing main (East) breakwater is planed to be repositioned on a future phase operation. The entire length of the western breakwater extension is protected with CORE-LOC®. Three sizes of CORE-LOC® units were used: 0.7, 1.4 and 2.4 m³. About 6 000 units representing 13 500 m³ of armour concrete were made.

Hydraulic conditions ♦ Max. waterdepth : -11m CD ♦ Design wave Hs: from 3.80 to

4.40 m ♦ Wave period Tp: 7s ♦ 3D model tests were carried

out by the DHI in Oct. 2002 Construction aspects ♦ 49 CORE-LOC® moulds – 110

days precasting ♦ Land-based placing (2 shifts /

day) ♦ CLI follow-up during

construction – 5 site visits

Storage on 3 levels

Placing units on the crest

09/01 MFN

Gela breakwater strengthening

CountryItaly

OwnerPort of Gela - Sicily

ContractorDragomar – Di Vicenzo

DesignerPr L. Franco – M. Napolitano

Date2001-2002

Sogreah's services◗ Technical assistance within the

context of a licence agreement for the use of the CORE-LOC™ technique

Context The 1.2-km long offshore caisson breakwater of Gela industrial harbour on the SW coast of Sicily was built in the early 60s. The 60 caissons (20.4 m x 14.0 m) are seated on a thin rubble foundation lying in 12-13 m of water. The breakwater is quite damaged and needs strengthening.The Contractor proposed an alternative with CORE-LOC™ blocks so as to meet the strict limits for permissible overtopping flows under design storm wave conditions (0.1 l/m/s with the 1-year storm and 1.0 l/m/s with the 100-year storm) and for the

tolerable hydraulic damage of the armour under the 100-year storm. The breakwater is to be protected with 3.9 m3 and 5 m3 blocks.Fabrication of the CORE-LOC™ blocks started at Gela early in 2001 with block placement scheduled for the second half of 2001 and 2002.

Hydraulic conditions◆ Maximum water depth beyond

breakwaters: 13 m◆ Significant wave height

Hs = 5.4 m◆ Wave period Tp = 12.8 s

Sogreah's role Throughout the works Sogreah provided technical assistance to the Contractor.This involved supplying the necessary technical information for applying the CORE-LOC™

technique and training of the placing gang. Positioning drawings were produced in close liaison with the Contractor in order to take into account the equipment being used and the anticipated placing schedule.Sogreah's specialist made several site visits to ensure that the CORE-LOC™ technique was correctly applied and to upgrade the placement rate and quality.

12/00 MFN

Tory Island harbour extension

CountryIreland

OwnerDepartment of Marine and Natural Resources

ContractorIrishenco Ltd

Date1999-2000

Sogreah's services◗ Technical assistance within the

context of a licence agreement for the use of the CORE-LOC™

technique

Context Tory Island, at the north-western end of Ireland, is the country's remotest island. It is 5 km long and 2.5 km wide, and has only about 175 inhabitants. Tory Island has a daily ferry service but is sometimes completely cut off from the rest of the world for several days, or even weeks when the weather is very bad.The aim of the project was to improve access conditions at the harbour, in particular to enable the ferry to enter and berth safely regardless of tide level. The breakwater is protected by a facing of 5 m3 CORE-LOC™

artificial blocks. As the island is so isolated, lying 15 km offshore, the blocks were fabricated on the mainland and then transported there by barge.

Hydraulic conditions◆ Maximum water depth beyond

breakwaters: 7.5 m◆ Significant wave height

Hs = 5.8 m◆ Wave period Tp = 18 s Sogreah's role Throughout the works Sogreah provided technical assistance to the contractor.This involved supplying the

necessary technical information for understanding and applying the CORE-LOC® technique and preparing positioning drawings in close liaison with the contractor in order to take into account the equipment being used and the anticipated placing schedule.Sogreah's specialist made several site visits to deal with questions from the owner and contractor, and to ensure that the CORE-LOC® technique was correctly applied.