In November 2014, Cajun was awarded a contract to install
pre-cast concrete piling for the heater foundations of the
Ethane Cracker Unit at the Sasol Mega-project in Westlake,
La. The project was owned by Sasol Chemicals, USA, with design
and management services by Fluor Technip Integrated (FTI). This
startup involved two driving cranes, along with one receiving and
handling crane to support them. The piling installed for this unit
were 1,648 each 18-inch by 66-foot PCCP and 194 each 14-inch by
66-foot PCCP, with the piling material being furnished by the client.
Cajun worked closely with the client to manage both the pile
delivery and installation schedule. Due to soil conditions and pile
spacing, quite a bit of upheave was noticed in the installed piling.
After working with the engineers, Cajun coordinated cutting of the
piling to the correct design elevation prior to installation of the
concrete foundation.
While performing this work, Cajun was approached by FTI to
assist with the redesign of a storm water retention pond, referred
to as Pond #6. The original design was for a structural concrete
lined pit. Due to the proximity of existing underground pipelines,
as well as overhead power lines, open cut excavation for this
installation was not an option. Cajun proceeded to design and
install a braced sheet pile sump consisting of PZC26 sheet piling
with walers and struts in lieu of a cast-in-place concrete structure.
This resulted in not only a cost savings for Sasol, but also aided in
constructability.
As work progressed, Cajun was awarded with pile installation
in other units of the facility, including the LDPE, LLDPE, EO/EG
and the interconnecting pipe rack foundations. This resulted in a
total installation of 13,396 PCCP, ranging in size from 14 inches by
40 feet to 18 inches by 66 feet. In addition to the PCCP, there were
also numerous ACIP piling (5,931 total), drilled shafts (291 total)
Photos courtesy of Cajun Industries
Sasol
Mega-project
Pile Installation
Cajun installed thousands of different
pile types and increased its contract
value by more than 700 percent on
this mega job
Submitted by Cajun Industries
This resulted in an increase of
more than 700 percent of the
original contract value for Cajun.
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