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
CLIs involvement
Sublicense granted to the Contractor and
technical assistance provided during the
construction

Background

Hydraulic conditions

The Karachi Port is the primary seaport

of Pakistan that is aptly referred to as
Gateway to Pakistan.

Length
1.
2.
3.

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)

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.

of three breakwaters:
Oyster breakwater- 2506 m
Manora breakwater-1100 m
Keamari breakwater- 300 m

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

View of the breakwater

CAPE PRESTO
P
ON SINO
O IRON
N PORT
Country
Au
ustralia WA

Owner
O
CIITIC Pacific M
Mining

Contractor
CIITIC Pacific M
Mining

ontractor
Co

Designer
D
Sa
andwell (Cannada Vancouver)

Constructio
on period
20
008 - 2010

CLIs involv
vement
Su
ublicense graanted to the Contractor
an
nd technical assistance provided
p
du
uring the connstruction

Ba
ackground
CITIC pacific mining own a land in the
ape Preston re
egion where an
n iron
Ca
miine is to be se
et up. In orderr to export
the
e iron ore to C
China, a new port
p
facility
ha
ad to be built, 40km away frrom the
ex
xtraction zone.. The new Cap
pe Preston
po
ort facilities allo
ows now to lo
oad the
ba
arges which wiill be used for loading
the
e vessels moo
ored of shore.
Th
he loading faciilities have to be fully
pro
otected againsst the waves generated
g
by
y cyclones even when the su
urge is
ve
ery important. The breakwatter has a
cru
ucial role of prrotecting the facilities,
f
wh
hich explains tthe height of the
t
strructure. This sstructure is linked to the
ma
ain land by a llong causewayy,
pro
otected with a
armour rocks only.
o
were fabricate
ed in
Alll of the units w
Th
hailand and sh
hipped over du
uring the
construction. Alll the clearance
e of
qu
uarantines procedures were applied
an
nd obtained in due time. 30 trips were
ne
ecessary in ord
der to deliver the
t whole
pro
oduction.

Hydraulic cconditions

Length oof CL structure

e: 1750m
Max. waater depth (toe
e):-6m
Top of th
he crest: +20m
Design w
wave Hs: 6.6 m
Wave peeriod Tp: 18 s
MWL +66.10
3D modeel test: CHC (C
Canada) in Jan
nuary
2009
portant risk of surge
Cyclone area with imp

CORE-LOC storing ya
ard
Thailand)
(T

CORE-LOC
Construc
ction aspectts

CORE-LOC
C units prod
duced abroad
10 600 CO
ORE-LOC un
nits
Up to 27 llines in the slo
ope
Placementt carried out in 8 months
Breakwateer completed in13months
CORE-LOC
C sizes:
3.9m3
6.2m3
8.5m3
11m3
quantity: 69 500m3
Concrete q
5

Loading on the vessels

ailand)
(Tha

Underlay
yer profiling

AL DUQM PORT
Country
OMAN

Owner
Ministry of Transport and
Communication

Contractor
CCC-STFA JV

Contractor

Designer
Royal Haskoning, UK

Construction period
2007 - 2010

CLIs 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 storing yard

CORE-LOC Construction aspects

47 500 CORE-LOC units

Up to 18 lines in the slope
Placing with POSIBLOC system

Placing with POSIBLOC

(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
Placing with POSIBLOC

B
BUSAN
N-GEOJE FIXED LINK, IM
MMERSED
D TUNNEL
L (BGT)
)
Country
So
outh Korea

Owner
O
Da
aewoo Enginneering & Co
onstruction
Co
ompany LTD
D

Contractor
Ha
an Jun Comppany

Designer
D
Co
owi

Constructio
on period
20
007 - 2009

CLIs involv
vement
Su
ublicense graanted to the Contractor
an
nd technical assistance provided
p
du
uring the connstruction

Ba
ackground
A new fixed linkk to connect th
he city of
usan and the G
Goeje island was
w carried
Bu
ou
ut in mixing an
n immersed tu
unnel and
tw
wo major bridg
ges over the sttrait.
Th
he dual carriag
ge way tunnel is 3.300m
in length and go
oes down to -5
50m under
e sea level. Th
he tunnel lays in a
the
tre
ench dug in th
he sea bed.
Th
he entrance off the tunnel on
n the
ea
astern side is p
protected against the
po
ossible vessels impacts up to
o -25
me
eters with a ru
ubble mound made
m
of
qu
uarry run. Thiss device equipment is
pro
otected againsst the wave acction
tha
anks to a reve
etment of
CO
ORE LOC and
d ACCROPODE
E II
un
nits.
ave been place
ed on
If many units ha
ach side of the
e tunnel, most of them
ea
ha
ave been laid o
on the upper flat
f berm
of the tunnel. M
More than 95%
% of the
nits have been
n placed underrwater and
un
up
p to -28m.
Th
he CORE-LOC
units and th
he
AC
CCROPODE III units were placed
p
by
ussing a POSIBLO
OC system.

Hydraulic cconditions

Length oof CL structure

e: 218 m
Upper beerm width: 10
02m
Max. waater depth (toe
e):-28m
Top of th
he crest: -8m
Design w
wave Hs: 8.7 m
Wave peeriod Tp: 16.2 s
Design rreturn period: 10 000years
3D modeel test: DHI May
M 2007 and SOGREAH
S
April 20008
Typhoon
n area

CORE-LOC
C casting ya
ard

CORE-LOC
Construc
ction aspectts

CORE-LOC
C units prod
duced at 50km
m
The CORE
E-LOC units were barged to
t the site
3.500 COR
RE-LOC unitts of 5m3
Placementt on a wide fla
at surface
Placementt carried out with
w POSIBLOC
C system
Placementt from a barge
e
Placementt of the units in 48 days

CORE-LOC
C placement

Placement from a barge

NEWBIGGIN BAY
Country
United Kingdom

Owner
City of Newbiggin

Contractor
Westminster Dredging Company LTD

Designer
Atkins

Construction period
March 2007- August 2007

CLIs involvement
Sublicense granted to the Contractor
and technical assistance provided
during the construction

Background

Hydraulic conditions

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.

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 feeding barge

CORE-LOC aspects

Fabrication at 20km from the structure

1288 CORE-LOC units
Placement completed in 2 months
CORE-LOC sizes: 3.9m3
CORE-LOC placement

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

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
CLIs 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.

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 m of tetrapods. The core
Loc single layer was preferred
since it saved 4 000m 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

1.4m Core Loc moulds

Total project duration: about 12

months for the construction of
the port.
15 forms of three Core Loc
sizes were made locally: 1.4m,
2.4m and 5.0m (roundhead).
Land placement using theodolite
method.
3 site visits by CLI.
Handling trial test

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
CLIs involvement
Sublicense granted to Petrojet and
technical assistance:
for the casting operations: to Petrojet
for the placement: to Archirodon

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 700m.

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):
6.2m: 30 sets
11.0m: 40 sets.
Number of Core Loc units
3 200 units of 6.2m (rear side)
3 900 units of 11m (seaside +
roundheads).
Placement with floating
equipment equipped with DGPS.
Nine site visits by CLI.

View of one 11 mCore loc block cast

Breakwater seaside view

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
CLIs 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 3m
Core-Loc units on the seaside.
Roundheads are armored with
5m units.
Total quantity of armour concrete
is about 45 000m

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 5m 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
CLIs involvement
Sublicense granted to the Contractor
and technical assistance provided
during design (modeling) and
construction.

Background
Ras Laffan industrial
located north of Qatar.

Hydraulic conditions
city

is

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: 1.4m (trunk)
and 2.4m (roundheads).
Total volume of armour concrete
placed: 14 000m

Max. waterdepth : -6m

Design wave Hs: 4.30 m
Wave period: 11s
3D model tests carried out at
ENEL and Sogreah
laboratories.

Construction aspects

Hauling units on trailers

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
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
CLIs 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 m.
About 6 000 units representing
13 500 m 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

Storage on 3 levels

49 CORE-LOC moulds 110

days precasting
Land-based placing (2 shifts /
day)
CLI follow-up during
construction 5 site visits

Placing units on the crest

Gela breakwater strengthening

Country
Italy

Owner

Port of Gela - Sicily

Contractor

Dragomar Di Vicenzo

Designer

Pr L. Franco M. Napolitano

Date

2001-2002

Sogreah's services
09/01 MFN

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

Technical assistance within the

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

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 CORELOC technique was correctly
applied and to upgrade the
placement rate and quality.

Tory Island harbour extension

Country
Ireland

Owner

Department of Marine and

Natural Resources

Contractor

Irishenco Ltd

Date

1999-2000

Sogreah's services

12/00 MFN

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

Technical assistance within the

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

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 CORELOC technique was correctly
applied.