Widening Amazonehaven - Rotterdam | The Netherlands

The ECT Delta Terminal, situated at the Amazonehaven in the Port of Rotterdam, was designed to receive 7000 TEU container ships. In order to upgrade the terminal for ships of 18,000+ TEU, the width of the basin had to be increased with 55 m from 255 to 310 meters.

The first part of the project (sections A1 and A2) began in 2010 and consisted of a 900m long new quay wall, including both dredging works and the demolishing of the existing quay wall. After tender the Design and Construct contract was awarded to the combination Besix-Van Oord. Together with ArcelorMittal the reference design of the tubular combined wall was partly redesigned from a Ø1524mm solution into a solution with Ø1420mm stock pipes. The tubular piles were further optimized by segmenting the piles in different thicknesses, placing the thickest material in the sections with the highest bending moments.

In other parts of the quay wall, where extra demands were given regarding the deflection, the initial solution was redesigned in a more optimal Ø1580 x 17mm solution, which was produced at ArcelorMittal's spiral mill in Heijningen. Both the tubular piles and infill sheets were installed using vibratory hammers. An impact hammer was used to deepen the tubes over the last few meters, generating a sand plug to increase the bearing capacity. In view of minimizing the possibility of declutching, the sheet piles were equipped with interlock guiders and a monitoring system. The installation of the infill sheets was facilitated by water jetting.

Testing program

The second part of the project, a 1,500 m long quay wall (A3), started at the end of 2012 and was tendered as a normal RAW tender. In cooperation with the Rotterdam Port Authority ArcelorMittal was allowed to set-up a testing program for the new steel grade AMLoCorTM. Therefore, approximately 150m of the quay wall was redesigned for a tubular combined wall with AZ infill sheets in this new corrosion-resistant steel grade.

As cathodic protection was foreseen for the rest of the quay wall in the form of aluminum anodes, extra care was taken to isolate the test sections from the rest of the quay wall. In total three transition points were defined; two between the test section and the rest of the quay wall and one between the AMLoCorTM section and reference section; for which insulation piles were foreseen. The entire test section was then divided into four sub-sections of 37.14 meters; three in AMLoCorTM and one in normal carbon steel as a reference; each closed off by a separate concrete cap to ensure electrical insulation.

To accommodate for the corrosion measurements in total nine measu­ring boxes were welded respectively at the back of the infill sheets and inside the tubes and spread out evenly over the length of the test section. While the AMLoCorTM material itself was delivered directly to the Port Authorities, the installation and the detailed engineering of the test section were incorporated in the tender for section A3.

Eventually, section A3 was awarded to Besix as well. During the execution, the design of transition points changed into three grouting columns to provide more guarantees regarding the electrical isolation between the different sections. These grouting columns were designed by MOS Grondmechanica and eventually executed by Smet-Keller.

In March 2014 the new quay wall with accompanying dredging works was completed and in the same month, the first corrosion measuring campaign at the test section took place. For a period of five years, these measurements will be repeated on a yearly base.

 

Materials list:

Sections A1 and A2
(in total approximately 7,930 tons)
Ø1580 x 17mm
triple PU28-1
length 33.05 - 37.05m
length 18.20m
X70
S355GP
± 3,250 tons
± 490 tons
Ø1420 x 16/21.6/16mm
triple PU28-1
length 32.55m
length 19.70m
X65/X70
S355GP
± 1,840 tons
± 830 tons
Ø 1420 x 17/25.3/23.4/17mm
triple PU28-1 / AZ26-700
length 35.05m
length 21.20m
X70
S355GP
± 1,240 tons
± 280 tons
Section A3
(in total approximately 10,400 tons)
Ø1524 x 18/20mm
triple PU28 / AZ26 / AZ26-700
length 32.3 - 36.3m
length 19.6 - 21.1m
X70
S355GP
± 6,200 tons
± 1,550 tons
Ø1067 x 14mm
triple PU28
length 32.30m
length 17.75m
X70
S355GP
± 390 tons
± 170 tons
Ø 914 x 12mm
triple PU28
length 31.30m
length 16.20m
X70
S355GP
± 860 tons
± 500 tons
Test section carbon steel
Ø1016x13mm
AZ20-700
length 31.30m
length 16.20m
X60
S355GP
± 150 tons
± 40 tons
Test section AMLoCorTM
Ø1016x12mm
AZ20-700
length 31.30m
length 16.20m
Blue X60
Blue 355
± 420 tons
± 120 tons

Total = 18,330 tonnes

Owner: Havenbedrijf Rotterdam
Designer/Supervisor: Ingenieursbureau Gemeentewerken Rotterdam
Main contractor A1 and A2: Besix - Van Oord
Main contractor A3: Besix

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