Within the scope of the project, the existing steel pipe system was dismantled, removed, and segregated as scrap. Structural strengthening was achieved by driving a single row of interlocking (tongue-and-groove) steel pipe piles along the front façade of the existing quay structure composed of concrete blocks. The strengthening works were executed through an integrated and holistic approach, encompassing the construction of capping beams, gravity blocks, and tie-back systems; site concrete casting; dredging and scour protection works in front of the quay; and the installation of cathodic protection systems on the steel piles.
Main Works Executed Within the Scope of the Project
Site Preparation and Demolition Works
Pipelines, bridge components, and loading arms located on the existing pier and no longer in use were dismantled. Excavation and backfilling works were then carried out in accordance with the project elevations, preparing the site for construction activities.
Precast Production and Fabrication Process
A total of 40 gravity blocks designed as precast elements, along with the tie rods connecting these blocks to the capping beams, were fabricated at our steel construction facility located in ALOSBİ. Following fabrication, the elements were transported to the site, where wrapping and installation works were meticulously completed.
Pile Preparation and Pre-Fabrication Works
Welding teams were mobilized concurrently in the breakwater area. Gasket welds and interlocking (tongue-and-groove) joint welds were completed for 139 steel pipe piles with a diameter of Ø1016 mm and a length of 32 m, rendering the piles ready for driving.
Seabed Preparation and Pile Driving Works
Prior to pile driving, seabed dredging works were carried out to ensure suitable ground conditions. Within the scope of the project, a total of 151 steel piles were driven. Initial driving was performed using a vibro hammer and finalized with a diesel hammer. Subsequently, a total of 2,575 meters of drilling works were completed. Reinforcement cages prepared in advance at the mobilization area were placed inside the piles, followed by concrete casting operations.
Testing, Measurement, and Quality Control
To verify the load-bearing capacity and structural integrity of the piles, Dynamic Load Tests (PDA Tests) were conducted at specified intervals. The obtained data were documented, and quality assurance processes were duly completed.
Superstructure Construction and Connections
Concrete casting works for capping beams with a total length of 171 meters were completed. Upon achieving the required concrete strength and quality criteria, the installation and connection of tie rods and gravity blocks were finalized.
Infrastructure, Backland, and Site Concrete Works
In the backland area, galvanized sleeve pipelines for infrastructure networks were installed in accordance with project elevations, and manholes for fire protection and electrical lines were constructed. Following filling and compaction works, a total of 1,850 m² of site concrete was cast, rendering the area ready for operation.
Quay Reinforcement and Protection Works
To enhance quay safety and durability, reinforcement works were carried out. Within this scope, a total of 5,200 tons of fill material ranging between 1 and 4 tons in size were used to strengthen the quay front.
Waterproofing and Surface Protection Applications
In order to mitigate the adverse effects of seawater on concrete structures, the concrete surfaces on the quay and the underside of the capping beams were impregnated with water-repellent construction chemicals, with the support of diver teams.
Fittings and Berthing Systems
To ensure safe vessel operations, 9 Quick Release Hooks and 17 fenders were supplied and installed.
Cathodic Protection Systems
A Sacrificial Anode Type Cathodic Protection System was implemented to protect the steel piles against underwater corrosion. Within this framework, a total of 745 underwater anodes were installed on the piles, and monitoring and inspection test boxes were fabricated for system control.
