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İzmir Aliağa Star Refinery Projects

İzmir Aliağa Star Refinery Projects

Within the scope of İzmir Aliağa Refinery Project; which is the largest private sector investment project in Turkey, several sub-contract works have been carried out under different main contractors.

Under these subcontracts; Terrace 5&6 Permanent SBMA Anchor Works, Terrace 7 Permanent Anchor Works, DS1 Soil Nailing and Drain Works, Star Refinery Project Piling Works, Petkim Container Port Shoring Works and Terrace 63 Piling Works & Reclamation Area and Cofferdam Support Secant Piling Works have been completed.

Terrace 5&6; Terrace 7 and DS1 Ground Anchors and Soil Nail Works

Within the scope of the project, permanent anchors and soil nail works with a construction life of 75 years have been executed in order to minimize the risk of landslide potential at Terrace 5 & 6, Terrace 7 and DS1 areas. In the project KASKTAŞ’s proprietary high-capacity Single Bore Multiple Anchor (SBMA) technology is used. A total length of 27,320 m SBMA Anchors, 5,050 m of Anchors, 27,600 m of Soil Nails and 5,330 m of drains were constructed.

Prior to 660 no. of production anchor works; investigation tests consisting of both SBMA type and SUT type (Single Unit Type) test anchors with a length of up to 54 m and consist of 11-14 no. of strands were carried out in order to verify a static load of 195 tons and a seismic load of 300 tons of seismic loads. During these preliminary tests, a maximum anchor capacity of 375 tons was achieved. Manufacturing of permanent anchors was made in a special closed yard at site. With the help of systems and equipment used in this manufacturing yard, anchors were prepared flawlessly in its required quality before drilling phase.

  • High capacity anchors were executed in sedimentary rock layers like mudstone, siltstone, sandstone and limestone interbedded with tuff and tuffite layer in İzmir Aliağa region
  • A special software which had been developed for this project and operated via cloud was used during both testing and locking off anchors. With the help of this software anchor stressing test was able to be monitored in site and head office at the same time. By transferring the information obtained from stressing works to computers, it is possible to record the anchor test in the project. Taking advantage of this tool, all drilling, injection and stressing data were kept in record
  • An intensive monitoring program is carried out within the project. Owing to this program, in order to observe long term behavior, vibrating wire type load cells were used on 10% of production anchors. Additionally to monitor lateral displacements and movements, inclinometer were also used. These data are very important to observe and investigate real time performance of shoring system at site.

Petkim Container Port Shoring Works

Within the scope of Aliağa Petkim Container Port shoring works, permanent anchors were executed in order to remedy and minimize risk of landslide potential. In order to strengthen a cantilever bored piled shoring system; which had been constructed by Others, Single Bore Multiple Anchors (SBMA) were designed and executed by KASKTAŞ. The shoring project was calculated with high capacity SBMA anchor technology; which is a proprietary product of KASKTAŞ.

8,950 m of prestressed SBMA type anchors were executed. Prior to the production anchors, investigation tests were performed with Single Unit Test (SUT) and SBMA type test anchors in order to verify that production anchors would satisfactorily carry 200 tons of static load and 300 tons of seismic load. In these tests, a maximum anchor capacity of 330 tons was achieved. Manufacturing of permanent anchors was made in a special closed yard at site. With the help of systems and equipment used in this manufacturing yard, anchors were prepared in accordance to the designated and required quality.

  • High capacity anchors were executed in sedimentary rock layers like mudstone, siltstone, sandstone and limestone interbedded with tuff and tuffite layer in İzmir Aliağa region
  • A special software; which had been developed for this project and operated via cloud was used during both testing and production anchor installation works. With the help of this software anchor stressing test was able to be monitored on site and at the head office simultaneously. Taking advantage of this tool, all drilling, injection and stressing data of the SBMA Anchors were kept in record
  • An intensive monitoring program is carried out within the project. Owing to this program, in order to observe long term behavior, vibrating wire type load cells were used for 20 no. of production anchors. Additionally to monitor lateral displacements and movements, inclinometer were also installed. These data are very important to observe and investigate actual performance of the shoring system in real time.

Star Refinery Piling Works

Bored piles under foundations of 3 different units were constructed within the scope of project. These 3 units were:

  • Unit-100 Crude/Vacuum Distillation Unit
  • Unit-190 Delayed Cooker Unit
  • Unit-445 Waste Water Treatment Unit.

Construction of bored piles having a total length of 37,950 m with variable diameters of 65 cm, 80 cm and 100 cm were accomplished successfully under foundations of these three units in tuff and clayey formations. A total of 13 no. of preliminary pile tests were carried out with the aim of determining the pile capacities for the foundation of 3 different units located in 3 different regions prior to construction works. Pile design has been determined according to the results of these preliminary compression and tensile tests. Moreover, a total of 11 no. of working pile tests were also carried out after production piles were completed. Besides PIT and PDA tests were also executed on production piles.

  • In accordance with the extremely strict target work schedule in the project, bored piling works were carried out by using excessive number of machinery and equipment
  • Bored piles at U-445 Unit were constructed within the Power Plant under operation. Therefore all activities were performed in accordance to the comprehensive HSE and quality control programs implemented in the project.

Reclamation Area and Terrace 63 Piling Works; Cofferdam Bracing Secant Piling Works

Reclamation Area and Terrace 63 piling works were carried out. Within the scope of project, bored piles having a total length of 29,200 m and variable diameter of 120 cm and 150 cm were constructed. Length of bored piles varies between 7 m to 40 m. Moreover 5,690 m of secant piles were successfully installed for the Cofferdam Bracing Works.

Project Description

İzmir Aliağa STAR Refinery Projects, 2014 – 2017

  • Terrace 5 & 6 Anchorage Works
  • Terrace 7 Anchorage Works
  • DS1 Soil Nailing Works

Project Features

Owner
SOCAR
Client
TSGI Mühendislik
Contractor
Yenigün Construction
Key Quantities
Single Bore Multiple Anchor (SBMA) 27,320 m
Anchor 5,050 m
Soil Nail 27,600 m
Sub-Horizontal & Passive Drains 5,330 m
Project Duration
Start Date 01.11.2014
Finish Date 01.02.2017
Duration 27 Months

Location

İzmir, Turkey

 

Project Description

İzmir Aliağa STAR Refinery Project, 2014 – 2017

  • Reclamation Area and Terrace 63 Piling Works

Project Features

Owner
SOCAR
Client
Es Construction
Key Quantities
Bored Pile 29,200 m
Project Duration
Start Date 16.01.2016
Finish Date 29.10.2016
Duration 10 Months

Location

İzmir, Turkey

 

Project Description

İzmir Aliağa STAR Refinery Project, 2014 – 2017

  • Petkim Container Port Shoring Works

Project Features

Owner
PETKİM
Client
Es Construction
Key Quantities
Single Bore Multiple Anchor (SBMA) 8,870 m
Project Duration
Start Date 01.01.2015
Finish Date 01.09.2015
Duration 9 Months

Location

İzmir, Turkey

 

Project Description

İzmir Aliağa STAR Refinery Project, 2014 – 2017

  • Star Refinery Project Piling Works
  • Cofferdam Bracing Secant Piling Works

Project Features

Owner
SOCAR
Client
TSGI Mühendislik
Key Quantities
Piling Works Secant Piling Works
Bored Pile 37,950 m
Berliner Wall 2,000 m
Bored Pile 5,690 m
Project Duration
Piling Works Secant Piling Works
Start Date 01.01.2015
Finish Date 12.08.2015
Duration 8 Months
Start Date 06.10.2016
Finish Date 14.01.2017
Duration 3 Months

Location

İzmir, Turkey

 

 

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