Seawater Intake for LNG Terminal

The new LNG port terminal at Mundra was developed by a joint venture between Gujarat State Petroleum Corporation (GSPC) and Adani group. This complex will double the capacity of imported gas to India, meeting the demands for Natural Gas in western and northern parts of the country.

Project Detail

D-wall for the underground Chamber of the LNG Gas intake facility.

Client

ITD Cementation Ltd.

Date

2014

Estimate Budget

Industries

LOCATION

Mundra Port – Gujarat (India)

The client has had previous experience using the G3® System and PolyMud® and was confident in achieving the best results in the execution of this specific D-wall project. The polymer slurry would stabilize the soil during the excavation of the 800mm and 600mm width panels, having “T” shape to create wall buttresses. The buttresses will replace the need of D-Wall anchoring.

The structure build is an underground facility to house the seawater intake to be used in the LNG plant cooling system. The full project included also the execution of 35 numbers of 600mm dewatering wells up to 10m depth

Challenges

Project with demanding specifications, panel geometry and special soil conditions (backfilled soil and minimum fine matrix). Fluctuating water table level with the tidal influence, generated by the high soil permeability and proximity to the sea.

Project with a very particular framework. The area where the trench excavation took place was located on an artificial peninsula created through backfilling into the Kutch gulf. All the reclaimed land was made of sand mobilized directly from the surrounding seabed. The average depth of the old basin was of 10.5m: where the backfilling of the area created a transition (discontinuity) of sand with gravel to silty sand.

Geometry of the D-wall panels, having “T” shape – buttressed wall.

Solution

GEO presented a fully environmentally friendly solution. The use of the products was approved by the main contractor that did not allow the use on bentonite because of proven contamination. The execution of the D-wall panels underwent according to program and the G3 System was effective in the soil stabilization, even while facing constant slurry level drop caused by the high soil permeability.

Full technical support from project kick-off, with slurry batching plant arranged according to project needs. This support included the disposal of the slurry. Simple process, completed directly on site and with negligible cost.

Even with the demanding project specifications, panel geometry and special soil conditions (backfilled soil and minimum fine matrix), it was possible to assure stabilization and a final average concrete overbreak of 9.67%.

Key Figures

Scope:

A total of 64 D-wall panels (60 “T” shaped and 4 “L” shaped), of 800mm and 600mm thickness and having average depth of 22m. Plus, 35 dewatering wells of 600mm, to 10m depth.

Achievements:

Successful stabilization in soil strata composed mainly by Sands, with minimum matrix and high permeability; coastal area in very close proximity with the sea (Kutch gulf) and permanent contact with underground salt water. Cleaning of the panels could be done within 30min and no de-sanding was required.

Geology:

Backfill made of medium dense Sand on the first 9m, then a layer of very dense Sand with gravel and shell fragments from 9.0 to 10, followed by silty Sand also with shell fragments up to 12.0m, from 12.0m to 13.5m, dark sandy silty clay, that changes to silty Sand with some clay intercalations strata from 13.5 to 18.0m. Sand from 18m to the bottom of the panel (22.5m).

Technologies Used

G3® System

The G3® Soil Stabilization System is a next-generation polymer technology designed to transform non-cohesive soils into stable, predictable environments for excavation and ground engineering. By forming a strong cross-linked network within the soil, the G3® system improves soil cohesion, minimizes fluid loss, and enhances operational efficiency, making it ideal for challenging soil conditions.

G Line

The G Line is a versatile polymer-based soil stabilization system used in geotechnical excavations to support soil structures. It is designed for use in various soil types and conditions, offering efficient mixing, rapid hydration, and compatibility with both fresh and salt water. The G Line components (GMud, GNet, G+) work together to enhance soil cohesion, reduce fluid loss, and promote particle suspension, making it ideal for applications in deep foundation projects.

XG Series

The XG Series, developed by GEO, is a range of innovative products based on a natural polymer for use in drilling and soil stabilization. Designed for high solubility and viscosity control, Cross-Gel XG serves as an efficient drilling fluid with long-lasting stability, effective sediment transport, and continuous reuse capability. The series includes complementary products—XG Break, XG Clean, and XG Shield—to optimize performance, manage fluid viscosity, and maintain polymer structure over extended operations.

Bentonite Suspension

A bentonite suspension system is a mixture of bentonite clay and water, forming a gel-like fluid that exhibits thixotropic properties, meaning it thickens when at rest and becomes more fluid when agitated. This suspension is used primarily in industries like construction, drilling, and geotechnical applications for its ability to provide stability and lubrication.

GelPro

GelPro is a highly soluble anionic polymer that forms a high-viscosity slurry when mixed with water. It hydrates quickly and requires minimal equipment for use, offering immediate application for soil stabilization. GelPro is ideal for stabilizing various geological formations, offering ease of hydration and consistent slurry formation. It can be mixed directly in the excavation or slurry batching plant without the need for pH adjustment or specialized mixers.

GMud Ultra

GMud Ultra is an anionic polymer that creates a high-viscosity slurry upon mixing with water. It hydrates quickly and requires no special equipment, offering fast application in less demanding soil profiles. Designed for use in less complex geological conditions, GMud Ultra simplifies soil stabilization with minimal equipment. For more difficult formations, additional G3 System products are recommended for enhanced performance.

PolyGel

PolyGel is an acrylic anionic polymer, available in dry granular form, known for its excellent hydration and solubility rates. It provides a balanced price-quality solution for soil stabilization. PolyGel is effective in soil stabilization and can be used in conjunction with other G3 System products to meet specific project requirements. It is also environmentally friendly, ensuring reliable results.

Fluid Loss Blockers

GEO’s fluid loss blocker system includes two products, GFiber and GBlock, designed to prevent fluid loss during soil stabilization. Fluid loss can compromise excavation stability, particularly in permeable or fractured soils. GFiber, made from natural mineral fibers, and GBlock, a fast-swelling synthetic polymer, create barriers in the soil to control seepage effectively. This system is compatible with support fluids such as the G3 System, Gline, XG series, Bentonite, and standalone slurries.

Micropile

Micropiles are small-diameter piles made from high-strength materials like carbon steel or ductile cast iron, driven into the ground to provide additional load-bearing capacity for structures. They are ideal for both new construction and foundation reinforcement in existing buildings, especially in areas with weak soil or limited access. Micropiles are often used where traditional foundation methods are impractical, offering a flexible, cost-effective solution with minimal disruption. Their installation requires minimal equipment, making them suitable for tight spaces or urban environments where heavy machinery is not feasible.

Bi-Directional Static Load Test

Bidirectional Static Load Testing (BDLT) is an advanced and efficient method for evaluating the load-bearing capacity of deep foundation piles and barrettes. This innovative testing technique is crucial for projects that require precise measurement of both skin friction and end bearing capacity in high-capacity foundations. The method involves performing full-scale static loading tests that evaluate the load performance of piles under axial compressive loads, which is essential for ensuring the stability and integrity of any foundation system.

Water / Wastewater Treatment

Our comprehensive array of specialized polymers is designed for water, wastewater, and sludge treatment, and all our products meet NSF certification, Halal certification, and applicable local certifications. We take on the challenges of water treatment across multiple sectors, including municipal, industrial, mining, agriculture, construction, civil engineering, and dredging, to ensure water is preserved and reused for the benefit of future generations.