Sasol LCCP

WESTLAKE, LA
WESTLAKE, LA

Cajun was awarded civil, concrete foundation, underground pipe and deep foundation work for the first of two new facilities. The overall program involves construction of a $12 billion ethane cracker, which will convert natural gas to ethylene. Cajun’s site work scope includes preparation of a 1,150-acre site, establishment of two retention ponds and installation of all underground piping. Other work includes major foundation, underground piping and deep foundation (piling) work for the ethane cracker and a linear low-density polyethylene process unit. Foundation and underground work for offsite utility and infrastructure support systems/facilities for the six process units already planned for the expansion is also part of the scope of work. Additionally, the offsite utility and infrastructure support systems/ facilities work includes interconnecting pipe racks; a large capacity cooling tower and associated foundations; site preparation, drainage and foundations for rail-loading spurs; site substation foundations; storage tank and boiler foundations; raw water treatment clarifier unit foundations; alcohol unit foundations; electrical duct bank and control room data conduit underground utility; and permanent plant asphalt roads.

Accomplishments

  • Both Cajun and its client are committed to sustainable operations. This focus includes the beneficial use of trees that have been harvested as part of the site preparation. Accordingly, Sasol recently donated a portion of the felled trees to the Calcasieu Parish Sheriff’s Office Farm Firewood Program. Cajun assisted with the loading and transport of the trees to the office’s facility.

Statistics

  • 52 month duration
  • 11,000,000 man-hours
  • 2,260 peak manpower

Work Performed

Site Work

  • 1,150 acres – Clearing and grubbing
  • 1.7 million CY – Excavation/disposal of unsuitable soil
  • 1.3 million CY – Fill placed
  • 389,005 tons – 610 limestone placed
  • 1,595,000 SY – Geotextile fabric placed
  • 42,000 LF – Underground gravity storm water drainage with box culverts and catch basins
  • 60,000 LF – Fire water piping installed
  • 1,474,000 SF – Permanent & temporary sheet piling installed
  • 13,965 EA – Precast concrete piles installed
  • 7,700 EA – Augered Cast-in-Place (ACIP) piles installed

Concrete Foundations

  • 215,000 CY – Structural concrete and paving formed and placed (incl. 32 sumps and 6 elevated structures)
  • 64,000 SY – Asphalt road paving installed
  • 673 LF – Pre-cast electrical duct banks installed
  • Underground Pipe
  • 40,954 LF – Underground gravity storm water piping; box culverts and catch basins
  • 63,834 LF – HDPE piping installed
  • 2,720 LF – Ductile iron piping installed
  • 64,668 LF – Carbon steel pipe – up to 108” diameter