New Shell Plant Construction Packages

Delivering Construction Excellence in a Petrochemical Plant Project Project Highlights Early Works Marine Package • 400 lf of sheet pile/pipe pile combi-wall bulkhead for a load-on/load-off dock • 700 lf of sheet pile bulkhead for a roll-on/roll-off dock • 26 coffer cell mooring dolphins, each 26 ft in diameter • Approximately 15,000 cy of dredging Site Work and Earthwork Packages • Over 2 million cy of earthwork • Over 75,000 lf of drainage piping • Over 300 acres of finish grading • 230 shaft foundations • Over 250,000 sf of geosynthetic liners • Up to 12,000 sq of sheet piling for temporary shoring • 800,000 cy of structural/trenching excavation and backfill operations Sheet Pile Packages • 12,000 lf of piling for temporary shoring and external formwork for deep foundation walls • 132 pairs of PZC sheet pile • 35 wide flange king piles • 242-ft combi-wall using PZC sheet piles and W33 x 169 king piles • 21 pairs of PZC39 by 37-ft-long sheet pile Fay was heavily involved in the construction of Shell’s new ethylene cracker plant in Beaver County, PA, across a series of projects between 2015 and 2022. Located on the Ohio River, the plant converts ethane into polyethylene. Fay’s strong performance working with the client, quality workmanship, and ability to meet schedules enabled the company to secure the main site works package and substantial additional site work focused on various concrete and grout scopes, along with site indirect maintenance work. At the project’s peak, Fay employed over 250 personnel, including operators, laborers, teamsters, carpenters, cement masons, iron workers, and supervision. Early Works Marine Package The primary scope of work was constructing two riverfront bulkhead facilities: a west load-on/load-off (LOLO) dock with 400 lf of sheet pile/pipe pile combi-wall bulkhead and an east roll-on/roll-off (RORO) dock with 700 lf of sheet pile bulkhead. The LOLO dock served as a secondary receiving station for large building materials and equipment too large to be shipped by truck to the petrochemical plant. The added docks helped crews better coordinate the shipping and retrieval process during the later construction phases of the project. Any suitable excavated material from the east RORO dock area was transported to be used as backfill for the west LOLO dock site. Fay demolished existing mooring dolphins and replaced them with 26 new mooring dolphins about 26 ft in diameter with filled coffer cells. Fay also drove 24-in pipe for the RORO dock and the water treatment clarifier, and drove pile exceeding 300 tons for the LOLO dock. After piling, Fay installed tiebacks to serve as connectors between two sandwiched sheet piles to prevent the front-face piles from deflecting. East steel dock piles were 65-ft-long with a diameter of 24 in and west steel dock piles were 84-ft-long with a diameter of 24 in. Site Work and Earthwork Packages Site work services included excavation, grading, roadways, rail yard, power conduits, retention ponds for storm water and shoreline improvements for erosion protection. Fay’s scope included excavation and backfill operations at numerous locations, including the Ethylene Cracker Unit, Cogeneration Area, Outside Battery Limit, and Polyethylene Units 1, 2, and 3. Fay performed over 2 million cy of earthwork, installation of over 75,000 lf of drainage piping, over 300 acres of finish grading, drilling of 230 shaft foundations, installation of over 250,000 sf of geosynthetic liners, and sheet piling of up to 12,000 sf for temporary shoring. Fay also performed 800,000 cy of structural/trenching excavation and backfill operations in preparation for underground piping and foundation construction. The Fay team also installed a 138-kilovolt duct bank and constructed a concrete slab for a new building. This work included excavation and subgrade preparation, formwork and reinforcement, rebar and concrete placement, and backfill operations. In addition, Fay established temporary sloping to allow drainage of dewatering activities, keep excavated areas free of water, and control surface runoff. Fay also provided indirect maintenance services throughout the project including road and walkway maintenance, erosion and sediment controls, cleaning, general hauling, rock crushing and snow removal. Sheet Pile Packages These packages included installing approximately 12,000 lf of piling for temporary shoring and external formwork for deep foundation walls. The piling consisted of Z-profile sheet pile and wide flange beam king piles using a vibratory hammer. Fay set and drove 132 pairs of PZC sheet pile and 35 wide flange king piles, fabricated an 18-ft, 9-in by 11-ft waler system and drove 55-ft-long sheet pile for the detention pond sump, and installed a 242-ft combi-wall for the rail loading facility using PZC sheet piles and W33 x 169 king piles. Fay also installed 21 pairs of PZC39 by 37-ft-long sheet pile for the east portion of the pellet pit. A crawler crane and clam bucket were used to excavate the sump box approximately 31 ft down from the top of the sheet pile. Crews utilized the fabricated waler system as the sheet pile template for driving operations. Award-Winning Performance Fay won Bechtel’s Global Supply Chain Excellence Award two years in a row and four contractor/safe crew awards from the owner’s representative for working safely through the duration of the project. **************** “Your scope of work has increased significantly throughout the duration of the project, which is a reflection of your capability and consistently high performance.” - Erin Young, Purchasing and Expediting Manager Our Team is Ready to Help You To learn how our team of heavy construction experts can help solve your infrastructure challenge with safe and innovative solutions, contact us.