Soil Improvement for Future Clean Energy Facility

We are currently performing this soil improvement project to make way for the construction of our client’s clean energy complex, which will advance the country’s energy independence. The clean energy complex positions Louisiana as a critical player in strengthening America’s energy independence and as a global leader in next-generation energy production by producing low-carbon hydrogen.

Collaborating closely with the client and the Engineer of Record early in the process, we provided valuable input on design, value engineering, and constructability to address any potential critical issues early. This included optimizing scope, material procurement strategies, and methods for stabilizing the region’s incompetent soils. Situated on 1200 acres of sugarcane fields historically located within a major American river floodplain, the site presented significant obstacles.

The site development scope of work included the excavation and placement of 1 million cubic yards of soil, the stabilization of 550,000 cubic yards of soil with cement, the installation of over 1.5 million square yards of geosynthetic materials, and the installation of over 200,000 linear feet of silt fencing.

To support the foundation construction, the project required two fully operational batch plant to be constructed, maintained, and operated onsite to meet the substantial demand for ready-mix concrete totaling over 400,000 cubic yards.

Once construction commenced, the project team encountered several significant challenges, including regional and seasonal weather conditions, local jurisdictional constraints, permitting restrictions, and environmental factors. The region’s year-round wet soil conditions posed significant concerns, complicating site preparation and logistics. Additionally, schedule constraints related to the procurement of bulk materials required for the project added complexity. Local and regional vendors were unable to supply the large quantities of materials needed within the necessary timeframe. The import and placement of materials included approximately 929,000 tons of aggregate, 780,000 cubic yards of structural sand, and 40,000 tons of Portland cement, all critical for building heavy haul roads and stabilizing the facility. Forgen was also tasked with sourcing 22,500 precast reinforced concrete piles for foundation construction.

One of the most impactful delays occurred early in the project when a named storm struck the area, followed by record rainfall over the subsequent weeks. This extreme weather event delayed progress by seven weeks, severely affecting the soil conditions across the site. The already challenging wet soil conditions were exacerbated, making site preparation and infrastructure establishment even more difficult.

Compounding these issues were local jurisdictional constraints that restricted the construction of positive drainage systems. This limitation prevented effective site drainage, further complicating efforts to stabilize the area and proceed with construction activities.

We worked collaboratively with our client as a unified team to overcome the challenges encountered both prior to and during the commencement of construction. The solutions implemented included:

Pre-Construction Planning: Conducted a comprehensive civil constructability review, design optimization, and phase sequencing to ensure timely facility turnover.

Material Logistics Solutions: Imported aggregate, Portland cement, and precast reinforced concrete piles using international maritime vessels, ensuring sufficient supply for the project.

Site Accessibility: Successfully managed access through the design and construction of specialized bridges to cross jurisdictional waterways, enabling heavy equipment movement across the site. Additionally, off-road dump trucks with flotation tires and low ground bearing pressure bulldozers were utilized to navigate challenging terrain.

Bulk Material Staging: Acquired and prepared adjacent space near the project site for staging bulk quantities of aggregate, Portland cement, and precast reinforced concrete piles, optimizing material handling and storage.

Conveyor System Implementation: Designed, procured, constructed, maintained, and operated a conveyor system to efficiently transport aggregate from international vessels to designated staging areas. Additionally, a bridge was constructed over a major railroad, further optimizing logistics and ensuring seamless material flow.

Soil Stabilization Testing: Performed multiple mix designs for test strips tailored to real-time soil conditions, using Portland cement and lime in various site areas. This process identified a cost-effective solution by eliminating lime as a reagent, reducing reliance on the more expensive material.

Innovative Soil Stabilization Methods: Initially bid with soil stabilizers to remediate incompetent soils, Forgen adapted by using excavators for bucket mixing cement in areas with poor soil conditions. As site conditions improved, the team efficiently combined bucket mixing with soil stabilizer use to expedite the scope of work.

Access Road Preparation: Stabilized the main access road by incorporating calcium sulfate to dry and strengthen the surface, ensuring it could support heavy equipment operations.

Schedule Recovery Efforts: Addressed the seven-week delay by extending work hours and workdays, effectively recovering lost time and pulling the schedule back on track.

Dewatering Efforts: Employed numerous large-scale pumps to manage water levels and ensure the site remained operable.

Most haul roads and access infrastructure are now fully established. This progress has significantly reduced the impact of regional weather conditions on the scope of work, enabling operations to proceed with increased efficiency and reliability.

The successful completion of this project will enable our client to further their exceptional legacy of contributing to America’s vital energy infrastructure.