Project: Savage Facility (KCS)
Location: Port Arthur, TX
Asset: 1,800-ft stacker/reclaimer crane track at a petroleum coke facility, supporting equipment weighing about 1.5 million pounds plus a material conveyor belt
CHALLENGE
The stacker/reclaimer track at this petroleum coke facility runs 1,800 feet and supports equipment weighing about 1.5 million pounds along with a material conveyor belt. Built in 1969, the crane rail sits on 32-foot-long prestressed concrete ties spaced on 10-foot centers, with three 8-foot ties beneath each rail between the long ties. In the 50 years since construction, only localized tie and subgrade maintenance had been done. Over time, some locations along the track fell significantly outside the grade profile (elevation difference between fixed points along one rail) and cross-level (elevation difference between rails) tolerances required for stacker/reclaimer operation.
SOLUTION
Superior densified and stabilized the deteriorated subgrade beneath the track in place, injecting grout to tighten the soil (compaction grouting) and bring the track back to new-construction tolerances of plus or minus 1/4 inch cross-level and 1:400 for grade and profile (1 inch vertical over 33.33 feet horizontal). Across the 1,800-foot track, 1,376 locations were drilled and grouted. The grout pattern used 1 vertical and 1 diagonal injection beneath each rail of the long ties, plus 2 verticals under each rail of the center short tie, densifying the soil and lifting the track into tolerance.
RESULTS
1,376 locations drilled and grouted using 11,925 cubic feet (442 cubic yards) of grout material.
The deteriorated subgrade was stabilized and the track brought back to new-construction tolerances (plus or minus 1/4 inch cross-level, 1:400 grade and profile).
The project ran from September 2020 to April 2021, with an approximately 3-week break in December 2020, and was completed two years ahead of schedule.
