Grouting campaign – Organizational and Planning

Grouting is part of the Foundation Installation scope. Grouting is required in the following cases:
(1) Grouting between Monopile and Transition Piece
(2) Grouting foundation piles to Jacket Sleeves
(3) Grouting void above suction pile foundations

Grouting for offshore wind project is done using a dedicated vessel.
A CSV (Construction Support Vessel) is required with 2000 m2 deck, 300 t crane AHC preferred, Dynamic Positioning.
Grouting operations are usually independent from other Installation activities, thus grouting activities are not in the Critical Path and rarely affect the overall construction time.Personnel organizational Chart …… add here
List required teams onboard
Marine Operations Manager (overall)
OCM on board the CSV reports to

Mobilization Location

Mobilization should take place at r the grouting campaign will take place. The exact location/quay will be selected based on availability.

Mobilization Planning

Equipment and Material

1.1    Typical Grouting Spread –

The grouting subcontractor will provide the equipment required. Below is a list of a typical grouting spread:

Equipment/MaterialNumberWeightDimensions
Grout Mixer112 t20 ft container
Workshop Container112 t20 ft container
Refrigeration Unit15,5 t20 ft container
Sodium Silicate Storage Tanks430 t20 ft container
ISO Cement Silos627,5 t20 ft container
Cement in vessel Dry Bulk, 6x54t=324 tTotal324 tVessel Dry Storage
Silicate Pump1(TBD)(TBD)
Heating Elements2(TBD)(TBD)
Air compressor1(TBD)(TBD)
Waste Skips21,4 t4x2x1,5 m
Grouting Hose (Delivered in Pieces)200 m

Notes:

  • Cement (462 t). The cement is delivered from local suppliers in 26-30 t per load. Each load will take approximately 1 hour to unload. Cement will be stored in vessels dry bulk tanks (324 t) and in to six ISO silos on deck (6x23t=138t). Loading time for 462 tons of cement will be 17 hours (17 lorries).
  • Sodium Silicate (102 t). Core will provide 4 No. ISO Tank Containers for storage of Sodium Silicate onboard the installation vessel. Sodium silicate will be transferred from the delivery truck to the ISO tanks at the quayside. The ISO tanks will then be lifted onto the vessel using the spreader frame supplied by Core.
Seafastening Containers
(1) HEB200 Beams, L=10.5 m.
Fitted with twistlock sockets, wingplates and stiffeners.
6 pcs0.7 t
Seafastening Containers
(1) HEB200 Beams, L=7 m.
Fitted with twistlock sockets, wingplates and stiffeners.
2 pcs0.45 t
Bunded area fabrication material
Steel Plates 3 mm, UPN100 beams.
Spare Steel Material:
– Seafastening plates (20x)
– D-rings 3-5t (10x)
– UPN100, L=6 m (1x)
– L50x50x5mm, L=2m (6x)
– 15 mm plate (approx. 1m2) (1x)
– Round bar D=20 mm, L=2m (6x)
– 1½ in pipe SCH40, L=2m (2x)
– 6in pipe SCH40, L=2m (2x)
– Wire Rope D=5-7mm (L=5m)
Total0.3 t
Grouting Hose deployment auxiliary
– polypropylene rope 8 mm
– 24 x buoys
– 20x Caribinas
– bend stiffener for hose
– hose saddle c/w lifting point
2t Drop Bags (gravel) – if scour protecting is installed110 pcs2 t

Contractor project team will arrange for:

  1. Offloading equipment on quayside
  2. Secure storage area for equipment/material until they are lifted on board the installation vessel.
  3. Procurement and installation of seafastening
  4. Procurement and installation of bunding around the perimeter of the waste skips and mixing
  5. Procurement of Drop Bags (gravel).

1.1    Deck Layout

A typical Deck layout is shown in the Figure below. Material and equipment on deck are fitted in ISO containers. Foundation beams will be installed on deck and container will be secured with twist locks. Miscellaneous equipment will be seafastening will alternative means (dog plates, lasting).

ESTIMATED GROUTING CYCLE – TASK DURATIONS Breakdown

Task DescriptionDuration
Sailing to Location?? hrs
DP Trials and Positioning2 hrs
Deck and ROV preparations2 hrs
Launching ROV0.5 hrs
Grouting bucket voids at Leg A7.5 hrs
   Grouting hose deployment1 hr
   Connection to manifold and opening valves2 hrs
   Mixing, pumping, monitoring, closing valves2 hrs
   Disconnect from IN 2 and connect to IN 30.5 hrs
   Grouting void above bucket0.5 hrs
   Close valve IN 3 and disconnect hose0.5 hrs
   Flush and retrieve hose0.5 hrs
   Shift vessel and reposition for grouting Bucket Leg B0.5 hrs
Grouting bucket and voids at Leg B7 hrs
   Grouting hose deployment0.5 hrs
   Connection to manifold and opening valves2 hrs
   Mixing, pumping, monitoring, closing valves2 hrs
   Disconnect from IN 2 and connect to IN 30.5 hrs
   Grouting void above bucket0.5 hrs
   Close valve IN 3 and disconnect hose0.5 hrs
   Flush and retrieve hose0.5 hrs
   Shift vessel and reposition for grouting Bucket Leg C0.5 hrs
Grouting bucket and leg voids at Leg C7 hrs
   Grouting hose deployment0.5 hrs
   Connection to manifold and opening valves2 hrs
   Mixing, pumping, monitoring, closing valves2 hrs
   Disconnect from IN 2 and connect to IN 30.5 hrs
   Grouting void above bucket0.5 hrs
   Close valve IN 3 and disconnect hose0.5 hrs
   Flush and retrieve hose0.5 hrs
   Retrieve ROV0.5 hrs
Shifting and positioning to next foundation1.5 hrs
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