This paper presents the challenges faced during the implementation of the foundation works included in the design and construction contract for an iron-ore export berth in Port Hedland, Western Australia. The project comprised a 306-m-long wharf extension, seven berthing dolphins, and related marine support structures. The foundation of the structure comprised 143 open-ended steel piles of 1.2 m in diameter, all with a driving shoe and driven through various soil or rock formations. One key element of the project was the penetration of a 3-m-thick siltcreted conglomerate layer of medium strength present at approximately 14 m below the seabed. All piles needed to be driven through this layer to acquire sufficient tension capacity. Therefore, the selection of the hammer and the confirmation of each pile’s axial capacity and lateral stability were of high importance in delivering the project within the limited construction time frame of 1 year. An extended pile testing program using a Pile Driving Analyzer during the initial drive and subsequent restrikes permitted successful construction of the foundation without any delays. A careful evaluation of the tests as well as a comparison of the driving behavior of the nontested piles with the tested ones allowed (1) to estimate pile capacities, (2) to estimate the benefit of time-dependent increase of pile capacity and define setup values, (3) to utilize fully any pile over-length, and (4) to establish driving protocol based on actual soil conditions. The results of this case study might be used as a reference for establishing a construction support schedule for foundation works via testing and might serve as a reference regarding the properties of the soil-rock formations derived from the signal-matching analyses used for the dynamic load tests at the project site.
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