By Sathish Nair R

Posted July 4, 2025

At Paradigm, we believe that even the most complex environments can be transformed through precision, innovation, and multidisciplinary collaboration. This belief was fully realized in a recent project completed in partnership with our European client—an infrastructure upgrade at an industrial waterfront.

From challenging soil conditions to extreme tidal pressures, this case tested the limits of geotechnical, structural, and marine engineering. Here’s how intelligent design turned a constrained brownfield site into a future-ready logistics hub.

Project Overview

The project aimed to expand operational capacity along the River, accommodating high-load fabrication work and heavy-duty marine logistics. With limited space and poor subsoil conditions, the design team had to innovate from the ground up—literally.

Overview Plan

Key Challenges

1. Soft Subsoils (Boom Clay)

Boomse Klei—a highly plastic clay layer—posed challenges related to settlement, bearing capacity, and lateral displacement. The site’s geotechnical behavior required robust retaining and foundation strategies.Our geotechnical consulting team conducted extensive subsurface modeling and soil-structure interaction assessments.

2. High Tidal Variability

Water levels fluctuations introducing considerable hydrostatic pressure on quay structures and demanding watertight integrity under both operational and accidental load scenarios.

3. Industrial Performance Requirements

The dockside had to accommodate:

  • A 450-ton gantry crane runway

  • Access roads and trailer zones

  • Connection to the Factory, used for steel production

  • Integration of dry and insert docks for ship component handling

Our Solution: Engineering with Precision

🧱 Combi-Wall Quay Structure

To create a durable retaining wall system, the team deployed a combi wall consisting of:

  • Steel tubular piles (Ø1829 mm, X52)

  • AZ18 S355 sheet piles

  • Anchor system: Titan 40/20 ground anchors, spaced at 1.25 m with a capacity of 230 kN/anchor

This hybrid system provided the strength of large-diameter pipes with the interlocking capability of sheet piles—ensuring both stiffness and watertightness across the entire quay face.

🧬 Soil Reinforcement and Stabilization

To counteract clay-based settlement and provide a stable working platform:

  • Geogrid-reinforced granular layers were used in MSE (Mechanically Stabilized Earth) zones

  • Gravel beds served as high-stiffness base materials beneath structural loads

  • Boom clay properties were modeled using advanced FEM tools

🧱 Concrete & Structural Integration

Reinforced concrete slabs and prefabricated foundations supported steel columns, crane rails, and structural loads throughout the site. Anchor bolt sizing and grout pad detailing followed Eurocode 3 standards for steel stability during all assembly phases. These were supported by structural steel detailing drawings tailored for dockside assembly constraints.

Our rebar detailing services ensured accurate placement of reinforcement and reliable anchorage in all structural elements.

Engineering Tools & Coordination

Our team delivered this solution with full integration of:

  • Eurocode 1 – Load combinations and environmental actions

  • Eurocode 3 – Steel structure design and detailing

  • Eurocode 7 – Geotechnical assessment and safety verification

Detailed plans, cross-sections, and soil profiles were developed in tandem with the construction team to ensure alignment during execution. Special attention was given to phased work zones and construction tolerances.

Results: A Future-Ready Industrial Platform

The upgraded dock now supports:
✅ Efficient loadout of oversized steel components
✅ Secure docking of marine structures
✅ Safe, durable foundation for a 450T gantry crane
✅ Long-term geotechnical and structural performance under variable conditions

Conclusion

This case exemplifies the transformative power of structural engineering when precision, collaboration, and creativity meet. At Paradigm, we are proud to contribute to projects that redefine what’s possible at the interface of land, water, and industry.

Looking to bring clarity to complexity on your next infrastructure challenge?
Get in touch with Paradigm—and let’s build something extraordinary.

About Author

The author Sathish Nair R is working as General Manager in Paradigm, a leading structural engineering consultancy dedicated to delivering innovative, efficient, and resilient solutions for complex infrastructure and industrial projects across India and beyond. With over 20 years of experience spanning civil, port, and industrial engineering, the author brings a hands-on, performance-driven approach to design and execution. From metro tunnels to power plants, and from urban high-rises to heavy-duty quay structures, he is passionate about turning structural challenges into sustainable opportunities. His leadership at Paradigm reflects a deep commitment to engineering excellence, digital collaboration, and integrated project delivery.