2024 OPA Winner: Plaquemines LNG Driven Pile Megaproject

The Venture Global Plaquemines LNG Project in Port Sulphur, Louisiana, stands as a great achievement in the world of liquefied natural gas (LNG) infrastructure. Encompassing a 632 acre (255 ha) site, 20 miles (32 km) south of New Orleans along the Mississippi River, it's designed to be one of the largest LNG export facilities in the U.S., with the capacity to handle up to 20 million metric tons (22 T) of LNG per year. The project's scope includes multiple LNG trains, storage tanks and large marine terminal infrastructure. The construction involves significant civil works, including deep foundation and flood protection systems. Given the scale and complexity of the project, the construction process is highly intricate, involving a multitude of deep foundation disciplines and coordination among various contractors and stakeholders. Cajun Industries was tasked with several critical components of the piling and civil construction phase, including the development of hurricane protection systems and the execution of extensive deep foundation scopes through the life cycle of the project. This involvement in the project began with a small-scale precast concrete test pile program using just one pile driving rig in 2020. By May 2024, operations had expanded significantly, with a peak workforce of 200 employees, 30 piling rigs and 15 different piling scopes. These scopes included a design-build flood protection system for the project's laydown yard and construction support facilities, single-piece pipe piles up to 145 ft (44 m) long, precast concrete piles up to 120 ft (37 m) long, 41 cofferdams with sheet piles up to 80 ft (24 m) Jong, as well as 140 ft (43 m) long H-piles. The scope also encompassed a comprehensive test pile program featuring more than 150 load tests. Over the course of the project, the team executed more than 575,000 safe man-hours, installing 18,300 piles of various types and sizes. These efforts equated to the installation of more than 1,965,9001ft (600,000 m) of piling or 372 mi (600 km), weighing a staggering 312 million lb (142 million kg). For perspective, one could travel three round trips to outer space when comparing the linear footage of piling.