The Construction of Mega Tuas Port

 

 

We previously covered Singapore's maritime status and the significance of the Mega Tuas Port. You can read the full article here.

 

As of now, Phase 1 of the Mega Tuas Port has already installed a total of 221 caissons and is on track to complete the entire reclamation work by 2021, with around 2,000 workers and supervisors on site. Meanwhile, the second phase has already begun.

 

The Mega Tuas Port is designed to accommodate container ships up to 24,000 TEU with a water depth of 24 meters. Once operational, it will be capable of handling any size of cargo vessel in the world, making it the largest port globally.

 

Discover more about the key construction equipment used in this massive project.

 

So, how is the Mega Tuas Port built?

 

The Maritime and Port Authority of Singapore (MPA) is constructing the port using caisson technology. This method involves prefabricated structures that are sunk underwater to create a solid foundation for the port.

 

Caisson technology has been used for centuries in port infrastructure. For the Mega Tuas Port, caissons are being used to build the breakwater and seawall, essential for land reclamation.

 

 

In Phase 1, caisson installation is proving to be a safer and more efficient alternative to traditional methods like piling. The same technique will be applied in all remaining phases. These caissons are among the largest in the world—each weighing 15,000 tonnes and measuring 40m in length, 28m in width, and 28m in height—equivalent to a 10-story building.

 

 

The image above shows the process of building the seawall, which forms the perimeter of the port. Once the seawall is in place, land reclamation inside the structure begins.

 

To install the caissons, a rock mound foundation must first be built on the seabed:

1. A mega dredger digs a trench along the caisson installation area to the required depth. The world’s largest grab dredger, with a bucket capacity of 200 cubic meters, is being used for this task.
2. The trench is filled with sand using the Temarock vessel.
3. A layer of rock is then laid over the sand.
4. The Temarock vessel compacts the sand using a tamping arm.
5. Finally, a smaller rock layer is added and leveled for precise caisson placement.

“TEMAROCK is a next-generation vessel that combines rock laying and compaction into one process. It replaces the need for multiple vessels and divers, improving both efficiency and safety.”

 

 

Meanwhile, the caissons are being fabricated on-site in two separate yards, allowing for simultaneous production. This helps speed up the overall timeline.

 

1. Caissons are cast layer by layer, with each unit requiring approximately 1,000 cubic meters of concrete. They are typically 28 meters high and weigh around 15,000 tonnes—equal to the weight of 8,000 cars.
2. Once completed, they are moved onto a floating dock.
3. The caissons are then towed to their final location and submerged from the dock before being placed precisely.
4. Upon reaching the site, the caissons are ballasted with seawater to sink onto the foundation.
5. Finally, sand and concrete are added to create a solid deck on top of the caisson.

“To handle the large volume of reinforcement steel needed, an Automatic Rebar Machine using Robotics System (ARMS) is employed. This system automates cutting and bending, significantly reducing manual labor and increasing safety.”

 

 

Once the caissons are in place, the internal area is reclaimed to form solid land. Afterward, the port facilities and equipment are installed.

 

The project also emphasizes sustainability by reusing excavated materials from other construction projects. This approach has reduced the need for sand by up to 70% in Phase 1 and 50% in Phase 2, resulting in significant cost savings of around S$2 billion.

 

Here’s a glimpse into the construction process of the Mega Tuas Port. Watch the video below to see Phase 1 in action.

 

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