Several national and international projects are currently underway to develop port areas and increase their capacity to handle larger ships and higher volumes. This requires stronger protection against erosion, as currents and waves increasingly affect quay structures and foundations. Traditionally, boulders have often been used as erosion protection in ports. However, stone-based solutions have proven to be both costly and logistically demanding, which also risks creating delays in the overall construction process. In addition, the traditional stone solution has a much higher impact on CO2 emissions, making concrete mattresses a much more sustainable solution for the future.
Challenges with traditional boulders
In major port projects, the use of boulders requires large quantities of material to be transported and placed on site. In one example from an international project, 430,000 m³ of stone was needed to protect the quay structures. In addition to the high cost of materials, logistics and installation became a significant bottleneck, as the boulders had to be placed before the actual deck construction could begin. This risked creating major challenges and delays in the overall construction process, so concrete mattresses were chosen instead.
Concrete mattresses – a smarter solution
To meet these challenges, many projects are now turning to concrete mattresses as an alternative to stone erosion protection. Concrete mattresses offer a range of benefits:
- Material savings: Instead of needing 430,000 m³ of stone, concrete mattresses can reduce material needs to only 26,500 m³ of concrete. This drastic reduction in material volume leads to significant cost savings.
- Flexible installation: A major advantage of concrete mattresses is their flexibility. Unlike stone blocks, which must be placed before the deck is built, concrete mattresses can be installed at any time – before, during or after deck construction. This means that erosion protection is no longer on the critical timeline of the construction project, allowing for faster progress and fewer delays.
- Environment: In addition to financial and time savings, concrete mattresses also have a reduced environmental impact. Replacing large volumes of stone reduces the carbon dioxide emissions generated by the extraction, transportation and installation of materials. In addition, the development of climate-friendly concrete has allowed us to reduce the carbon footprint of concrete by a further 50% and in some cases up to 95%.
Technical performance and durability
Concrete mattresses are designed to withstand harsh marine conditions and offer long-term protection.
Example: In a slope with normal water flows, we construct a concrete mattress with a thickness of 0.15 meters of concrete, which is significantly less than the corresponding 3.6 meters of different fractions of stone required for the same dimensioning. In areas with high wave intensity and at the end of the existing surface, we usually upgrade the concrete mattresses to a thickness of 0.2 – 0.5 meters depending on the prevailing forces and make them extremely resistant to both wave and ship impact.
Conclusion
Concrete mattresses offer a smart, cost-effective and environmentally friendly solution for erosion protection, not least in large port projects where the surfaces are extensive. With significant material savings, a flexible installation process and robust long-term performance, it is a solution that meets the demands of today’s marine infrastructure projects.
Please contact us and we will help you with advice, design and product development to find the best solution for your next port project.
