Sacyr has extensive experience in port and harbor construction that has now been transferred to the second phase of the Central Breakwater in the Expansion of the Port of Bilbao. With this project, Sacyr provides agile and sustainable construction solutions to culminate three decades of works in Bilbao's port area. 

Miguel Tejeda, Project manager, explains that the initiative stems from the growing demand for freight traffic at the port and the need to expand port facilities in the Pass due to the rezoning of port areas located upstream of the estuary for urban development purposes.

The Central Breakwater represents the final stage in the Expansion of the Port of Bilbao in the Outer Pass.

In the Summer of 2024, the Bilbao Port Authority awarded a joint venture, led by Sacyr Engineering and Infrastructure, the contract for this second phase. This phase encompasses a 310,000 sqm area and is scheduled to be completed within two years.

The project applies construction methods such as the use of reinforced concrete caissons and the development of a mass concrete superstructure, with an optimized design aimed at minimizing disruptions to existing port operations and maximizing the efficiency of the new quay. 
 

The floating dock is made of four towers that have been brought by ship from Lisbon.

Additionally, the project includes the construction of 1,011 as an meters of new berthing docks: 664 meters for the new A3 Quay and 347 meters for the existing A4 Quay.

The caissons will be manufactured on-site using the Sacyr Uno floating dock.

The dock measures 56 meters in length, 36 meters in beam, and 15.9 meters in depth. During the process, the designed prop will be adjusted afloat, utilizing the naval stability of the caisson to optimize the slab construction for the subsequent caisson. 

The floating dock comprises four towers and 16 ballast tanks, enabling the platform to be submerged to the desired depth. This allows for smooth formwork sliding and ensures the stability of the entire assembly.

The main construction works include the fabrication of new concrete caissons and their subsequent filling with sand dredged from maritime deposits. Additional activities include constructing the breakwater, creating pier backs with land-based placement of riprap, executing the seaside and landside superstructures, extending the rainwater drainage network and installing port equipment.

The second phase will focus exclusively on building the vertical quay using reinforced concrete caissons topped with a mass concrete superstructure. 18 concrete caissons in total will be constructed using a floating platform or caisson-builder that facilitates continuous production.

Once completed, the caissons will be floated to their designated positions at the quay. They will be anchored by filling their cells with water until they sink to rest on the prepared foundation. Afterward, the cells will be filled with material, the joints will be sealed using concrete piping, and the gaps between the caissons will be filled with gravel.

Environmentally Friendly Construction

The project has undergone an Environmental Impact Assessment and has received the corresponding Environmental Impact Statement (EIS). It incorporates measures to mitigate turbidity during construction, such as the use of containment barriers and anti-turbidity curtains. Air quality and noise levels will also be closely monitored.

Furthermore, the filling material for the esplanade will be sourced from excavation surpluses from nearby projects.

The materials to fill the caissons will be extracted from a marine area parallel to the Petronor dike, located two miles off the coast to the north, spanning approximately 7.9 square kilometers.

Extensive Port Construction Experience

Sacyr has considerable expertise in port infrastructure projects, such as the extension of the Punta Sollana dock in the Port of Bilbao, the jetty at the Port of Langosteira in A Coruña, the protective works and Cruise Ship Dock at the North Extension of the Port of Valencia, the expansion of the Port of Garrucha (Almería), the fishing port of Blanes (Girona), and the Port of Marín.

Sacyr's maritime bases have allowed the company to develop many projects in the Azores Islands.