LNG-Terminal, Brunsbüttel

German LNG Terminal GmbH is pushing ahead with the construction of an onshore LNG terminal in Brunsbüttel, which will enable the import of liquefied natural gas from 2027, as well as hydrogen derivatives at a later date. A central component of the project is the construction of two LNG tanks. Under the direction of the general contractor CS Gas North (Cobra Sener), the umbrella consortium of PORR Spezialtiefbau (NL Oldenburg) and König GmbH, Stade, carried out the deep foundations. In total, more than 5,800 Fundex piles with a diameter of 44/56 cm and a length of around 23 metres were installed. These piles displace the soil completely without transporting material upwards. This eliminates the need for further soil transport, improving the project's carbon footprint.

In spring 2022, the German government decided to implement two major projects for energy security and the energy transition – one in Wilhelmshaven and one in Brunsbüttel, in close shoulder-to-shoulder collaboration with the Dutch state-owned infrastructure company Gasunie and with the involvement of RWE. Energy import terminals will therefore be built, which will enable the reliable import of conventional natural gas in liquid form (LNG) in an initial step, followed by ‘green’ LNG, as well as the modern forms of energy, probably hydrogen derivatives.

The aim is to be able to start regular operations as early as possible in 2027, which will ensure the continuous and future-oriented import of energy.

Subsoil requires careful planning

German LNG Terminal GmbH is building a combined import and distribution terminal on a 31-hectare site on the Lower Elbe. The soil conditions on site posed particular challenges for the deep foundations. Beneath a gravel working level, there was a layer of clay up to 19 metres deep before the sand layers with sufficient load-bearing capacity were reached.

Despite narrow pile positions and the challenges posed by soil displacement, the project went according to plan thanks to modern technology and coordinated processes. Up to eight drilling rigs were in use at the same time to produce over 5,000 piles in the planned runtime.

Highest safety standards

The construction site meets the highest safety requirements. Clear divisions between driving and walking paths, advanced protective equipment and innovative alarm trolleys ensure an accident-free working environment.

Watch our project video* :                                                                                                                           PORR Germany . LNG-Terminal, fundex pile

In addition, strict regulations against fire and flying sparks apply. To avoid sparks, reinforcement cages were cut electro-hydraulically instead of being burned.

Efficient logistics and sustainability

With eight drilling rigs in operation, the daily demand for reinforcement cages was extremely high. Three suppliers delivered 2-3 truckloads of reinforcement cages to the construction site every day. The concrete was delivered directly from Brunsbüttel to minimise transport distances and to be able to react flexibly to demand. Sustainability was also a central aspect: hazardous substances were stored safely, drips were collected during refuelling, and oil binders were available for emergencies. These measures are based on a specially developed checklist by the PORR special civil engineering team, which systematically analyses environmental aspects.

Successful load tests

‘We have already impressed with our expertise and experience from the previous contract at the LNG terminal in Stade. Particularly noteworthy is our technical solution with a low-noise and vibration-free pile system that does not extract soil,’ explains PORR project manager Martin Puchler.

Trial loads carried out in summer 2024 further optimised the technical and economic implementation of the project. With a low-noise and vibration-free pile system, experienced teams and a clear focus on environmental awareness, the project set new standards in energy supply.

‘Our team was motivated and showed above-average commitment every day. By optimising and combining processes with our joint venture partner, we were able to exceed the planned daily output,’ says Puchler happily.

(*video platform Vimeo)