As global trade through the Gulf of Mexico continues to grow, the Port of Lake Charles has launched a major expansion to modernize its infrastructure and increase cargo handling capacity. The reconstruction of City Docks Berths 4, 5, and 6 will replace aging wharf facilities and transit sheds with a stronger, more efficient structure designed to support increased commerce in southwest Louisiana.
To accomplish this, contractor Cajun Industries is overseeing the installation of more than 916 precast piles and 100 pile caps, requiring 2,600 cubic yards of concrete to restore the wharf and prepare the site for the port’s next phase of growth.
Complex Marine Conditions Pose Unique Challenges
Unlike traditional building construction, pile cap installation in a marine environment presents significant challenges. Crews worked over open water with limited space between caps, while contending with varying pile positions that demanded flexibility from the forming system.
The pile caps themselves stretched nearly 100 feet in length, requiring the formwork to be divided into sections to accommodate lifting and placement. Safety was a primary concern, with Cajun Industries committed to delivering steady progress without compromising worker well-being.
“We pour five caps per week. We know we can do more, but at Cajun, we put our employees’ health and safety above all else,” said Gerardo Villegas, Superintendent for Cajun Industries. “As we progressed, we saw how fast, efficient, and safe VPS is. We’d highly recommend using the PERI VPS system.”
VPS: Closing the Gap Between Safety and Efficiency
To meet these challenges, Cajun Industries and PERI USA selected the VARIOKIT Pier System (VPS). VPS offered the advantage of being fully rentable while also providing crews with wide, safe working platforms and adaptable soffit geometry.
Key features of the VPS solution included:
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Ten VPS sets in rotation, allowing five pile caps to be completed each week
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Sliding panel adjustments to handle differing soffit geometries and pile positions
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Divided VPS sections to simplify the lifting of long caps
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Compatibility with Cajun’s existing side formwork, maximizing efficiency
“VPS closes the gap between safety and efficiency,” explained Francisco Gonzalez, Product Manager at PERI USA. “It gave crews open, flexible working space like traditional dance floor systems, but with the added benefit of a new stripping method that allowed them to safely strip soffits from above, without needing a crane.”
Innovation Through Collaboration
As a relatively new system, VPS required training and support to shorten the learning curve. PERI’s technical and sales teams provided jobsite visits, engineering input, and continuous feedback loops to ensure Cajun crews assembled and used the system safely and effectively. This partnership also led to the introduction of new VPS components tailored to the project’s specific marine conditions.
A Model for Modern Maritime Construction
The Port of Lake Charles expansion is more than an infrastructure upgrade—it is an investment in the region’s economic future. By strengthening the wharf and transit sheds, the project enables the port to accommodate larger volumes of cargo, further positioning southwest Louisiana as a hub for global trade.
With an anticipated completion in 2025, the Lake Charles project demonstrates how engineered formwork systems and collaborative planning can redefine safety and efficiency in marine construction.
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