GENERAL PRESENTATION - Concrete Layer Innovations

GENERAL PRESENTATION

Proposing 4 unreinforced Concrete Armour Units: 

ACCROPODE 

CORE-LOC 

ECOPODE 

Invented in 1981 by 

SOGREAH 

Invented in 1995 by the 

USACOE 

Invented in 1996 by 

SOGREAH 

ACCROPODE II 

Invented in 1999 

by SOGREAH 

Representing a total of more than 230 applications worldwide

CLI Single layer techniques 

HISTORY 

ACCROPODE II VS. 

ACCROPODE 


CORE-LOC 

ACCROPODE II 

ADVANTAGES & CM 

CORE-LOC 


ECOPODE 

CLI SERVICES 

CLI is a subsidiary of SOGREAH located in Tours; France 

Licensee of SOGREAH and CHL 

on behalf of the USACE 

Technology provider 

Licensor/inventor 

SOGREAH Armouring Division 

- Assistance for design reviews 

- Acts on behalf of for 

tailored technical assistance 

during construction 

Client / Sub-Licensee


History 

ACCROPODE unit 

HISTORY 


ACCROPODE 


CORE-LOC 

ACCROPODE II 


CORE-LOC 


ECOPODE 

CLI SERVICES 

-TETRAPOD invented by SOGREAH in 1952 

-ACCROPODE developed from the Tetrapod experience 

-Pioneer in conventional single layer armouring 

-Invented and patented in 1981 by SOGREAH 

-180 applications around the world


History 

CORE-LOC unit 

HISTORY 


ACCROPODE 


CORE-LOC 

ACCROPODE II 


CORE-LOC 


ECOPODE 

CLI SERVICES 

-Developed by the US Corps of Engineers at WES 

-Patented in 1995 

-Ideal for moderate wave exposure 

-Widely used in the Middle-East 

-About 50 projects worldwide


Time and cost 

ACCROPODE II 

vs. ACCROPODE 

HISTORY 


ACCROPODE 


CORE-LOC 

ACCROPODE II 


CORE-LOC 


ECOPODE 

CLI SERVICES 

-An ACCROPODE II (called “A2” for short) solution saves 

a few percent of concrete compared to an equivalent 

ACCROPODE (“A1”) solution 

-A2 installation on the breakwater requires less constraints 

due to an easier/simpler interlocking (higher output) 

-Overall, A2 saves materials and construction time 

compared to A1

HISTORY 


ACCROPODE 


CORE-LOC 


ACCROPODE II 


Time and cost 

ACCROPODE II vs. CORE-LOC 

CORE-LOC 


ECOPODE 

CLI SERVICES 

-Robustness: The A2 optimised shape, benefits of improved 

characteristics of every aspects from the original A1 (containing 

embedded A1 know-how), and is considered in this respect 

to possess a structural advantage over the CL. 

-Hydraulic stability: Due to its higher porosity, the CL armour will 

be able to dissipate a little more efficiently the wave energy. 

This advantage is somehow offset by the effects of the A2 friction 

enhancers (which also help limiting settlements along the slope). 

-Concrete consumption rate: the CL saves about 2% less 

concrete than the A2. 

-Practical aspects: CL concrete strength requirements 

are greater than A2: 35MPa grade vs. 25 to 30MPa. In line with this 

advantage, a shorter striking, lifting and placement time is expected 

in favour of the A2. 

Because of its simpler overall geometry, A2 placement output rates 

will be greater. 

Mould cost, ease of casting, handling ad storage: minor differences


New Shape 

ACCROPODE II unit 

HISTORY 


ACCROPODE 


CORE-LOC 

ACCROPODE II 


CORE-LOC 


ECOPODE 

CLI SERVICES 

-Shape optimised from the ECOPODE and ACCROPODE 

-More balanced / rugged facets / progressive fillets 

-”Pyramids” friction enhancement, limit settlements, 

extra locking effect and greater wave energy dissipation 

-New geometry leading to 3 key areas of improvements: 

Hydraulic stability performance 

Structural integrity 

Practical aspects


Greater Sturdiness 


HISTORY 


ACCROPODE 


CORE-LOC 

ACCROPODE II 


CORE-LOC 


ECOPODE 

CLI SERVICES 

-ACCROPODE sturdiness confirmed over the years 

-Shape optimisation: increased robustness due to trimming 

-Pyramids on front facets: features with multiple advantages 

-Pyramids are partially sacrificial indicators under loading 

-Concrete strength Rc28d = min 25 MPa for units ≤ 4 m 3 

and min 30 MPa for larger units 

1.80 

1.60 

1.40 

Von Mises stresses (MPa) 

1.20 

1.00 

0.80 

0.60 

0.40 

ACCROPODE II 

ACCROPODE 

0.20 

0.00 

0 5 10 15 20 25 

Volume (m 3 )


Hydraulic performance 


HISTORY 


ACCROPODE 


CORE-LOC 

ACCROPODE II 


CORE-LOC 


ECOPODE 

CLI SERVICES 

Extensive physical modeling and initial field feedback: 

-The new shape allows improvements in stability: 

Better spreading in interlocking 

Greater hydraulic stability Slight Kd increase 

-Placement grid adjustment in order to : 

Simplify placement procedures 

Minimise settlements on armour slope


Installation and Maintenance 


HISTORY 


ACCROPODE 


CORE-LOC 

ACCROPODE II 


CORE-LOC 


ECOPODE 

CLI SERVICES 

-Easier placement due to: 

-Maintenance: 

A more uniform (symmetry) unit geometry 

Less placement constraints 

The tuning of the positioning grid 

Good records: First generation unit (A1) has 

shown to require minimum maintenance 

Considering that the second generation (A2) 

offers improvements on key aspects, it is then 

expected to require even less maintenance


Construction Methods (CM) 

ACCROPODE II 

HISTORY 


ACCROPODE 


CORE-LOC 

ACCROPODE II 


CORE-LOC 


ECOPODE 

CLI SERVICES 

A typical arrangement is a staggered layout in lines which required the minimum 

precast yard area. 

Unit casting area S can be evaluated by using S = 1.24 H 2 , H being the height of the 

unit.



ACCROPODE II 

HISTORY 


ACCROPODE 


CORE-LOC 

ACCROPODE II 


CORE-LOC 


ECOPODE 

CLI SERVICES 

MAIN CASTING SPECIFICATIONS 

. Mould preparation: 

Wheels height adjusted – Shells fully connected 

- Safety platform secured 

•Base waterproofing: levelled sand bed 

over lean concrete slab 

•Transport by mix-trucks: 

In general < 45 minutes for ready-mix concrete 

•Casting: 

•No cold joint – High workability / low W/C 

•Ht of fall >2m = use a chute 

•Each vibrated layer should not exceed 50cm 

•Casting time: 

20 mn in normal conditions 

40 mn in cold / humid wheather conditions 

•Attention : Max heat of hydration < 65°C 

•Vibration: 2 or 3 inches poker – external 

vibrators not advised 

Form-oiling 

Connecting shells 

Concrete pumping 

Half-mould (shell) set in place in place 

Mould ready for casting 

Vibration

HISTORY 


ACCROPODE 



CORE-LOC 

ACCROPODE II 



CORE-LOC 


ACCROPODE II 

ECOPODE 

CLI SERVICES 

•TYPICAL CYCLE: 

•Hardening of concrete: 

In general between 15 and 24 hours to reach the 

minimum striking strength Rc7days 

1- Concrete hardening 2- Striking 

•Mould Striking min Rc7d: ≤ 4m 3 6MPa min 

between 5m 3 and 15m 3 7MPa min 

≥ 15m 3 10MPa min 

•Unit curing: 14 days with suitable curing compound 

+ 

•Cleaning and form-oiling: each re-use 

3- Curing 

4- Cleaning and form oiling 

•Transport to storage yard min Rc: ≤ 4m 3 15MPa 

min 

between 5m 3 and 15m 3 20MPa min 

≥ 15m 3 25MPa min 

•Storage time: 

Units must have gone through their curing, be 28d 

aged and reach the Rc 28d before being installed 

5- Transport to storage 6- Storage

HISTORY 


ACCROPODE 



ACCROPODE II 


CORE-LOC 

ACCROPODE II 


CORE-LOC 


ECOPODE 

CLI SERVICES 

Slinging : 

HANDLING 

A2 units can be lifted when min Rc28d = 15 MPa for units ≤ 4 m³ and 20 MPa for units between 5 and 

15 m³, 25 MPa for larger units 

Typical handling 

machinery: 

Cranes or fork-lift 

trucks or front-end 

wheel loaders can be 

used depending on 

the distance of 

transport and unit 

size 

Two ways of slinging 

the units can be 

considered



ACCROPODE II 

HISTORY 


ACCROPODE 


CORE-LOC 

ACCROPODE II 


CORE-LOC 


ECOPODE 

CLI SERVICES 

STORAGE method: 

-Nested in tight rows: Area needed 

per level: 0,55 H2 

-H = the unit height 

N.B: 

-The storage area must be carefully 

levelled 

-Suitable bearing capacity of the soils 

-Two-levels storage is feasible, the 

second level must however not 

extend until the edge of the first 

stored level, for safety reasons; 

-If safety requires, the second level 

can be strapped in groups. 

-Some space must be given between 

the units so that they can easily be 

slinged or fork-lifted for their removal 

when ready for placement



ACCROPODE II 

HISTORY 


ACCROPODE 


CORE-LOC 

ACCROPODE II 


CORE-LOC 


ECOPODE 

CLI SERVICES 

TRANSPORT OF ACCROPODE II BY DECK BARGE

HISTORY 


ACCROPODE 


CORE-LOC 


ACCROPODE II 


CORE-LOC 


Advantages of 

the CORE-LOC unit 

ECOPODE 

CLI SERVICES 

CORE LOC 

‘’Highly dissipating and most cost-effective’’ 

1. Developed at the Waterways Experiments Station (WES) 

2. Superior hydraulic stability 

3. High porosity ratio Low overtopping 

4. Ideally suited to moderate wave conditions 

5. Least concrete consumption 

6. Substantial number of projects worldwide

HISTORY 


ACCROPODE 


CORE-LOC 



CORE-LOC PROCESS SEQUENCE 

ACCROPODE II 


CORE-LOC 


ECOPODE 

CLI SERVICES 

View of CORE-LOC moulds 

Form oiling 

Sand bed being prepared

HISTORY 


ACCROPODE 


CORE-LOC 


ACCROPODE II 



CORE-LOC 


CORE-LOC 

ECOPODE 

CLI SERVICES 

Mould setting 

Platform mounting 

Concreting 

Assembling 

Mould removal



CORE-LOC 

HISTORY 


ACCROPODE 


CORE-LOC 

ACCROPODE II 


CORE-LOC 


ECOPODE 

CLI SERVICES 

Water sprinkling 

Applying curing 

compound 

Two typical casting methods 

Fork-lifting a 5m3 unit



CORE-LOC 

HISTORY 


ACCROPODE 


CORE-LOC 

ACCROPODE II 


CORE-LOC 


ECOPODE 

CLI SERVICES 

Storage yards 

Handling a 11 m³ unit 

Transporting 1.4m³ units



CORE-LOC 

HISTORY 


ACCROPODE 


CORE-LOC 

ACCROPODE II 


CORE-LOC 


ECOPODE 

CLI SERVICES 

Deck barge transport 

Placement from land 

TRANSPORTING CORE-LOC units in a cargo ship



CORE-LOC 

HISTORY 


ACCROPODE 


CORE-LOC 

ACCROPODE II 


CORE-LOC 


ECOPODE 

CLI SERVICES 

Posibloc display installed in crane cabine 

Barging units out to site 

Placing from a barge 

Virtual display of Core-Loc in-progress placement – Side view

The environmentally friendly unit 


ECOPODE 

HISTORY 


ACCROPODE 


CORE-LOC 

ACCROPODE II 


ENVIRONMENTALLY FRIENDLY 

CORE-LOC 


The ECOPODE single layer: an 

alternative solution to armour rocks 

ECOPODE 

CLI SERVICES

HISTORY 


ACCROPODE 


CORE-LOC 

ACCROPODE II 


What exactly is ECOPODE? 

CORE-LOC 


ECOPODE Origin 

ECOPODE 

ECOPODE 

CLI SERVICES 

Man-made geometry: 

i.e. the ACCROPODE 

+ = 

Architectured 

aspects adaptable 

to specific site 

conditions 

The ECOPODE unit 

Developed at SOGREAH in 1996

Design – Materials volumes comparision 

ECOPODE 

HISTORY 


ACCROPODE 


CORE-LOC 

ACCROPODE II 


CORE-LOC 


ECOPODE 

CLI SERVICES 

Solid materials volumes for various configurations 

Armour 

Underlayer (filter) 

Core 

Rocks - 2/1 slope 

Rocks - 3/2 slope 

ECOPODE 1m 3 - 4/3 slope 

ECOPODE 2m 3 - 4/3 slope

Manufacturing - Mould principle 

ECOPODE 

HISTORY 


ACCROPODE 


CORE-LOC 

ACCROPODE II 


CORE-LOC 


ECOPODE 

CLI SERVICES 

The mould system is similar to an ACCROPODE 

mould in its operating principle: 

casting 

Two half shells that are assembled before 

Opening of the mould using small jacks 

A complete set of mould consists of the 

following: 

Coffrage ACCROPODE II 

A tubular structure (« spider frame ») 

Two symmetrical shells made of composite 

material (same shape and texture as the Master) 

The inside of the shells is lined with a 

special « gel coat » allowing easy opening of the 

mould 

Coffrage ECOPODE II

Fabrication of ECOPODE units 

HISTORY 


ACCROPODE 


CORE-LOC 

ACCROPODE II 


ECOPODE application 

CORE-LOC 


ECOPODE 

CLI SERVICES 

Casting procedures ACCROPODE and 

ECOPODE are identical: 

Same concrete characteristics 

Same casting method 

Same production cycle (1 unit a day per set of mould) 

Concrete coloring as an option

ECOPODE Placement principle 


HISTORY 


ACCROPODE 


CORE-LOC 

ACCROPODE II 


CORE-LOC 


ECOPODE 

CLI SERVICES 

The ECOPODE placement principle is 

identical to the ACCROPODE II: 

Conditions: 

Conventional similar equipment is used 

(cable cranes and slings) 

Adapted rock underlayer (W/7 to W/15) 

Simplified placement rules: 

Placement in a single layer 

Placement according to a defined grid 

Ramdom orientation of the units

Views of ECOPODE armour 

HISTORY 


ACCROPODE 


CORE-LOC 

ACCROPODE II 



CORE-LOC 


ECOPODE 

CLI SERVICES 

New process: Ospedaletti marina, liguria, Italy – Works in progress

HISTORY 


ACCROPODE 


CORE-LOC 


ACCROPODE II 


Knowledge-based technical 

assistance 

CORE-LOC 


ECOPODE 

CLI SERVICES 

CLI offers knowledge-based support at key stages as 

the project develops: 

-Design stage: 

Armour design: respond/interact to/with 

Designers provide specific advice and comments 

Physical modeling (often recommended): 

supply required model units to Laboratories; provide 

advice and comment tests results 

-Construction stage: 

Tailored assistance provided to the Contractor 

from the beginning of the manufacturing up to the end 

of placement of the armour units


Assistance on Site 

HISTORY 


ACCROPODE 


CORE-LOC 

ACCROPODE II 


CORE-LOC 


ECOPODE 

CLI SERVICES 

-Typical sequence of technical assistance provided during implementation: 

Provision of the Technical documentation and mould drawings 

Review and advice about the Contractor construction methods 

First site visit at start of the units manufacturing 

Supply of the positioning drawings based on the relevant data provided by 

the contractor 

Second visit before or at the beginning of the placement 

Several visits during the placement 

-In addition to timely site visits, interactive support is made available to the 

Contractor throughout the construction until completion of the works.

GENERAL PRESENTATION - Concrete Layer Innovations

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