One of the busiest container terminals on the East Coast recently became the stage for a marine construction effort that demanded accuracy, adaptability, and uninterrupted port operations. Russell Marine's sheet pile toe wall installation at the at the Wando Welch Terminal in Mount Pleasant, South Carolina, is now featured in PileDriver magazine and International Construction Equipment, Inc. (ICE®) is proud to have played a key role in the project's success.

Completed two to three months ahead of schedule, the work delivered a critical submerged structure while maintaining full terminal functionality, protecting one of the region's most important economic gateways.

The project required the installation of 861 steel sheet piles, NZ 38 and NZ 28 sections, forming a 3,800‑foot toe wall located approximately 48' (ft) below the water's surface. This wall will support current operations and future dredging efforts as the Port of Charleston prepares for larger vessels.

Initial plans called for a larger hammer, but real‑world conditions quickly proved that precision mattered more than raw power. Russell Marine transitioned to the ICE® 66B vibratory hammer, paired with a 60' (ft) extension, to achieve the control needed for underwater placement in heavy currents and a constrained footprint.

The 66B's responsiveness allowed crews to maintain interlock integrity and alignment, which is essential for a linear installation of this scale. The hammer's performance was further supported by Hydrauli‑Flex™ hose, which provided the durability and pressure stability required for continuous marine operations. With hydraulic systems running biodegradable oils to protect the environment, high‑quality hose performance was critical to preventing leaks and minimizing downtime.

The Wando Welch Terminal operates three berths, yet the project footprint occupied less than half of one. That meant every movement had to be carefully sequenced to avoid interfering with vessel loading, unloading, and logistics operations.

Maintaining uninterrupted port activity was non‑negotiable. Any delay could have had far‑reaching economic impacts.

To support precision driving, crews used practical field tools such as "tattle tale" ropes to monitor sheet behavior in real time. Heavy currents added complexity, requiring constant control and coordination throughout the driving process.

Russell Marine also collaborated on a custom pile driving template system designed specifically for the project's constraints. The system eliminated the need for falsework piles, reduced material and time requirements, allowed safe passage of ship‑to‑shore cranes, and integrated anchor points, handrails, and ladders for crew safety. This thoughtful engineering ensured that construction could proceed efficiently while maintaining the high safety standards required in a busy marine environment.

With schedule pressure and port continuity at stake, minimizing downtime was essential. The team implemented on‑site strategies to rapidly address equipment needs, including immediate access to replacement hydraulic components. This approach kept production steady and prevented delays that could have affected both the project and terminal operations.

The Wando Welch Terminal toe wall installation demonstrates how driven sheet pile systems supported by adaptable equipment like the ICE® 66B can succeed in complex, real‑world marine environments. From underwater installation in strong currents to working within an active terminal, the project highlights the importance of aligning design, equipment, and strategy with site‑specific demands.

This update builds on ICE®'s earlier coverage of the project, showing how innovation, flexibility, and dependable equipment continue to push boundaries in marine construction.

Learn more about the ICE® 66