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Kakrapar Atomic Power Station 3&4

Kakrapar Atomic Power Station 3&4

Kakrapar Atomic Power Station is a nuclear power station in India, which lies in the proximity of Surat and Tapi river in the state of Gujarat.

Unit 3&4 is India’s first pair of indigenously designed Pressurized Heavy Water Reactors (PHWRs) of 700 MW unit size located at Kakrapar in Gujarat, where two units of 220 MW PHWRs are already in operation.

First concrete for Kakrapar 3 and 4 was in November 2010 and March 2011 respectively, after Atomic Energy Regulatory Board (AERB) approval.

Since then, Dextra had supplied 540,000 Bartec rebar couplers, to connect slabs and columns of reactor and control buildings.

Moreover, Unitec bolted couplers were installed to connect rebars without the need of any thread preparation.

Finally, headed bars were mounted onto the reinforcement bar end, drastically reducing rebar congestion.

The commercial operation of Unit-3 is expected to be in March 2021 while its twin unit, Unit-4, is anticipated a year later after.

Sources of images: https://en.wikipedia.org/wiki/Kakrapar_Atomic_Power_Station, https://www.nucnet.org/news/kakrapar-3-indigenous-phwr-achieves-first-criticality-7-3-2020, https://www.asiavillenews.com/article/a-look-at-the-kakrapar-3-reactor-54367

Green Duba Integrated Solar Combined Cycle Power Plant

Green Duba Integrated Solar Combined Cycle Power Plant

Duba ISCC Green Power Plant 1 is a large power infrastructure project taking place in the North West of Saudi Arabia, on the Red Sea. The ISCC (Integretad Solar Combined Cycle) technology is adding 50 MW of solar power to the gas & steam turbine generating 500 MW.

For that project, Dextra supplied Double Corrosion Protection Ground Anchors used as a permanent anchoring solution for the excavation works preparing the pumping chamber. A total of 264 anchors (Grade 1080/1230, Ø32 & 40mm) have been supplied and installed on 4 layers.

The Double Corrosion Protection anchors supplied for this project were pre-grouted at Dextra factory (first layer of grout between steel bar and HDPE sleeve). The pre-grouted segments were reconnected at site thanks to couplers. Pre-grouted anchors not only save time and money on site operations, they also allow an overall better anchor quality by performing the first grout layer in a factory-controlled environment.

 

Installation at site was carried out by foundation contractor BAUER, which performed drilling, lifting, installation, grouting and post-tensioning operations. Dextra offered guidance during the early steps of the installation by sending a team of geotechnical specialists at site.

The general sequence of installation is the following (illustrated in pictures below):

  1. After unpacking from shipping racks, splicing of segments with couplers, covered by heat shrink sleeves.
  2. Transportation of assembled anchor from assembly to site to lifting area (13kg per linear meter).
  3. Wiring cable at the head of anchor to control the descent. Grouting pipe also pre-installed along the anchor.
  4. Inserting the 30 meters anchor into drilled hole together with grouting pipe.
  5. After grouting and stressing, a head cap filled with grease is installed on the anchor head, maintain the anchor fully isolated from the corrosive outside environment.

For more information about our excavation and ground solutions in the Middle East, please contact our Dubai office.

Queensland Curtis LNG (QCLNG)

Queensland Curtis LNG (QCLNG)

The Queensland Curtis LNG (QCLNG) project is located on Curtis Island, Gladstone, in Queensland, Australia, involving conversion of coal seam gas (CSG) reserves into LNG and expansion of exploration and development of CSG reserves in southern and central Queensland.

The gas field, pipeline, LNG plant, swing basin and channel, and shipping operations are all part of the project development. The project’s construction began in late 2010.

Dextra contributed to the project by delivering 307 tons of marine tie bars and accessories in grade 460. The tie bars serve as an anchorage for the marine offloading facility’s anchor walls.

Bang Pakong Power Plant

Bang Pakong Power Plant

Bang Pakong Power Plant is Thailand’s first power plant using natural gas from the Gulf of Thailand as main fuel.

Located on the left bank of the Bang Pakong River in Chachoengsao Province, it comprises both thermal units and combined cycle blocks, with a total capacity of 2,490 MW*.

The plant is built to compensate for the power-generating capacity that was lost after the 1,050-megawatt Bang Pakong Combined Cycle Power Plant was terminated in 2014.

Dextra supplied a wide range of Bartec rebar couplers from size 12mm to 32mm, for the construction of the plant’s cooling tower and combined cycle blocks. The couplers were used to reinforce and connect precast columns and precast beams.

Moreover, Groutec couplers were installed in precast columns for a fast and easy connection with the foundation at the construction site: once the precast columns are lifted and placed into position, the embedded couplers are injected with grout.

Dextra products: Bang Pakong Power Plant

*Electricity Generating Authority of Thailand. Bang Pakong Power Plant, 2019, www.egat.co.th/en/information/power-plants-and-dams?view=article&id=37.

Wheatstone LNG Plant

Wheatstone LNG Plant

Wheatstone LNG is a liquefied natural gas plant located in Western Australia. The plant is owned and operated by Chevron Australia.

Dextra has been involved on the project between 2013 and 2014 for the design and delivery of marine tie rods systems between sheet pile walls and combi walls.

To ease installation and allow a multidirectional rotation angle of the tie rod assembly of ± 5°, Dextra Captive Nuts were installed into the pile reinforcement and cast in concrete.

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Dextra also supplied the waling beam systems (channels and bolts) that allow to support the tie rods on the sheet piles.

Dextra systems are now anchoring the quay structure of the offloading facility, visible as a L shape in the photo above (copyright top picture: Chevron Australia).

Dunkirk LNG Terminal

Dunkirk LNG Terminal

The LNG Dunkirk Terminal is a new natural gas built in the North of France. The project belongs to EDF (France’s main energy company), Fluxys & Total. The new LNG Terminal facilitates the importation of liquid natural gas (LNG), which is transported at low temperature at -163°c. The terminal aims to answer the growing French and Belgian consumption of natural gas, answering 20% of the national consumption of the two European markets. It is the second largest LNG terminal in continental Western Europe.

For this major energy infrastructure project, Dextra collaborated with Bouygues Travaux Public for the supply of Griptec, Dextra’s most advance rebar splicing solutions. Dextra supplied the Griptec sleeves while our local network of fabricators serviced the bar end preparation.

Griptec was used for the three reservoirs external walls in vertical applications. Griptec Headed Bars were also installed in congested areas as substitute to hook bars.

Griptec was also used on various part of the project to create temporary openings, which allow the movement of men and equipment though the reinforcement. For more information about similar application, please refer to Tanger Med 2 Port project, also by Bouygues.

For more information about the availability of Griptec and rebar splicing solutions in Western Europe, please contact our Paris office.

Singapore SLNG No.2

Singapore SLNG No.2

Singapore LNG (SLNG) 2 is a Liquid Natural Gas terminal facility located in Singapore. The terminal hosts 4 large LNG tanks and is able to receive the largest LNG carriers (Q-Max carriers). The terminal acts as a LNG hub for South East Asia.

For Singapore LNG offloading facility, Dextra has been assisted contractor Samsung with the design and supply of full marine tie rods system used between two sheet pile walls.

Dextra tie rods assembly were based on Grade 500. Anchored onto the sheet pile wall thanks to waling beams by the use of plates and nuts.

To ease installation and allow some flexibility to the sets, large diameter ball cages were installed to provide a multidirectional rotation angle of ± 10°.

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To provide length adjustment and splice the long tie rods together, turnbuckles were also provided.

Belo Monte Dam

Belo Monte Dam

Belo Monte Dam is a hydroelectric dam set up on the Xingu River, in the state of Pará, North of Brazil. It will become at its inauguration the second largest dam in Brazil and just the fourth largest dam in the world, with a total maximum capacity of 11,233 MW.

For this major dam project, Dextra Do Brasil continuously delivered to contractors its Rolltec mechanical rebar splicing solution between 2011 and 2016.

Rolltec is the most popular rebar splicing solution in Brazil, providing a competitive alternative to lap splices.

A total of 250,000 couplers have been used on the Belo Monte dam, used across all parts of the structure.

The rebar preparation is supported by a unique light equipment, operated by a single operator.

The Rolltec machine is relatively easy to transport and convenient to install even on most remote locations such as dam construction sites.

Fécamp Offshore Wind Farm

Fécamp Offshore Wind Farm

The 497 MW wind farm, located between 13 and 22 kilometers off the coast of Fécamp, France, includes 71 Gravity Based Structures (GBS: Gravity Based Structures), each of which will support a 180-meter-high windmill. The project will generate electricity equivalent to the power needs of more than 416,000 homes.

Dextra Fortec couplers and headed bars were supplied for these benefits.

Fortec couplers

  • Used for temporary openings to facilitate the movement of materials and personnel during the various stages of construction.
  • Acted as concrete wall starter bars to connect with continuation bars.
  • Aided constructability with climbing formwork for fast cycle GBS building.
  • Improved rebar congestion, avoiding overlapping splices.
  • Dextra couplers are based on a Parallel Thread technology. The same couplers are used for standard connection (when the continuation bar can be rotated) and position connection (when neither bar can be rotated). For Fécamp, the site was equipped with sets of threading equipment.

    Headed bars

  • Improved buildability and on-site productivity by reducing rebar congestion and the steel/concrete ratio.
  • Can be used as shear wall cross ties as an alternative to rebar with hooked anchorage.
  • Suitable for sequenced concrete pours.
  • Suitable for seismic design.
  • Fast to install: reduced labour and crane time.
  • Head can be removed for ease of rebar positional adjustment.
  • Improved concrete compaction and surface quality (reduction of honeycombing).
  • Dextra headed bars were used as an efficient solution for the vertical reinforcement of the foundation. They are an excellent alternative to standard hooked bars, which are difficult to install, particularly when bent on both ends, and to a bonded length of straight or bent rebar acting as an anchorage.

    Download the project case study

    Karachi Nuclear Power Plant (KANUPP)

    Karachi Nuclear Power Plant (KANUPP)

    Karachi Nuclear Power Plant (KANUPP), Pakistan’s first nuclear plant, is undergoing a 2.2GW capacity extension with two pressurized water reactor units of Chinese design (PWR, Hualong 1).

    This historical power plant has been in service with a single 137MW reactor unit (Kanupp-1) since 1972. It is owned and operated by Pakistan Atomic Energy Commission (PAEC).

    The construction of the Kanupp-2 and Kanupp-3 reactors begun in August 2015 and May 2016, with the start of commercial operations scheduled for 2021 and 2022, respectively.

    Dextra Griptec coupler was selected for the connection of steel rebars to reinforce the reactor’s concrete shell, designed to successfully withstand an aircraft crash (APC).

    More than 1 million units of Griptec standard, position, and transition couplers, mainly in diameter 40mm, have been delivered.

    Griptec is well-known for its reliability and performance in tension, compression, and fatigue, thanks to the unique design of the product that complies with the world’s most stringent projects specifications, especially for nuclear reactor building construction.

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