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Melbourne Metro

Melbourne Metro: five new underground stations

The Melbourne city’s metropolitan rail service operates 226 six-carriage trains across 998 km of tracks. The Metro has 15 lines and 222 stations, serving more than 400,000 passengers a day across the city.

In 2017, the construction of a 9 km long tunnel and five new underground stations were announced for greater capacity and additional coverage of the suburban area of the city.

The construction started in 2018. Dextra was involved in the project by supplying rebar connectors with fully automated rebar preparation equipment for the stations’ structure reinforcement works.

Griptec couplers were chosen thanks to the unrivaled performance in tension, compression and fatigue, and 400,000 units have been delivered.

Moreover, Dextra also supplied:

  • 5,300 GFRP Astec Combination Bolts. It is used at the CBD cavern location. The 19m width of the cavern allowed for the construction of two conventional 7m tunnels, built in parallel with the middle segments secured by GFRP CB Bolts, that can be cut to make the gallery wider.
  • 2,400 GFRP Geotec GR45 – 25mm dowels of 11.8 meters long were used to secure the face during the excavation.
  • 900 GFRP Astec soil nails ST50 – 41 were applied to secure several stations under construction. Some of them are outside of the boundary of the project since the GFRP can remain on the ground outside of their property and can easily be cut later.
  • 16 soft eyes were used in d-wall and bored pile of five stations.

Dextra was able to support and share their expertise on GFRP at design stage and produce the GFRP shaped solutions as per the owner expectation. Thanks to the cuttability of the GFRP, the TBM can pass through the d-wall in a limited time without any damages.

The Metro tunnel and its new stations are due to open in 2025 and predicted to be a new landmark of the city.

(photo credit: Hugh Llewelyn at https://bit.ly/2S0kbAG)

Khaosiung National Stadium

Khaosiung National Stadium

The National Stadium of Khaosiung is a large open air stadium located in the Zuoying district of Kaohsiung, Taiwan. It was formerly known as the World Games Stadium or Takao Stadium. This is a multi-purpose stadium and currently the largest sport facility of Taiwan in term of capacity: 55,000 seats.

The arena was built in 2007 in anticipation of the 2009 World Games. Its main purpose now is to host football / soccer events, although its particular non circular shape also make it suitable venue to host baseball events.

For this project, Dextra supplied carbon steel Tension Bars used as cross-bracing incorporated into the secondary trusses of this complex steel structure, revealing the “nest-shaped” architecture of the stadium.

Jizan Refinery Terminal

Jizan Refinery Terminal

Jizan Refinery & Terminal is an oil megaproject built for Saudi Aramco in the Jizan Economic Area, located on the Red Sea, West coast of Saudi Arabia.

For this project, Dextra engineered and manufactured marine tie rods systems used for the construction of quays of the marine terminal.

In total, Dextra delivered 412 tie rod sets in size M98. The grade 500 rods were connected to combi walls on both side thanks to Dextra designed captive nuts accessories, cast in the concrete piles.Captive Nuts allow a convenient angle of adjustment of 5° in all directions.

The assemblies, as long as 36 meters, were split into three main segments and reconnected thanks to couplers and hinge-couplers.

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For more information about the availability of high performance bar solutions in Middle East, please contact our Dubai office

Hatta Pumped Storage Hydro Power Plant

Hatta Pumped Storage Hydro Power Plant

The Hatta Pumped Storage Hydro Power Plant project is located near the community of Hatta in the Hajar Mountains, 140 km southeast of the city of Dubai.

The plant will use water stored in an upper reservoir at the Hatta Dam, utilizing pumped storage technology with solar-powered pumps at the Mohammed bin Rashid Al Maktoum Solar Park.

The project was awarded to a consortium, including STRABAG Dubai LLC and STRABAG AG, Austria’s Andritz Hydro, and Ozkar, an Oman-based construction company. France’s EDF is consulting on the project.

It will comprise a turbine shaft with a diameter of approximately 36m and a depth of almost 70m, for the placement of two turbines with a total expected power output of 250MW. In addition, a 1.2km long pressure tunnel and two road tunnels with a length of approximately 470m and 440m are to be excavated.

Dextra was involved in the excavation of the hydro tunnels by supplying thousands of GEOTEC™ steel bolts, including Self-Drilling Rock-Bolt, soil nails and combination bolts, diameter 22 to 32mm, for rock mass and slope stabilization.

Dextra GEOTEC™ steel bolt systems are available for every ground condition in various applications such as roadways, hydro power and underground oil/gas storage, sub-sea, and sewer tunnels.

The project is scheduled to be commissioned in early 2024.

It is part of the Dubai Clean Energy Strategy 2050 program, which has a goal of providing 75% of Dubai’s total power generation from clean energy sources by 2050.

Abu Dhabi International Airport

Abu Dhabi International Airport

Abu Dhabi Airport is the main airport of Abu Dhabi, capital of the United Arab Emirates and located around 15km east of the city. Abu Dhabi is the second busiest airport in the UAE, after Dubai International.

Dextra has been involved in the construction of the new Midfield Terminal (Terminal 3), which will enter in service end of 2017, significantly boosting the airport capacity and allowing offering new gates for large airliners like the A380.

Dextra has been involved in several parts of the new terminal: foundation, concrete structures, roof and façade.

Foundations& Concrete structures

For the foundation piles,
Bartec couplers have been used for the reconnection of prefabricated cages making the foundation piles, as well as other concrete applications. A solution complemented by the use of
Sonitec sonic logging tubes. The tubes, used for Crosshole Sonic Logging integrity testing, are delivered by segments which can be easily reconnected by hand thanks to their bell mouth, saving time upon installation. A total of 650,000 Bartec couplers and more than 110,0000 Sonitec tubes have been installed on Abu Dhabi Midfield Terminal.

Roofing and Façade

For the roofing structure, Dextra engineering team supported to provide two customized structural solutions.

For all applications requiring structural members to work in compression, Dextra supplied its Compression Strut solution. Compression Strut are simple to install thanks to their fork end, and conveniently allow for minor length adjustments at each fork. A total of 529 Compression Struts have been installed on this project.

For trusses where the effort is in tension, Dextra supplied its Tension Bar Systems. Similarly to compression struts, Tension Bars can be installed easily thanks to fork ends, provide adjustment capability at forks and in-line turnbuckles. Dextra Stainless range has been chosen for this application, guaranteeing unmatched aesthetics thanks to its mirror surface finish.

Delhi Metro Phase 3

Delhi Metro Phase 3

The Delhi Metro is the largest and busiest rapid transit system in India, serving Delhi and its satellite cities of Ghaziabad, Faridabad, Gurgaon, Noida, Bahadurgarh and Ballabhgarh. It operates over 2,700 trips daily.

The system currently consists of 10 color-coded lines passing 253 stations with a total length of 348 km, including a mix of underground, at-grade, and elevated stations.

The development of the network was divided into phases. Phase 1 and Phase 2 were completed by 2006 and 2011, respectively. Phase 3 has 35 underground stations and 3 new lines, totaling 167 km, and is scheduled to be mostly completed by the end of 2020.

The total length of the underground corridors in Phase 3 is 54 km, more than 20 km longer than the total underground sections in Phases 1 and 2 combined, making it one of the most challenging construction phases.

More than 20 tunnel boring machines were used simultaneously to expedite the tunnel work through 10 Dextra soft-eyes installed in diaphragm walls. Thanks to the cuttable nature of GFRP (glass fiber reinforced polymer) bars, TBMs can get in or out of shafts/stations in few minutes.

Furthermore, 450 sets of active anchors were applied to retain walls during the excavation work. The anchors are also made of GFRP, hence the tendons can be excavated by any standard equipment, and no anchor removal is required.

Moreover, around 2.3 million Bartec couplers were installed to connect rebars in various parts of the concrete structures of the stations. Bartec is a bar-break performance system, designed to withstand an ultimate tensile performance of up to 800 MPa.

2,800 sets of Shear Key post-tensioning systems were also inserted into the concrete reservation as a permanent seismic restrainer for the connection of the elevated metro segments.

Al-Zour LNG Import Terminal

Al-Zour LNG Import Terminal

The Al-Zour LNG Import Terminal is the world’s largest liquefied natural gas (LNG) import terminal, located 90 kilometers southeast of Kuwait’s capital. The project included the construction of a re-gasification facility, eight LNG storage tanks with a capacity of 225,000m³ each, marine facilities including two marine jetties, and berthing facilities for loading, and other components such as 14 HP pumps, boil-off gas (BOG) and flare facilities.

The facility was expected to produce approximately 22 million metric tonnes (MMT) of natural gas a year and would have a storage capacity of 1.8 million m³ of LNG. The liquefaction capacity of the terminal would be 30 billion cubic metres a day (bcm/d).

Dextra supplied 202 tons of grade 700 marine tie bars and 166 tons of wailing beams for the construction of marine facilities of this project. Tie bars were used as anchors between sheet piles or concrete walls.

The import terminal was completed in November 2021 and it reached full operations in February 2022. The LNG terminal is providing the Middle East country with a stable gas network in the long run, allowing it to respond to the rising call for energy diversification and sustainable energy.

Image credit: Hyundai Engineering Co.

Brasília Mané Garrincha Stadium

Brasília Mané Garrincha Stadium

The Brasilia Stadium, also called Estádio Nacional Mané Garrincha or National Stadium of Brasilia, is a football and multipurpose arena which was rebuilt between 2010 and 2013 in preparation of the 2014 FIFA Worldcup in Brazil.

The 2013 version of the stadium can sit up to 72,000 people, making it the second largest stadium in Brasil in capacity.

For this project, Dextra Do Brasil delivered to contractor Grupovia & Andrade Gutierrez its Rolltec rebar coupler solution as well as Rolltec Headed Bars.

Rolltec is the most popular rebar slicing solution in Brazil, providing a competitive alternative to lap splices and more importantly allowing advanced applications simplifying project management and operations.

For the called Estádio Nacional Mané Garrincha, rebar couplers were used as a way to connect rebar cages which have been previously prefabricated on the ground.

Rolltec allow a swift rebar cage reconnection by simply pulling the coupler by hand from the top cage to the bottom cage. In total, more than 57,000 Rolltec couplers were used the columns of the stadium.

6,000 Rolltec Headed Bars were also used on this project as a replacement to hook bars in congested parts of the reinforcement. Rolltec Headed Bars use the same standard thread profile as coupler, simplifying rebar production.

The Rollltec solution was supported by a Rolltec machine installed at the stadium construction site. The commissioning and maintenance of the machine was done by Dextra do Brasil local engineers, ensuring the training of operators and guaranteeing high productivity of the equipment.

Santo Antônio Hydroelectric

Santo Antônio Hydroelectric

Santo Antônio Dam is a hydroelectric dam set up on the Mareira River, in the state of Rondônia, Brazil. The dam is powered by 50 turbines for a total capacity of 3,580 MW.

For this major dam project, Dextra Do Brasil delivered to contractors Odebrecht & Andrade Gutierrezits its Rolltec rebar coupler solution.

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

On the Santo Antonio dam, rebar coupler were used to reconnect bent rebar. To do so, a straight bar is previously threaded (A/B/C thread length). The bar is then bent according to project requirements.

If needed, to protect the thread coupler can be temporarily set up onto the rebar as well.

Please consult us for more technical information about coupler applications on bent bars.

King Abdulaziz International Airport (KAIA)

King Abdulaziz International Airport (KAIA)

The King Abdulaziz International Airport (KAIA) is an international airport located in Jeddah, Saudi Arabia.

The airport, named after the founder of Saudi Arabia, King Abdulaziz Al Saud, is the country’s third largest and the busiest airport.

It has four operational passenger terminals: the North Terminal, South Terminal, the Hajj Terminal, and Terminal 1. The Hajj Terminal was created specifically for Muslim pilgrims who travel to Mecca every year for the Hajj.

Dextra supplied more than 300,000 Bartec couplers which were installed in bridge and exchange, tunnel, railway station, terminal, ATC tower, and car parking structures.

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