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Category: Projects

Jizan Refinery Terminal

Posted on by Sir Gwi

Jizan Refinery Terminal: A Major Oil Infrastructure for Saudi Aramco

The Jizan Refinery & Terminal is a large-scale oil megaproject built for Saudi Aramco in the Jizan Economic Area, located on the Red Sea, on the west coast of Saudi Arabia.

For this project, Dextra engineered and manufactured marine tie bars systems, which were used in the construction of the quays of the marine terminal.

In total, Dextra delivered 412 tie rod sets in size M98. The Grade 500 steel rods were connected to combi walls on both sides using Dextra-designed captive nut accessories, which were cast into the concrete piles. Captive Nuts allow a 5° angle of adjustment in all directions, ensuring flexibility during installation.

Each assembly, measuring up to 36 meters in length, was divided into three main segments and reconnected using couplers and hinge couplers for efficient transport and installation.

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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

Posted on by Sir Gwi

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 Dubai.

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

The project was awarded to a consortium that includes STRABAG Dubai LLC, STRABAG AG, Austria’s Andritz Hydro, and Ozkar, an Oman-based construction company. France’s EDF is acting as a consultant for the project.

It will comprise a turbine shaft with a diameter of approximately 36 meters and a depth of nearly 70 meters, designed to accommodate two turbines with a total expected power output of 250 MW. Additionally, a 1.2 km-long pressure tunnel and two road tunnels, approximately 470 meters and 440 meters in length, will be excavated.

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

Dextra’s GEOTEC™ steel bolt systems are available for various ground conditions in applications such as roadways, hydropower, underground oil and gas storage, subsea, and sewer tunnels.

The project is scheduled to be commissioned in early 2024.

It is part of the Dubai Clean Energy Strategy 2050, which aims to provide 75% of Dubai’s total power generation from clean energy sources by 2050.

Abu Dhabi International Airport

Posted on by Sir Gwi

Abu Dhabi International Airport

Abu Dhabi Airport is the main airport of Abu Dhabi, the capital of the United Arab Emirates, located approximately 15 km east of the city. It 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 is set to enter service at the end of 2017. This expansion significantly boosts the airport’s capacity and provides new gates for large airliners, such as the A380.

Dextra played a key role in several aspects of the new terminal, including the foundation, concrete structures, roof, and façade.

Foundations & Concrete structures

For the foundation piles, Bartec couplers were used to reconnect prefabricated cages forming the foundation piles, as well as for other concrete applications. This solution was complemented by the use of Sonitec sonic logging tubes. The tubes, used for Crosshole Sonic Logging (CSL) integrity testing, are delivered in segments that can be easily reconnected by hand thanks to their bell mouth, saving time during installation. A total of 650,000 Bartec couplers and more than 110,000 meters of Sonitec tubes were installed at the Abu Dhabi Midfield Terminal.

Roofing and Façade

For the roofing structure, the Dextra engineering team provided two customized structural solutions.

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

For trusses where the force is in tension, Dextra supplied its Tension Rod Systems. Similar to the Compression Struts, Tension Bars are easily installed thanks to fork ends, provide adjustment capability at the forks, and feature in-line turnbuckles. Dextra’s Stainless range was selected for this application, ensuring unmatched aesthetics with its mirror surface finish.

Delhi Metro Phase 3

Posted on by Sir Gwi

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 serving 253 stations with a total length of 348 km, including a mix of underground, at-grade, and elevated stations.

The network’s development was divided into phases. Phase 1 and Phase 2 were completed by 2006 and 2011, respectively. Phase 3 includes 35 underground stations and three new lines, totaling 167 km, and is scheduled for substantial completion 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 stages.

More than 20 tunnel boring machines (TBMs) 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 enter or exit shafts and stations in just a few minutes.

Furthermore, 450 sets of active anchors were installed to retain walls during the excavation work. The anchors are also made of GFRP, eliminating the need for anchor removal.

Approximately 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 strength of up to 800 MPa.

In addition, 2,800 Shear Key post-tensioning systems were installed in concrete recesses as permanent seismic restrainers for the connection of the elevated metro segments.

Al-Zour LNG Import Terminal

Posted on by Sir Gwi

Al-Zour LNG Import Terminal: The World’s Largest LNG Import Facility

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, each with a capacity of 225,000 m³
  • Marine facilities, including two marine jetties and berthing facilities for loading
  • 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 per year and have a storage capacity of 1.8 million m³ of LNG. The liquefaction capacity of the terminal was estimated at 30 billion cubic meters per day (bcm/d).

Dextra’s Contribution to the Marine Facilities:
For this project, Dextra supplied:

  • 202 tons of Grade 700 marine tie bars, used as anchors between sheet piles or concrete walls
  • 166 tons of waling beams, essential for reinforcing the marine infrastructure

The Al-Zour LNG Import Terminal was completed in November 2021 and reached full operations in February 2022. The terminal now plays a critical role in Kuwait’s energy infrastructure, providing the country with a stable gas network to support energy diversification and sustainable energy initiatives.

Image credit: Hyundai Engineering Co.

Brasília Mané Garrincha Stadium

Posted on by Sir Gwi

Brasília Mané Garrincha Stadium

Brasília Stadium, also called Estádio Nacional Mané Garrincha or the National Stadium of Brasília, is a football and multipurpose arena that was rebuilt between 2010 and 2013 in preparation for the 2014 FIFA World Cup in Brazil.

The 2013 version of the stadium can accommodate up to 72,000 people, making it the second-largest stadium in Brazil by capacity.

For this project, Dextra delivered to the contractor Grupovia & Andrade Gutierrez its Rolltec rebar coupler solution as well as Rolltec-headed bars.

Rolltec is the most popular rebar splicing solution in Brazil, providing a competitive alternative to lap splices and, more importantly, enabling advanced applications that simplify project management and operations.

For Estádio Nacional Mané Garrincha, rebar couplers were used as a way to connect rebar cages that had been previously prefabricated.

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

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

The Rolltec solution was supported by a Rolltec machine installed at the stadium construction site. The commissioning and maintenance of the machine was carried out by Dextra’s local engineers, ensuring the training of operators and guaranteeing high productivity for the equipment.

 
 
 

Santo Antônio Hydroelectric

Posted on by Sir Gwi

Santo Antônio Hydroelectric

The Santo Antônio Dam is a hydroelectric dam built on the Madeira River in the state of Rondônia, Brazil. It is powered by 50 turbines, with a total capacity of 3,580 MW.

For this major dam project, Dextra supplied its Rolltec rebar coupler solution to contractors Odebrecht & Andrade Gutierrez.

Rolltec is the most popular rebar splicing solution in Brazil, providing a competitive alternative to lap splices. The rebar preparation is supported by a unique, lightweight machine operated by a single worker. The Rolltec machine is relatively easy to transport and convenient to install, even in remote locations such as dam construction sites.

At the Santo Antônio Dam, rebar couplers were used to reconnect bent rebar. To achieve this, a straight bar is first threaded (A/B/C thread length) and then bent according to project requirements.

If needed, a coupler can be temporarily set up on the rebar to protect the thread.

For more technical information about coupler applications on bent bars, please contact us.

King Abdulaziz International Airport (KAIA)

Posted on by Sir Gwi

King Abdulaziz International Airport (KAIA)

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 busiest airport.

KAIA has four operational passenger terminals: the North Terminal, South Terminal, Hajj Terminal, and Terminal 1. The Hajj Terminal was specifically created for Muslim pilgrims traveling to Mecca each year for the Hajj.

Dextra supplied more than 300,000 Bartec couplers, which were installed in various structures, including bridges, tunnels, railway stations, terminals, the ATC tower, and car parking facilities.

Perth City Link

Posted on by Sir Gwi

Perth City Link

The Perth City Link is a transport and urban development project taking place in Perth, Western Australia. It aims to reclaim more than 13.5 hectares of land previously occupied by connecting railways by sinking a train line, thus making land available at the surface to reconnect two parts of the city with streets, commercial, and residential buildings.

For this project, Dextra was involved between 2012 and 2014 in the early foundation works:

  • Supplied Dextra Rolltec mechanical rebar splicing solution, which was used for the vertical connection of rebar in D-Walls and micropiles. Rebar couplers were used to reconnect cages that had been prefabricated by our rebar partner fabricator in Perth.
  • Dextra also supplied its Sonitec sonic tubes used for Cross Sonic Logging (CSL) integrity testing of the foundation piles.

For more information about foundation solutions available in Australia, please contact our Bangkok office.

Maitree Super Thermal Power Project

Posted on by Sir Gwi

Maitree Super Thermal Power Project: A Bangladesh-India Joint Initiative

The Maitree Super Thermal Power Project is a 2×660 MW coal-fired power station being developed by the Bangladesh-India Friendship Power Company (BIFPCL), a 50-50 joint venture between the governments of Bangladesh and India. The power station is located in Rampal, Bangladesh.

For this project, Dextra supplied more than 400 assemblies of Grade 700 Marine Tie Bar systems to connect piles and waling beams for a 1.2 km-long jetty at the coal power plant.
Dextra’s Marine Tie Bar systems consist of steel bars and anchorage accessories, which function as anchorage to tie back seawalls to anchor walls.

Key Features of Dextra’s Marine Tie Bar Systems:

  • Available in three carbon steel grades, with yield stress up to 700 MPa.
  • Selection of 24 bar diameters, up to M162, ensuring optimal performance for various project requirements.
  • Standard range of anchorage components, allowing easy installation and connection to all types of marine walls.

The construction of the Maitree Super Thermal Power Project began in 2017 and was planned for completion by 2022.