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Mecca Mataf Expansion

Mecca Mataf Expansion

Mataf is the surrounding around the Kaba, center of the holiest mosque in Islam, located at the Grand Mosque of Mecca. It is at the place where the tawaf, the anti-clockwise circumambulation around the Kaba, takes place.

The Mataf expansion, is a large project planning to add 1,300,000 sqm to the existing 400,000 sqm of existing space. The renovation will feature a new basement and 3 additional floors, adding capacity for hundreds of thousands of additional worshippers.

For this very special project,Dextra Middle-East, has been involved in the supply of rebar couplers and anchor solutions.

Megacolumn

For the megacolummns, Dextra offered to contractors an opportunity to connect cages vertically, while coping for possible misalignment.This was done using Bartec Caging assemblies, which can perform a misalignment adjustment equivalent to one bar diameter.

While allowing reconnection, the Bartec Caging Assemblies were also used to temporarily lock the large column template (visible in red in photos) and guarantee the correct set up of column reinforcement.

Megacolumn footing

Dextra Bartec Headed Bars, which use the same type of threads as the couplers, were also installed at the footing of megacolumn as a way to cope with reinforcement congestion.

The anchors, compact and easy to set up, can be set on bars at the final stage of reinforcement installation. In that case, the anchors were installed from the top of the raft on the vertical bars.More than 100,000 Headed Bars were used on this type of applications during the project, those are visible as the X shape at the column footing.

Column-to-beam connections

For more standard applications, Bartec couplers were also used to perform the horizontal connections between columns and the beams.

Bar-Boljare highway – Four viaducts

Bar-Boljare highway – Four viaducts

The Bar-Boljare Highway Project is a key infrastructure project led by the Ministry of Transportation and Maritime Affairs of Montenegro. It aims at improving the connections within the country and also between Montenegro and the rest of Europe in order to boost the country’s economy and tourism.

The project, built by China Road and Bridge Corporation (CRBC), embodies a new successful example of the cooperation between China and Eastern Europe. The new 2×2-ways highway spans over 40 km. It is built in challenging terrains and yet satisfies both EU & Montenegro standards of road infrastructure. Its schedule is ambitious too: both roads and viaducts should be built in under 4 years.

For the Bar-Boljare Highway Project, Dextra supplied its Bartec rebar coupler solution, used the splicing of rebar in the piles of the four viaducts. Dextra Bartec splicing solution was chosen on that project for its compliance with ISO 15835 S2, which defines rebar coupler and reinforcement to be resistant to violent earthquakes conditions. A total of 230,000 Bartec rebar couplers have been supplied to CRBC.

The Broadway London

The Broadway London

The Broadway London project consists of six buildings, ranging between 13 and 19 stories tall. The mixed-use development is located between Westminster and Victoria, directly adjacent St James Park Station on a 1.7-acre triangular site.

The development contains 268 luxury apartments. Its ground floor will house 25,000 sq. ft. of high-end retail units, while 1st to 3rd will provide 116,000 sq. ft. of prime commercial space. It also has a colonnade between the east and west buildings, with feature landscaped residents’ gardens on the roof terraces.

The buildings have been named after three of the world’s most revered diamonds – The Sancy, The Paragon and The Cullinan – six new jewels in Westminster’s crown.

Dextra supplied over 20,000 units of Groutec S coupler, installed in 1,200 square and circular precast columns.

Groutec is a mechanical splicing system designed for the connection of precast elements in compliance with Eurocode 2, BS 8110, ACI 318, IBC, AASHTO. It is available in 3 models: slim “S”, large tolerance “L” and fully grouted “F”.

The project is due for completion in December 2021.

Doha Link (Jaber Causeway)

Doha Link (Jaber Causeway)

Doha Link is a marine bridge project currently being built West of Kuwait City. It will ultimately be connected to Main Causeway Across Kuwait Bay, another sea link project North of Kuwait City, which connected make together the Jaber Causeway sea link, one of the largest civil engineering project ever built in the Middle East.

The Doha Link stretches West of Kuwait City, It will ultimately solve traffic congestion and offer a direct itinerary thanks to a 7.7km bridge structure built on shallow waters across the Kuwait Bay.

Rebar splicing solution

Dextra has been involved in the early stage of the construction project to provide a technical solution for the splicing of the very large rebar cages making the onshore and offshore foundation piles.

Rolltec® couplers for large diameter rebar (32, 36 and 40mm) were used for the connection of cages and piers. Two grades of rebar are used across the project: ASTM Grade 60 and Grade 80. Rolltec being compatible by design with the higher ASTM Grade 80, same couplers may be used on all applications, simplifying stock keeping.

In addition, smaller diameters couplers for rebar 12mm and 16mm were used for the superstructure and the footing of light poles

One of the main advantages of Rolltec for remote projects its very light machine set up. Rolltec is supported by a single one-man machine, offering a high level of productivity. Because the equipment is relatively small and the rebar preparation efforts were taking place simultaneously on both sides of the sea link construction, Dextra dispatched up to 4 machines on each side of the project to support the piling efforts.

Sonitec tube solution

With large piles of 2.5m diameter and 60m depth in average, it was compulsory for GS E&C to conduct sonic logging tests to examine the integrity of concrete piles, requiring to install 8 tubes in each cage.

To achieve very long tube length and optimize cage preparation output, Dextra Sonitec was the preferred choice of the contractor. Thanks to its light weight and unique Push-Fit® connection feature. Sonitec provides enough flexibility during the cage construction, lifting and assembly of the cage, and remove needs for additional time-consuming welding operations.

Wasl Tower

Wasl Tower

The Wasl Tower is a 302m super-high-rise structure in downtown Dubai, surrounded by the Burj Khalifa, the tallest building in the World, and the new City Walk Development.

The tower will have the world’s tallest ceramic façade which will help regulate the internal temperature of the building as well as reducing the surrounding noise.

Moreover, vertical gardens and several shading and cooling design innovations are going to further minimize the overall carbon footprint of the building.

The project will comprise offices, residential areas, service apartments, a 5-star Mandarin Oriental hotel, along with bars, restaurants, a spa and a swimming pool.

With its structural concept of three 300m-high core shear walls connecting to four large outriggers, high-performance rebar couplers are required to reinforce and connect concrete beams and columns.

More than 280,000 Bartec standard couplers, weldable couplers, headed bars and RepairGrip swaged couplers were delivered for that purpose.

The project is anticipated to be completed in 2021.

Source of images: https://www.unstudio.com/en/page/11705/wasl-tower, https://www.facebook.com/UNStudioArchitecture/

SPARK Dry Port and Logistics Zone

SPARK Dry Port and Logistics Zone

The development of the dry port in Saudi Arabia’s King Salman Energy Park (SPARK) is set to revolutionize the logistics landscape in the Eastern Province. This ambitious project, which serves as a vital link between Dammam and al-Hasa, is poised to significantly improve customs services while supporting economic growth objectives and Aramco’s initiatives within the SPARK industrial complex.

A noteworthy aspect of this groundbreaking venture is the extensive use of Dextra’s 2.4 million linear meters of Glass Fiber Reinforced Polymer (GFRP) rebar for slab-on-grade applications in areas subject to heavy loads.

GFRP rebar is a composite material made by reinforcing a polymer matrix with high-strength glass fibers. Unlike conventional steel rebar, which is susceptible to corrosion when exposed to moisture and aggressive chemicals, GFRP rebar is inherently corrosion resistant. This key attribute makes it an ideal choice for a wide range of construction applications, especially in harsh environments where traditional steel rebar would quickly deteriorate.

Akkuyu Nuclear Power Plant

Akkuyu Nuclear Power Plant

Akkuyu Nuclear Power Plant is a nuclear power plant under construction at Akkuyu, in Büyükeceli, Mersin Province, Turkey. It will be the country’s first nuclear power plant.

The four 1,200 MW VVER +3 units, with a total capacity of 4800 MW, is the world’s first nuclear power plant project implemented on BOO (build-own-operate) principles by a subsidiary of Rosatom – Akkuyu NGS Elektrik Uretim AS (Akkuyu Project Company).

Major construction of the first unit started in March 2018, and it is expected to become operational in 2023.

Construction of the second unit started 2 years later and is anticipated to be completed by 2024, with Unit 3, and 4 to follow in 2025 and 2026, respectively.

Dextra provided more than 700,000 Fortec+ couplers and lock nuts to date, along with bar end preparation equipment, for the use at all 4 reactors and ancillary areas.

Fortec+ is a parallel threaded mechanical splicing system designed especially for nuclear projects for the connection of concrete reinforcing bars from Ø12 to 50 mm (ASTM #4 to #18), in compliance with Eurocode 2, ASME Sec III Div 2.

With the addition of a lock nut, it was fully engaged onto the extended thread of the connecting bar and help eliminate the residual deformation of the splice.

10 sets of bar end preparation system machines were also delivered at the site. The bar end preparation can be achieved in 3 steps: cutting the end of the rebar, cold forging to enlarge the sawn end of the rebar, and threading.

Fortec+ system adds a fourth step, consisting in a quality testing at the end of the rebar preparation process. The threaded bar end is tensile tested at 90% of the rebar yield strength to guarantee its performance.

Photo credit: https://www.dailysabah.com/business/energy/construction-starts-on-2nd-unit-of-turkeys-1st-nuclear-power-plant-akkuyu?gallery_image=undefined# big (by Energya and Natural Resources Ministry)

Hinkley Point C Nuclear Power Plant

Hinkley Point C Nuclear Power Plant


The Hinkley Point C (HPC) nuclear power station is one of the biggest and most technologically complex projects in Europe.

HPC is the first nuclear power station to be built in the UK in a generation, and its construction requires a highly skilled workforce and the very best construction and engineering solutions.

The HPC Project is located in Somerset, South West England, and will consist of two nuclear reactors capable of generating 3.2GW of low-carbon electricity.

The new power station is being constructed in the same area as the existing Hinkley Point A and B stations. The former has ceased operation for quite some time, while the latter is decommissioning in 2022.

Dextra was entrusted with the supply of mechanical splices of concrete reinforcement for parts of HPC, particularly the reactor’s aircraft impact protect shell.

More than 2.5 million Griptec couplers are supplied for the construction of HPC.

Griptec is designed to comply with the most stringent project specifications, and has proven to be a popular system of choice for EPR nuclear power stations, having been used for the construction of the Flamanville 3, Taishan 1, and Taishan 2 power stations.

The Griptec mechanical splice consists of two steel sleeves which are swaged onto the end of the reinforcing bars by a specific machine that was designed and patented by Dextra.

This swaging machine incorporates a systematic non-destructive pull test. Griptec is the only coupler system that provides an automatic quality control of each processed bar.

Besides Griptec couplers, Dextra is also supplying 3 million headed bars to the project. These are reinforcing bars that are bent on one side and fitted with an anchorage head on the other side and are used for the transverse reinforcement of concrete slabs, rafts, and walls. They allow a much faster and safer site installation than conventional double-bend bars.

When complete, HPC will provide low-carbon electricity for around six million homes.


Fuqing reactors 5 & 6

Fuqing reactors 5 & 6

Fuqing Reactor 5 & 6 are the first reactors of type Hualong One, based on a 100% Chinese design. Reactors have a capacity of 1,000 MW capacity, with start of operation scheduled for 2019 and 2022.

Dextra has been present on site since the beginning of the construction of the reactor 5 in 2015, and is now involved on the 6th reactor.

For this challenging project, Dextra has been supplying its Griptec rebar splicing solution, which are used for rebar splicing into the APC shell.

Griptec is the preferred rebar splicing solution of the nuclear industry thanks to its unique performance level and an automatic testing process which systematically tests all the connections produced as part of its standard cycle: a guarantee that 100% of the connections perform above project requirement.

More than a million Griptec connections will be used over the years for those two projects, supported by two Griptec equipment installed at site.

Dextra is also supporting the contractor teams at site with two Dextra engineers rotating to ensure operator training, setting and preventive maintenance services, this in order to ensure optimal production day and night thorough production peak times.

Taishan EPRs 1&2

Taishan EPRs 1&2

Taishan EPRs are two nuclear reaclors of EPR type of 1750 MW capacity built by Areva and located near Taishan, in the Guangdong province of China.

Dextra has been present on site since the beginning of the construction in 2009 and until 2016. The reactor operations are planned to start in 2017.

For this challenging project, Dextra has been supplying its Griptec rebar splicing solution, used in the concrete structure of the reactor.

Bartec rebar coupler solution as well as Headed Bars were also used on other building of the project.

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