Dextra Group | Reliable Connections

Rajasthan Atomic Power Project (RAPP) 7&8

Rajasthan Atomic Power Project (RAPP) 7&8

The Rajasthan Atomic Power Project (RAPP) is a nuclear power plant in Rawatbhata, Rajasthan, India, with 6 pressurized heavy water reactor (PHWR) units and a total installed capacity of 1,180 MW.

The plant’s owner and operator, the Nuclear Power Corporation of India (NPCIL), is expanding the plant’s capacity by building 2 additional reactors, Units 7 and 8.

In July 2011, the first pour of concrete (FPC) for the 7th reactor, with a capacity of 700MW, was completed. The unit’s start-up transformer (SUT) was also commissioned.

The 8th reactor, which will similarly have a capacity of 700MW, is scheduled to be finished in December 2021.

Dextra has supplied almost 500,000 Bartec couplers for the reinforcement of reactor buildings, auxiliary buildings, and spent fuel storages.

The 2 PHWR reactors will boost the plant’s existing capacity by 1,400MW, 700MW of which will be allocated to the state of Rajasthan.

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.

The first concrete pour for Kakrapar 3 and 4 took place 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 to start a year later.

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 located in the northwest of Saudi Arabia, along the Red Sea. The ISCC (Integrated Solar Combined Cycle) technology adds 50 MW of solar power to the gas and steam turbines, generating a total of 500 MW of electricity.

For this project, Dextra supplied Double Corrosion Protection Ground Anchors, used as a permanent anchoring solution for the excavation work preparing the pumping chamber. A total of 264 anchors (Grade 1080/1230, Ø32 & 40 mm) were supplied and installed across four layers.

The Double Corrosion Protection anchors supplied for this project were pre-grouted at the Dextra factory, applying the first layer of grout between the steel bar and HDPE sleeve. The pre-grouted segments were reconnected on-site using couplers. Pre-grouted anchors not only save time and reduce costs during on-site operations, but they also enhance overall anchor quality by ensuring that the first grout layer is applied 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) Project: A Major Coal Seam Gas to LNG Development

The Queensland Curtis LNG (QCLNG) project is located on Curtis Island, Gladstone, Queensland, Australia. It involves the conversion of coal seam gas (CSG) reserves into liquefied natural gas (LNG), as well as the expansion of CSG exploration and development in southern and central Queensland.

The project encompasses multiple components, including gas fields, pipelines, an LNG plant, a swing basin and channel, and shipping operations. Construction began in late 2010.

Dextra contributed to the project by delivering 307 tons of marine tie bars and accessories in Grade 460. These tie bars serve as anchorage for the anchor walls of the marine offloading facility.

Bang Pakong Power Plant

Bang Pakong Power Plant: Thailand’s First Natural Gas-Fueled Power Facility

Bang Pakong Power Plant is Thailand’s first power plant to use natural gas from the Gulf of Thailand as its primary fuel source.

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

The plant was built to compensate for the loss of power-generating capacity following the decommissioning of the 1,050 MW Bang Pakong Combined Cycle Power Plant in 2014.

Dextra’s Contribution to the Project:

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

Additionally, Groutec couplers were installed in precast columns, providing a fast and efficient connection to the foundation at the construction site. Once the precast columns were lifted and placed into position, the embedded couplers were injected with grout, ensuring a secure and reliable connection.

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 (LNG) plant located in Western Australia. The plant is owned and operated by Chevron Australia.

Dextra was involved in the project between 2013 and 2014, contributing to the design and delivery of marine tie bars systems used to connect sheet pile walls and combi walls.

To facilitate installation and enable a multidirectional rotation angle of ±5°, Dextra Captive Nuts were embedded within the pile reinforcement and cast into concrete.

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Additionally, Dextra supplied waling beam systems (including channels and bolts) to provide structural support for the marine tie bars on the sheet piles.

Dextra’s systems are now anchoring the quay structure of the offloading facility, which can be identified as an L-shaped structure in the image above (copyright top picture: Chevron Australia).

Dunkirk LNG Terminal

Dunkirk LNG Terminal: A Key Energy Infrastructure in France

The Dunkirk LNG Terminal is a new natural gas facility built in northern France. The project is owned by EDF (France’s main energy company), Fluxys, and Total. The terminal facilitates the importation of liquefied natural gas (LNG), which is transported at an ultra-low temperature of -163°C. It plays a crucial role in meeting the growing demand for natural gas in France and Belgium, supplying 20% of the total national consumption of these 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 Publics to supply Griptec, Dextra’s most advanced rebar splicing solution. Dextra provided the Griptec sleeves, while our local network of fabricators handled bar end preparation.

Griptec was used in the following key applications:

  • Three reservoir external walls: Installed in vertical applications to reinforce structural integrity.
  • Congested areas: Griptec Headed Bars were used as a substitute for hook bars, optimizing space and reducing congestion.
  • Temporary openings: Griptec was also applied in various parts of the project to create temporary openings, facilitating the movement of personnel and equipment through the reinforcement.

For more information on similar applications, please refer to the Tanger Med 2 Port project, also completed by Bouygues.

For details about Griptec and rebar splicing solutions in Western Europe, please contact our Paris office.

Singapore SLNG No.2

Singapore SLNG No.2: A Key LNG Hub in Southeast Asia

The Singapore LNG (SLNG) No.2 terminal is a liquefied natural gas (LNG) facility located in Singapore. The terminal houses four large LNG storage tanks and is capable of receiving the largest LNG carriers, including Q-Max carriers. As a strategic LNG hub for Southeast Asia, the terminal plays a crucial role in the region’s energy infrastructure.

For the Singapore LNG offloading facility, Dextra assisted contractor Samsung with the design and supply of a complete marine tie bar system, used to reinforce the sheet pile walls.

Dextra’s tie bar assemblies were manufactured using Grade 500 steel and were anchored to the sheet pile walls using waling beams, plates, and nuts.
To facilitate installation and provide flexibility, large-diameter ball cages were installed, allowing a multidirectional rotation angle of ±10°.

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Additionally, to adjust tie rod lengths and splice long tie bars together, turnbuckles were supplied as part of the system.

Cape Town Stadium

Cape Town Stadium

The Cape Town Stadium, also known as the New Green Point Stadium, is a football and multi-purpose sports venue located in Cape Town, South Africa. It was built to replace the older Green Point Stadium, which had a capacity of 18,000 seats, and to provide a larger arena with a capacity of 55,000 seats, in preparation for the 2010 FIFA World Cup hosted by South Africa. The older stadium was demolished in 2007, and construction of the new venue was completed on schedule in December 2009, a few months before the first World Cup match.

For this large stadium project, Dextra supplied its Bartec rebar coupler solution, the primary rebar coupler solution offered by Dextra in South Africa. The company provided 70,000 high-performance rebar couplers, efficient rebar preparation equipment, and training and after-sales service throughout the construction phase to ensure efficient production and adherence to the project schedule.

Bartec couplers were used to splice bars vertically in the stadium’s foundations and columns.

For more information about rebar coupler availability in South Africa, please contact our Paris office.

Belo Monte Dam

Belo Monte Dam

The Belo Monte Dam is a hydroelectric dam built on the Xingu River in the state of Pará, northern Brazil. Upon its inauguration, it will become the second-largest dam in Brazil and the fourth-largest 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, offering a competitive alternative to lap splices.

A total of 250,000 couplers have been used in the Belo Monte Dam, incorporated across all parts of the structure.

Rebar preparation is supported by a unique lightweight machine, which can be operated by a single person.

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