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A66 Salzbachtal Bridge, Germany

 

A66 Salzbachtal Bridge, Germany

 
 

The A66 Salzbachtal Bridge, located in Wiesbaden, Hesse, is a 304-meter-long, four-lane motorway bridge on the A66. Originally constructed in the mid-20th century, the bridge has been subject to wear and tear due to increasing traffic loads and aging infrastructure.

Foundation piles are fundamental to the stability and longevity of bridge structures. Ensuring their integrity is crucial to preventing potential structural failures. Dextra played a pivotal role by supplying approximately 10,000 linear meters of Sonitec CSL (Cross Sonic Logging) tubes.

Sonic tubes are essential components in the CSL testing method, which is widely regarded as one of the most reliable techniques for assessing deep foundation integrity. Sonitec, designed for easy installation within the reinforcement cage, facilitates accurate cross-hole sonic logging, allowing engineers to precisely detect and locate defects within the piles.

 

(Image credit: PORR Deutschland, Wilhelm Schütz)

Cross Island Line (CRL) MRT, Singapore

 

Cross Island Line (CRL) MRT, Singapore

 
 

Dextra has played a pivotal role in the construction of Singapore’s Cross Island Line (CRL) MRT project, supplying Glass Fiber Reinforced Polymer (GFRP) soft-eyes, Bartec couplers and Headed Bars for several crucial packages. Dextra continues to support the ongoing packages of this extensive project.

The CRL is set to become Singapore’s eighth MRT line and its longest fully underground line, stretching over 50 kilometers. The project is being executed in three phases, with the first phase anticipated to be operational by 2030.

To minimize the environmental impact on the forested areas of the nature reserve, engineering solutions were meticulously chosen to further mitigate environmental disruption. These solutions include digging deeper into the ground and employing a large diameter boring machine, capable of accommodating two train tracks within a single tunnel. This approach not only reduces the surface footprint but also enhances the efficiency of the tunneling process.

Tunnel Boring Machines (TBMs) are a staple in Singapore’s subterranean infrastructure projects, adept at operating under a variety of ground conditions. The use of GFRP soft-eyes supplied by Dextra is integral to these operations. Soft-eyes are essential components in TBM tunneling, acting as temporary openings that allow the TBM to break through concrete walls without compromising structural integrity. The GFRP material is preferred for its high strength-to-weight ratio, corrosion resistance, and ease of installation, ensuring safe and efficient tunneling operations.

Dextra‘s expertise and reliable supply of GFRP soft-eyes, Bartec couplers and headed bars have significantly contributed to the progress of the CRL project, aligning with Singapore’s commitment to sustainable and innovative infrastructure development. As the CRL project advances, Dextra remains a key partner, supporting the construction of this monumental MRT line that will eventually enhance the daily commute for millions of Singaporeans.

 

Tai Po Railway Pier – Reconstruction of Tai Po Kau Tide Gauge Station

 

Tai Po Railway Pier – Reconstruction of Tai Po Kau Tide Gauge Station, Hong Kong

 

In the dynamic coastal landscape of Tai Po Kau, New Territories, Hong Kong, infrastructure projects demand robust and resilient solutions. One such endeavor, the Reconstruction of Tai Po Kau Tide Gauge Station project, required innovative materials to withstand the unique challenges posed by its environment. Dextra stepped in to provide approximately 1,000 meters of Glass Fibre Reinforced Polymer (GFRP) rebar for the slab of the Tai Po Railway Pier, showcasing the efficacy of advanced composite materials in marine construction.

The Tai Po Kau Tide Gauge Station project aimed to revitalize the existing infrastructure, enhancing its resilience against tidal forces, corrosion, and environmental degradation. Recognizing the limitations of traditional steel reinforcement in marine environments, the project sought alternatives that could offer superior durability and longevity. Dextra’s GFRP rebar emerged as the ideal solution, offering exceptional resistance to corrosion, rust, and chemical degradation commonly associated with saltwater exposure.

GFRP rebar, composed of high-strength glass fibres embedded in a polymer matrix, delivers mechanical properties comparable to steel but with added benefits. Notably, GFRP rebar exhibits significantly lower thermal conductivity, reducing the risk of thermal bridging and enhancing structural integrity in extreme temperature variations. Furthermore, its non-magnetic properties eliminate electromagnetic interference, making it suitable for sensitive applications such as tide gauge stations.

The application of GFRP rebar within the Tai Po Kau Tide Gauge Station project encompassed both straight and bend bars, catering to the diverse structural requirements of the public pier. Dextra’s expertise in custom fabrication ensured precise bending and shaping of the rebar to fit the intricate geometries of the pier structure, facilitating seamless integration and minimizing construction complexities.

Laem Chabang

Laem Chabang

The Port of Laem Chabang, on the Gulf of Thailand, is the largest and busiest port in Thailand, before Bangkok port, and the 4th busiest port in South-East Asia. It is located in the Chonburi proving, a couple of hours drive from Bangkok and Dextra main production facility.

Dextra has been involved with contractor Italian-Thai for the engineering and supply of the steel structures behind Laem Chabang new pier.

Dextra engineered and supplied its Marine Tie Rods systems in Grade 700, the highest in our range.

Higher grades offer a improved performance/steel ratio compared to grades 355/510 and 500/660, allowing to pick smaller diameter bar which ultimately provide steel savings and facilitate logistics and installation efforts.

The rods making the long tendons were anchored into concrete piles and spliced with turnbuckles and couplers.

A total of 206 tons of marine tie rods have been supplied for this Laem Chabang expansion project.

Mubarak Al-Kabeer

Mubarak Al-Kabeer

Mubarak Al-Kabeer is a large seaport, located on the island of Bubiyan, East of Kuwait, opened towards the Persian Gulf.

Dextra has been involved on the Stage 2 of the first phase of the construction, between 2011 and 2012, together with Hyundai E&C, the contractor on this project.

For this large project, Dextra supplied marine tie rods to anchor the quay of the offloading facility.

The system provided were taking advantage of Dextra large diameters M134 tie rods, anchored into the combiwalls thanks to Ball Cages (± 10° rotation capability in all directions) and Captive Nuts (±5° rotation capability in all directions.

To accommodate the long tendons, provide adjustment length and offer additional flexibility during installation, turnbuckles and Hinge Couplers (± 90° vertical adjustment) were also added in line where required.

Manila International Container Terminal (MICT) – Berth 7

Manila International Container Terminal (MICT) – Berth 7

In 1988, International Container Terminal Services, Inc. (ICTSI) won the 25+25 year concession to operate the Manila International Container Terminal (MICT), one of the three terminals in the Port of Manila.

Since then, MICT has increased its annual capacity five-fold, becoming the largest and most modern container terminal in the Philippines.

It is now considered at par with the best terminals in the world with its guaranteed efficiencies and modernized operational and administrative systems.

MICT Berth 7 is the expansion project of the existing Berth 6 that will help alleviate congestion at off-dock container yards.

Dextra was involved in the project by supplying 110 sets of Marine Tie Bars, grade 700, bar diameter 85mm as an anchorage to tie back the main concrete wall casted on top of tubular steel piles to a sheet pile anchor wall connected with crane rail beam.

Dextra offers its marine tie bar solution in 3 steel grades, up to a yield stress of 700Mpa and 22 thread diameters, allowing a close match to the performance requirements and an economic use of material.

Aqaba Container Terminal

Aqaba Container Terminal

The Aqaba Container Terminal (ACT) is is located on the northern shores of the Gulf of Aqaba, in the Southern part of Jordan. It is the only container terminal in Jordan, and the second largest on the Red Sea in term of capcity.

Dextra participated to the creation of ACTs new berth between 2011 and 2012, as part of a project which aimed to increase the terminal capacity to 1.2 million TEUs. The expansion started operations in 2013.

For this project, Dextra has been supplying its Marine Tie Rods solutions to BAM International. Rods were supplied in Grade 500 in two different sizes: M105 and M125.

The long tendons were connected to the combi-wall on one side with a Dextra Ball Cage, allowing multidirectional angle of ±10 degrees, which greatly eases the installation process when at the same time addressing possible soil settlement.

On the opposite wall, tie rods were anchored using swivel plate and nuts, set up over waling beams. Dextra swivel accessories also allow a rotation angle of ±7 degrees in every direction.

For more information about our marine solutions in the Middle East, please consult our Dubai office

Port of Douala

Port of Douala

The Port of Douala is a large sea port opened to the Atlantic Ocean, part of the Wouri department in Cameroon. It is the main port of Cameroon and the busiest Central-African Port, with agreements that allow it to serve the countries of Tchad and Central African Republic, which do not benefit from a direct access to sea.

To support the ambitious development plan of Port Autonome de Douala, Dextra has been working with contractor BESIX for the engineering and supply of the steel structures support Douala Pier 51, a 165m-long quay wall.

Dextra engineered and supplied in 2015 systems of Marine Tie Rods in diameter M100 and in Grade 700, the highest in our range. Higher grades offer an improved performance/steel ratio compared to grades 355/510 and 500/660, allowing to pick smaller diameter bar which ultimately provide steel savings and facilitate logistics and installation efforts.

The rods making the long tendons, up to XXX meters long, were spliced with turnbuckles and couplers. The rods were anchored into the combi walls thanks to the use of Captive Nuts accessories, which allow a multidirectional rotation angle of 5° in order to ease the installation.

Tanger Med 2 Port

Tanger Med 2 Port

Tanger Med 2 is the expansion of Tanger Med, a multipurpose deep-water sea port located in a few kilometers East from Tangier, in Morocco, facing Gibraltar.

The port expansion aims to increase yearly capacity of the port, the largest in Africa, by 5.2 million containers.

For this large infrastructure project, Dextra supporter contractor Bouygues with a rebar splicing solution for the reinforcement of the caissons.

Dextra supplied its Rolltec solution, which is AFCAB-cerfified, a requirement on this project. Two Rolltec machines were installed to support the threading activities: 360,000 threads in total (180,000 Rolltec couplers).

Couplers were use in the reinforcement of the caisson, which were as tall as 20 to 24 meters. Couplers provided:

 

  • Temporary openings to solve congestion issues in the reinforcement within the caisson. Rebar couplers allow to create a safe passage for men and equipment during installation phase.
  • Horizontal wall-to-slab connections (from the inside of the caisson perimeter to slab). For this application, couplers were left pending, allowing the slip form to go up.

MA Tanger Med 2 Case Study Rolltec MA Tanger Med 2 Case Study Rolltec1

 

For more information and additional applications examples on this project, please refer to our dedicated Case Study.

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Download case study

Port Autonome de Pointe-Noire

Port Autonome de Pointe-Noire

Port Autonome de Pointe-Noire is a large sea port opened to the Atlantic Ocean and part of the Republic of Congo. The port is connected to the country capital Brazzaville by a 500km rail link.

The seaport plays an important part in the development of the region and contributes to the growth of trade with neighboring countries (Democratic Republic of Congo, Angola, Gabon). More than 600,000 go each year through the port of Pointe-Noire, a figure in constant growth.

To support the ambitious development plan of PAPN, Dextra has been working with contractor SAIPEM for the engineering and supply of the steel structures behind several of Pointe-Noire 16-meters deep quays.

Between 2011 and 2012 for the construction of Quay G, Dextra supplied more approximately 1,000 tons of Marine Tie Rods in Grade 700, the highest in our range. Higher grades offer a higher performance/steel ratio, allowing to pick smaller diameter bar which ultimately provide saving in logistics and installation efforts.

Dextra also supplied the Waling Beams installed onto the Combi Walls. Waling beams act as an interface between the steel walls and the large diameter tie rods. As Waling Beams support the rods, their shape, spacing and installation is very dependent of the tie rods configuration. To guarantee full compatibility and ensure the smooth sequence of installation operation, Dextra always recommend to design and deliver waling beams together with the tie rods assembly.

Later between 2015 and 2016, Dextra participated to a secound round of project delivery for the construction of the Quay D.

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