NovoCrete soil stabilization

n Applications On Site

Sinoboom joins nickel ore project in New Caledonia Sinoboom will be supplying its access equipment to the Koniambo Nickel Ore Project in New Caledonia, one of the world’s first large-scale nickel-iron ore production projects to adopt modular construction and off-site assembly. The equipment will be used by China CMIIC Engineering & Construction Corp, eight of the 18 module contracts in the project with gross engineering weight of over 12,000 t. The access equipment to be supplied will include scissor lifts, articulated boom lifts and telescopic boom lifts, covering working heights from 8 to 44 m - with key components sourced from the world’s top brands complying with CE certificate and AS1418 complied. Sinoboom is also under negotiation with CMIIC for equipment supply in other overseas projects. n Enquiry: [email protected]

Sinoboom is supplying a wide range of access equipment to the Koniambo nickel ore project, including scissor lifts, articulated boom lifts and telescopic boom lifts, covering working heights from 8 to 44 m.

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n Applications On Site

Gomaco paves on Iowa Highway The paving contractor Manatt’s recently completed 20.1 km of a 20.9 km project in Iowa, USA. The company is building the new section of Highway 30 in Marshall and Story counties with its Gomaco paving equipment, including a PS-2600 placer/ spreader, two-track GP-3000 paver, fourtrack GHP-2800 paver, and a T/C-600 texture/cure machine. The new concrete highway is 7.9 m wide, 254 mm thick, and slipformed in one paving pass. The Iowa Department of Transportation’s (IDOT) specifications for pavement smoothness utilise the zero-blanking band with both incentive/disincentive pay built into the contract. Profile indexes on roadways with speeds greater than 72.4 km/hr require a measurement of 411 to 630 mm/km for full pay. Anything under 410 mm/km earns incentive pay, with greater incentives offered as the numbers go lower. Anything over 631 mm/km is penalised with a disincentive, and even higher numbers require corrective measures. Manatt’s equipped its 2004 modelyear GHP-2800 paver with Gomaco’s new 5400 series mould and a rear-loading, front-inserting 5400 series bar inserter. The company also upgraded the paver’s G21 to a G22 controller to test new software upgrades. Improvements from the G21 to G22 include a new display with high-resolution deviations meters on the run screen. The meters display possible machine deviations in multi-coloured (green, yellow and red) bar graph meters. They also assist the operator in finetuning both grade and steering performance on the paver. In addition, the G22 features new, proprietary smooth paving software which detects and eliminates any stringline hits and rod and knot bumps. Gomaco worked closely with Manatt’s during the testing. Two pan-mounted GSI (Gomaco Smoothness Indicator) units on the GHP-2800 would constantly monitor the paving results. The process began the first day with Manatt’s using its standard settings on the G22 and recording the results. The second day, Gomaco adjusted the sensitivities. Then, on the third day, the new G22 software was installed and used for finetuning the paver. The software, available for G22 and G+ control systems, has been designed in-house by Gomaco. Prior to this, the operator working at the control console would need a person on the ground watching for leg movement while going through

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Above: Manatt’s 8 km of profilographed pavement averaged 283 mm/km in the left wheel tracks and 280 mm/km in the right wheel tracks after the G22 with new, proprietary smooth paving software was installed on the paver. Right: Two paver-mounted GSI units monitor the smoothness in each driving lane. The information is instantly displayed and reviewed on a single touch-screen mounted on the side of the GHP-2800 paver.

the threshold calibration procedure. The groundman would communicate movement to the operator and the operator would set and record the threshold and the process would be repeated for each leg of the paver. From the first day of operating with the new G22 software to the end of the project, Manatt’s rideability readings continued to improve. Profilograph readings were taken using Manatt’s high-speed profilograph. After approximately 8 km of new concrete roadway was slipformed with the new G22 software and GSI monitoring capabilities, Manatt’s averaged 283 mm/km in the left wheel tracks and 280 mm/km in the right wheel tracks. The haul road was located on the right side of the GHP-2800 paver. On IDOT’s pavement pay chart, pavement segments averaging 345 mm/km or less earn maximum incentive pay. In the state of Iowa, that equals an incentive of US$950 per 0.16 km segment per lane. Paving production on the Highway 30 project averaged approximately 2,905 cu m

per day, with several days averaging over 3,058 cu m. Manatt’s had its mobile batch plant on site mixing the IDOT approved concrete mix. Concrete was delivered to the job-site in trucks carrying 6.1 cu m loads. The trucks dumped onto the belt of the Gomaco PS-2600 placer/spreader working ahead of the paver. The paver’s 5400 series bar inserter placed a 762 mm long, #4 bar every 914 mm into the 254 mm thick concrete slab. A burlap drag was applied behind the paver, followed by the Gomaco T/C-600 applying the texture and curing compound. n Enquiry: [email protected]

n Applications On Site

Globetrotting with Sennebogen Sennebogen crawler cranes have been used successfully all over the world. Among these highlights is the Sennebogen 690 HD dutycycle crawler crane, which has been used by Tuksu Engineering & Construction with a 15 t diaphragm wall grabber in a large building project in Singapore, part of the MRT Downtown Line 2 expansion. With a load capacity of 90 t, a 447 kW diesel engine and an extremely robust construction, the 690 HD can meet very tough requirements. The duty-cycle crawler crane product range from Sennebogen includes 10 models with loads ranging from 20 to 200 t and engine power of 119 to 708 kW. In France, the Sennebogen 683 telescopic crawler crane with a boom length of 42 m and a load of up to 80 t was recently used by Matière, a leading company in the production of iron and concrete bridges. Matière uses its own patent for underpasses under motorways and railway tracks. These underpasses are tunnels with a width of up to 11.5 m and are made up of ready-mixed concrete arches that are connected accordingly. The weight of the concrete arches varies between 5 and 25 t. The heavy finished parts must be transported and assembled safely and precisely at the site. The Sennebogen 683 is ideal for lifting, transporting and positioning these heavy loads. The compact and extremely robust construction also offers the highest possible flexibility on site. The crawler chassis means that the crane is also ready for use quickly even on difficult terrain and under extreme conditions and easy to manoeuvre in the tightest of spaces through simple crawler movements.

A Sennebogen 683 is also currently working in the Middle East. It is being used to lay a drinking water pipeline in the city of Alain, Abu Dhabi, with a total length of 45 km under the harshest of conditions. The gigantic pipes have a length of 18 m, a diameter of 1.6 m and weigh between 10 and 13 t. These pipes are unloaded from special HGVs with the Sennebogen 683 and positioned to be installed in the pipeline trenches at a later stage. The dry desert climate with temperatures of over 40 deg, sand storms and dust pose a real challenge on this construction site. While in Germany, the Sennebogen 5500 crawler crane has been used at the construction of a new library in Stuttgart. Designed by the Korean architect Eun Young Yi, the iconic building represents an investment of €80 million and has become the centre for culture and development. The prefabricated facade elements, consisting of concrete and glass building blocks, were unloaded on site by the 180 t crawler crane and were mounted individually in a grid to form an outer facade. To be able to reach all four sides of the building optimally, the Sennebogen 5500 was configured with a 41.1 m main boom and a 35.5 m luffing jib. In this way the parts, weighing up to 15 t, could be lifted precisely and safely into the desired position. n

A Sennebogen 690 HD duty-cycle crawler crane with a 15 t diaphragm wall grabber working in a large building project in Singapore, part of the MRT Downtown Line 2 expansion project.

A Sennebogen 5500 crawler crane being used at the construction of a new library in Stuttgart, Germany. The crane was configured with a 41.1 m main boom and a 35.5 m luffing jib.

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Enquiry: [email protected]

n Applications On Site

Cat machines prepare for smooth sailing The Portuguese village of Cascais is a popular tourist destination. The attention was even greater this year with the arrival of one of the world’s premiere sailing races, the America’s Cup, in August. For this, the Cascais municipality realised it had to make improvements to Avenida Marginal, the waterfront thoroughfare that leads to the village and the main attractions. The main issue with the road was its drainage. According to a report, in times of heavy rainfall, stormwater tributaries accumulate, forming a river and making it dangerous to cars and pedestrian circulation. Work had to be completed before the America’s Cup crowd arrived. Yet the seasonal tourists also meant the road had to remain open while the work took place. Sanestradas, a local paving contractor, was chosen to complete the job. The project involved a 1 km section of Avenida Marginal. Much of the road’s surface was in good shape, with the exception of about 65 m. That section of road had been damaged during a building construction project. The 65 m would also be the location for a new drainage system, with rainfall channelled to it via curbs along the remainder of that 1 km section. Directing the water to those drains created another challenge. About 300 m of the road was so level that water did not flow. A simple solution would have been placing a new surface lift with a slightly steeper grade. But that choice was dismissed because of low curbs - an average of only 100 mm. Applying a new bituminous layer to create the grade would have simply caused rain to run over the curbs. The flooding would have continued. Cascais municipal officials came up with a strategy. First, they proceeded with the new drainage system. The 65 m of existing curb was removed, and the ditch floor area replaced with two 200 mm layers of crushed, aggregate base of extensive granulometry. That base featured irrigation fluidized MC70 bitumen at an impregnation rate of 1 kg/sq m. A binder layer with a thickness of 11 cm was placed on top, followed by the wear layer with an average thickness of 6 cm. The remainder of the road did not need new base layers or improvements. Therefore, the milling team removed 6 cm of material. The paving team then placed an AC 14 Surf 35/50 (BB) wear layer over both the rebuilt and milled portions of the project. The project teams were given just two weeks to complete the work, but the time was actually considerably less because work was only allowed at night. The teams began work at 8 or 9 pm and continued until about 7 am the following morning. In addition, Avenida Marginal had to remain open to traffic with no limitations on Fridays, Saturdays and Sundays to allow tourists to come and go unimpeded. That meant the two weeks was in actuality eight days. Further complicating the project was the requirement to keep traffic circulating, though in a limited manner. This led to a process of milling one lane for two nights, then tandem paving and compacting for the next night. At that point, the lane was completed. A Cat PM102 Cold Planer removed the 6 cm of asphalt in the required areas. The PM102, smaller than the Cat PM200, was chosen because its size made it a better fit for the narrow road. Yet the machine delivered the required productivity, as it had to mill a lane in only two nights. The tight timeframe left no margin for error. Because of this, two service technicians from STET, the Cat Dealer in Portugal, stayed on the jobsite throughout the night in case they were needed. When an entire lane was milled, tandem pavers went to work. Delivery trucks end-dumped the material into the pavers. Sanestradas chose the new Cat AP555E with an AS4252C screed. Working just a few meters ahead of it was the tried-and-tested Cat AP655D. Caterpillar had a technician specialised in handling pavers on hand to ensure smooth integration of the new AP555E.

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Work was carried out at night, from 8 or 9 pm to around 7 am the following morning, and the road had to remain open.

Tandem pavers helped to meet the project tight deadlines.

With magnificent views of the Atlantic Ocean,the Portuguese village of Cascais is a popular tourist destination.

Three Cat compactors - the CB434D, PS300B and CB34 - easily kept pace with the two pavers, and met density specifications. The PS300B worked in breakdown mode, and was right behind the second paver, the AP555E. The longitudinal joint was done ‘hot’, and easily compacted, because the first paver worked only a few dozen meters ahead of the second. The compactors worked at a distance that enabled compaction and kept pace with the paving train. The number of passes depended on the pace of the paver and the delivery trucks. The compactors treated the two freshly placed mats as if they were one and worked across the entire width of the lane. The Cascais municipality authorities kept a close watch on the jobsite, and were pleased the road was completed in time for the America’s Cup. n Enquiry: [email protected]

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March 13-15, 2012 I Charlotte, North Carolina, USA

n Residential Project

Milano Residences to open in Manila

W

ork has recently started on the Milano Residences, an upmarket residential project in Manila, the Philippines. The project, scheduled for completion in 2015, is being developed by one of the largest real estate companies in Asia, Century properties. It is designed by Broadway Malyan and with public space interiors by renowned luxury brand Versace Home. When completed, it will be an iconic landmark within the Century City masterplan, reinforcing the diverse and changing skyline of Modern Makati. The 53storey tower will boast 340 flexible one- to three-bedroom apartments, with prime units including penthouses, town houses and Italian-inspired ‘loggia’ lofts that feature private plunge pools and skygardens. “This is a major milestone in this prestigious and high-profile residential project, which has drawn on the diverse skills, expertise and experience of our global team of expert designers,” said Prof Jason Pomeroy, director at Broadway Malyan. “The scheme demonstrates the emerging trend of luxury branded condominium living in Asia, with hospitality-type boutique facilities and concierge services set to become regular features of high-end residential developments in the region, and the increasing role of luxury brands in the added lifestyle value of such developments.” The Milano Residences has been designed to embody the character of traditional Italian spaces by fostering ‘indoor-outdoor’ living through the use of sky loggias, sky piazzas and sky terraces that are reinterpreted through a series of vertical skycourts and gardens that punctuate the tower. The Italianate

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references compliment the Versace-branded interiors, while ensuring the building retains a grounded and timeless quality. Sustainability has been a key driver in the design, with a passive design approach that employs narrow floor plates and high ceilings optimise daylight penetration and further opportunities for natural ventilation. The design also includes a green roof and an abundance of densely foliated vertical open spaces to help collect excess rainwater, irrigate planting within the building and reduce ambient temperatures. Meanwhile, materials have been selected on the basis of their environmental credentials as well as aesthetics. Broadway Malyan is currently delivering a wide portfolio of award-winning projects, including in the Philippines, Singapore and wider Asia region in support of the region’s burgeoning green building movement. n

Images: Designed by Broadway Malyan and with public space interiors by renowned luxury brand Versace Home, the Milano Residences features sustainability. The passive design approach employs narrow floor plates and high ceilings optimise daylight penetration and further opportunities for natural ventilation.

n Residential Project

Absolutely Fabulous T

wo spectacular high-rise buildings are currently twisting and turning upwards into the Canadian sky. These curvaceous towers, the Absolute World, form part of the new Absolute City Centre development in Mississauga, Ontario, which consists of five apartment and office blocks with heights of up to 170 m. The rotations of the Absolute World towers are exceptional - the southern tower features a varying rotational movement and the northern tower twists uniformly upwards. The attractive, undulating sequence of curves featured on the southern high-rise building has resulted in it being given the nickname of Marilyn Monroe by the enthusiastic local population. For both buildings, the complete enclosure of the upper

With protection provided by the RCS climbing protection panel, the two twisting Absolute World towers rise steadily upwards in regular weekly cycles.

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floors through the Peri RCS climbing protection panel ensured the safety of the construction site team, which led to higher productivity. Due to the different rotations by different degrees at different levels, two unusual climbing methods have been developed with the help of the modular construction system, adapted specifically to suit the respective project requirements and building geometry.

Absolute Tower South With the 170 m high Absolute Tower South, the elliptically shaped ground plan rotates by 208 deg over the course of 56 floors – featuring twists of between 3 and 8 deg from storey to storey. To ensure safe working conditions, also at great heights along with increasing productivity levels, the working area of the three uppermost floors in each case is completely enclosed with the RCS climbing protection panel. As for crane and weather-independent moving of the 30 RCS units, the contractor is working efficiently with the mobile RCS selfclimbing technology. During the climbing procedure, the climbing rails are firmly connected to the building by climbing shoes. Compensating the offset between the individual floors is achieved by system steel girders anchored to the slabs: on the other hand, universally usable RCS climbing rails cantilever up to 2 m beyond the edge of the slab and support the climbing protection panel. Through the large usable compensation area, the number of levels is minimised where the RCS units have to be re-adjusted due to the rotation of the storeys. For the floor-by-floor planning of the enclosure, Peri took into consideration all possible obstacles and discontinuities to determine an optimal element arrangement and – separate for each floor – the corresponding anchor positions.

Absolute Tower South: the three uppermost floors under A view of the Mer de Glace glacier. construction are completely enclosed. Cantilevered climbing shoes compensate for the offsets of the individual storeys.

n Residential Project Absolute Tower North Construction of the 150 m high, 50­ - storey counterpart in the north took place a few months later. For its realisation, Peri designed an extremely cost-effective climbing variant.As the rotation of the elliptical-shaped floors is a constant 4 deg in each case here, the RCS protection panel itself uniformly turns in an upward direction. In addition, the climbing rails are inclined at an angle of 26 deg to the vertical and connected to the storey slabs by means of RCS system climbing shoes and projectspecific modified slab shoes. Likewise, the RCS units are climbed hydraulically – moving with the crane would not be possible due to the inclined climbing track. That this unique climbing method is possible with the RCS rail climbing system as well as being applicable in construction site conditions was proven beforehand by Peri with corresponding calculations along with a test set-up. n Enquiry: [email protected]

PROJECT TEAM Real Estate Developer: Fernbrook Homes, Concord Cityzen Development, Toronto General Contractor: Dominus Construction, Toronto Contractor Structural Work Premform Limited, Toronto Field Service: Peri Toronto, Canada and Peri Weissenhorn, Germany

On the northern tower, the RCS enclosure climbs upwards at an angle – hydraulically and therefore crane­independent using the RCS self­climbing devices.

Two landing platforms are integrated in the RCS protection panel solution. These allow fast and simple transport of materials.

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Protected by the RCS climbing protection panel, safe and fast forming is carried out even at great heights using Skydeck. Site personnel is well protected against falling at all times and against strong winds when working at all heights. All images © Peri GmbH

n Safety Feature

TRAM-ming around the world

New Zealand Crane Group is installing TRAM to every all terrain crane in its fleet above 80 t capacity.

T

RAM (Travel Restraint Access Module), produced by Chicagobased Standfast Corporation, enables users to walk on top of the crane boom with absolutely no risk of falling. The user has a double lanyard that clips onto a moveable handlebar at waist height. The handle is fixed at foot level to a rail along the length of the boom. By tying off at waist level rather than foot level, TRAM users have no distance to fall in the event of a slip or trip, and still have total freedom to do their work. The handle, or arm, rotates 180 deg to aid manoeuvrability and to allow the arm to fold down for storage when not in use. As the user climbs up the side of the crane, he or she clips the lanyard onto the arm. Squeezing the hand brake releases an air-powered spring that pushes the arm gently but firmly to vertical, helping the user climb up and over onto the top of the boom. Similar assistance is given in descent. A deadman’s brake prevents the arm moving along the rail unless the hand brake is squeezed. TRAM was originally developed for worker safety on bulk liquid tankers but has now been refined for cranes after several pilot installations in Europe and Australia have proved the concept. The product is becoming an increasingly popular way to improve safety on cranes around the world.

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New Zealand takes the lead The New Zealand Crane Group is installing TRAM to every all terrain crane in its fleet above 80 t capacity - the first company in the world to commit to such a full-scale programme across its entire fleet. According to NZ Crane managing director Deane Manley, crane workers had been taking too many risks for too long when pinning jibs onto booms. “It has been standard industry practice for years to climb on top of booms without adequate fall protection, but this has just got to stop. It is clearly hazardous but no one seemed to know of a better way before. At 4 m above the ground, a fall from that height is enough to kill someone. When we found out about TRAM it was clear that ignorance was no longer an excuse.” Most of the company’s cranes are Grove brands. The first two machines that were recently fitted with TRAM were a GMK 5170 and a GMK 4100. The company has ordered a further 10 TRAM units to be fitted to its other cranes before December this year. For the first installations, TRAM Australia Pacific, Standfast’s agent in the region, worked closely with long-standing Grove distributor Tidd Ross Todd (TRT) and NZ Crane to produce a methodology for fixing the rail to the booms. The precise method for

n Safety Feature fixing the rail to the boom can be different for each crane type, depending on such diverse features as the location of rope retainers and angle of tilt of the cab. Previous TRAM installations have seen the rail welded or banded on the boom. TRT engineering director Robert Carden proposed a chemical bonding solution instead, where the brackets that hold the rail are bonded to the boom by pressure injecting an epoxy resin into the joint. “We have used this method for the past six years to bond the fibreglass insert into our steel booms for live-line aerial platforms. We have also used it to bond the trailing boom trailer mast mounts under the boom of a GMK 4100 and GMK 5130-1.” TRAM Australia Pacific director Martin Jones designed a bracket that forms to the contour of the boom and laps over each side of the boom at the top, to resist shear forces. “Grove have been very helpful in supplying me with drawings of their boom profiles. This allowed me to manufacture brackets more easily knowing that they fit perfectly.” The bonding process has been designed and tested to AS/NZS 1891.4: 2009 Industrial Fall Arrest Systems and Devices – Selection Use and Maintenance, and certified to equivalent international standards. The TRAM unit itself is also independently certified as meeting all relevant international standards. While welding and strapping have both worked perfectly well on other installations, Mr Jones believed that bonding has the benefit of looking very neat. The requirement for overnight curing adds to the installation time and there was an additional cost to the first two units simply because they were the first, but costs are expected to reduce rapidly. With the methodology in place, tested and proven, Mr Manley said that NZ Crane and TRT will do the remainder of the installations themselves. The two Groves with TRAMs already fitted are now back at work on the North Island grid update project, a NZ$230 million project to build a new 400 kV power transmission line from Whakamaru to Auckland. NZ Crane’s customer here is BBUG, a joint venture of Balfour Beatty and United Group. For Mr Manley, the benefits of TRAM go beyond being able to sleep at night knowing that his workers are more likely to get home alive. There are also commercial rewards. It helps to position the company as likely supplier of choice for any customer like BBUG that takes safety seriously. And it has been a key component of a safety programme that has secured a 20 percent discount on insurance premiums for the

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Above: The precise method for fixing the rail to the boom can be different for each crane type, depending on such diverse features as the location of rope retainers and angle of tilt of the cab. Below: AmQuip has become the first crane rental company in North America to fit TRAM to its cranes.

country’s mandatory Accident Compensation Corporation (ACC) scheme.“It’s a no brainer. The only reason why you wouldn’t fit TRAM is because you are too miserable.”

Entering North American rental market AmQuip has become the first crane rental company in North America to fit TRAM to its cranes. The company is initially targetting its largest telescopic boom cranes, where workers need access to the top of the crane to assemble attachments. “We have identified 20 of our largest all-terrains as a priority for TRAM,” said

AmQuip VP for Risk Management, Jeff Hammons. “We take safety seriously and most of our business is with customers who are equally safety sensitive. Neither AmQuip nor its customers can accept employees being unprotected on top of cranes any longer. TRAM provides a safe and convenient solution while still meeting compliance with OSHA’s new Crane and Derrick standard, 1926.1400.” The first AmQuip units to be fitted with TRAM are four of its Grove GMK 7550 cranes, including two that have Grove’s Mega Wing attachments. The first installation was completed mid-August. The next three

n Safety Feature AmQuip has identified 20 of its largest all-terrains as a priority for TRAM.

installations will be completed by the end of September. The GMK 7550 is a 550 US t (450 t) capacity telescopic crane with a five-section, 60 m main boom and jib extensions up to 73 m. Ascent and descent is often the riskiest part of working at height. TRAM makes this not just safer but easier too. As the user climbs up the side of the crane, he or she clips the lanyard onto the handle. Squeezing the hand brake releases an air-powered spring that pushes the arm gently but firmly to vertical, helping the user climb up and over onto the top of the boom. Similar assistance is given in descent. A deadman’s brake prevents the arm from moving along the rail unless the hand brake is squeezed. “We spent a long time researching ways to assemble large cranes in a safer way,” said Mr Hammons. “When we discovered TRAM, it was a clear choice not just because it is so effective, but because it is also convenient and very easy to use. “I have found, in my 20-plus years providing safety and risk management services, that if something is not convenient and comfortable, people won’t use it. TRAM meets all our criteria. It allows the employees to go about their work at their normal pace with no impediment – it prevents them from falling, and it stows away when it is not in use.” AmQuip Crane Rental LLC is a leading US crane rental company, serving the Northeast, Mid-Atlantic region, and most Midwest and Southern states.

Global move Standfast has now retrofitted TRAM in Europe and Australia to several sizes and makes of both telescopic and lattice boom mobile cranes from 60 up to 600 t capacity upwards, as well as on gantry beams of overhead travelling cranes. Early crane installations

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required a degree of modification to fit each application, depending on the design of the crane. However, with growing demand from crane owners worldwide, Standfast has now developed, refined and standardised its methodology for either welding, banding or bonding TRAM rails to most crane types. Crane owners that have already installed TRAM systems include Australian hire companies Boom Logistics and Hanchard Cranes; wind power company Suzlon Energy Australia; New Zealand Crane Group; Ainscough Crane Hire of the UK; and Royal Saan of the Netherlands. As well as providing crane owners with a retrofit safety solution, Standfast supplies TRAM systems to Terex Cranes for fitment on original equipment. Terex offers TRAM as a recommended option on its larger all terrain cranes and has been recently specified by several Terex customers including King Lifting in the UK. Standfast is also in discussions with other OEM manufacturers that are under pressure from customers to develop improved height safety measures that are both practical and affordable. “The TRAM fall restraint system has attracted a lot of interest from crane owners and manufacturer alike. Safety authorities all over the world are really tightening up on working at height since falls are the biggest cause of industrial accidents. They are pressuring major contractors to raise their game in eliminating fall risk,” said Standfast CEO Cameron Baker. “Producing a system that offers riggers safety while still giving them the freedom to do their work seems to have been quite a challenge for the crane industry. Fall arrest systems that leave guys dangling in the air and risking shock trauma are clearly inadequate. Fall restrain systems like TRAM that prevent falls in the first place are a far better approach.” n Enquiry: [email protected]

n Industrial Development

Below The Ice

A view of the Mer de Glace glacier.

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n Industrial Development

S

ince 1973, the Bois hydroelectric power station owned by EDF company has been located under a glacier known as Mer de Glace (Sea of Ice), believed to be the biggest in France. Thanks to the snowmelt, the power station has an annual production rate of 115 mil kW/h, enough to supply a small town of 50,000 inhabitants. About 95 percent of the electricity is produced during the seven months of ice melt. However, global warming has been speeding up this process for a number of years. To face up to the reduction of the glacier, EDF decided to modify the plant and move the water captation facilities to a higher altitude. Following in-depth research of the zone, EDF decided to move the new site 1,000 m further up the mountain to a point where the glacier is still around 130 m thick, which will enable the plant to exploit the glacier for several more decades.

The Aiguille Verte (1.422 m high) in the Mont Blanc complex.

Unique power station The Bois power station is almost unique in the world. It is believed that there are very few power stations of this type - the Emosson plant, also in Vallorcine in Upper Savoy, which uses water from the Argentière; and Tour glaciers (both belonging to the Mont Blanc massif); and a further two similar plants in Norway. The operating principle is as follows: the captured water is channelled into a tunnel, then made to flow into a well around 300 m deep. The force generated by the falling water produces 100 percent renewable energy - 3 cu m of water derived from melted snow produces approximately 2 kW/h. The Bois underground power station is perfectly integrated into the landscape and does not compromise the natural beauty of Mont Blanc, a site under environmental protection. Site activities, which are still ongoing, also have a low impact on the natural environment and tourist activities of the glacier. EDF is particularly careful about reducing outdoor activities to a minimum and not leaving the tools and equipment used on view.

Challenging site This exceptional site requires meticulous organisation and special logistics, because at an altitude of 1,500 m and with extremely low temperatures during the winter, conditions are particularly hard and reaching the site is arduous. In fact, those who work on the site use a private cable car while the materials are mainly transported by helicopter. Each trip to and from the site for the personnel lasts three minutes. After getting

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Helicopters are used to transport around 40 big-bags to the site every hour.

n Industrial Development

out of the cable car, they have to go through a tunnel 1 km long, either on foot or by bike, and then climb 320 steps roped together before reaching a platform, which marks the starting point of the two new tunnels under construction. In collaboration with mountain guides from nearby Chamonix, the work squads from the construction company use technicians specialised in working at high altitudes. Professional miners are also involved in the project. Work goes ahead non-stop 24 hours a day, seven days a week and 365 days a year. In June 2008, a first muck disposal tunnel was opened to have access to the outside. Then, between January and April 2009, a temporary pipeline was made to feed the power station while work was being carried out. Since May 2009, a survey tunnel is being dug in order to study and establish the exact position for the future captation point for the water. The digging of the second tunnel started in June 2009, to connect the new captation point with the power station as soon as possible. The 2,400 m tunnel has been excavated in the rock using mainly explosives. Below the ice, on the other hand, the survey tunnels are being excavated using jets of hot water.

Above: The stairway on the site with its 320 steps and 45 deg slope, and the adjacent elevator used to transport materials. Above left: The platform at the heliport where the big-bags of Mapeshaft BS 15 are picked up.

Special products Mapei’s UTT (Underground Technology Team) division has developed two products specifically for this site - Mapeshaft BS 15 and Mapeshaft BS 15 CHF. Mapeshaft BS 15 is a premixed, ready-to-use concrete characterised by controlled rheology and fluidity and high resistance to sulphates. After adding water, it forms a high-strength, durable class S4 concrete that remains fluid for at least 30 minutes. Mapeshaft BS 15 CHF is a premixed, ready-to-use, controlled-rheology concrete. The hydraulic binders contained in the product make it highly resistant to sulphates and highly durable. After adding water, it also forms a class S4 concrete, which remains fluid for at least 30 minutes. The two types of concrete are transported by helicopter in bigbags, then mixed using a mixer located underground in a specially created hollow. Afterwards, they are transported into the tunnels to build the foundations, the service zones adjacent to the tunnels (such as the canteen and maintenance areas) and other parts of the structure, such as the roof of the tunnels and the watertight doors between the tunnels, which are fixed on frames made by anchoring Mapeshaft BS 15 CHF. When the work is completed, the service life of the plant and production of hydroelectric energy will be extended, whereas if the Bois plant was to be abandoned, the French energy network would be deprived of an important source of renewable energy. n Enquiry: [email protected]

The existing muck disposal tunnel, which leads to the initial water captation point.

The article courtesy of Realta Mapei International no. 33.

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What’s next for your business? What new equipment will drive productivity? Spend time at World of Concrete to see, try, compare and test-drive the latest products and equipment up close and under actual job site conditions. Meet face-to-face with top equipment suppliers, exchange ideas with colleagues and attend focused seminars covering everything from concrete fundamentals and business management to safety and risk management.
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n Product Feature

Leica DISTO entering three dimension T he new Leica 3D Disto is a three-dimensional measurement and projection system designed for site measurement, marking points or checking of dimensions. It requires only one user, and she/he does not need to have surveying knowledge. Thus it is ideal for both surveyors and non-surveyors such as engineers, architects, interior designers and consultants. The 3D Disto is equipped with a handheld controller wirelessly connected using WiFi to the 3D measuring device (sensor). The controller is a 4 ft 8 in TFT high resolution touch screen LCD with 800 x 480 pixels and 16 million colours encased in a rugged housing with a 32 GB Flash Memory. The sensor consists of the laser measurement module mounted on motorised chassis that allows for 360 deg horizontal and 250 deg vertical movement. This results in versatility for the user to remotely control and measure points in a space from one step up position.

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The 3D Disto can perform levelling by itself, with or without a tripod. Users just place it on a relatively flat surface and turn on the system, and the sensor will take less than a minute to self level. Even uneven surfaces of up to 3 deg incline will not pose a problem with the system. Viewfinder function on the controller in full colour with up to 8x zoom magnification makes finding and aiming to a point very easy. Moving the pointer to a target can be done on the touch screen by sliding the cross hair to the target, tapping on the target or using the on screen navigation arrows, or just manually swivel and tilt the laser measurement module. The screen layout is logical and simple with all the necessary information available such as the main keys, results, software in use, function keys and hardware status around the border of the screen. In the centre displays the points measured by the sensor and the

n Product Feature lines that automatically connects between points. The functions are logically grouped into various application software including measurement, room scan, toolkit and projector. The general situations where a Leica 3D Disto could benefit the user include: • Site measurements to generate or verify electronic blueprints, such as turnkey renovation/retrofitting works and building inspection. • Complex site marking/layout before installation/erection works, such as positioning for bulky installation or erection. • Repetitive site marking/layout, such as grid layout (sprinkler, lighting) identical space to space layouts for fittings or building services like electrical or pipe outlets, etc. • Profiling a surface to measure/develop a template such as swimming pool covers, awnings and counter tops. • Precision measurement (dimensions and areas) in inaccessible locations like roofs, skylight and outdoor facade.

Viewfinder function on the controller in full colour with up to 8x zoom magnification makes finding and aiming to a point very easy.

Easy measurement Every point is captured in a three-dimensional coordinate, and the system provides detailed information between points or a group of points such as direct (tie) distance, horizontal offset, vertical offsets, angles/slopes, sloped area, horizontal area, perimeter, volume and input/calculated height. Area of any shape inclined at any angle can be measured as long as the system can see all the corners and users can measure up the areas that they need to omit. This is very useful in situations such as roof skylights or windows in exterior painting. Volume measurements allow the users to input the height or simply measure a point anywhere on the ceiling and the floor, and the points do not need to be in a vertical alignment. Systematic capture of points and the ability to edit points and lines can easily be turned into a simple two dimensional plan. Each line can be ‘unfolded’ into elevation view to capture details on each wall such as doors, windows or any needed details. Shortcut functions for rectangular or round shapes reduce the measurement details. The file is saved in dxf format and can be viewed in 2D or 3D, and edited using the CAD software on a computer. A unique function of the room scan software is the ability to scan/profile a surface horizontally and vertically. Depending on the level of detail, users can set the interval of the scan. They can skip points or pause the scan at any point to edit the scan interval. The system also allows them to add or remove points, or lies once the scan is completed. So whether it is a curved doorway or irregular shaped wall, users have full control. The scanned profile can be used as a template for prefabrication or precutting of materials in applications such as counter tops or fittings to boats, archways etc. The software essentially helps users to find a position on the wall, floor or ceiling in various ways, including transferring a point vertically up or down; targetting a point beside, below or above a reference point on the wall; transferring levels another wall; finding points a set distance from Meter Mark on the wall; and finding a point(s) parallel to a reference line on the floor. Such application solution would benefit any user who needs to mark out a number and variety of points or lines before any installation or erection work can be carried out. This ensures that components or structures can be correctly positioned in situations of space constraints or where repositioning is almost impossible.

Above: The Leica 3D Disto screen layout is logical and simple featuring all the necessary information. Left: Precision measurement (dimensions and areas) in inaccessible locations such as roofs, skylight and outdoor facade, can be done by using the 3D Disto.

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n Product Feature Relocation Using three to five reference targets, the system can secure its current and subsequently a new location, ensuring that users’ measurements can continue consistently. This enables greater flexibility to relocate the unit for these situations: capture hard to reach areas, mapping a project with multiple rooms, mapping project done over several days, and sensor gets accidentally bumped or moved. Pictures of measured points can be captured with each point to help users easily recall those points. The relocation function automatically captures the image of each reference target in case a new operator takes over the task the next day. Results can be quickly translated to estimates and quotes on the spot. Users select the data they wish to use, tap on the value and a calculator appears. There are many functions in the Leica 3D Disto, however, most functions come with a guide called Assistant that will display a simple diagram on what to do at each step of a function. A printed, quick start pictorial guide is also available. The file can be saved in several formats such as dxf, csv and txt formats, which are CAD, Excel and Notepad ready formats. File transfer can be done either by cable connection to a PC or via the 1 GB USB portable drive supplied. n

Systematic capture of points and the ability to edit points and lines can easily be turned into a simple two dimensional plan. Each line can be ‘unfolded’ into elevation view to capture details on each wall such as doors, windows or any needed details.

Enquiry: [email protected] Website: www.leica-geosystems.com/en/Leica3D-Disto_94606.htm

The dxf file created with 3D Disto (opened by de’caff DXF viewer).

Above: Using the remote control or touch screen control allows users to work at their own pace. This is ideal for situations such as positioning lights or sprinklers in an open office or placing an intricate design on a wall. Left: The file can be saved in several formats such as dxf, csv and txt formats, which are CAD, Excel and Notepad ready formats. File transfer can be done either by cable connection to a PC or via the 1 GB USB portable drive supplied.

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n Focus on India

New light of the Himalaya 82

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n Focus on India

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he Alaknanda River runs through the foothills of the Himalaya Mountains and is currently a major water source for northern India. In 2005 GMR Energy started developing a 330 mW hydroelectric dam and power plant on the riverbanks to help meet the growing seasonal demand for power in northern India.

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The project includes a 40 m high dam, a 3 km long headrace tunnel and an underground penstock leading to an underground power station with two 70 mW run of river turbines. The total head of water on the project is 480 m. The dam and power plant is located just outside the town of Srinagar in Uttarakhand (formerly Uttaranchal) State in northern India. This site was chosen due to its location on the river and proximity to mountain run off. It provided the best chance to develop hydro electricity and manage the level of the river. The site is nestled in a mountain valley. While the surrounding mountains are vast and breathtaking, it is a very remote region that presents challenges to travel and yearround work schedules. Getting to the site requires a 340 km drive from New Delhi on sometimes unreliable, winding mountain roads, which can take 12 to 14 hours in travel time. The location has snowfall for between four and six months a year, so construction cannot take place during the winter. As a result, it is anticipated that it will take about double the normal length of time to complete a project of this kind. The project is scheduled to achieve commercial operation in 2014. After which, most of the power generated by the dam and power plant will be channelled to serve the national capital territory of Delhi, the second largest metropolitan area in India with a population of nearly 14 million people. In addition, it is an active seismic zone at risk of earthquakes. In September 1803, the area suffered a powerful earthquake that shook the whole region and devastated the town of Srinagar. As a result, the engineering and construction teams have taken noticeable steps to improve the soil stabilisation on the slopes surrounding the project area. Concrete is bound to crack if it is not properly placed or cured. Therefore, waterproofing concrete with a straightforward, dependable and guaranteed system offers an indispensible level of protection, particularly for dam walls with steel reinforcement. If water enters cracks in the concrete, it can damage the reinforcing steel below the concrete surface. Steel expands when it corrodes, which leads to more cracks and water ingress. Over time, the concrete deteriorates and fails, which can result in devastating floods. The town of Srinagar is all too familiar with the devastation of floods. In August 1894, over 10,000 mil cu ft of water from the breached Gohna Lake completely swept away the original town of Srinagar. Modern day Srinagar was re-established by the British between 1897 and 1899. They used urban planning methodology to create a new

n Focus on India

grid-iron patterned town on the upper third terrace southeast of the previous city site. The town was granted urban status in 1931 and today is a major economic, cultural and educational centre in the region.

Building a strong structure Due to the extreme risk potential in building or waterproofing a dam, governments and engineers are turning increasingly to integral crystalline waterproofing manufacturers for help. Integral systems can add decades to the life of a concrete structure. Unlike membrane systems that can deteriorate over time, integral systems become part of the concrete matrix, waterproofing from the inside out. This gives these systems added reliability over other waterproofing systems as they cannot be punctured or torn. In addition, integral systems will not be worn away by constant exposure to water, salts or other contaminants and are not affected by UV rays or concrete expansion and contraction. Finally, integral systems are a green solution. They can extend the serviceable life of structures by decades and also allow the concrete to be recycled after

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Top and bottom: While the surrounding mountains are vast and breathtaking, the project site is very remote that presents challenges to travel and year-round work schedules. It also has snowfall for between four and six months a year, so construction cannot take place during the winter. Due to this, it is expected to take about double the normal length of time to complete a project of this kind.

n Focus on India its useful life is over. For hydroelectric dams, which are a green form of energy, integral waterproofing systems make sense. Kryton became involved in the project in 2010 after taking part in a site review meeting. The company is working with the on-site Ready Mix plant to optimise the mix design. Achieving the optimum mix is proving to be challenging due to the vast annual temperature fluctuation at the site. In addition, Kryton is helping the on-site construction team to test and apply its surface-applied waterproofing system, Krystol T1 and T2, and its internal system, Krystol Internal Membrane (KIM), to the dam face, canal and two tunnels. Going forward, the 1.8 km long canal leading to the pen stocks and two spillway tunnels that are each 1 km long will be waterproofed entirely using KIM. Krystol T1 and T2 will be applied to the upstream section of the dam face, which measures 128 m by 340 m. In all, approximately 1,000 t of Kryton’s waterproofing systems will be used to treat tens of thousands of square metres of concrete. n Enquiry: [email protected]

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Approximately 1,000 t of Kryton’s waterproofing system will be used to treat tens of thousands of square metres of concrete at the massive dam.

24.10.11 08:23

n Focus on India

Building roads in India the Wirtgen way R

oad construction in India faces the big challenge of having to complete huge projects in the shortest possible construction time. Thousands of kilometres of roads are needed and planned to be built over the next years to expand the network of traffic arteries in the booming economy. This requires fast-paced, reliable and economical construction processes, and soil stabilisation meets these requirements. Application examples from Nagpur (NH7) and Angul provide an insight into the standard practice. The black cotton soils predominant in the Nagpur area have a CBR (California Bearing Ratio) value of less than 3 percent but maximum plasticity and swelling pressure values exceeding 0.65 kg/ cu cm. In view of the highly plastic and compressible nature of the soil, the contractor decided to use locally available fly ash (pond ash) in the stabilising process. Laboratory testing showed 15 percent by mass of fly ash to be the optimum quantity to be added for stabilisation of this type of soil as it drastically reduced the free swell index from 0.65 kg/sq cm to 0.33 kg/sq cm, while increasing the CBR value to more than 10 percent at the same time. Stabilisation was performed in three layers. The first and bottommost layer was stabilised at a depth of 200 mm, and the second and third layers were stabilised at a depth of 150 mm each, introducing 15 percent by mass of fly ash into each layer to increase the CBR value to exceed 10 percent. In a first operational step,

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the soil was dumped on site, levelled with a motor grader and then compacted to a thickness of 200 mm using a vibratory roller. The fly ash was spread on top of the compacted layer in a second step, and the Wirtgen WR 2400 then stabilised the layer to the specified working depth. The required quantities of water were supplied by a water tanker. After completion of the stabilising process, the layer was pre-compacted in one plain roller pass. Final compaction was effected in four vibratory passes to achieve the required minimum field density of 98 percent of the maximum dry density (MDD). The process was repeated for the second and third layers at a thickness of 150 mm each. The high-performance WR 2400 stabiliser has a capacity of 400 cu m per hour and stabilises up to 8,000 sq m per day. These exceptional performance levels are ensured by the machine’s variable mixing chamber as well as the mixing and milling rotor with quickchange toolholder system. Wirtgen soil stabilisers, such as the WR 2400, improve or stabilise soil by mixing in binding agents, thus producing highquality construction material. The most frequently used binding agents include lime, cement and fly ash, as well as special binding agents specifically tailored to the soil to be treated. Introducing lime into the soil, for example, adjusts the optimal water content, which greatly improves the soil’s compactability. Adding cement stabilises

n Focus on India the soil and improves its bearing capacity. Soils treated in this way are eminently suitable for the construction of all types of roads. Soil samples taken on site are subjected to mix design testing in road laboratories in order to determine the suitability of construction materials and construction material mixes for the intended application. Soil classification determines the type and quantity of binding agents to be used. Compressive strength is determined and documented in a final step. If site conditions require the addition of water or special liquid binding agents, tanker trucks coupled to the Wirtgen soil stabiliser deliver them to the machine’s injection system via hose connections. The injection systems are fitted with up to 16 spraying nozzles, which can be switched on or off separately to precisely adjust the spraying width to the specified mixing width. In addition, the spraying nozzles are cleaned automatically to ensure permanent operational readiness. The microprocessor-controlled injection system is operated and monitored from the operator’s cabin. Job parameters, such as advance rate, daily production rate and consumption rates, are also indicated and saved. n

Project Information The Nagpur (NH7) job site: Total area: 600,000 sq m Quantity removed: 300,000 cu m Completion time: 80 days Milling width: 2.40 m Advance rate: 12 m/min Milling performance: 300 cu m/h The Angul job site: Total area: 200,000 sq m Quantity removed: 70,000 cu m Completion time: 30 days Milling width: 2.40 m Advance rate: 10 m/min Milling performance: 300 cu m/h

Enquiry: [email protected]

Main: Tanker trucks supplying water or liquid binding agents can be directly connected to the soil stabiliser. The microprocessor-controlled injection system can be relied on to apply the binding agents in precisely metered quantities. Left: The high-performance WR 2400 stabiliser from Wirtgen has a capacity of 400 cu m per hour and stabilises up to 8,000 sq m per day. These exceptional performance levels are ensured by the machine’s variable mixing chamber as well as the mixing and milling rotor with quick-change toolholder system. Below: Soil stabilisation has become a standard construction method on largescale construction projects around the world.

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n Focus on India

When safety matters... A

dvanced Construction Technologies (ACT) is in the course of improving safety and transforming the demolition industry in India, with the support of Volvo Construction Equipment machines. The company, which is considered a pioneer in the Indian demolition industry, is one of Volvo CE’s 13 dealers in the country. ACT’s managing director Mohan Ramanathan, often called ‘The Demolition Man’ after decades in the industry, is trying to introduce safer, more efficient ways of working. “The demolition industry in India is around 15-years behind the western world,” he said. “I am trying to convert people to modern ways of working and raise awareness of safer, more efficient and cost effective methods compared to traditional, labour intensive processes.” ACT has been the gateway for many demolition technologies to enter India. In 2006 Mr Ramanathan introduced silent demolition technology to the country by using a hydraulic concrete crusher mounted on a Volvo excavator. It is believed that this was the first time a crusher was used with an excavator in India’s demolition industry. In 2008 Mr Ramanathan brought over the first Volvo ultra high reach excavator, marking the introduction of this technology in Asia. “Slowly we are starting to move away from manual demolition towards a much safer and more efficient mechanical way of working.” However, Mr Ramanathan explained that using excavators and attachments in Indian demolition is still a relatively new concept because there is not enough awareness of the Left: Mohan Ramanathan, managing director of ACT, is often referred to ‘The Demolition Man’ after decades in the industry.

Right: Volvo EC240, EC460 and EC360 excavators with demolition attachments work to demolish a terminal at Mumbai International Airport. Facing page: Volvo EC460 demolishes abandoned structures in Ahmedabad.

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technology available. “With the combination of the redevelopment of walled cities, old infrastructure waiting to be replaced and plans for enhancing the use of land, there is great potential in this market – and so it is vital that we are up to date with the latest demolition techniques. That’s where Volvo Construction Equipment comes in. The machines are really starting to transform the demolition industry now, but there are still challenges to overcome.” ACT, which started as a family business 60 years ago, sells and rents Volvo machines in Tamilnadu and Kerala, two southern states in India. Mr Ramanathan’s fleet of machines, which consist of Volvo EC140, EC210, EC240, EC360 and EC460 excavators with both a 22 m and 26 m boom, are used with demolition attachments such as hydraulic breakers, crushers and shears. The machines work on demolition jobsites across India and are currently being used on a major project in Ahmedabad, west India, where a large power station is being demolished. The fleet is also hard at work dismantling structures in Chennai, south India, to make space for an underground Metro Rail project. Before Mr Ramanathan introduces new technology to the Indian demolition industry

he makes sure it fulfils certain requirements. His philosophy states that it must be the most economical and effective technology available in the field. Secondly it must be the safest and the fastest. And finally it should be the most modern method that can easily be adapted to Indian conditions. “These requirements are what led me to Volvo Construction Equipment machines. Volvo has the best hydraulics and that is extremely important because we are always using hydraulic attachments. The machines are built with increased safety and stability. They are tough, reliable, fuel efficient and environment-friendly. Volvo excavators are so much more efficient, saving valuable fuel and therefore money.” He continued, “Demolition is a very exciting and challenging area. The cause of most accidents in this industry is the use of inappropriate methods and a poor understanding of the structure. But things are starting to change. It is essential that we modernise to increase safety, efficiency and environmental care – with the help of Volvo Construction Equipment we are moving towards a better and safer way of working in India.” n Enquiry: [email protected]

n Focus on India

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n Focus on India

Putzmeister breaks new record

P

utzmeister has achieved a new record in long distance concrete pumping in India with its stationary concrete pump type BSA 1409 D. Concrete was pumped as far as 1,100 m in a tunnel - believed to be the longest distance achieved in the country so far. The tunnel, measuring 3 km long with a diameter of 2.50 m, is part of the Bhilangana III hydro power plant project with capacity of 24 mW. The power plant is located in Ghuttu, Tehri Garhwal, in the north Indian state of Uttarakhand. The project was a great challenge. The entire concreting logistics were developed in Ghuttu – the last point that can be reached by road at the Bhilangana River. Detailed planning, from a suitable installation site for the pump to the laying of the pump line and mounting the casing, was essential for ultimate success. The concrete pump was set up against the pump direction for more stability. From the hopper outlet the pump line continued initially over two 90 deg elbow, which reduced the transfer of the pressure

in the line to the pump. The pump line was screwed to the concrete bases using U-shaped supports. A shut-off valve in the delivery line prevented the backward flow of concrete and water as the tunnel pipe continued on diagonally and had a downward slope against the concrete pump. A specially produced concrete block over the pump line before the tunnel entry detected the force of the pump. The tunnel concreting required a continuous pumping process of 105 cu m of concrete of strength class C25 into the 1,100 m distance. For the team, this meant concreting day and night, in sections of 67 m long for the roof and sidewalls and 70 m for the base. If the end of a casing section was reached, the base was then concreted in reverse direction. The concrete was placed using an elbow pipe. The thickness of the concrete layer was between 200 and 250 mm. The concrete mix was monitored constantly before and during concreting. n Enquiry: [email protected]

Putzmeister BSA 1409 D has pumped concrete as far as 1,100 m in a tunnel in India, claimed to be the longest distance achieved in the country to date. The tunnel is part of the Bhilangana III hydro power plant project.

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n Focus on India

A shut-off valve prevented the backward flow of concrete and water from the pump line that had a downward slope.

Above: Placing of the concrete in the casings at the tunnel walls to support the roof. Above right: The concreting team was working in the tunnel around the clock Right: In the Pooja ceremony concrete pumps and equipment received divine blessings for the demanding task ahead.

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n Focus on the Middle East

Unveiling

Qatar’s new iconic landmark

T

The 15,000 sq m Incubator Centre consists of the administrative hub and business centre.

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he new Qatar Science and Technology Park (QSTP) in Doha forms an integral part of Qatar’s National Vision 2030, which aims to transform the country into one of the world’s most powerful economies within two decades. A home for technologybased companies from around the world and an incubator of start-up enterprises, the project was initiated by the Qatar Foundation set up by His Highness the Emir of Qatar and chaired by his wife Her Highness Sheikha Mozah Bint Nasser Al-Missned. A key feature of the QSTP is its co-location with top international universities at the Education City, a 1,000 ha campus of schools, colleges and national facilities. These universities offer degrees identical to their ‘home’ campuses and are building world-class research programmes, giving QSTP tenants the opportunity to undertake collaborative research and recruit highly educated graduates. The masterplan for the project encompasses 123 ha of land, which is integrated with the facilities of the Qatar Foundation. Construction of the Phase One comprised 115,000 sq m of development with 45,000 sq m of dedicated office and laboratory space. At its heart is the 15,000 sq m Incubator Centre (IC) incorporating the administrative hub and business centre. This building is flanked by the first two tenant buildings (ITTCs), each 20,000 sq m.

n Focus on the Middle East

Highlight of the Qatar Science and Technology Park is an Incubator Centre flanked by the first two tenant buildings.

Distinctive design

IC and ITTC buildings

Aurecon undertook the structural, civil, facade, security, and fire life safety design for the QSTP and worked closely with the architect, Woods Bagot, to ensure the successful realisation of the project. The Qatari model adopted for project is unique, focusing on features that are not seen in other international development, including the ability to create a place where pedestrians are more important than cars and build a safe place to work, interact and develop collaborations. Woods Bagot’s design of the building is striking and contemporary, whilst respectful of the Qatari culture and adapted for the desert climate. It separates motor vehicles from pedestrians and the podium provides a pedestrian-only landscaped environment under the ‘veil’ shade structure that links the buildings. People can move freely between the activity hubs in the tenant building atrium spaces and the IC’s retail outlets and service facilities.

The framing systems were driven by the vehicular / road arrangements at ground level and the need to provide large flexible spaces at tenancy levels with minimum column intrusion. The foundation design took account of the site conditions of loose desert sands overlying limestone bedrock. Foundations were founded on the limestone bedrock with desert sands recycled onsite for use as bulk filling. Bituminous protection was specified for below ground concrete works to account for the aggressive soil conditions. Design for the podium incorporates significant flexibility including extensive future penetration allowance; loading allowance for extension of two-storey ITTC building across the podium; 400 mm hard or soft landscaping, with an equivalent of 10 kPA loading capacity; and 21.6 m clear span concrete super ‘T’ beams spanning over roadways utilising standard bridge construction. The functional requirements drove large clear spans in excess of 21 m by 21 m in structural steel framing to the tenancy areas with composite steel beams and concrete slabs on metal structural formwork decking. Concrete stair and services cores contributed to the lateral stability. The roof and facade structure is supported on the main floors, and column grid - all of which are framed in structural steel to facilitate rapid construction. Interstitial floors are designed for notional plant loads with heavier plant installations involving either spreaders or beams spanning between trusses to support. All roof areas considered 100 mm sand loading. Robustness statutory requirements were implemented with additional redundancy incorporated to critical structural elements. Wind tunnel testing was also used to accurately determine wind pressures. The interior of the Incubator Centre.

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n Focus on the Middle East

Veil challenge The veil structure is a distinctive architectural element, featuring the sinusoidal wave form contributing to the recognition of the QSTP building in the Qatar landscape. The continuous flowing profile of the veil provided sufficient challenges in designing standardised 1,800 x 900 triangular-modules that fit within the main structure to provide the effect of continuity, whilst maintaining a uniform thickness throughout. The solution was for an innovative unitised, factory assembled doubly clad modules that could be lifted directly onto the steel structure and fixed into the required positions using a minimal number of three-way adjustable bracket system. In this way, there was no requirement to use scaffolds or to provide for overhead fixing of the soffit panels, resulting in significant time-saving. These unique brackets also allowed for differential movements between panels and accommodated movements due to structure and temperature effects. Veil elements at the building’s expansion joints were provided with four-way movement elastomeric joints (up-down, in-out, along plane and rotational between planes). The veil screens were based on a unitised system, allowing for uniform and high quality of manufacture, assembly and site installation. These modules are based on 1800W x 900 triangularelements, similar to the main veil. The design of tapered cladding to the uniform-sized columns required consideration of ease of fabrication and installation to ensure minimal misalignment of adjoining panels. Maximising commercially available cladding material and minimising waste was achieved. Off cuts were specified for use in the secondary framing and stiffening of the panels. Aurecon’s response to latent site conditions including a large sink hole was timely and innovative. Aurecon specified for the 70 m by 50 m by 12 m deep hole to be backfilled with cyclopean concrete, a blend of large 400 mm boulders and lean mix concrete. This resulted in 80 percent less concrete by volume whilst achieving the required bearing capacity.

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Top: View below veil looking towards the Education City. Above: The continuous flowing profile of the veil provided sufficient challenges in designing standardised 1,800 x 900 triangular-modules that fit within the main structure to provide the effect of continuity, whilst maintaining a uniform thickness throughout.

n Focus on the Middle East Complicated facades Apart from the veil, the QSTP facades include the glazed walls, metal-clad columns, metalclad beam trusses and trafficable overhead glass ceilings. The engineering loads for the facade elements were based on a scaled model wind tunnel testing. Many of these facade elements have complicated geometry, so the designs were modelled on fully unitised construction where possible. This provided for high quality manufacturing, assembly and installation. Facades were engineered with consideration to the limitations of size of commercially available cladding materials and glass, effects on transportation, lifting and installation capacities of cranes on site. Attention in the jointing and connections of the facade elements to accommodate movements due to structural and temperature effects required interaction between the structural and facade engineers and architects from the very early stage of the project. Aurecon’s design of the fixing of the facade elements to the structure aimed to maximise the benefits of unitised construction whilst providing the required ease of access, both during construction and for maintenance replacement when necessary. The number of fixings to the structure was engineered to a minimum, reducing site installation time and both material and labour costs, including supervision monitoring. The facade elements and the specified materials for the support framing were detailed to minimise dissimilar metal interaction.

Speedy construction

Above: Veil detail. Top right, middle, and right: To speed up construction, Aurecon developed three packages of work to facilitate a staged approach to contactor engagement and materials procurement.

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To achieve rapid construction and adhere to the tight schedule, the project was built within the following key principles: speed of construction, simplicity of construction, ease of future expansion, structural efficiency, mix of materials and local capability. Concrete columns were used in the car park for resistance to aggressive soils, durability and the need to be able to start on site quickly with well-known local materials and processes (concrete, formwork) and fire resistance. The choice of a concrete podium slab also allowed rapid mobilisation using well-known local materials and processes, fire resistance and durability in supporting landscaping. Aurecon’s design relied heavily upon keeping the podium a regular slab/beam profile to facilitate the opportunity for standardisation of formwork and reinforcing systems.

n Focus on the Middle East Aurecon opted for a steel-framed superstructure with slab cast on profiled metal decking to capitalise on the speed of construction possible with this material, having allowed sufficient lead time to procure, shop draw and fabricate the elements. In addition, Aurecon developed three packages of work to facilitate a staged approach to contactor engagement and materials procurement. This was aimed at assisting in minimising problems encountered through long lead times, etc. The packages comprised Bid Package 1 (concrete foundations, concrete podium columns, concrete podium banded slab, initial works for landscaping structures, base of core walls and bridge area); Bid Package 2 (bulk structural steelwork for IC and ITTC buildings); and Bid Package 3 (carpark earthworks and slab, remainder of core walls, masonry walls, structural formwork and slabs to IC and ITTC, veil structure, additional landscaping structures, facades and all other remaining elements). The Bid Package 1 was designed as a self-sufficient package of work, whilst the Bid Package 2 steelworker was novated under the Bid Package 3 head contractor.

Environment-friendly building Shading was used extensively to improve ambient conditions. External podium areas provide a sustainable landscape setting with concentrations of green scapes contrasted by more sculptured arid element areas. Recycled materials were also used where possible to reduce reliance on new materials.Flyash as a replacement for cementitious material was specified in the concrete for all elements. In

addition, materials that can be 100 percent recycled at the end of life were used wherever possible. The design is structurally efficient minimising material use. The QR800 million project was opened in mid 2008. ConocoPhillips, ExxonMobil, Shell and Total are establishing research and training centres that add value to Qatar’s hydrocarbons sector; local software company iHorizons joins Microsoft and Cisco in developing new IT applications; EADS and GE are at the forefront of industrial technologies; SMARD is Qatar’s first bio medical research company; and Gartner Lee is specialising in environmental management. n

Top: Aurecon’s design of QSTP is structurally efficient minimising material use. Above and below left: The development was opened in mid 2008 and has attracted many major international companies.

All images © Woods Bagot and Aurecon

Project Team Owner: Qatar Foundation Architect: Woods Bagot Structural, civil, facade, security and fire life safety engineers: Aurecon Services Engineer: Hyder Project Manager: KEO Cost Consultant: Davis Langdon

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n Focus on the Middle East

College of the North Atlantic

Aurecon and Woods Bagot have also previously worked together to build the College of the North Atlantic in Doha, which was aimed to address a technical skills shortage in the city. The facility includes a total of 26 buildings comprising libraries, auditoriums, laboratories, workshops, computer labs, classrooms and other teaching related facilities. Woods Bagot was the design architect of the project while Aurecon was responsible for the delivery of all engineering services including mechanical, electrical, plumbing, fire, structural and civil engineering. Work on the project started in 2001 and was completed in 2006. A key design feature included creating a plan layout of the buildings and interconnecting walkways, which created a representation of the historic wadi (creek) system in the area. This required the design of various structures that ‘wrapped’ over the buildings to maintain the wadi alignment in plan view. These ‘wraps’ were major concrete structures, which spanned over the rectilinear buildings at an oblique angle, creating a twisting effect when viewed from the ground.

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Among the main challenges during construction was to create a large number of precast concrete panels from only four moulds. These moulds were arranged in such a way that they could form a variety of facades shapes, which were then used for shading. Aurecon has also developed a reinforced concrete waffle pod for the floor system that was used throughout all buildings, which kept the selfweight of the floor to a minimum and maximised repletion of formwork (on a 9 x 9 m grid), but allowed the flexibility to utilise the

space for many different uses. One of the key considerations here was to provide sufficient floor stiffness to accommodate the large quantity of masonry partitions. In addition, Aurecon had to provide interconnectivity between the buildings via long span pedestrian bridges, all of which had to accommodate thermal and differential movements through a variety of movement joints. n All images © Woods Bagot and Aurecon

n Focus on the Middle East

The Potain cranes on the KAFD project are lifting steel, wood, concrete blocks, shuttering and other materials.

Potain rising above Riyadh

M

anitowoc’s cranes continue to play a major role at large construction developments in Saudi Arabia, including 90 Potain cranes on the US$10 billion King Abdullah Financial District in Riyadh. This massive 1,600 sq km development will reportedly include 40 skyscrapers and aims to redefine Saudi Arabia’s capital as a global centre for finance. The timeline for construction on the financial district is very tight, so the main contractors are using as many cranes as possible. Each skyscraper has up to six cranes, and the smaller buildings have three to four cranes. The cranes are working 20 hours a day, six days a week, to ensure the ambitious three-and-a-half year

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project stays on schedule. NFT, the regional Potain dealer for Saudi Arabia, placed all the Potain cranes on KAFD. The company has 550 employees in four offices throughout the Middle East. Its central office is located in the UAE, but it also has branches in Saudi Arabia, Qatar and Kuwait. With deadlines critical to the project’s success, making sure the cranes stay operational is essential. NFT has a team of engineers working at the site, and they are supported by local Manitowoc Crane Care. Main contractors on KAFD include Saudi Binladin Group, Saudi Oger Ltd, SaudiCo and El Seif Engineering. Work began in November 2008 and is expected to be completed at the end of this

n Focus on the Middle East Each skyscraper has up to six cranes, and the smaller buildings have three to four cranes. The cranes are working 20 hours a day, six days a week, to ensure the ambitious three-and-a-half year project stays on schedule.

year. The cranes arrived in stages and the first 20 arrived in February 2009. The second and third instalments, each of 35 cranes, followed in late 2009 and then June 2010. Saudi Binladin Group purchased the majority of these cranes. The crane models span almost the entire top-slewing range from Potain. They include cranes from the MD, MDT, MR and MC ranges. There are 28 of the 7 t MR 225 A cranes and 21 of the 10 t MD 208 A cranes on the project – the two most popular models. Other cranes include the Potain MD 345, MR 295, MC 175, MC 205 B and MC 310 K12. Many will eventually reach heights of 200 m and nearly all are working with their maximum jib. The cranes are lifting steel,

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wood, concrete blocks, shuttering and other materials. Most loads weigh between 2 t and 3 t although the largest weigh up to 6 t. The financial district will host a large financial community, including the headquarters of the Capital Market Authority and the Tadawul Stock Exchange. It will also house numerous regional offices for banks and financial authorities and will create an estimated 50,000 jobs. The King Abdullah Financial Academy will be part of the development as well, which will offer education and training to financial professionals. In addition, there will be six mosques, one Grand Mosque and housing for 8,000 people. n Enquiry: [email protected]

n Focus on the Middle East

Doka formwork solutions for supertowers

A total of 108 high-performing Automatic climbers SKE50 and 1,800 sq m of Large-area formwork Top 50 are making up for the time lost on the Lamar Towers project by a previous change of contractor.

D

oka is underlining its strong market position in the high-rise sector with a slew of exceptional new projects that are all destined to join the list of the world’s tallest buildings. Among them is the Lamar Towers in the Saudi Arabian port city of Jeddah. The 70-storey cores of these 300 m high twin towers are being built using 108 high-performing Automatic climbers SKE50 and 1,800 sq m of Large-area formwork Top 50. This equipment was chosen to make up for lost time caused by a change of both contractor and formwork supplier.

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In order to get the project up and running again as quickly as possible, the new contractor, Al Joudah Contracting, decided to have the whole system – wall formwork elements and four platform levels, pre-assembled by the Doka Ready-to-Use Service at the Jeddah Branch. On this previously commenced tower project, the main difficulty lied in assembling the system and putting it into use for the first time. The towers were begun by another construction company using a slipform. This means that it is now necessary to safely mount the platforms and the formwork, and anchor them to the existing concrete at a height

n Focus on the Middle East

An artist’s impression of the Lamar Towers (left), and CMA Tower.

of around 25 m. For this, Doka’s expertise in shifting large, professionally pre-assembled platform assemblages and elements has already proved highly advantageous. Doka is also supplying the formwork for the floor-slabs, and the protection-screen system Xclimb 60 to safeguard all slab-forming operations. Another high-rise project Doka involved in is the 400 m high CMA Tower, claimed to be the tallest building at the King Abdullah Financial District in Riyadh. It is characterised by its colossal nonagonal (ninesided) structure core, measuring over 40 m in the diagonal. Over 10,000 cu m of concrete went into the pouring of its foundations alone. Completing the massive CIP concrete core to be built on these foundations will take 100 casting sections and two years of construction work. According to Doka, this is the most voluminous enclosed shaft core that it has ever formed. The gigantic dimensions of the building remain unchanged all the way from bottom to top, making even just the shaft core of the CMA Tower the same sort of size as a whole conventional skyscraper. Around 3,000 sq m of timber-beam formwork and 105 Automatic climbers SKE100 are in use here. n Enquiry: [email protected]

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Over 10,000 cu m of concrete went into the pouring of the CMA Tower’s nonagonal foundation alone.

n URA Architectural Heritage Awards 2011

The Fullerton Heritage: Clifford Pier & Customs House Built in 1933 and the late 1960s respectively, the single-storey Clifford Pier Building and the two-storey Customs House, formerly the Customs Harbour Branch building, once facilitated the arrival of leisure seekers and traders to and from Singapore. Today, the two unique and historical buildings have been expertly refurbished into stylish Food & Beverage establishments. The majesty of the voluminous Clifford Pier has been preserved with respect and expert precision. Two of its star architectural treasures kick off a list of many that have been earnestly brought back to life – the signature concrete arched trusses in rib band form and its magnificent multi-hued, stained glass fanlight. Unique elements, such as the brackets supporting the roof with their original Shanghai plaster finish and the authentic antiquated artefacts, including the cast iron red lamps and commemorative plaques, have been salvaged. To update the building for air-conditioning, glass panels were introduced behind the building facade, and service trays neatly suspended along the aisles so as not to camouflage the cherished textures of the past. The restoration of the Customs House provided the added challenge of connecting the building to the rest of the waterfront development. Its watch tower, centrally located at its waterfront facade, was cleaned up, restored and repainted to preserve its maritime heritage. Even its distinctive concrete ‘butterfly’ facade at its two longitudinal elevations was carefully restored. New modern shopfronts were sensitively added to its first storey such that they blend harmoniously with the former utilitarian building. Of notable mention was the voluntary retention and restoration of the building’s definitive umbrella-like pavilion. The building’s previous functional office layout was reconfigured and reinvented into hip dining establishments. The new third storey roof space was a creative solution to house the mechanical and electrical equipment without detracting from its architecture. Vertical green planter strips were introduced to soften the appearance of the building and act as a transition between the old and the new. A feature wall was created at the other end of the building to relieve the rather plain facade housing the new substation for the development. Nestled between the two historical buildings is the new six-storey The Fullerton Bay Hotel. Connected to the Clifford Pier building by a covered link way, it was conceived with side facades of glass to reflect and suggest a subtle link between its two conserved neighbours at either side. Horizontal lines on its feature walls are an attempt to echo the rustic facade of the Clifford Pier Building. n

Clifford Pier has been restored to F & B establishment.

View of Customs House and pavilion.

Night aerial view of the integrated old and new development.

Image © DP Architects Pte Ltd

Clifford Pier during refurbishment.

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Owner: Sino Land Company Limited Architect: DP Architects Pte Ltd Engineer: Beca Carter Hollings & Ferner (SEA) Pte Ltd Contractor: Kim Seng Heng engineering Construction (Pte) Ltd

n URA Architectural Heritage Awards 2011

2 Cable Road Built in 1913 by a former government architect, David McLeod Craik for the Municipal Commissioner, Mohamed Namazie, this two-storey grand old Blackand-White bungalow has been restored and given a new pair of wings. The placement of the symmetrical new extensions and a linear lap pool at its front demonstrates a novel approach to integrating the ‘old and new’. The original bungalow has been renovated and enhanced to meet its owner’s brief for additional living spaces for his grown-up children. Much of the original fittings and features of the house have been retained and repaired where possible. Components that were in advanced state of disrepair, such as the original doors and windows, were removed and replaced. The patterned floor tiles, which cover much of the ground level living spaces, were cleaned and kept. Existing timber balustrades of the main staircase and ornamental timber lattices in the interior of the house were also meticulously reinstated along with the original columns at the entrance foyer of the bungalow. Among the prized architectural features of the house is its original lantern roof, the timber structures of which have been left exposed to dramatic effect. Providing a constant visual reminder that one is within a heritage house, the accentuation also shows off the grand height of the bungalow as it allows natural air and light in. The verandah above the square front porch of the house has also been revitalised into a beautiful feature sunroom that extends from the master bedroom. Both the entrance porch and the verandah, which were previously openair, have been enclosed by frameless glass to cater to the owner’s preference for air-conditioned spaces. As the bungalow was sited on an odd-shaped piece of land, the final layout of the new against the old was not an easy decision. Having the symmetrical, new wings flanking the linear pool in front of the bungalow was bold and unconventional. Keeping them to a single-storey each has ensured that the new additions do not obscure the front facade of the main house. The look of the new is intentionally kept modern, abstract and simple so as not to distract from the old. The materials used, such as grey granite and white marble, plaster and paint, complement the restored bungalow well. n

Image © RT+Q Architects Pte Ltd

Image © RT+Q Architects Pte Ltd

Owner: Mr Ong Kok Thai Architect: RT+Q Architects Pte Ltd Engineer: E3 Consulting Engineers Contractor: Huat Builders Pte Ltd

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n URA Architectural Heritage Awards 2011

9-19 Kreta Ayer Road Constructed between 1840 and 1900, the six units of narrow twostorey transitional style shophouses in the Chinatown Historic District of Bukit Pasoh, have been converted into one modern, open-plan corporate office space. Before approaching the challenge of adapting the old space for a new use, the project team used the Top-Down approach in the restoration process. Exercising maximum retention, sensitive restoration and careful repair, the team carefully reinstated the key elements of the buildings’ traditional exterior. The original moulded capitals, pillars and the granite thresholds on their facades and five-footways were restored as were the precast vents at the front and rear of the shophouses. Additional ground beams and footings were introduced to take care of the new loading and to ensure the integrity of the party walls. To achieve the single volume of space, the party walls were opened up to the allowable maximum of 50 percent. On each level, great care was taken to ensure that the new space still echoed the shophouse character and proportions. The double layer floors concealed the mechanical and electrical conduits and ensure sound insulation by absorbing the footfall of busy executives above. To minimise the sloping site, steps were neatly introduced at passageways with workstations ingeniously placed to camouflage the level differences. The firemen’s requirements were fulfilled by installing the fire rated roller shutters such that they blend in with the party walls, thus minimising their bulk. Besides reinstating the pintu pagars of original design on all the shophouses, the iron security bars were also retained.

The team is commended for the many ways of introducing natural lighting into the interior spaces. These spaces originally stifled by dark corners and dim corridors have been illuminated by new skylights between the passageways, vertical slot openings in the restrooms, new jack roofs at every unit and the generous French window openings that wrap around the lush roof deck gardens at the open-to-sky second storey terraces. n Owner: Hanru Investments Pte Ltd Architect: Liu & Wo Architects Pte Ltd Engineer: KH Consultants Contractor: Soon Soon Lee Construction Pte Ltd

2 Dickson Road This four-storey 1920s Art Deco style building in the Little India Conservation Area was once the Hong Wen School. Today, it has been rebuilt as Wanderlust Hotel with 29 rooms. The triumph of this project lies in the way the project team had given the revitalised old building a new sense of place within the eclectic urban montage of Little India. Most of the architectural elements on the external envelope, such as the intricately painted ceramic tiles on its front facade and the classic stained glass windows at the upper storeys, have been restored. Keeping the property’s original structural grid intact, the project team reworked the old school layout by creating various room types and sizes on each floor. Each floor was designed by different interior decorators, each with contrasting themes, furnishings and colours. No two rooms are the same. A new roof deck garden with a jacuzzi and restaurant were incorporated. The functional elements of a modern-day hotel have also been creatively subsumed into the final development. One of these is the new lift core, which was added to the original and revitalised airwell to provide easy accessibility to the rooms above. To create a statement, the brickwork of one of the walls around the airwell was exposed and landscaping introduced within it. Extensive micro piling was required to reinforce the structure for its new purpose. The retention of the airwell preserves an important element of the building’s past while serving the original purpose of bringing natural daylight into the heart of the hotel. In addition, with the clearing away of the unsightly air-conditioning units at the rear of the building, a new uber chic rooftop sundeck has been created, tucked behind the authentic envelope of the building. n

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Owner: K.M.C. Holdings Pte Ltd Architect: DP Architects Pte Ltd Engineer: S B Ng & Associates C E Contractor: Shanghai Chong Kee Furniture & Construction Pte Ltd

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