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Evolution towErThe 249-m high Evolution Tower is
part of Moscow’s international trade centre, ‘Moscow City’, which is
currently said to be the largest investment project in the Russian capital. Due to the fact that each of the 52 upper floors is constantly twisted by 3° whilst being arranged around the central core of the building, the skyscraper experiences an elegant rotational movement in a clockwise direction from the base to the top by more than 150°. Main contractor on the project is CJSC Renaissance Construction of Moscow.
Formwork solutionThe elegant rotation of the building is made even more striking through the spiral-shaped design of the distinctive rectangular columns on the building corners. The corner columns are thus not only inclined, but also feature a twist. The project-specific Peri self-climbing formwork concept is based on ACS and RCS system components whilst a special gallows construction accelerates the shuttering and striking procedures.
In addition, the climbing formwork for the rectangular columns fulfils two other tasks: in the area of the building corners, the external formwork serves as slab edge formwork when forming the floor slabs, whilst the RCS formwork scaffold unit also acts as a climbing protection panel and thus part of the building enclosure.
Facing page: With an elegant 150° rotation, the Evolution Tower spirals almost 250 m into the Moscow sky. Inclined and crane-independently climbed RCS protection panel units are being used here to provide a very high level of safety.
Right: The site management team from Renaissance Construction standing in front of the Evolution Tower.
russia
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Core walls and floor slabs are concreted in one pour, with each floor divided into three concreting sections. Up to the 26th floor, four ACS P climbing units have been used to form generously-sized working platforms whilst Vario GT 24 wall formwork elements serve as internal and external formwork. Furthermore, the core floor plan changes and, for this, one of the ACS platforms is quickly converted to a gallows variant through the use of four ACS G brackets. As a result, the following storeys can also be efficiently climbed. For forming the floor slabs, customised Uniportal slab tables keep pace with the fast rate of working.
The top three floors under construction are tightly enclosed with the RCS climbing protection panel. The units climb the constant twist of the building in an inclined position, also crane-independent with the help of the mobile climbing hydraulics. The permanently installed rail-guided system also ensures a fast and safe climbing procedure in inclined positions. The climbing rails are connected to the building by means of corresponding slab shoes. In combination with the four climbing units of the rectangular columns,
Above: Even the landing platforms are rail-climbed, and without any crane support due to the use of the mobile RCS climbing hydraulics.
Above left: The inclined positioned climbing rails of the RCS climbing protection panel are permanently connected to the building by means of corresponding slab shoes.
a gap-free enclosure is achieved – for safe and quick working operations particularly at great heights.
Moreover, on the sides of the building, RCS landing platforms are climbed for use as temporary storage areas and for moving of loads with the crane. The climbing procedure also takes place here without a
crane, hydraulically with the help of the mobile climbing devices. On its inclined climbing path, the continuous vertically positioned circular columns present a permanent obstacle. Therefore, the RCS platforms were designed in a way that they can be temporarily moved on varying positions, by means of flexibly adaptable
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forward and reverse inclinations without any time-consuming modification work.
The special feature of the Moscow Evolution Tower is the combined climbing formwork utilisation for the vertical core walls and twisted corner supports in connection with the obliquely climbed protection panel and landing platform. In addition to the detailed formwork planning, a previously used test set-up was therefore an important part of the Peri overall solution. This meant that the applicability under construction site conditions could be demonstrated very early on, and the optimisation potential for daily on-site working operations could be accelerated through fine-tuning adjustments. n
Vario girder wall formwork for the core walls climbed with help of the ACS self-climbing system in regular weekly cycles with 4.30 m concreting cycle heights. Im
ages
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Continued on page 92...
Construction work on the Delhi Metro - aimed to carry six million passengers daily – started in 1998. With phases 1 and 2 completed on time and within budget (US$5.57 billion), two million passengers currently use six metro lines, 142 stations and 190 km of track. Efficiency is high with almost 100 percent of trains running within one minute of schedule. Phase 3, which started in 2012, will add two new lines, 10 route extensions, 112 km of track and 26 new underground stations. Several of the new underground stations will be 22 m deep, passing under existing operational underground corridors. Phase 3 is scheduled to be completed by 2016, within its US$6.75 billion budget. Phase 4, which has just started, is due to finish in 2021.
Reliable air powerSpecialist Indian contractor Indigo InfraProjects is currently working on the Kalkaji and Vasant Vihar underground metro stations, part of the Phase 3 project. Formed in 2012, Indigo InfraProjects is known for its expertise in ground engineering techniques including anchoring, shoring, shotcreting and rock bolting.
To help with its work on the project, Indigo InfraProjects is using Atlas Copco portable air compressors for air power duties. Following the initial order in 2012 of two XAH 210s and an XAHS 486, Indigo InfraProjects ordered two XAT 266s that were delivered in January
Delhi Metro phase 32013 and another two in March 2013. The entire range of Atlas Copco compressors offers reliability, easy maintenance and flexibility. Each model features robust designs, powerful engines and a soundproof canopy for easy manoeuvrability on rugged terrains. “We undertook a range of discussions with Indigo InfraProjects to study their requirements before determining the most optimal compressors for this application,” said Jasveen Singh, territory manager India, Atlas Copco Portable Energy.
The latest model to join the Indigo InfraProjects fleet is the Atlas Copco XAT 266. “The XAT 266 offers Indigo InfraProjects the reliability and power they require with optimised maintenance and running costs,” said Anil Singh, site manager with Indigo InfraProjects. “The XAT 266 truly is a unique compressor: no other compressor in the market offers an air delivery of 260 l/s (550 cfm) at 10.5 bar (150 psi), making it the right choice for shotcreting. It is also best in its class in terms of fuel economy as well as running and maintenance costs. Lastly, it is the only compressor in its class to use a six-cylinder Ashok Leyland (AL6DTi) engine, which lowers maintenance costs by 10 to 15 percent compared to compressors using other engine brands.”
The other two models in the fleet – Atlas Copco XAH 210 and Atlas Copco XAHS 486 – are both powered by Cummins engines.
The Delhi Metro Phase 3 project is expected to be completed by 2016, which will add two new lines, 10 route extensions, 112 km of track and 26 new underground stations. Some of the new underground stations will be 22 m deep, passing under existing operational underground corridors.
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The XAH 210 has an operating pressure of 10.5 bar (150 psi) and a free air delivery of 210 l/s (450 cfm) and the XAHS 486 offers 12 bar (175 psi) of pressure and 229 l/s (486 cfm) air delivery.
Both the Kalkaji and Vasant Vihar underground stations lie on the Outer Ring Line (Line 8), which will have 26 new stations and 37.25 km of track to connect Janakpuri West with Botanical Gardens in the east of Delhi.
Kalkaji stationKalkaji station is located near to the Kalkar Temple, one of the oldest and most revered ancient temples of India dedicated to the goddess Kalka. It will provide an important interchange hub for the ‘Violet’ line, providing connections to Central Secretariate, in Central Delhi, and Faridabad in the South Eastern suburbs.
At Kalkaji, Indigo InfraProjects is using an Atlas Copco XAT 266 for slope stabilisation shotcreting on the excavated slopes of the cut and cover station. Over an area 20 m deep, 25 m wide and 500 m long, a mix of cement, 6-10 mm aggregates, 3 percent sand and crushed dust is sprayed to a depth of up to 100 mm over predetermined areas. “In this type of situation, it is essential to have equipment that you can rely on,” said Mr Singh.
On the same project, Chennai-based Pavai is also using a truck-mounted XAH 210 for shotcreting duties. During its four-month contract, Pavai is contracted to shotcrete about 3,500 sq m, down to the excavated depth of 24 m. “We have been using this compressor since 2006,” said K. Baskar, project foreman, Pavai, “and it has proved itself to be completely reliable.” Pavai is another 100-percent Atlas Copco compressor fleet contractor with 17 units.
Vasant Vihar stationLocated in one of the world’s most expensive residential areas, Vasant Vihar houses more than 50 diplomatic missions in southern Delhi. The site of the Vasant Vihar underground station has been divided into three sections by two existing highways that cross the 24 m deep by 28 m wide excavation. Temporary bridges will be built to maintain traffic flows and relieve congestion.
At the new station on the Outer Ring Line, Indigo InfraProjects is installing rock bolts along the cut and cover excavated station. The anchor holes are 15 m deep with a diameter of 152 mm and an angle of 20° in predominately fragmented rock. For the first 3 m bench, the company is drilling a line of 19 holes, each 4 m apart. On completion of each hole, pre-stressed seven ply cables are inserted and then filled with 53 grade concrete. Each hole takes up to three hours to drill. Two subsequent lines of anchoring, each 4 m apart, are to be installed with further lines awarded on sight of the excavated rock face at depths of up to 24 m.
For this task, Indigo InfraProjects is using an XAT 266 to power an Atlas Copco ROC 203 drill rig. The XAT 266 provides a free air delivery of 550 cfm at 10.5 bar. Compared to the older-model XAH 210, the extra pressure of the XAT 266 is invaluable, according to Mr Singh. “If the hammer
...continued from page 90
becomes ‘locked’ in the rock, the instant extra power is easily able to retrieve the hammer.” He added, “Fuel consumption is also really good for the extra power output using less than 20 l/hr.”
On completion of each line of rock anchoring, main contractor for the Visant Vihar underground station, L&T-SUCG (Shanghai Urban Construction Group) JV, will install I-piles in a ‘solder piling’
application along the bench to a depth of 22 m and 1 m apart before inserting wooden planks to further protect the bench slope.
L&T-SUCG is using an XRH 1100 Atlas Copco compressor with a free airflow of 1,100 cfm to insert the I-piles. Atlas Copco compressors are also used for shotcreting the top 3 m bench with a 50-70 mm thickness over the 24 m length together with a wire mesh support. n
Top and above: Indigo InfraProjects is currently working on the Kalkaji and Vasant Vihar underground metro stations using Atlas Copco portable air compressors for air power duties, including XAH 210, XAT 266 and XAHS 486 models.
02994 Terex SE Asia Construction Magazine A4 Ad-Update 17-9-13.indd 1 17/09/2013 16:01
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The HOBAS pipe system has been installed at the Upper Kokawita hydropower plant project site in Sri Lanka.
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in the depths ofthe sri lanka rainforest
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According to the Sri Lanka Sustainable Energy Authority, hydropower has played a major role in Sri Lanka’s electricity generation since the commissioning of the first hydroelectric power plant in 1950. Thanks to its humid climate conditions and hilly terrain, the country offers excellent opportunities for generating hydroelectric power both through larger government-owned and private small hydropower plants. In 2012, a new small hydro facility was put into service at the Wewa Ganga river in the village of Kokawita, close to the city of Kalwana in the southwest of Sri Lanka. HOBAS was chosen to supply its pipe system to the project.
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The terrain on site posed some challenges to the pipe installation process. It is hilly, made up of partly loose and partly very rocky soil, and the planned pipe route along the Wewa Ganga riverbank was very difficult to access. Using a 20 t excavator, the pipe sections were transported to their required positions and then installed according to the soil conditions. Approximately half of the 478 m long pipeline was laid on supports above ground (275 m), while the other half was buried (203 m).
The installation work took about 12 months to complete. The HOBAS GRP pipes have a nominal diameter of 2,000 to 2,200 mm and stiffness of 5,000 and 10,000 N/m. They are designed for a nominal pressure of 1 to 4 bar. The power plant features a capacity of 1.2 MW, head of 17 m and flow rate of 10 cu m/sec.
Top and above: The terrain on site posed some challenges to the pipe installation process. It is hilly, made up of partly loose and partly very rocky soil, and the planned pipe route along the Wewa Ganga riverbank was very difficult to access. Using a 20 t excavator, the pipe sections were transported to their required positions and then installed according to the soil conditions.
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About half of the 478 m long pipeline was laid on supports above ground (275 m), while the other half was buried (203 m).
HOBAS said its client, Terraqua Kokawita Pvt Ltd, is very satisfied with the minimal head loss in HOBAS pipes thanks to their mirror-like inner surface and very much appreciates their proven durability; this makes HOBAS pipes ideal for a sustainable, environment-friendly energy project. Pacific Hydro Electric SL Pvt Ltd was the designer and constructor of the project, including the pipe routing. The hydropower plant is now able to provide 1,000 homes in Kokawita with clean energy.
GRP pipe system From an economic and ecological perspective, hydropower is believed to be increasingly important due to its various advantages over other conventional methods of power generation. Despite the initial investment obstacle, small hydropower plants are said to have proven cost-effective thanks to their long service life of often more than 70 years and low maintenance costs. Dams, canals, intakes and penstocks obviously cost a very different share of the total for different sites, said HOBAS. A lot depends not only on the topography and the geology, but also on the construction method and the materials. The penstock usually constitutes a major expense in the total budget - as much as 40 percent is said to be not uncommon in high head installations. Therefore it is worthwhile choosing the material carefully in regard to surface roughness, design pressure, method of jointing, weight and ease of installation, service life and maintenance, explained HOBAS. The company pointed out that the trade-off is between head loss and capital cost; however, in terms of penstock design, there is a possibility to have minimal head loss and save on capital cost at the same time by installing a HOBAS GRP pipe system – this is due to the fact that it can be laid in curves using fewer or no fittings.
Continued overleaf...
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Curved installationSince penstocks of small hydropower plants are often set in remote places - which are sometimes difficult to access - the topography does not allow a fully straight pipe line, said HOBAS. The constructors are confronted with horizontal and vertical curves that can be realised with conventional elbows, or alternatively by curved installation with for instance shorter angular cut pipe sections and flexible joints, which in turn accommodate a deflection that is higher than what relevant GRP product standards provide, explained HOBAS.
The company said while some deflection can be accommodated in the HOBAS FWC Joint to achieve curves with larger radii, shorter pipe sections will produce smaller ones, and angular cut pipes will reduce the radii even further, especially in larger diameter lines. The penstock, mounted above ground on saddles or installed underground, is this way optimally routed, and no or fewer fittings and concrete thrust blocks are utilised. With the remote and difficult-to-access construction sites, each omitted cast-in-situ concrete block represents substantial cost and time savings. Besides the above mentioned economic benefits, curved installation, angular cut or not, substantially increases the pipe’s efficiency for there are less hydraulic losses than if elbows are employed, added HOBAS.
Quality assuranceAccording to HOBAS, to verify the leak tightness of joints with angular deflected and angular cut pipes, stringent tests to ISO 8639 have been conducted at the TÜV and governmentally (ISO 17025) accredited TechCentre in Wietersdorf, Austria. Apart from the pipe system itself, external factors play an equally decisive role and need to be carefully checked to verify if curved installation is suitable for the respective project, said HOBAS. Drawing from numerous laboratory tests with more than half a century of experience, the company provides support for such feasibility studies to ensure that each project receives a hydraulically and economically optimised pipe solution.
In addition, HOBAS explained that special attention needs to be paid to the correct installation of the line and should always be conducted to the individually prepared method statement by HOBAS and the latest respective standards. For underground constructions, appropriate pipe trenching and bedding, soil conditions (groundwater interference, soil type etc.) and field conditions (slope, traffic, frost heave etc.) need to be ensured. For penstocks mounted above ground, the saddle design and the fixation of the pipe or coupling need to be taken into consideration. During every project phase HOBAS also provides support and know-how. n
To verify the leak tightness of joints with angular deflected and angular cut pipes, stringent tests to ISO 8639 have been conducted at the TÜV and governmentally (ISO 17025) accredited TechCentre in Wietersdorf, Austria.
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Untitled-3 1 23/9/13 2:22 PM
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Ilkal graniteAccording to legend, Ilkal granite (also known as Cat’s Eye granite) was first discovered 2,000 years ago – but remained a little known rarity for two millennia. This all changed in 1983 when rich deposits were discovered in a small corner of South West India – allowing Ilkal granite to be exploited for its beauty and decorative worth.
The Purthagere and Kadur villages are surrounded by some of the wildest mountain scenery in the region. This is where Dolphin International is based, a company founded by Badrinath Kandkur, Subhash Harihar and Manjunath Kandkur. It is then able to harvest this valuable natural resource for building and construction purposes in India and all over the world.
First established in 1987 under the name of National Granites in the Bagalkot District of Karnataka, the company has paved its way to success in the granite field by pursuing quality granite materials and adding ancillaries over a decade. From a small quarry in southeast Bagalkot, Karnataka, the business has expanded such that it now operates across four large quarries, encompassing over 60 acres of land and creating a wealth of jobs in surrounding villages. About 150 employees are dedicated to efficient quarrying operations.
The company, along with two other international partners, has been the backbone for quality control of rough granite blocks supplied to Taiwan and China. It is able to
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achieve monthly procurements of more than 1,500 cu m of almost all types and colours of the stone. The granite blocks are cut and polished for use in flooring, cladding, kitchens, bathrooms, memorials, statues and more.
Volvo Construction Equipment (Volvo CE) excavators and wheel loaders are used to transport the granite across the four sites, stocking up the stone ready for onward transit. Dolphin International is Volvo CE’s first Indian customer to take delivery of a Volvo EC480 excavator machine.
Dolphin International first purchased construction equipment from Volvo CE in 2004 and today the company owns seven machines including an EC480 DL excavator,
Continued on page 102...
Above: The Volvo speeds around the quarrying site.Left: A rough block of rare Ilkal granite. Below left: The smaller fragments also get put to good use.
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three EC240s, two EC290s and an L220F wheel loader. “We needed an excavator that could extract granite blocks of up to 45 t,” said Badrinath Kandkur, partner at Dolphin International. “That’s no mean feat – but our EC480 makes it look like child’s play.”
According to Mr Kandkur, productivity has shot up by over 25 percent since the EC480 was first brought into service. With fuel consumption at just over 30 l an hour, it is a clear win-win for Dolphin International. Little wonder then, that the company soon plans to add four more EC480s to its fleet.
“You see, that’s the point with Volvo equipment. Not only do you save on fuel consumption, you boost your activity too,” highlighted Mr Kandkur. “And when you consider efficiency, service aspects and user-friendly features, it becomes clear why owning Volvos makes good business sense.”
Every Volvo in the company’s seven-strong fleet is hard at work in the quarries day after day. “Getting big orders is the easy part. It’s only when you deliver the granite that you realise its true value,” said Mr Kandkur.
Desert Cream GraniteThe Barmer district in West India spreads across 28,387 sq km of land and forms part of the Great Indian Desert, also known as the Thar Desert. In summer months temperature can soar to 51°C and drop to freezing point in winter. Like many other districts in the desert region, Barmer is known for its folk music and dance. Unlike other areas, though, Barmer is also home to a specialty stone – the durable and beautiful Desert Cream Granite.
Pacific Stone Mart, a leading exporter operating out of Barmer District in Rajasthan State, is said to be a pioneer in the manufacturing of natural stone products in India. It mines a large variety of natural stone and manufactures, supplies and exports the material, catering for the needs of general contractors, developers, architects, homebuilders, designers and dealers.
The company produces blocks, slabs and cut-to-size tiles for wholesale. The precious Desert Cream Granite is available in a range of sizes, block dimensions often dependent on the transport logistics of worldwide delivery. The stone is sent to suppliers in the US, Europe, Middle East and Asia.
Pacific Stone Mart operates a fleet of Volvo excavators, helping to extract and transport blocks across the site. It was the first company in Rajasthan to buy a
Volvo EC380D-series excavator, a move that encouraged other quarry owners in surrounding areas to follow suit.
“Now we believe that we are also the first company in India to place an order for a Volvo L350F block handler,” said BR Agarwal, founder and owner of Pacific Stone Mart. “Being the first off the mark comes naturally to us I guess.”
Pacific Stone Mart also owns other Volvo excavator models, including an EC360BLC, five EC210s B-Prime series and six EC380Ds. The site’s goal is to produce 50,000 cu m of granite this year. “This is easily achievable with our Volvos in action,” said Mr Agarwal. “Our experience with Volvo equipment so far can be summed up in a few words – a job well done on time. We rarely have problems with our machines and help is always on hand if we need it.”
Volvo CE operates a comprehensive service network in the area complete with its
own workshop to ensure machine downtime is kept to a minimum.
“The L350F block handler can deliver so much with ease,” added Mr Agarwal. It has incredible power, advanced features and an amazing care cab, which is really comfortable. I think that the Volvo L350F is more fuel-efficient than other machines in its class. Now, if that’s not a huge advantage to my business, then what is?”
Pacific Stone Mart has ambitious plans that will see the company increase output volumes and venture into new overseas markets, creating a higher demand for the best quarrying and mining equipment. “There are no prizes for guessing which machines we will choose,” concluded Mr Agarwal. “There’s huge demand for this variety of stone. Customers worldwide rely on us to deliver the finest quality stone on time – and we depend on our Volvo fleet to make sure that we can deliver.” n
...continued from page 100
Above and left: Pacific Stone Mart operates Volvo machines to help carry out its work.
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KEDA.indd 1 23/9/13 4:24 PM
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n Focus On The Middle East
To get from the European to the Asian side of Istanbul in Turkey, people and goods have to cross the Bosporus Straits. So far, two road bridges as well as ferries provide the only transport link between the two parts of the city and the two continents. The tense traffic situation for the nearly 14 million residents of the city and for international transit traffic should be improved considerably in the near future, thanks to the construction of a new road tunnel under the Bosporus.
The route of the Istanbul Strait Road Tube Crossing Project runs around 100 m below sea level at its deepest point. The interior diameter of the tunnel will be 12 m so that two lanes in each direction can be accommodated. They will extend one above the other on two levels. A Herrenknecht tunnel boring machine will build 3.34 km of the tunnel with a total length of 5.4 km, which will begin its underground mission from a launch shaft on the Asian side. “The project is certainly one of the most challenging tunnelling operations currently being addressed in the world,” said Georg Schleer, Herrenknecht’s project manager.
Extensive geological and hydrogeological preliminary investigations showed that the tunnel builders must reckon with water pressures of up to 12 bar. The executing Turkish-South Korean construction consortium YMSK, consisting of Yapı Merkezi İnşaat ve Sanayi AŞ and SK Engineering & Construction Co Ltd, ordered a specially developed Herrenknecht TBM type Mixshield with a diameter of 13,660 mm for this project.
“The machine’s engineering presented us with a real challenge,” said Mr Schleer. “Even if the pressure is extremely high up front at the tunnel face, the client must be able to change the cutting tools
Bosporus challengequickly and safely if necessary.” The result was a new type of cutting wheel, where time- and cost-consuming access for maintenance work under pressurised air can be reduced. The complete cutting wheel is accessible from the rear of the machine under atmospheric pressure. From there, all disc cutters and a large part of the cutting knives can be changed safely. In addition, the Mixshield is equipped with a special, newly developed lock system. It allows pressurised air access at well over 5 bar where necessary.
To detect strong material wear early and to tackle necessary maintenance accesses in a targeted manner, wear detectors are integrated into the excavation tools as well as in the steel construction of the cutting wheel. Moreover, the disc cutters are equipped with the DCRM monitoring system (Disc Cutter Rotation Monitoring), which was developed by Herrenknecht. It provides data about the rotational movement and temperature of the disc cutters in real time to the machine operator in the control container. Thus, conclusions can be drawn regarding the condition of the tools and change intervals can be better planned. In the Herrenknecht factory in Schwanau the Mixshield was named YILDIRIM BAYEZİD. This is the name of a sultan, who drove the expansion of the Ottoman Empire successfully forward at the end of the 14th Century. After its dismantling, transport and assembly at the job site, the Herrenknecht Mixshield is set to start its tunnelling work in Istanbul at the end of 2013.
Following the opening of the tunnel, the new quick link between Europe and Asia will initially be operated for 26 years by the Joint Venture Avrasya Tüneli İşletme İnşaat ve Yatırım AŞ (ATAŞ) and subsequently handed over to the government of Istanbul. n
The Herrenknecht Mixshield with a diameter of 13.6 m for the Istanbul Strait Road Tube Crossing Project was completed in early July 2013 in Schwanau.
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Work is currently underway on the New Doha International Airport (NDIA) in Qatar. The project is part of a massive expansion programme for Qatar in advance of the 2022 FIFA World Cup as well as to boost the country’s tourism industry. In 2011, Substrate Technology Inc (STI) was chosen as the equipment supplier for the epoxy terrazzo flooring installation in one of the airport’s concourses. The overall scope of work for STI’s products was in excess of 60,000 sq m.
STI supplied 14 Prep/Master grinding and polishing machines, in sizes from 800 to 1,100 mm, and STI diamond tools for epoxy terrazzo grinding and polishing. According to STI, epoxy terrazzo is becoming more popular due to its design capabilities, high strength, long-term durability and low maintenance costs over the course of its 30-year life. “It is the perfect flooring choice for a high-traffic venue like NDIA, which also needs to convey in appearance the prestige of the nation it serves as entrance to,” said Josh Jones, president of STI. “The aggregate and metallic strip design created by the architects and decision makers is a work of beauty to compliment the NDIA’s impressive design, colour scheme and sheer size. As an increasingly adopted product, epoxy terrazzo is fast becoming a flooring choice, leaving behind the theory that airports must be clad in natural stone.”
To prepare for the epoxy terrazzo installation, the manufacturer requires the use of a shot-blaster to profile the concrete surface. This method is said to provide the perfect mechanical key that the epoxy terrazzo needs to adhere to the concrete floor. In the case of NDIA, the concrete was in a rough state and because of inequalities in elevation, shot-blasting alone would not flatten the floor to acceptable levels, explained Mr Jones. The contractor, upon consultation with STI, chose to use the Prep/Master machines already on-site to do this grinding portion of the work. “Although the Prep/Master machines were purchased for the epoxy terrazzo installation, it is no problem to use the machines for the preparation of concrete as was required. This change in condition did not hinder the contractor because he was without the need of any new or additional machinery to correct the concrete’s condition,” said Mr Jones.
sti ‘takes the floor’ at ndia
STI has been chosen as the equipment supplier for the epoxy terrazzo flooring installation in one of the airport’s concourses. The company supplied 14 Prep/Master grinding and polishing machines, in sizes from 800 to 1,100 mm, and STI diamond tools.
The New Doha International Airport is part of Qatar’s massive expansion programme to prepare for the 2022 FIFA World Cup as well as to boost the country’s tourism industry.
Epoxy terrazzo installationAfter flattening and grinding the floor with the Prep/Master machines, the epoxy terrazzo installation was ready to commence. The installation of epoxy terrazzo is a labour-intensive process of mixing the raw components of stone or glass aggregates, epoxy and other natural materials at the worksite. This mixture is then placed on the floor and screeded to a consistent depth before it cures and hardens. After eight hours (minimum drying time), the next phase of work begins.
The STI Prep/Master machines were started with 24 grit STI Turbo diamond tools to do the initial dry grinding of the epoxy terrazzo in order to smooth and flatten the floor. This portion of the work is done with the assistance of dust collectors provided by STI
Below left and right: The overall scope of work for STI’s products was in excess of 60,000 sq m.
