Job Report Slipform Paver SP 500. Airfields of premium quality for King Abdulaziz International Airport

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1 Job Report Slipform Paver SP 500 Airfields of premium quality for King Abdulaziz International Airport

2 All-clear for the heavy-weight Airbus A380 Royal mission King Abdulaziz International Airport in the Saudi Arabian city of Jeddah is frequented by over 15 million passengers per year. Jeddah is considered the most important seaport on the Red Sea and is located approximately 80 km from Mecca, the centre of Muslim pilgrimage. The airport was opened in April 1982, having been named after Abd al-aziz ibn Saud, founder and former king of the Kingdom of Saudi Arabia. Being one of currently three international commercial airports in the country, it has three runways and extends across a total area of 105 square kilometres. Wirtgen SP 500 sets the stage for landing and take-off of the Airbus A380 Ever-increasing air traffic and higher aircraft tonnages were the reasons for expanding Royal Terminal III at King Abdulaziz International Airport. In a first construction phase, the aircraft parking area was therefore expanded by 31,000 square metres. In addition, expansion has begun on the airfield of the royal terminal that handles the flights of the royal family and state visitors. This is also where, in the future, handling of the giant Airbus A380 will take place on an area of 34,000 m². King Abdullah ibn Abd al-aziz entrusted Binladin Group Rush Projects with these two construction projects and, being the executing agency, the company decided to use the SP 500 slipform paver. A good choice, as Project Manager M. Ali Mubayedh explains following completion of the first construction phase: The machine has produced excellent paving results, and the service life of the airfield has been extended thanks to its consistently high compaction performance. The paver is absolutely reliable, and the final product is of excellent quality. What s more, we were able to significantly increase daily production rates, M. Ali Mubayedh adds, explaining the merits of the SP 500 slipform paver.

3 The seaport of Jeddah is located on the shore of the Red Sea, around 80 km from Mecca, the centre of Muslim pilgrimage. Ground handling of the super Airbus A380 will soon also be possible at King Abdulaziz International Airport. Project details Client King Abdullah ibn Abd al-aziz Location King Abdulaziz International Airport, Jeddah, Saudi Arabia Project designation Upgrade Face Extension of KAIA Royal Terminal III Executing agency Binladin Group Rush Projects Subcontractor Kabbani Construction Group Concrete laboratory Soil & Foundation Co. Ltd. Total investment volume 155 million Saudi riyals (33 million euros) Investment volume airfield 66 million Saudi riyals (14 million euros) Labour approx. 18 construction workers plus project management team Paving area 1 st phase 31,000 m² Paving area 2 nd phase 34,000 m² 2 // 3

4 The spreading auger installed in the SP 500 distributes the previously delivered concrete across the full paving width. The SP 500 in detail The SP 500 is a true multipurpose slipform paver, for it is capable, in the standard version, not only of producing concrete slabs of up to 6.0 m in width and 40 cm in height for motorway or airport construction but also of paving small and large poured-in-place concrete profiles, such as curbs or safety barriers. The hydraulically telescoping machine frame additionally enables paving widths larger than 6.0 m in accordance with customer specifications. There s even more: the SP 500 s wide range of applications is increased further by a large number of options, such as hydraulic or electric vibrators, spreading auger or spreading plough, dowel bar inserter, finishing equipment, pivoting legs or the innovative stringless 3D control system. In addition, its modular design enables the paver to be fully configured to customer-specific requirements, and components to be easily retrofitted at a later date. The slipform paver has also stood the test when it comes to special applications in complex tunnel construction and in slab track construction for high-speed trains. The SP 500 impresses with ease of operation and an excellent view of the construction site from the operator s platform.

5 Reliable machine and experienced staff save time and money The concrete was placed to perfection by subcontractor Kabbani Construction Group whose gang comprised a paving train and crew of around 18 as well as workers in charge of cutting joints or supplying dowel bars. The excellent paving result was, not least, due to the ample experience in the operation of Wirtgen machines the subcontractor had gained in comparable projects on other airports, such as Cairo International Airport in Egypt. Paving at a width of 5.0 m and concrete thickness of 40 cm, the Wirtgen SP 500 demonstrated its great staying power and reliability. There was not a single technical problem during production of the first section despite extreme conditions at temperatures of sometimes over 50 degrees Celsius. The machine went smoothly six days of the week. Without working a single hour of overtime, we were able to complete the project even earlier than scheduled, enabling us to save costs on top, adds the project manager. Excellent teamwork: the SP 500 and staff from Kabbani Construction Group. The construction project is supported by experienced Wirtgen service engineers. 4 // 5

6 The side tie bar inserter inserts tie bars in the side of the concrete slab at specified intervals. Mature technologies: dowel bar inserter and side tie bar inserter M. Ali Mubayedh is enthusiastic about the Wirtgen technologies, which include the operating principle of the dowel bar inserter as well as the side tie bar inserter. Designed for accuracy and flexibility, the dowel bar inserter precisely placed the 500 mm long, plastic-coated iron dowel bars into the concrete in longitudinal direction by means of electric high-frequency vibrators and in a hydraulically controlled vertical movement. This process ensured that the dowel bars were inserted in their correct final positions across the entire working width. The finishing beam and super smoother then came into play, ensuring perfect evenness of the freshly paved concrete slab. This eliminated the requirement of a second mould otherwise required for smoothing the concrete surface. To ensure a finished concrete slab of perfect quality, a surveying team continually checked the surface during the paving operation and once again in a final inspection after completion of the paving process. Operation of the paving train and the work of our surveying teams go hand in hand on all of our construction sites. Quality is our top priority, and quality-consciousness is also embodied by our team, says Mohammed Nour Almaarawi, Maintenance Manager at Al-Saubai Machineries, the local Wirtgen dealer. The super smoother made of high-quality material ensures perfect surface quality.

7 Second construction phase to be completed by the end of 2012 Following the successful completion of the first project phase, work on the new parking area for the Airbus A380 has already begun. Once again, extremely high demands are placed on the concrete slab especially in terms of the great forces exerted by the giant heavyweight. Smooth logistics are of vital importance here as well to ensure successful completion of the concrete paving operation, explains Mohieddine Sadek, the Managing Director at Al-Saubai Machineries. As Wirtgen s dealer in Saudi Arabia of many years, he has been involved in numerous largescale projects and is fully familiar with conditions such as those prevailing on King Abdulaziz International Airport. He is confident, therefore, that the second phase of construction will be completed as scheduled by the end of Our reliable SP 500 slipform paver is already busy again, paving metre after metre of concrete. That means we are right on schedule. The Wirtgen SP 500 slipform paver enables easy production of day joints. Rutting and deformed pavement stretches are not an issue thanks to the tremendous compressive strength of the new concrete slab. 6 // 7

8 Illustrations and texts are non-binding and may include customized fittings. Subject to technical changes. Performance data depend on operational conditions. No EN-10/12 by Wirtgen GmbH 2012 Printed in Germany Wirtgen GmbH Reinhard-Wirtgen-Str Windhagen Germany Phone: +49 (0) / Fax: +49 (0) / Internet: info@wirtgen.com