Big Project ME Concrete Supplement 2014

CONCRETE SUPPLEMENT 2014 ALSO INSIDE pouring machinery piling in focus concrete science precast powers on

THE HARD FACTS ABOUT

CONCRETE Big Project ME breaks down the concrete industry as the demand in the GCC looks set to rise and rise

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EDITOR’s COMMENT

Group Chairman and Founder Dominic De SouSa Group Ceo naDeem HooD Group C0o Gina o’HaRa

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Concrete concerns Infrastructure project awards across the GCC are forecasted to reach $86 billion in 2014, a report by Ventures Onsite has found, indicating that the demand for concrete is set to skyrocket across the region.

With 40% of the concrete demand in the Middle East coming from the GCC, it’s no surprise that experts from around the world are descending upon Dubai for the International Concrete Technology Forum at Middle East Concrete (November 17-20).

The significance of this increase in demand for this most essential of building materials is put into context when we think of the massive shortfalls caused by previous construction booms, which saw the supply unable to cope with demand.

What’s interesting about this current scenario is that concrete suppliers are actually worried that their supplies will exceed the demand in the market, as our interview with Jean-Francois Dufour shows.

From one extreme to another, it seems like the concrete market is in for an interesting ride.

Registered at imPZ Po Box 13700 Dubai, uae Tel: +971 4 440 9100

A ConCrete future

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Gavin Davids Editor

concrete SUPPLeMent 2014

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every effort to ensure the accuracy of

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MARKET REVIEW GCC CONCRETE

A CONCRETE FUTURE

What are the standards of concrete production in the GCC, and who is the regional market leader? Neha Bhatia investigates for Big Project ME about improved specifications. If you go back 20 or 30 years, chances are the concrete being manufactured at the time wasn’t up to the mark.

“That’s no longer the case though. There’s a greater understanding about the local environment now, so factors such as temperatures, quality of sand, water to cement ratios and so on are kept in mind while producing concrete.

We’re in a desert region, but you’d be surprised

Coping with Counterfeits “I’m not scared of counterfeits in the market anymore.

It’s a part of our business and if you look around the market, around 99% of all firms which produce counterfeit products copy Putzmeister. In a way, it’s a compliment for us because when you imitate, you only pick the best, not the second or third best in the market. It’s a sign we’re doing well, but it also means competition for us that we have to be two steps ahead of.

“It also boils down to the contractor. If he’s working on a project which will complete within a year, chances are he will pick counterfeit equipment as a cheap solution.

But for contractors in it for the long run, Putzmeister is a better investment not just because of how good our products are, but also because the after-sales services, operator training and parts availability we enable is unmatched in the market. It depends on the contractor’s intentions, though.”

Jens Bawidamann, Regional Director, Putzmeister Middle East

at how few qualities of sand are actually capable of being used for concrete production.”

These specifications have an impact on the applicability of concrete on any given project, but different building codes in each city, even within the same country, can translate into limitations for concrete suppliers.

Abdel Razzak Dajani, Managing Director of Xtramix Group in Abu Dhabi, explains what this means for his firm: “Dubai tends to undertake a lot of private sector projects, while more government projects are found in Abu Dhabi. Our manufacturing plant is in Mussafah in Abu Dhabi, but to participate in a project in Dubai is not always easy since the building standards there are different.”

Xtramix’s total output is 2,700 m3/hr and it uses 220 concrete trucks, 45 mobile pumps and 20 stationary pumps and other equipment. Its long run in the market alongside parent firm Al Jaber Group has allowed the firm to procure the high volume of machinery and maintain it even during difficult economic times, which, as Dajani says, the GCC hasn’t fully recovered from.

“The concrete market has been struggling since 2011, when the market dropped to almost a third of its total capacity when compared with volumes for 2005-2010. While it hasn’t recovered from the economic slowness, there are signs that the 2015 will be a better year for the market. The awards of high-worth projects in sectors like infrastructure and housing is healthy for the concrete market.” $156 billion of projects has been awarded in the GCC, largely by governments and statebacked companies, according to a report by intelligence house MEED, and up to $180 billion of contracts for new construction projects will be awarded in GCC states this year.

Infrastructure contracts alone will be worth $45 billion in 2014, the report adds.

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0% of Boston city’s buildings face structural deterioration by 2050, and the concrete cover of local code-compliant buildings in the city could start to fail in 2025.

These grim predictions were announced by two researchers at Northeastern University in Boston, civil engineer Matthew Eckelman and graduate student Mithun Saha, who claim that concrete may not be entirely resistant to the climate change patterns expected in the future.

Rising temperatures, as Eckelman and Saha told the Boston Globe last month, could damage structures made out of concrete, including bridges and roads. Reinforced concrete is typically vulnerable to corrosion and decay over time.

Whether or not building codes account for the ramifications of climate change, global warming will undoubtedly have an impact on the performance and durability of modern reinforced concrete. One way to supplement concrete standards is to improve the current parameters.

Laith Haboubi, Commercial Director of Grace Construction Products’ operations in the Middle East and India, says the UAE has consistently taken steps to enhance the quality of the concrete manufactured and used within its boundaries.

“I’d say the UAE has some of the highest specifications for concrete in the world, and the standards for its use are very high here,” Haboubi tells Big Project ME. “It’s driven by a number of things, but three factors pushed for by the government and local municipal bodies are notable. Specifications for concrete were initially aimed at improving the quality and durability of concrete, and now the focus also includes sustainability.”

Haboubi, who has been in the UAE for a decade now, is quick to point out that this evolution was gradual and staggered. “Durability is one of the key factors which contributed to increasing awareness

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MARKET REVIEW GCC CONCRETE

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HigH specifications The UAE has some of the highest specifications for concrete in the world which is aimed at combating the extreme weather conditions in the region.

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MARKET REVIEW GCC CONCRETE

the power of preCast “Xtramix has many divisions, such as readymix, precast and the like in both, the UAE and Qatar, so I notice trends in the market. Right now, precast is becoming a more preferred option, even more than readymix to an extent, and I can see the difference in the demand for the two. It’s especially the first choice on housing projects.

“It makes sense for contractors to pick precast because, for starters, it means they don’t have to hire additional staff, which is something they’re shying away from at the moment.

Furthermore, precast is quicker than traditional concrete pouring and also provides better quality, because it is produced in a controlled environment. In such cases, it makes more sense for the contractors to use precast than go the traditional way.”

Abdel Razzak Dajani, Managing Director, Xtramix Group

“if you go back 20 or 30 years, cHances are tHe concrete being manufactured in tHe uae at tHe time wasn’t up to tHe mark. tHat’s no longer tHe case tHougH. tHere’s a greater understanding about factors sucH as temperatures, quality of sand, water to cement ratio” “If we speak about markets within the GCC, Saudi Arabia, which is physically larger than the other countries, has the highest need for concrete due to a lot of infrastructure projects launched and ongoing in the country,” Xtramix’s Dajani says. “The cost of production in Saudi Arabia is far less than in the UAE because the standards of production are very different. Qatar is also tendering for a lot of large-size projects right now, so its concrete market will move in the right direction too.”

Qatar’s construction sector hopes Dajani’s words come true. At the Qatar Contractors Forum 2013, Samer Said Khoury, President of the Consolidated Contractors Company, admitted that a shortage of locally-developed construction materials, including cement, continues to worry contractors operating in Qatar.

Qatar National Cement Company is constructing a new factory to increase its capacity to more than five million tonnes per year, but according to the Wall Street Journal, up to 10 million tonnes of cement a year will be required if construction continues to pick up in preparation for the 2022 World Cup. The fact that cement prices in the country increased by over 50% in the run-up to the 2006 Asian Games should ring a bell of caution, and Putzmeister’s Bawidamann feels there may be concrete shortages in the future.

“I’m not directly involved in the process of concrete production, but I know Qatar depends on supply from abroad, so I would consider the country should prepare itself for shortages of concrete. I won’t speculate about concrete production, but I know our products have a good market in Qatar,” he says.

The GCC’s construction boom is evidently going to be the engine of growth for concretedriven industries in the region, where governments and the private sector are working hard to guard themselves against market fluctuations they have suffered in the past. With contract awards worth $22.6bn in the second quarter of 2014 alone,

Japan to Dubai via supertalls “The development of a new product can take anything between three to six months. We work with our research and development teams in our head office as well as in other international locations to try and replicate any relevant products and solutions for the region. For instance, we worked with our counterparts in Japan because they tend to build a lot of supertalls which require solid concrete solutions. Since the Middle East is working on such projects, it made sense for us to incorporate that solution in our local portfolio.

“Even DaraSet AF, an accelerating admixture for concrete which accelerates cement hydration, resulting in shortened setting times, was adapted from the original formula used by our offices in Germany. It went a long way in reducing our research process, which otherwise would have taken very long had we started development from scratch.”

Alexander Grosskord, Product Manager – Concrete, Grace Construction Products (Middle East & India)

Saudi Arabia is striding ahead with investment and operations on its megaprojects across the infrastructure, rail, housing and commercial sectors. The concrete sector will be watching the Kingdom closely, and if Bawidamann is to be believed, there’s much to look forward to.

“Saudi Arabia has been a consistent performer for us, and besides the last quarter of 2013 when the labour laws stagnated the industry, we haven’t had any problems in the Kingdom,” Putzmeister’s regional head says.

“It’s a large country with a huge population, so if you look at all the work the government is doing there, it shows huge potential for concrete companies.”

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Jens Bawidamann, Regional Director for Putzmeister Middle East, knows this is a recovery from tougher days. His job has enabled him to extensively study the GCC concrete market, and as he tells Big Project ME, the last market crisis greatly hurt the concrete sector.

“People just stopped ordering equipment,” Bawidamann laughs, as he recounts his experience of the market at the time. “The crisis obviously led Putzmeister to reorganise, reshuffle and introduce new machines and methods at the international level, but from our point of view, we’ve still emerged from the crisis stronger and better in all regards.”

Bawidamann claims a large part of Putzmeister’s plans for new product development and launch depends on the firm’s local dealer networks: “One of our strengths is the strong local networks we have established worldwide, and they’re naturally present in the Middle East too. So the first step of our planning process depends on the information we’re provided by our dealers. The next source of information is our own people in the market, and that’s followed by the information we receive from our clients and end users.”

While that might be a time-consuming process, consensus on which GCC member is the largest market for concrete is reached quickly.

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Al Garawi Group

Al Garawi Galleria, Al Orouba-King Fahad Highway Junction Olaya P.O. Box 41122, Riyadh 11521, Saudi Arabia Tel.+966 1 4196096 / 4195058 Fax. +966 1 4196101 / 4196103 email: infoalgarawigroup@saudi.net.sa / www.algarawigroup.com

Al Garawi Group an authorized distributor of the following licensee for Saudi Arabia, U.A.E., Bahrain, Qatar, Oman, Jordan, Lebanon, Kuwait and Yemen.

Wolverine World Wide, the global footwear licensee for Caterpillar Inc.

Medco

P.O. Box: 17301, Jebel Ali, Dubai, U.A.E. Tel.: +971 4 881 8821 Fax: +971 4 8818944, Showroom: Al Kwakeb Building, (B-Block) Sheikh Zayed Road, P.O. Box: 2904, Dubai, U.A.E Tel.: +971 4 343 7400 / 343 7500 Fax: +971 4 3437600 email:medcodxb@emirates.net.ae

ADVERTORIAL BASF

the complete formula

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BASF’s Master Builders Solutions provide a full range of innovative solutions to challenges faced by the concrete industry

CONCRETE SUPPLEMENT 2014

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ADVERTORIAL BASF

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aving the right admixture partner is vital to any concrete producer’s success.

BASF is recognized as the global leader in the field of Admixture Systems.

Under our brand Master Builders Solutions, we have developed innovative solutions to the challenges faced by the concrete industry including applications of high performance concrete, durable concrete, self-compacting concrete, waterproof concrete and a host of other options to meet market needs.

Our global supply consists of a full range of admixtures including our classleading MasterGlenium range formulated using polycarboxylic ether (PCE) polymers manufactured in-house by BASF. MasterGlenium allows the maximum water reduction hence giving the highest strength and durability to the concrete.

However, it is only when the concrete is fully compacted that the desired performance can be achieved. For this matter, Smart Dynamic

While BASF gets ready to reach 150 glorious years of creating chemistry in 2015, there is another celebration that our company is having this month: the first anniversary of the launch of Master Builders Solutions.

We have good reason to celebrate! Our brand for the construction industry has been enthusiastically received by our customers worldwide. The new names and packaging of the products under the Master Builder Solutions brand have had an immediate resonance.

Master Builders Solutions is aimed to offer complete solutions and promote connectedness.

We believe that our company must go beyond simply acting as a supplier of materials as a strong relationship between employees and customers is the key to overall success.

Our experts worldwide share knowledge with stakeholders to drive sustainable and tailored solutions across diverse markets. Our sales force and technical services team offer crucial assistance during the various project phases to ensure seamless application and project completion.

The comprehensive portfolio under the Master Builders Solutions brand encompasses concrete admixtures, cement additives, chemical solutions for underground construction, waterproofing solutions, sealants, concrete repair and protection solutions, performance grouts, performance flooring and tiling solutions.

Happy Birthday Master Builders Solutions!

Concrete utilising BASF's patented MasterMatrix technology produces a cost-effective selfcompacting concrete allowing contractors to reduce the cost of placed concrete and assuring structural engineers the durability they specified will be actually be achieved in the structure.

To increase the life-cycle of structures –especially in regions like the Middle East with high temperatures and humidity combined with air-borne and groundcontaining chlorides–, we offer the inclusion of corrosion-inhibiting admixtures and/or hydrophobic pore-blocking water proofers.

The protection of steel reinforcement in concrete is critical if the structure is to reach its designed life time.

Our admixtures are formulated for use with locally available materials (cement, supplementary cementious materials and aggregates) and to cope with the extreme local climatic conditions.

Many of the projects are reaching record heights (e.g. Burj Khalifa) and BASF Construction Chemicals has unique polymers to improve concrete rheology allowing faster and higher pumping with less wear-and-tear on equipment and quicker turn-around of truck mixers. Our in-house polymers allow excellent workability retention to help the ready-mix company get the concrete to site within specification but once placed gain strength quickly to benefit the contractor and client with fast construction.

fast construction David Bowerman of BASF Construction Chemicals says that their products help speed up the pace of construction.

In addition to the mentioned benefits of Master Builders Solutions admixtures, our technical experts assist customers in the design of their concrete mixes to ensure they are the most cost-effective and sustainable.

Our Green Sense Concrete (GSC) technology takes this one step further by producing an Eco Efficiency Analysis to prove how much more sustainable our GSC mix is than the originally proposed mix. With this service package, BASF helps manufacturers improve the performance characteristics of concrete such as resilience, workability, durability and environmental friendliness.

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moving forwards

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comment dubai municipality

bigprojectMe.com

abdullah rafia

Ushering in eco cement The most important component of concrete is also the most hazardous one. Thankfully more sustainable options are making their way into the construction market

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ubai Municipality is eager to implement the latest innovations from the construction sectors across the world, in order to upgrade the quality of buildings in Dubai. According to our strategic plan to transform Dubai into a green city, we are always on the lookout for the best global practices and eco-friendly applications used in them. Cement is one of the major components of reinforced concrete, however it can be harmful to the environment due its high carbon dioxide (CO2) emissions and other toxic substances released during manufacturing.

Thus, DM will soon approve the use of the eco-friendly cementitious materials and an administrative circular will be issued to all stakeholders in construction sector to use the same. A guide book will also be published soon.

After extensive research on eco-friendly cement and its advantages and disadvantages, we concluded that it should replace ordinary cement that is widely used nowadays. It has been scientifically proven that manufacturing

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“dubai Municipality will soon approve the use of the eco-friendly ceMentitious Materials�

NOVEMBER 2014

1 tonne of typical cement produces 1.1 tonnes of CO2, about 164kg of dust and emits other poisonous substances which contributes to global warming, increases respiratory diseases such as asthma, pulmonary ossification and lung cancer, and causes kidney failure.

Moreover, cement factories produce about 50% of all the CO2 released from factories.

Many internationally-used cement alternatives were reviewed and it turned out that many developed countries have already began using it. This is because it helps not only in preserving the environment and reducing emissions, but also improves the durability of concrete. Several scientific research centers, after theoretical and practical deliberations, have recommended using eco-friendly cementitious materials.

Fly ash, ground granulated blast furnace slag (GGBFS), silica fume and fiberglass are some of the approved eco-friendly cementitious materials.

Researchers who have studied the characteristics that distinguish these ecofriendly cements from Portland cement, say the most important advantages are: improved life of concrete structures, reduced CO2 emissions of up to 80%, reduced instances of cracked concrete during the process of hydrogenation (in the early hours of casting), and reduced moisture and water permeability in the concrete, thus reducing the probability of steel corrosion.

The green cement also improves thermal insulation and fire resistance of the concrete, has better resistance to mineral deposit and maintains the concrete’s durability against pressure as effectively as Portland cement.

Moreover, the most popular cementitious materials, fly ash and GGBFS, cost the same as or sometimes lesser than Portland cement, and are also easily available in the market.

Using eco-friendly cementitious materials will support DM's sustainability plan, increase the lifecycle of concrete structures, and preserve the environment, health and safety.

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Leading through innovation

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Big Project ME looks where the piling and foundation is headed as the industry debates the need for new technologies and techniques

from the ground up

Special Feature Piling and Foundations

CONCRETE SUPPLEMENT 2014

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Special Feature Piling and Foundations

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uilding a structure of any kind is a complicated business. The slightest miscalculation can lead to expensive and time-consuming delays.

Given that the majority of construction projects in the region work to tight schedules, this could be catastrophic.

As such, it makes sense for contractors to get things right the first time around. Nowhere is this more important than with groundwork.

It’s better to spend up front and do a careful survey and analysis of the site than to start doing ground work and find your initial estimates and assumptions have been fatally flawed.

When it comes to piling, this is doubly important, given that it costs valuable time to install and operate piling machinery on-site.

Not only do contractors need to choose the right technology, but they also need to take into consideration what they’re building and the type of land they’re building on. Therefore, choosing the right piling technology can be considered as the key to having a successful build.

Perhaps it is this need for caution and conservatism that is stopping the adoption of new piling technologies and methods. As Peter Titus explains, there are fixed ideas in place in the Middle East, ideas that have helped the piling industry to achieve the levels it has today, but that have also held it back from pushing forwards.

“There are a large number of companies active in the sector,” says the managing director of Total Foundation Solutions. “If we’re talking about piling, I think you’ll find that the majority of the companies working in the GCC use the rotary bored-piling technique.”

“There’s very little of what is called CFA [Continuous Flight Auger] and if there is, it’s mainly used for small diameter, shallow piles such as housing projects. Whereas in the West, particularly in the UK, France and the US, CFA has been the dominant piling technique for the last 30 or 40 years. It’s much faster and lower in cost because of its speed, especially when compared to rotary bored-piling.”

“However, engineers in the Middle East, or shall we say geo-technical consultants, are a little bit behind the times on that. They’re not aware, it seems, that in the West there are piling machines that can drill down to 41m and are about 1.5m in diameter. They can cover a huge spectrum of the main piling requirements on projects and therefore it’s an opportunity that’s still being missed despite it not being a new technique,” he asserts during a phone interview with Big Project ME.

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complicated business Piling can be a complicated and expensive business if it’s not done right the first time around, experts say.

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Special Feature Piling and Foundations

bigprojectMe.com

A Quick Guide to PilinG The different types of piling can be differentiated from one another based on the choice of material used or the specific method/ technique adopted for piling.

“if we’re talking about piling, i think you’ll find that the ma jority of the companies working in the gcc use the rotary bored-piling technique”

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Usama Fawzy, branch manager for the Dubai operations of Bauer Spezialtiefbau, points out that it’s not as simple as saying that there is a lack of awareness in the industry. He says that for the most part, piling contractors and consultants are constrained by the nature of the soil that they have to deal with.

“The majority [of piling works] are common bore piles. In some light structures or villas, they’re going for steel plate, if the foundation is okay to work with steel plate. There are no driven piles here because of the rock formation.

You cannot drive piles here. There is some sort of special projects offshore that uses steel piles. But it’s still not driven, it has to be drilled because of the rock base,” he insists.

“All piles serve the same function, but you decide what type of pile to use according to the soil formation. Here in the UAE, after 4m, you find rock. Because of this, driven piles are not the solution. Driven piles work on pure sand soil formation where you can drive the piles in and the piles can take the load. In our situation, we can’t do this because you can’t drive it further, because of the rock.”

While Titus concedes this point, agreeing that there are situations where CFA might not be applicable, he asserts that the reluctance to try new methods is founded on a sense of conservatism that is prevalent throughout the construction industry.

“It’s really about traditions. The old criticisms of CFA existed when I was in university, and I’m in my fifties now!” he proclaims. “They’re still being upheld by senior geotechnical engineers as being the reason [why they’re not using the technology]. Even if they’ve come from those European countries [where it’s been in use for years], they’re reluctant because it’s so well established here.”

CONCRETE SUPPLEMENT 2014

traditional thinking Groundwork contractors are reluctant to embrace new methods of piling and foundation, Peter Titus says.

n

Driven Piles: this technique makes use of a pile driver which is used to drive in prefabricated piles into the ground. most driven piles are made of wood, concrete, or steel and the driving technique leads to soil displacement.

n

Drilled Piles: Drilled piles are also called Castin-drilled-hole piles (CIDh piles) and use extensive boring techniques to drill into hard earth. these include Auger Cast Pile, also called Continuous flight Auger Piling (CfA), Underreamed piles, Pier and grade beam foundation, tripod Piling and mini Piling.

Some of the most commonly used piling devices include:

n

Pile driver: A mechanical device used to insert or drive piles into the soil.

n

Hydraulic Hammer: A modern and state-of-the-art piling hammer for inserting/driving timber piles and pipes, etc into the ground.

Special Feature Piling and Foundations

PilinG the louvre The first package of enabling works,

not suitable Some groundwork experts believe that micro-piling is not suitable for new buildings under construction.

executed by Bauer International, was completed after 503,000 cubic metres of earth had been excavated to accommodate the museum basement. the Louvre Abu Dhabi achieved major developmental milestones with the finishing of the building’s detailed design and the completion of its infrastructure, which encompassed marine, excavation, piling and substructure works. more than 4,000 steel and reinforced concrete piles – a total volume of 21,000 cubic metres of concrete – were driven into the ground to serve as a base for the Louvre Abu Dhabi building.

“You can also make a jet-grout slab. So if you imagine that you’ve got to create a basement, without excavating from ground level immediately, you can create your basement wall using jet-grout columns. You can create your bottom plug and then you can excavate with minimum dewatering. It’s very widely used in all forms, anything with metros, tunnel systems – areas where you’re excavating below the water table, and where you’re trying to keep water away from your excavation or minimise the influx of water,” he explains further.

What is also an issue for the industry is that the government has tightened up regulations on the insertion of pilings, says Fawzy. This in turn has pushed contractors to be more conservative when conducting their estimations and analysis for groundwork.

While there have been advocates for the greater adoption of micro-piling in the region, he points out that there are some considerations that have to be taken into account.

“They’ve changed the zoning criteria for the UAE. The lateral load has become a little

“Very often, you’ll find a cfa specification in the tender document but no one actually addresses it because they don’t actually haVe the big cfa machines here, because of the traditions that they haVe”

high and we’ve started analysing the main load on towers. When it comes to micropiles, it’s not easy to take these kinds of loads because micro-piles are in diameters of 100mm to 250mm and you cannot get a proper sheer reinforcement to take the lateral load. Micro-piling makes for an efficient solution in case you’re making a remedial solution for an existing building, like if you’re adding an extra floor and the foundation is enhanced by micro-piles. But for new projects, you can’t use it,” he states emphatically.

Peter Titus is quick to disagree with this viewpoint, stating that it has been used in many forms, just under different names.

“Micro-piling is purely a description of the size of the pile. It is a form of piling where you’re literally coring. It tends to be under 300mm in diameter. You might micro-pile into rock, so you use a rotary core drill or you could use percussion drilling, a down the hole hammer, or an at-the-top hammer, where you’re literally driving a hammer into the ground with brute force. It’s fast. Micropiling is used in the Middle East,” he insists.

“You know, a micro-piling machine is the same as you use for anchoring, there’s a lot of anchoring machines in the Middle East. You anchor retaining walls, you anchor slopes, but when you use it vertically, it’s called a micropile. Very often, you might use a micro-pile for tension piles. You would put a vertical or even inclined anchor into a hard strata. There is micro-piling in the Middle East, I’m selling a number of machines in Saudi Arabia!”

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“Very often, you’ll find a CFA specification in the tender document but no one actually addresses it because they don’t actually have the big CFA machines here, because of the traditions that they have,” Titus continues.

These aren’t the only issues that the foundation and groundwork industry faces, he says. There are issues concerning the uptake of new technologies like jet grouting.

Jet grouting is when a micro-piling machine is used to drill a micro pile, down to a certain depth (usually 20m). A slotted tube is the inserted into the hole and highpressured grout is fired through, often at pressures of as much as 250m per second.

“You’re using the grout to cut the soil, so it’s a form of soil mixing. You then retract the pipe out of the ground and you’ve created a mixed soil-grouted column which is a pile. It’s called a ‘jet-grout column’. Typically it can be used as a pile, although it’s unreinforced of course. So it has limitations but you’re using the soil in place. You can make that column into a wall by making the columns adjacent to each other.

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At the 2014 Construction Machinery Show we sold 70 units and 100 more units are under discussion. We have delivered a positive message to our existing clients, our competitors, and grabbed new clients.

I think gaining such an appreciation from all members in the construction equipment sector is a great honour and will encourage us to work very hard to keep the same level of style, image, and standards.”

This year the CM Show team delivered an exhibition Saudi deserves. For years, we have seen a vision in this Show and this year the vision was achieved. We wanted quality traffic and we saw equipment and company owners; and we were able to offer some promotions to entice sales.

I saw an increase in our sales immediately.

Our principles, Doosan and Everdigm, really enjoyed themselves. We anticipate the upcoming years to be even better.”

The Construction Machinery Show was perfect from an awareness point of view.

We explained Roots Group Arabia’s capability of covering the construction industry with all of its needs and requirements. The attendance was good especially during weekdays and towards the end of the exhibition. See you next year.”

Al-Qahtani & Sons Khaled El Shatoury, Managing Director

Saudi Diesel Equipment Ahmed Alkooheji, Marketing Manager

Roots Group Arabia Abdulaziz Felemban, Brand Manager

Co-located with

Raz Islam Publishing Director raz.islam@cpimediagroup.com Mobile: +971 50 451 8213

Michael Stansfield Commercial Director michael.stansfield@cpimediagroup.com Mobile: +971 55 150 3849

Special Feature CONCRETE MACHINERY

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READY TO POUR 18

MIDDLE EAST

Concrete is a demanding industry, where plant failure can be catastrophic and margins are wafer-thin. Stian Overdahl discovers how manufacturers are tailoring their equipment to cope with the region’s diverse project mix

CONCRETE SUPPLEMENT 2014

Special Feature CONCRETE MACHINERY

catching the bus Liebherr launched its new Windows-based control system, MPS III, which uses a BUS system.

Rduch says that on a recent trip to Qatar there were numerous complaints that the price of concrete has actually fallen below the price of the raw materials. Prices for concrete also remain stubbornly low in the UAE. “When you’re reaching such poor pricing levels, it’s important to have a system that is accurate and you can rely on, and that you can use to economise on your costs as much as possible.”

Rduch is also seeing demand grow for mobile batching plants, especially for job sites in congested areas. Having concrete production on-site reduces the number of expensive mixer trucks needed to transport it, and it can also prove more environmentally friendly, and has in special cases been requested by the client.

As concrete is transported from the batching plant to the pour site, it is the concrete pump which is the key machine in the process. If a breakdown occurs during a major pour, a significant amount of concrete can be lost, and the pour may even have to be restarted. Concrete pumps from Chinese equipment manufacturers, notably Sany and Zoomlion, have long been popular in the Middle East, with many truckmounted pumps and stationary placing booms sold into the region during the boom years.

Subsequently, both companies purchased European manufacturers – Zoomlion bought CIFA in 2008, and Sany acquired Putzmeister in 2012 – and in both cases the parent company brand and the acquisition remain active in the market, in two different tiers – premium and value. Nevertheless, the acquisitions did give both Chinese manufacturers access to a high level of technology and engineering know-how.

Zoomlion has perhaps been the most vocal about its achievements in the R&D field, with its ‘101m’ the Guinness World Record-holder for longest boom, a 101-metre concrete pump which – built using four carbon fibre sections out of the total seven boom pieces – was the result of joint efforts between Zoomlion and CIFA’s R&D teams.

Of all the brand’s five product lines (concrete, construction cranes, mobile cranes, earthmoving

“When you’re reaching such poor pricing levels, it’s important to have a system that is accurate and you can rely on, and that you can use to economise on your costs as much as possible”

CONCRETE SUPPLEMENT 2014

MIDDLE EAST

I

n an industry where the cost of raw materials can change overnight, and where any inefficiencies in the mix or loss of concrete will have an impact on a company’s bottom line, getting the right concrete equipment and keeping it performing is essential. Broadly speaking, there are three main areas of equipment – batching plants, concrete pumps and mixer trucks, as well as a range of support equipment – tasked with ensuring a steady flow of concrete to a job site. In the Middle East, German brand Liebherr is focused on selling batching plants, mixer trucks and recycling plants. In the area of batching plants, Liebherr distinguishes itself through the use of high quality steel for long life and durability, as Oliver Rduch, senior regional manager - Middle East in Liebherr’s concrete equipment division, tells Big Project ME. They are also built with high-powered motors, essential since batching plants may run 24 hours a day, often for weeks at a time. And with maintenance practices in the region often quite poor, strong motors ensure that the batches continue to be forced through. He’s noticed that competing brands, says Rduch, stop and break down more frequently. An owner of a plant can expect it to be in use for at least 15-20 years without major overhauls, though Rduch knows of one plant in Kuwait that is close to 30 years old.

The other major aspect of a batching plant is its control system. In May this year Liebherr launched its new Windows-based control system, MPS III, which uses a BUS system that sends electronic signals between the weighing cells and the control system, giving a lightning fast response.

“This means that when the needed weight on the load cells has been reached, there is a much faster cut-off time so that you don’t add additional materials that are not catered for within the mix recipe,” explains Rduch. “You get optimal speed within the batching and weighing system, but also the optimal amount. Cement, fly ash and microsilica are very expensive, so if you can save even just 5% per year you’re making big winnings.”

The need for accurate systems is essential, especially when the price of concrete is low.

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Special Feature CONCRETE MACHINERY

More than just a puMp

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pump it up Junjin’s new 5-section XZZ28-5.11HP.

Beyond merely supplying a pump, manufacturers and dealers are often called upon to supply expertise and problem-solving for tricky pours.

Recently in Oman, a Putzmeister BSA 1004 D concrete pump was used to lay the foundations for a lighthouse project, as new lighthouses have been built on Masirah Island off the east coast and Ras Madrakah further south, to improve safety for shipping.

Assisted by Taylor Woodrow Oman and the Omani Putzmeister dealer IHE (International Heavy Equipment), the construction company Al Sarooj used a helicopter and a BSA 1004 D concrete pump manufactured in India to construct the foundations of the lighthouse and minimise the impact on the environment.

record breaker Zoomlion’s world record 101 metre boom truck-mounted pump.

While in Ras Madrakah the foundations were also laid using a helicopter, on Massirah the 65m³ of concrete required was transported through a pipeline more than 110m long from a temporary preparation site up the hill to the main site.

The pipelines were secured using ropes and chains, but had to be secured with stonefilled sacks in places. A GVHM 2/2 gate valve integrated in the pipeline prevented the concrete from flowing back towards the concrete pump during breaks in pumping.

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Two mobile concrete mixers were used to produce concrete with a maximum particle size of 20 mm. In order to monitor the concrete quality and prevent blockages, workers took samples from every batch that was mixed and continuously monitored concrete production. To overcome the height of 110m, IHE converted the drive end of the BSA 1004 D before pumping started so that the pump would produce a maximum concrete pressure exceeding 100 bar. As an added factor for the project, all of the concreting work had to be carried out at night due to the high temperatures. (Pictured model is the BSA 1005 D)

CONCRETE SUPPLEMENT 2014

and sanitation vehicles), concrete equipment has the largest allocation of sales and support staff in the region, and it has four exclusive distributors and one non-exclusive seller in the Gulf. Earlier this year it reported a sale worth in excess of $1 million to a Kuwaiti ready-mix company, following the CEO’s examination of a 43m truck pump in action with an existing ready-mix customer in Fujairah.

Saudi Arabia is the largest market for concrete pumps in the GCC, and the market is seen as a key growth opportunity on a global sale. The Korean brand JunJin offers a product attractive to the value segment, sold by KiCE Construction Equipment in Saudi Arabia, a company which also manufactures a range of static and portable batching plants, as well as offering concrete cooling systems. This year, JunJin launched its new pump, the XZZ285.11HP, built with a five-section boom. The biggest advantage of the model, mounted on an HD Chassis, is its total length – under 9m – meaning it can squeeze through cramped residential streets for pours on villa projects.

In late 2012, Liebherr acquired the concrete pump manufacturer Waitzinger, and while it has embarked on a process of optimising the manufacturing processes at the Waitzinger

“cement, fly ash and microsilica are very expensive at the moment in the gulf, so if you can save even just 5% per year you’re making big Winnings”

plant in Neu-Ulm, Germany, the limited supply of pumps it can produce means that the Middle East is not yet a priority for the brand, with its activities restricted to supporting the existing population of pumps already here. Once the production output is increased, other markets will eventually be targeted, including the Middle East.

In the mixer truck sector, Chinese manufacturers have also been able to find favour

Special Feature CONCRETE MACHINERY

multiple variations Shantui’s popular truck mixer unit has undergone 11 variations from the standard version sold in China.

The sale of 50 units of concrete machinery was the fruit of this effort,” said Jackie Chang, Shantui’s Middle East regional sales manager.

Making up the majority of the order – and its most popular truck mixer in the Middle East – was the 12-cubic-meter capacity HJC5256GJB3 concrete

Fleet trackIng to IMprove arrIval The use of onboard telematics and GPS on mixer trucks can also give managers a significant advantage when it comes to planning and managing a major pour.

With traffic in many of the GCC’s major metropolises at times grinding to a standstill, the last thing a manager wants is news from the driver that mixer trucks are delayed or stuck in congestion. If concrete takes too long to reach the site, it will in all likelihood be rejected by the consultant. On-board GPS can provide real time information about the location of the entire fleet, and if there is congestion in one area, a manager can re-route the remainder of the fleet through a different area, or else call in extra vehicles from elsewhere if necessary.

CONCRETE SUPPLEMENT 2014

MIDDLE EAST

with buyers, especially since the mixer drums are often built over vehicles that are cheaper than the European premium models. It’s a chance for major up-front savings, as the truck is much more expensive than the mixer unit – perhaps as much as three quarters of the total cost comes from the truck, and only a quarter from the mixer unit.

Shantui, for example, has reported significant sales of its mixer trucks, this year reporting a sale of 50 mixers sold in the Emirates, worth $3.2m, through its UAE partnership with GENAVCO and Juma Al-Majid Group of Companies. Given the relatively small number of ready-mix companies in any market, breaking down the door with a sale to a major firm is seen as an important market success, and Shantui heralded the sale – to one of the largest ready-mix concrete firms in the Middle East – as a breakthrough.

“Over the past year, Shantui has focused on localising its sales, relying on dealers to tap into customer demand and connect with end users. The local sales staff works in tandem with Shantui to connect Shantui’s unbeatable value chain all the way from the factory to the job site, providing after sales support, networking with customers and gaining trust.

truck mixer. The variant of the HJC5256GJB3 sold in the GCC has undergone 11 variations from the standard model sold in China, to both make it suitable for the environments of Middle East job sites and meet GCC import standards.

These variations include anti-corrosion steel and high-temperature proofing key components such as the engine and hydraulic pump. The mixer (pictured) is built over a Shaanqi chassis and powered by a Weichai turbo-charged engine.

Like its batching plants, the drums on Liebherr’s concrete mixer trucks are known for being hard wearing, and steel producer Thyssen-Krupp even has a special steel blend that it supplies exclusively to Liebherr, LH 37, referred to as a diamond steel for its hard-wearing characteristics, so owners get the maximum life out of a drum. The drum is built to be as close as possible to the chassis frame, to lower the centre of gravity and increase the stability of the vehicle while cornering or on hills.

“We build a frame upon which the drum sits for each chassis individually. We make sure that the quality of the frame is the same as the chassis, so that they work together when there is friction and movement between mixer frame and the chassis frame,” explains Rduch.

Buyers of a mixer drum can have Liebherr buy the customer’s specified vehicle direct from the manufacturer, or they can buy from their local vehicle dealer.

If it’s a European vehicle, the drum will be installed on the chassis in the Liebherr factory in Germany – mounted, painted and tested – then shipped RoRo to the Middle East. If the vehicle is from Asia, Liebherr has a factory in China where the process can be carried out.

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INDUSTRY EVENT MIDDLE EAST CONCRETE

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INDUSTRY EVENT Middle east ConCrete Renewed IndustRy ConfIdenCe sees LaRgest eveR edItIon of MIddLe east ConCRete thIs yeaR LoCatIon Dubai WorlD TraDE CENTrE dates 17 – 20 NoVEmbEr 2014 tIMIngs 11am – 7pm Daily tICket PRICe FrEE rEgisTraTioN oNliNE prior To ThE EVENT (WWW.miDDlEEasTCoNCrETE.Com) paiD rEgisTraTioN oNsiTE (aED100) oRganIseR Dmg WorlD mEDia (Dubai) lTD ContaCt nuMbeR +971 4 438 0355 eMaIL iNFo@miDDlEEasTCoNCrETE.Com Info

Middle east Concrete (MeC) is the only dedicated event and the most important meeting point for concrete experts in the region, looking to source new and innovative concrete products and solutions. the pioneering show brings together more than 355 exhibitors from over 32 countries with more than 20,000 international visitors. for more information, visit www.middleeastconcrete.com.

Middle east Concrete is held in dubai and is colocated with PMv Live and the big 5 – the Middle east’s largest building and construction event. hIghLIghts fRoM 2013 19,808 unIque vIsItoRs 131 PaRtICIPant CountRIes 355 exhIbItoRs CoveRIng 9,445 sqM 25 fRee to attend seMInaRs LIve PRoduCt deMonstR atIon

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MIDDLE EAST

the InteRnatIonaL ConCRete ConfeRenCe

CONCRETE SUPPLEMENT 2014

TECHNOLOGY FOCUS QUALITY CONTROL

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Probing questions

Denis BeauprÊ, Managing Director of IBB Rheology and an Associated Director with Unibeton, writes about the development of the IBB Probe system and why he believes it’s going to have a major impact on quality control in the ready-mix industry

Q

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uality control of readymix concrete is a difficult aspect of the construction industry because concrete properties change with time, particularly from fresh to hardened states. It is very difficult to replace concrete when it is cast in the formwork. Therefore, it is important to control quality before delivery.

Even when concrete is mixed at the factory, with controlled parameters, there is always variation because it is made of natural material.

Before the development of the IBB probe system described here, there was very little way to assess the quality of fresh concrete and even less to follow its evolution during transport.

The system presented in this paper is a revolutionary development made by IBB Rheology, a Canadian company specialising in fresh concrete rheology; and Unibeton Ready Mix, the largest concrete supplier in the UAE.

CONCRETE SUPPLEMENT 2014

Why this system?

This development was initiated to provide a better knowledge of the concrete used in high-rise pumping, in order to avoid blockage of the pipeline. During the last five years, the system has evolved to become part of a full quality control system for the concrete and delivery operations. From a concrete producer point of view, this is a big step toward quality.

For Unibeton readymix, it is an integrated part of its U-Track system: a system oriented toward customer satisfaction.

From a

client and consultant point of view, the traceability of the U-Track system is a dream come true. With this system, the consultant can be 100% sure that no water has been added to the mixture during transport or placement. This way, the concrete watercement ratio (W/C) remains unchanged.

The IBB Probe system

TECHNOLOGY FOCUS QUALITY CONTROL

“With the iBB proBe system, it is possiBle to track the quality of concrete continuously and to detect the Worst possiBle outcome, Water addition”

W/C is an important parameter for concrete properties, including workability, strength and durability. W/C is controlled at the batching plant, where the exact amount of water and cement is regulated during manufacturing.

During transport or at the request of workers, although it is forbidden to do so, water may be added to the concrete, resulting in lower mechanical performance and less durability.

Several strategies have been deployed to prevent water addition: • Flow metre can be installed on truck to monitor driver behaviour: driver can use washing hose to add water • Consultant can forbid truck to carry any water: not practical, producers do not like this • Consultant requires water tank to remain full until delivery is completed: difficult to enforce To monitor the addition of water into a readymix drum, it is common practice in many countries to install some sort of water metre (mechanical, magnetic or electronic) on the fixed water pipe. Although that can be very precise, there is always uncertainty on the total amount of water added because water addition can still be performed with the washing hose or by other means (at plant checkpoint, for example).

tracks the volume of concrete in the drum.

The display unit receives data from the probe via radio signal and displays some of the parameters.

The display has internal memory that stores all data. u-track

The IBB probe is a essential component of the U-Track System and uses a two-way communication device (the E-10 module) installed in the batching plant and linked with a database. Software on the batching plant

computer controls information flow between the user, the E-10 and the database. The manager improves overall performance by allowing the probe and the batching plant to exchange information and generate a report for each individual delivery, as well as helping control the operation and probe performance.

The manager has the following main functions: • Transmits new load information to the receiver, whih relays it to the probe • Displays the concrete property in the batching room just after loading • Lists all trucks with last load information, including age of concrete (time from batching) • Automatically logs the previous delivery from the receiver • Stores the log in the database and performs analysis • Shows graph of individual delivery The main purpose of the U-Track is to store the data for all deliveries. This is done

Figure 1: graphical log of one delivery

iBB ProBe

Figure 2: gPS system linked with ibb Probe and U-Track system for real time data

CONCRETE SUPPLEMENT 2014

MIDDLE EAST

The IBB Probe has been developed as a component to a more global system that monitors the quality of readymix concrete from production to delivery for both concrete and operations.

The IBB Probe has three components: a workability probe, a solar panel and a receiver/ display unit. A Manager System is optional.

The IBB Workability Probe is installed in the drum of the readymix truck. A solar panel helps keep the probe’s batteries fully charged. It is designed to measure fresh concrete properties, including workability (yield, viscosity and the more traditional slump or spread test) and temperature, continuously and automatically. It also measures the movement characteristics of the readymix drum (angle, speed, direction and number of turns) with proper calibration measures, and

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TECHNOLOGY FOCUS QUALITY CONTROL

Figure 3: Addition of superplasticizer (no temperature change)

automatically when the truck is based at the plant. When the data is stored, it is possible to search the data base using different filters: time of delivery, truck number, mixture name, destination. The data can be represented graphically, as in Figure 1 where the drum slump (cm), volume of concrete, temperature, drum speed and probe pressure are shown.

Connecting a GPS system to the U-track means the position and other characteristics of the readymix truck can be tracked in real time, as shown in Figure 3. admixture or Water addition?

The full traceability is revealed in Figure 3, which shows a trial record using 3 cubic metres of concrete with initial slump of 150mm and initial temperature of 30 degrees Celsius. The temperature of concrete measured directly into the drum of the readymix is quite stable, due to concrete’s high thermal capacity. This initial temperature has a natural tendency to slowly adjust to the outside temperature and gradually increase, in a slow physical or

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Figure 4: Comparison of slump measurement

CONCRETE SUPPLEMENT 2014

chemical process; it is rarely constant. This normally smooth temperature evolution can suddenly be modified when water of a different temperature is added to the drum. It does not take too much water or much temperature difference to affect concrete temperature, due to the water’s high thermal capacity. A change of less than 0.1 degree Fahrenheit can be detected and recorded by the IBB Probe.

In Figure 3, although the temperature does not change abruptly, the slump clearly changes

“from a client and consultant point of vieW, the traceaBility given By the u-track system is a dream come true”

Figure 5: graphical record of delivery no 1

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from 12cm to 17cm after the mixing period (at around 12:00); the change in slump is due to the addition of superplasticiser. During those trials, manual slumps were taken. Figure 4 shows how well the slumps estimated by the probe match the one measured manually by two operators, considering the variability of the slump test.

Figure 5 shows the record of one concrete delivery with similar parameters: drum speed in green (in rpm), ratio in blue (a volume estimate), slump in orange (in mm) and temperature in yellow ( degrees C).

The main observation is that the concrete slump was higher after mixing.

This was caused either by either water or admixture added during mixing.

The slump alone is not sufficient to distinguish between the above possibilities. However, we can see that the temperature of the concrete drops by 0.18 degrees after mixing. Because the temperature drop is small, the quantity of water added is also small, unless the water is the same temperature as the concrete. Knowing that the added water temperature was 10 degrees, it can be calculated that the amount of added water was 6 litres per cubic metre, which is small.

This U-Track clearly indicates that it is possible to monitor driver behavior to detect: • Admixture addition • Water addition • Unauthorised concrete unloading • Unauthorised washing conclusion

Quality control of concrete has always been problematic, because of the blackout between production and arrival on-site. Now, with the IBB Probe system, it is possible to continuously track the quality of concrete, and thus detect water addition.

Build it Beautiful.

There are four main elements of design; Texture, Color, Form & Shape and Protection. The Pieri® range of Grace architectural concrete products and systems offer a variety of durable design solutions that create a unique decorative system for any project.

Color Texture

Protection Form & Shape • Form Liners • Release Agents

• • • • • • • • •

Surface Hardeners Varnishes Anti-Graffiti Water Repellents Oil Repellents Anti-Stains Cleansers Curing Membranes Color Brightening

Contact us today for a project consultation!

grace.com/construction/en-ae/architectural-concrete Grace Construction Products Emirates Chemicals LLC, P.O. Box 5006, Dubai, U.A.E. +9714 232 9901 Pieri is a trademark of W.R. Grace and Co-Conn.

• Surface Retarders for precast concrete elements • Surface Retarders for exposed aggregates and paving concrete • Stencils for printed concrete

• Pigments • Mineral Facing Equalizers

COMMENT Grace construction Products

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Benoit Baulande & Pierre estePhane

Aesthetic Concrete: smart technology for imaginative designs and long lasting effect Aesthetics are artistic qualities applicable in construction. How far can an architect stretch their imagination in designing textures, surface finishes and the harmony of colours for building elements?

G

race Construction Products is a leading global supplier of concrete admixtures, fibres, release agents, surface treatment products and pigments of high technical quality to make concrete stronger, more durable and more creative. The precast industry, with its technical needs and manufacturing constraints in confined areas, is a key area of focus.

For many years, Grace has been deeply involved in the sustainable development of green products, making use of green chemistry.

The majority of new products introduced by their R&D laboratory are made from natural, renewable and biodegradable raw materials, while aiming mostly for aqueous solutions with very low VOC (volatile organic compounds) levels.

Release agents: act on aRchitectuRal concRete suRface finish

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There is a wide range of release agents available

NOVEMBER 2014

today, in four main categories: release agents based on mineral oil, synthetic oil, vegetable oil and emulsions. Mineral-based release agents such as Pieri LM are usually solvent-based. They facilitate the release of concrete elements on any non-porous form surface, such as steel, plastic or plywood (plastic coated or varnished), under normal site conditions. Synthetic-based release agents such as Pieri Clarol are used in complex cases with difficult casting work, and where improved release performance is needed (steaming, high vibration), they achieve facing of the highest quality.

Health, safety and environment considerations have led to advances to protect the user and the environment. Aquarol Synthetic release agents have been developed by omitting organic solvents.

A pioneer in this field since the 1990s, Grace also offers a wide range of vegetable oil-based release agents known as Pieri Decobio. These non-flammable, non-toxic, biodegradable release

agents provide user and site safety and proven performance. Developed with the criteria of today’s architects in mind, Grace offers release compounds containing 50 to 100% natural and vegetable origin components, and with rates of solvent from 0 to 20% maximum. suRface RetaRdeRs: act on concRete textuRe

Concrete texture addresses people's instinct to make contact with material. Indeed, the architect, designer, customer and owner all like to touch concrete, to feel its mineral aspect.

An exposed aggregate system was developed

by Grace in the 80s for use in industrial concrete panels (in Italy, Belgium, Spain and the Middle East) or hard landscaping units (France, Italy, Spain and the Middle East).

Exposed aggregate finishes were previously obtained by mechanical means or using acids, yielding varying results. Acid finishes can be

COMMENT Grace construction Products

aesthetic solutions for building facades, walls, bridges, sea walls and all precast concrete.

Pigments: act on colouR

When asked about the colour of concrete, most people say grey; but colour has been an option for decorative concrete for many years. The problem is that traditional colour techniques and pigments fade over time, particularly under various weather conditions and when using natural pigments containing impurities.

There have been several recent advancements in pigment. Grace offers synthetic pigments derived from a mixture of iron oxide and other metals (cobalt, titanium), which are used to obtain different colours – yellow, red, black and more.

They are very consistent in colour, non-fading and resistant to weathering, acids, alkalis and cement lime. They have little or no influence on time of setting of concrete and mortars. They are suitable for colouring cement, concrete, gypsum and lime.

The European standard EN 12878 (Pigments for the colouring of building materials based on cement and/or lime – Specifications and methods of test) covers pigments used for colouring building materials. It classifies pigments as Class A (low quality, which can contain impurities) and Class B (high quality without impurities). Class B pigments can be used in all types of concrete, including reinforced concrete. The dosage range in practice varies from 0.5 to 6.0% by weight of cement, depending on pigment, materials used and expected colour. A typical dosage rate is around 3.0%, above the 6.0% saturation threshold.

foRmlineRs: act on foRm and shaPe

Concrete is the most widely used construction material in the world, but mainly in a smooth, cold aspect. There are now new and exciting design materials changing form and shape by using formliners that are usually available in two types: • Polyurethane liners, offering 10 to 100 re-uses for building sites or precast • Polystyrene liners, generally used once for civil jobs These materials offer excellent flexibility in use and therefore allow an architect the freedom to be imaginative and work with specific and unique designs. With Grace Pieri formliners, architects can choose to create an artistic multi-dimensional aspect with concrete. Alternatively, formliners can be used to effectively reproduce masonry or soften the visual impact of concrete by using natural patterns that blend well with the environment.

Whatever the design requirements, formliners provide practical, economical and

“ConCrete texture is tyPiCally Considered to address the instinCt of PeoPle to Be in ContaCt with the material. indeed, the arChiteCt, designer, Customer and owner would all like to touCh ConCrete, to feel the mineral asPeCt of this material”

PRotection: act on duRability

The main issue with pigmented concrete is how to keep its colour consistent over an extended period.

For a long time, it was thought that concrete did not need any protection. This is not the case; concrete deteriorates, whether the cause is organic (green moss, algae), atmospheric (black ash, carbon), accidental (oil marks) or even voluntary (graffiti).

For successful and sustainable aging, concrete must be protected. There are different products and systems, including UV resistance, available.

The basic level of protection is hydrophobic impregnation, a water repellent that protects the concrete exposed to adverse weather conditions against humidity and all other influential parameters. This invisible treatment prevents water absorption and all pollutants, but allows air circulation so that the concrete can breathe.

Products such as Pieri Hydroxi 2000 allow concrete to remain dirt-free, especially in rainy seasons, when rain water can be supportive rather than damaging by washing the concrete surface. Grace offers other specialised coatings that provide colour revival, available in matte, satin or glossy aspect.

Protection against graffiti is a key challenge for urban societies. Grace offers two unique systems. Pieri Graffistop Mono is a single-use anti-graffiti treatment which protects mineral construction materials against all types of graffiti (felt-tip pens, aerosol sprays, etc). The product forms an invisible film which receives the graffiti.

Elimination by steam (high-pressure steam jet cleaner or household steam generator) dissolves the film and removes residues. This is environmentfriendly, as it does not require solvents.

Pieri Graffistop 2002 is a complete permanent surface protection process against graffiti or other stains. This product is an aqueous phase which does not change or alter the surfaces where it is applied, and allows the swift and simple removal of graffiti such as aerosol or felt-tip pen, with the possibility of cleaning up to 10 consecutive times.

As a part of our strong commitment and belief, Grace Construction Products has developed and introduced a wide range of complete solutions for all types of architectural concrete walls, floors and facades, proving that any construction project can be unique with a particular touch, while minimising any collateral ecological impact. n Benoit Baulande – Grace Pieri® Decorative Solutions - Technical Service Manager Europe benoit.baulande@grace.com Pierre Estephane, Ph.D - Grace Construction Products - R&D|Technical Services Manager (GCC, KSA) pierre.estephane@grace.com

NOVEMBER 2014

MIDDLE EAST

detrimental to the environment; they can also damage the concrete surface, causing it to become faded, dull and lacklustre.

Environmentally friendly options such as the Pieri DRC range of concrete surface retarders are used in the precast industry. These products are applied in-mould before casting, in place of a release agent to delay the setting of the concrete face. They attribute the exposed aggregate surface to the element after face washing, in different degrees and depending on the required depth of the textured finish, creating a durable finish.

With Pieri DRC, the depth of deactivation is determined by the selected grade, not by the thickness of the layer applied. Precast industry professionals prefer Pieri DRC because of its ease of application and consistency of performance.

Surface retarders present numerous benefits: • Aesthetics: architectural concrete of high quality that reveals the splendor of its textured finish and aggregates • Design flexibility: selecting from a wide range of aggregates and concrete pigments • Durability: a finish that requires minimal maintenance, regardless of climate • Uniformity: elimination of all concrete surface imperfections • Safety: Micro surface deactivation technology Grace Pieri DRC Micro creates a sandblasted effect or stone imitation with ease and security, eliminating conventional and hazardous techniques of acid etching or sandblast • Performance – a series of 10 different predetermined grades ensures consistency

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SPECIAL FEATURE PRECAST CONCRETE

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PRECAST POWERS ON

Big Project ME discovers how precast concrete can reduce time, costs and on-site hazards in the UAE

T

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he government of Jakarta, Indonesia has adopted the use of precast concrete in the construction of its infrastructure as it gears up to host a crucial Asian economic summit next year. Come 2015, member countries of the Association of Southeast Asian Nations (ASEAN) will formally launch the ASEAN Economic Community (AEC), aimed at economic integration between member states to promote competitive regional and global trade. With the ASEAN Secretariat seated in Jakarta, all eyes are now on Indonesia to speed up its rate of construction in time for the establishment of the AEC. Hediyanto Husaini, head of construction at Indonesia’s Public Works Ministry,

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has attributed delays in Indonesian infrastructure projects to the use of traditional concrete rather than more evolved forms which need less construction time.

“Unlike standard concrete, precast and pre-stressed concrete is much stronger, more efficient and more environmentally friendly,” he said at a seminar held in April 2014 in Jakarta, per the Jakarta Post.

Husaini estimates precast concrete accounted for only 25% of the Indonesian construction industry in 2012. According to Gulf News, precast made up 30% of the UAE’s construction market in 2011. However, the UAE market has changed over the last three years.

Construction activity in the UAE has

steadily increased since the property crisis hit the market in 2009; moreover, the country has bagged the World Expo 2020 – an event which will, the government of Dubai is confident, exceed global expectations.

As they each ready to host world events within a decade, the UAE and neighbour Qatar will both want to avoid Indonesia’s mistakes. For the UAE, construction of infrastructure for the Expo will require building materials that can enhance timeeffectiveness for the event’s planners.

Precast concrete, as is evidenced by the situation in Jakarta, is clearly a wiser option for large developments that have to be completed in short durations. But

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quicker to use Precast concrete slabs consume far less time on a project than traditional concrete systems do.

Design wiTh Care Matthew Palmer, general manager of United Precast Concrete, tells Big Project ME that designers need to be mindful from the very beginning of the project that precast concrete will be used.

“When you get a project with a lot of untypical designs, it can be problematic for precasters.

We have previously revamped designs which were initially intended for in-situ concrete; it is not impossible, but it would be ideal if designers and clients agree at the very beginning of the project that precast will be used, so that its benefits can be capitalised upon.”

which offers better cleanliness or quality.”

On-site quality control is particularly crucial in the UAE, given the numerous accidents and hazards that have surfaced of late in the country. In most cases, labourers not adhering to safety measures caused these incidents, but the Dubai Municipality also found subcontractors guilty of using incorrect methods and products on their projects.

Precast concrete substantially lessens both concerns, according to Matti Mikkola, chief executive officer of Dubai Precast, the firm that handled precast operations for Meraas’ Citywalk development in Dubai and New York University Abu Dhabi’s campus in the capital.

“The most obvious advantage of precast

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is the UAE construction scene equipped to optimise the benefits of precast?

Matthew Palmer, general manager at United Precast Concrete, believes the local market is yet to fully understand and accept precast concrete’s applications.

“Because precast concrete is factoryproduced, it offers benefits primarily in terms of economy and quality,” he says. “To me, the greatest advantage of using precast is the clean construction site it makes for. The mindset is where the resistance to precast mostly comes from. Some of them [clients and consultants] would ideally like to stick with the methods they know, and might be hesitant about instead going for a newer product

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is that it offers speed of construction.

Furthermore, because everything is factory-produced, there is a high degree of quality control,” Mikkola explains.

“Supervision is easier than on-site, where monitoring thousands of workers can pose challenges. Compared to the conventional system, we’re working at floor level and not heights or with scaffolds; this significantly reduces the risks of labour hazards for workers in the precast industry. It is a natural equation: the more machinery you have, the less labour you need, thus reducing the risk of incidents.”

As a result, precast companies provide in-house training facilities for their staff, and Palmer claims these training procedures further enhance the quality and standard of factory-produced precast.

“Most of our workers are employed only after it has been ascertained that they have the required skillset for the job,” he says.

“They are then trained on the job by a team of experienced people, and adequate quality control checks are conducted after each phase of precast fabrication to ensure the product matches designs and client’s requirements.”

Its inherent strength also doubles up as a flaw in the application of precast – the

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process of producing to set standards and specifications may sometimes make for inflexibility in modification. Precast concrete can be produced to tailor-made shapes, but the economics of undertaking this process means this costs more than using conventional methods does. This is a factor that could hurt precast in an architecturally ambitious country.

However, this bodes well for manufacturers of traditional concrete systems and steel structures, helping them maintain their products at competitive rates in the market.

“On some occasions, steel structures or in-situ concrete are just better systems

More preCasT, less labour Matti Mikkola, CEO of Dubai Precast, says the adoption of precast concrete can reduce labour costs for clients and contractors.

“Precast construction methods require much less labour than conventional construction methods. This is a significant benefit on the national level in the UAE. Increased utilisation of precast construction methods would reduce the requirement of especially unskilled foreign labour in the country.”

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the versatile option Precast concrete can be modified to suit project requirements of varied sizes.

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to use for a project,” Palmer admits. “The solutions will always differ based on the development’s requirements. What I urge for is that precast is not discounted as an option, and that consultants and clients design for precast once it has been decided as the choice for the project.”

The phases of manufacturing precast are as extensive as its applications – depending on producers’ preferences, between six and eight processes need to be undertaken before precast concrete can be transported to construction sites for use. However, precast systems are not limited in their applicability, and can be used across residential, commercial, mixeduse and infrastructural developments.

“Precast can certainly be used for construction of structures that follow standard designs, especially with large spans,” Mikkola states. “For instance, malls, car parks and big residential complexes can be built competitively with precast concrete systems.

“Buildings that are architecturally complex, have curved or geometrically challenging shapes for instance, might not be sensible to precast. It isn’t impossible to manufacture the precast components for them – it just wouldn’t make sense economically.”

concrete@saudidiesel.com.sa

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