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  1. 1. AA GTE (Civil)
  2. 2. CONTENTS:  Project Overview  Civil Construction and Fatima Fertilizer  My Working Areas ○ Roads and its Structures ○ Weigh Bridge ○ Nitro Phosphate (NP) Plant
  3. 3. Project Overview:  Salient Features:  Start of Land Acquiring in Year 2005.  Total Land Acquired 800 acres.  Estimated Cost in Rs. = 8,000 million  Start of project phase in April 2007 (NA plant).  Total no of plants/supporting areas are 50+.  Four Types of Fertilizer Products/Plants having design capacity. 1. Urea 1500 MTPD 2. CAN 1400 MTPD 3. NP 1200 MTPD 4. NPK 1000 MTPD
  4. 4. Project Overview:  Salient Features:  Other Supporting Plants having design capacity 1. Ammonia 1500 MTPD 2. Nitric Acid 1500 MTPD 3. Offsite & Utilities 50 MW  Gas consumption of 75 MMCFD  Civil Contractors 1. CNCEC China 2. IPL Pakistan  Civil Designers 1. NESPAK Pakistan 2. A & A Pakistan
  5. 5. Civil Construction and Fatima Fertilizer:  Civil Engineering role in the establishment of any kind of project is not ignorable.  The project like Fatima Fertilizer, its importance is more.  Fatima Fertilizer have structures  From simple pumps foundations to complex pile foundation under Prilling towers and Ammonia Tank.  From steel structures of Urea, CAN, Bulk Storage & Ware houses to concrete structures of Cooling Tower, Raw water Reservoir, Bagging, NA and NP plants.  From Technical building, CCR I & II, Substations to Strom water drains, water pits, area development and network of roads.
  6. 6. Civil Construction and Fatima Fertilizer:  In Fatima Fertilizer, basic form of structure is frame structure .  Frame Structure is a combination of beams and columns and load is transfer through this system to design foundation.  Two types of frame structures are used. 1. Steel Structures 2. Concrete Structures
  7. 7. Steel Structures:  Steel structures are basically composite structures having substructure of concrete and superstructure of steel e.g. • Ammonia & Urea Plants • CAN & NPK Plants • Bulk Storage (Phase-I) • Ware houses, Pipe Racks etc.
  8. 8. Concrete Structures:  Concrete structures comprise of both substructure and superstructure of concrete e.g. • Raw Water Reservoir and Treatment Plant • Cooling Tower & Urea Prilling Tower • Bagging (Phase I & II) • Bulk storage (Phase II) • NP Plant • Substations CCR I & II and Equalization Basin • Workshop, Technical Building, Laboratory, etc
  9. 9. Pictorial View of Civil Construction in FFCL: Construction View of Urea Prilling Tower and Plant
  10. 10. Nitric Acid Plant Foundation of Ammonia Storage Tank
  11. 11. Construction View of Cooling Tower Raw Water Reservoir and Water Treatment Plant
  12. 12. Construction of CAN Plant Construction of Ammonia Plant
  13. 13. Construction of Bagging (Phase – I) Construction of Bulk Storage (Phase – I)
  14. 14. Bagging (Phase – II) under construction NP Plant under construction
  15. 15. My Working Areas:  In Fatima Fertilizer during my Trainee period of 1 year, I worked on Roads and its Structures, Construction of Weigh Bridge and also play a vital role in the construction of NP plant.
  16. 16. Job Responsibilities:  Study of Drawings  Design Reviews  Survey of roads  Quality Control at site ( Formwork, Steel & Concrete)  Inspections before concrete  Checking of Bar Bending Schedule  Checking of Bills
  17. 17. Roads and its Structures:  Salient Features  Total length of Roads = 17.484 km  Completed Length of roads = 8.301 km  Remaining Length of roads = 9.183 km  Roads have Strom water drain and walkway on one side, and shoulders on both sides.  Designer = Akbar & Associates  Contractors = IPL, Farhan Munir & Company, AHCC  Type of Pavement = Rigid Pavement  Design Capacity = 90 Tons
  18. 18. What is Rigid Pavement?  Rigid pavements are generally constructed of a reinforced concrete slab or more recently a continuously reinforced concrete road base.  The pavement structure deflects very little under loading due to the high modulus of elasticity of their surface course.  A rigid pavement structure is typically composed of a PCC or RCC surface course built on top of either ○ the sub-grade or ○ an underlying base course.
  19. 19. Rigid Pavement: Typical Cross-section of a Rigid pavement
  20. 20. Why we (FFCL) preferred Rigid Pavement instead of Flexible Pavement (Carpet Road)?  Rigid Pavement lasts much, much longer i.e. 30+ years compared to 5-10 years of flexible pavements.  In the long run it is about half the cost to install and maintain. But the initial costs are somewhat high.  Rigid pavement has the ability to bridge small imperfections in the sub grade.  Less Maintenance cost and Continuous Traffic and Flow.  Low thermal variation as compared to Flexible Pavement.  Rigid Pavement has one draw back in terms of its repair i.e. we have to remove 2-3 panels instead of damaged portion as in case of Flexible pavements.
  21. 21. Pictorial View of Roads in FFCL KLP Road under construction
  22. 22. Roads in the Plant Area
  23. 23. Weigh Bridge:  Salient Features:  Total No of Weigh Bridges = 4  Weigh Bridges constructed= 2  Located near Gate # 1 or KLP Gate.  No of Load Cells = 8  Design Load measurement capacity = 120 Tons  Designer ○ Mechanical = Mettler Toledo ○ Civil = Akbar & Associates  Contractor = IPL
  24. 24. View of Weigh Bridge in FFCL
  25. 25. Nitro Phosphate (NP) Plant
  26. 26. Nitro Phosphate (NP) Plant:  NP plant started from Prilling Tower in 2009.  Estimated Civil Cost in Rs. = 279.1 million  Civil Designer = NESPAK  Civil Contractor = IPL  80% of Civil work completed.  Remaining 20% include Refrigeration area and Lime Drying unit, paints, brick masonry, and finishing works.
  27. 27. Nitro Phosphate (NP) Plant:  NP Plant is divided into four parts  Prilling Tower & Lift Well  Main Building  Substation  CN & AN Section, Refrigeration Area, and Lime Drying Unit
  28. 28. Salient Features:  Prilling Tower supported on 72 piles of length 27m.  Prilling Tower has height of 67.9m and diameter of 19m.  Lift Well has height of 70.1m, supported on 900mm thick raft foundation.  Main Building has dimensions of 67.5m x 27.5m x 37.3m supported on raft foundation.  Main Building comprise of 10 floors max on line 1-2.  Substation comprise of 2 floors supported on isolated foundation.
  29. 29. Special Techniques adopted at NP Plant:  Prilling Tower and Lift Well concrete done by using Slip Form Method.  Strengthening of Columns has to be decided.
  30. 30. Slip Form Method:  The most common method adopted for the construction of an RCC outer shell/prilling tower is by using the ‘slip form method’.  In this method the form work for the concrete literally slips up cm by cm to produce an integrated concrete column in the form of wall.  Continuous pouring of concrete ensures a joint free construction.  At a rate of 0.3 meters per hour, this is consider as fast construction method.
  31. 31. Components of Slip Form Method:  Slip form method is comprise of a complicated system of jacks and radial screws.  Radial steel yokes, which have an inverted “U” at both ends, support the slip form shuttering all around the shell/prilling tower.  Walers strengthen and keep the shuttering in place.  The working deck and scaffolding is supported from the walers and yokes.  The yokes are supported on hydraulic jacks, which move on jack rods embedded in the concrete.  As the concrete pouring progresses the jacks lifts up the yokes, together with the decks and slip form.  Screwed on pieces extend the jack rod as the work progresses.  The entire system of decks and shuttering appear as if floating on top of the tower.
  32. 32. NP Prilling Tower
  33. 33. Top View of NP Prilling Tower
  34. 34. Strengthening of Columns:  To increase the capacity of NP Main Building columns from 3500 Tons to 5500 Tons, the procedure that is used called Strengthening of columns.  Why Strengthening of columns needed?  Continuous changing of mechanical design of Cfit of NP main building, load on columns increased from 3500 Tons to 5500 Tons.  To counter this problem, columns has to be strengthened by using concrete and steel jacketing.
  35. 35. Lift Well Main Building View after Completion of Lift Well and Prilling Tower Main Building and CN Section under construction Prilling Tower Sub Station CN, AN Section and LD Unit
  36. 36. Any Questions????