Construction of Al Jewaibyah Regulating Tank (AJRT), Reinforced Concrete Elevated Tank (2x35.000m3) between 2007-2009, until "First Water"

2. AJRT RegulatingTank
2x35.000m3
ArealView
Man Made River Project
IV Phase - Ghadames Project

3. Al Jewaibyah Regulating
Tank 2x35.000m3
Construction
Reservoir schematic overview

4. Sub-gradeVerification
Test
Standard PenetrationTest
(SPT)

5. RegulatingTank
Structural Fill
Structural Fill applied in layers
over the sub-grade , level of
achieved compaction
determined over Field Density
Test (FDT)

6. Plate LoadTest
Conducted over the final layer
of structural fill.

7. RegulatingTank -
Structural Fill
Final layer of structural fill,
compacted, leveled and ready
for blinding concrete

8. RegulatingTank
BlindingConcrete
BlindingConcrete (Class C)
Design:
W=185kg/m3;
Cement=300kg/m3;
Agg=1.880kg/m3;
Add=2.4kg/m3.

9. AJRT Tank
Bottom Slab
Formwork drawing - bottom
slab plan

10. Base Slab - Corrosion
Protection
2mm thick PE Sheeting
between BlindingConcrete and
Base Slab concrete as corrosion
protection

11. Bottom Slab - Sections

12. Compressible Material
Extruded PolystyreneType I
(ASTMC578)
laid on the top of Blinding
Concrete (Class C)

13. Base Slab
Reinforcement
Steel ReinforcingWorks (ASTM
A615):
-Ø>14mmGRADE 60,Yield
Strength = 400MPa, deformed;
-Ø=12mmGRADE 40,Yield
Strength =280MPa, deformed;
-Ø<12mm MILD Steel,Yield
Strength =250MPa, round

14. Base Slab Formwork
RMD Kvikform Base Slab
shutter with visible black
corrosion protection (PE sheet)
for later overlapping to vertical
surface of the Reservoir wall.

15. Base Slab Formwork
RMD Kvikform, wall kicker
10cm height

16. Batching Plant
New Batching Plant erected for
supply of
RegulatingTank concrete
works

17. Batching Plant

18. Batching Plant &
Cement Silos

19. Batching Plant with
Chiller, Silos,
Aggregate Separator

20. Batching Plant Chiller
For regulation of concrete
temperature in Saharan Desert
climate. During the production,
concrete temperature on
delivery to the Site did not
exceed 32°C although ambient
temperature often reached
52°C.

21. Batching Plant
Controls

22. Batching Plant
Automatic mixing & control

23. Batching Plant
Aggregate Separators
Sand blowing for decrease of
fine materials

24. Concrete Quality
Control
Cylinder moulds for sampling of
concrete

25. Fresh Concrete Quality
Control -Workability
SlumpTest

26. Fresh Concrete Quality
Control –
Air Content

27. RegulatingTank –
Outlet Section Base
SlabConcrete
81nr of Base Slab modules (max
width 15x15m).
The sequential bay method of
construction has been used
with each consecutive bay
having at least two adjacent
free edges and not more than
two adjacent edges continuous
with previous bays

28. ConcreteWorks
Trowell of the Base Slab
concrete surface, over applied
curing compound BASF
Masterkure 106D; SIKA

29. Base Slab Structural
Concrete
Concrete ClassA:
(W=189kg/m3; C=386kg/m3;
W/C=0.49 ; Agg=1.830kg/m3;
Add=3,1kg/m3)
Cement –Type II,ASTMC150;
Additive BASF Lubricon L-200,
BASF MelcretTB101Type G

30. Construction Joints –
Water Stop
SCP Ltd - 25x8mm Dual Seal
SwellableWater Stop

31. SwellableWater Stop
SCP Ltd - 25x8mm Dual Seal
SwellableWater Stop

32. Walls –Work Plan

33. RegulatingTankWalls
Formwork
RMD Kwikform Shuttering
System

34. RegulatingTankWalls
Formwork
In total 55nr of Wall-segments
installed with concrete, max
modular wall-length = 15m’,
height = 6.06m; width = 0.45m

35. RegulatingTankWalls
Formwork

36. RegulatingTankWalls
Concrete Installation

37. Construction Joint
Base Slab /Walls /
Walls
SCP Ltd - 25x8mm Dual Seal
SwellableWater Stop
between each of 55nr modular
wall-segments

38. Construction Joint
Base Slab /Walls
SCP Ltd - 25x8mm Dual Seal
SwellableWater Stop

39. Walls,Columns & Roof
Slab - Sections

40. Columns Formwork
RMD Kwikform, Columns
Ø400mm

41. Columns Formwork
RMD Kwikform Column-kickers

42. RegulatingTank
Columns (500nr)
500nr Columns Ø400mm
Concrete ClassA (W=189kg/m3;
C=386kg/m3;W/C=0.49 ;
Agg=1830kg/m3;
Add=3.1kg/m3)

43. RegulatingTank – Roof
Slab Formwork
RMD Kwikform Scafffolding

44. Roof Slab - Sections

45. RegulatingTank – Roof
Slab Formwork

46. RegulatingTank
PartitionOverflow
Wall
PartitionOverflow Wall
dividing RegulatingTank
onto 2 separate Water
Chambers (2x35.000m3)

47. Roof Slab
ReinforcementWorks
Access Manhole openings–
DN600

48. Roof Slab
ReinforcementWorks
81nr of Roof Slab modules (max
width 15x15m), with 25x8mm
DualSeal Swellable Water Stop
in construction joint between
each slab

49. Roof Slab Concrete
Installation
Roof Slab d=300mm;
Concrete ClassA (W=189kg/m3;
C=386kg/m3;
W/C=0.49 ; Agg=1830kg/m3;
Add=3.1kg/m3)
Cement –Type II,ASTMC150;
Additive BASF Lubricon L-200,
BASF MELCRETTB101Type G

50. RegulatingTankView
during construction

51. Roof Slab
Survey verification of Roof Slab
plywood formwork (behind
visible tower-crane and
concrete pouring of columns)

52. RegulatingTank Roof
Slab
Reservoir height bottom to
roof slab -6,06m, 500nr
columns, 81nr base slab, 81nr
roof slab modules (max width
15x15m), with 25x8mm Dual
Seal Swellable Water Stop in
construction joint between
each slab

53. RegulatingTank Roof
Slab
The sequential bay method of
construction has been used
with each consecutive bay
having at least two adjacent
free edges and not more than
two adjacent edges continuous
with previous bays

54. RegulatingTank
Access Manhole
Sealing ofTie-rod holes,
finishing works remaining

55. Outlet Shafts &
Overflow

56. Outlet Shafts &
Overflow

57. RegulatingTank
Overflow Pipe
Penetration
Overflow Steel DN1600mm
Pipe Nozzle (25x8mm Dual Seal
SwellableWater Stop & elastic
sealing 2x1.5cm)

58. RegulatingTank –
Overflow PipeWall
Closure of Wall Shutter

59. RegulatingTank
Overflow Pipe
Shutter gaps sealing, centering
of the Steel DN1600 Pipe
elevation

60. RegulatingTankOutlet
Shaft 1
Outlet Shaft with Steel
DN1400mm Pipe

61. RegulatingTankOutlet
Shaft 2
ReinforcementWorks on Outlet
Shaft 2 with Steel DN1400mm
Pipe

62. Outlet Shaft 1
Formworks

63. Outlet Shaft 1
Concrete Installation

64. Outlet Shaft 1

65. Inlet & Drain Shaft

66. Inlet & Drain Shaft

67. Inlet Section –
Integrated Surge Shaft
RegulatingTank PartitionWall
visible at the back

68. RegulatingTank Inlet
& Surge Shaft
Inlet Pipes Steel DN1200mm

69. Inlet &Tank
Integrated Surge Shaft
Steel DN1200 Pipes

70. Inlet Surge Shaft with
Inlet DN1200 pressure
pipes
Wall’s reinforcement works,
pipe nozzles positioning and
anchoring in progress

71. Surge ShaftWall
Formworks

72. Surge Shaft

73. Surge Shaft Corrosion
Protection
All buried concrete surfaces in
contact with soil are protected
byCoalTar Epoxy coating,
average dry film thickness 150
microns to give overall dry film
thickness of 450microns.
Underside of bottom slab
protected by 2 PE sheets with
friction coefficient <0.1

74. Inlet Surge Shaft –
Tank’s Base Slab gap
To be filled with Soil cement.

75. Surge Shaft –
Compressible Material
Corrosion Protection:
AmerCoat 78 HBB Resin Black +
Cure (1:4);
DoeCote 1080H + DoeClean
1080 (1:4)

76. Surge Shaft –
Compressible Material
Corrosion Protection:
-Compressible material –
Polystyrene 5cm
-- 3nr layers of Coal tar Epoxy
(min 450 microns)

77. Inlet Surge Shaft Soil
Cement filling
Soil Cement Mix Design:
W=300kg/m3;Cement =
140kg/m3 (5% of Soil mass);
W/C=2.1;Agg=1760kg/m3;
Add=0.44kg/m3

78. Tank’s Integrated
Surge Shaft – Soil
Cement filling
Slump = 5 - 15cm;
Minimal 7-days strength =
0.7MPa

79. Integrated Surge Shaft,
PartitionWall between
Water Chambers

80. RegulatingTank Inlet
side overview

81. RegulatingTank
Overview during
construction

82. RegulatingTank Drain
Shaft – Reservoir
Sump
Base Slab reinforcement works,
Drain Steel Pipe DN250mm,
Sump (750x750x300mm)

83. Drain Steel Pipe
DN250mmWall
Penetration
Pipe nozzle wall penetration,
swellable water stop, elastic
sealant for prevention of water
leakage.

84. RegulatingTank Drain
Shaft –Tank’s Sump
Internal Expansion Joint with
Water Stop
between Reservoir Sump and
Drain Shaft

85. RegulatingTank Drain
Shaft –Tank’s Sump
Internal ExpansionWater-Stop
(400mm)
left for connection with Drain
Shaft

86. RegulatingTank
view during
construction works

87. RegulatingTank view
during construction
SupportingTower Crane,
Batching Plant Silos visible on
the right side

88. Inlet OverflowWeir
Wall
Height of Weir (Overflow Wall)
top
50cm lower than Roof Slab
bottom

89. RegulatingTank
CornerWalls
The sequential bay method of
construction has been used
with each consecutive bay
having at least two adjacent
free edges and not more than
two adjacent edges continuous
with previous bays

90. RegulatingTankView

91. RegulatingTankOutlet
SectionView

92. Details

93. Details

94. RegulatingTank Roof
Slab
MaintenanceOpening 3x3m

95. RegulatingTank Roof
Slab
MaintenanceOpening 3x3m

96. RegulatingTank Roof
Slab Maintenance
Opening 3x3m
View from inside of the tank

97. RegulatingTank Roof
SlabWorks
InletOverflow WeirWall visible
on left side

98. RegulatingTankOutlet
Shaft 2
Assembling of Steel Pipes
DN1400

99. RegulatingTankOutlet
Shaft 2
Welding of DN1400 Steel Pipes
in protected environment.
Reservoir Overflow DN1600
Steel Pipe visible on upper left
side

100. RegulatingTankOutlet
Section
Outlet DN1400 Steel Pipes
aligned and welded.
Reservoir Overflow DN1600
Steel Pipe visible on upper left
side

101. RegulatingTankOutlet
Piping DN1400
View towards downstream
PumpStation

102. RegulatingTankOutlet
Pipe – towards Pump
Station

103. RegulatingTankOutlet
View
Steel DN1400 Pipes, Outlet
ShaftsWalls Reinforcement
works visible

104. RegulatingTank Inlet
Section Shafts
Transition from DN1600 PCCP
(Pre-stressed Concrete Cylinder
Pipes) to DN1200 Steel Pipes

105. RegulatingTankView

106. RegulatingTankOutlet
with Overflow
Discharge

107. RegulatingTankOutlet
with Overflow
Discharge

108. RegulatingTankOutlet
with Overflow
Discharge

109. Overflow Discharge

110. RegulatingTank – on
FirstWater
FirstWater on
4th November 2009

111. RegulatingTank – on
FirstWater
FirstWater on
4th November 2009

112. RegulatingTank – on
FirstWater
FirstWater on
4th November 2009

113. RegulatingTank on
FirstWater
FirstWater on
4th November 2009