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Case Study
Bringing structuresto life
KAIA InfrastructureClient: General Authority of Civil Aviation of KSAContractor: Saudi Binladin PBADLocation: Jeddah, Kingdom of Saudi ArabiaProducts: Special Formwork, Rapidshor, Megashor, Maxima
As part of a major redevelopment of the KAIA Airport, which is focussed on improving its infrastructure through the construction of new terminals and enhanced transport links, RMD Kwikform engineers have developed a number of formwork and shoring solutions to support the new approach roads. The newly developed airport will be able to cater for 35 million passengers annually, more than doubling its existing capacity.
There were three main shoring elements of the project that RMD Kwikform was involved in – the roadside decks, curbside arch and the curbside road decks. Commenting on the project, Gabriel Hackett, Sales Manager for RMD Kwikform Saudi Arabia said: “This large-scale and multi-faceted project presented us with a number of challenges that we had to overcome. Primarily, each of the three sections of the road construction that we were involved in required a unique design solution to ensure it would be completed to budget, and to schedule.
“The construction of the roadside deck was challenging, primarily due to its scale, and the volume of equipment that was required. Over 1,000 tons of Rapidshor shoring, supporting 500 tons of specially fabricated steel deck panels, was used to construct the roadside decks.
The steel deck panels were placed on top of the Rapidshor, giving the profiled curved decks the high quality finish that was required to ensure this section was in keeping with the aesthetics of the other airport developments. The modular design of Rapidshor meant it could be quickly and safely erected, and dismantled throughout the phased programme. When it came to the deck, we had to specially design the steel deck panels in order to ensure they could be craned off the Rapidshor system after the concrete on the deck had been cured, and moved to the next section of road very quickly. This was an incredibly efficient way of dealing with this section of construction, and really utilised the strengths of the Rapidshor system.”
The next section of the elevated approach roads that RMD Kwikform was involved in was the construction of the curbside arches. Rapidshor shoring was used to support the specially fabricated steel forms, which were designed and constructed to form a twin leaning arch, which was to be used to support the road deck via a crosshead beam adjacent to the airport.
The customers’ brief was to design a system that would enable them to cast the complete pier, which included two arches and 12 columns, on one single pour. Due to the scale and complex geometry of the pier; 30m long, 15m high and 10m wide, a three dimensional model was created to ensure the accuracy
of the formwork. The formwork was purpose-made for this project and was designed to withstand a maximum concrete pressure of 105KN/m2.
This is a significant concrete pressure to design to and was as a direct result of the height of the single concrete pour as well the concrete mix requirements. Due to poor access for internal vibrators and a very dense reinforcement cage, a special free flow concrete mix was created to allow a continuous pour without cold joints. This was used to deliver the 315m3 of concrete required for both arches in just 16 hours.
On completion of the curbside arches and crossheads, the curbside road decks were constructed using a combination of Rapidshor, heavy duty Megashor and specially fabricated steel profiled decks. Each span segment was 36 metres long, 60 metres wide and 15 metres high, forming two independent road decks.
Speaking about the road deck solution, Gabriel continues: “We supplied a total of 16 individual falsework decks for this section of the road, equating to approximately 2,880 tons of Rapidshor and Megashor components. This was alongside 600 tons of the specially designed steel profiled decking panels. Again, dealing with this quantity of equipment could have been incredibly challenging logistically, but the ability to crane the steel decking panels into position onto the next section of the road, allowed our customer to reuse sections, which reduced the amount of equipment onsite.
“On the project, we also identified the opportunity to use Maxima panels to provide support to the crosshead beams. Because of the inherent strength and modular nature of Maxima, this reduced time and resources on site. In addition, we also used special steel profiled walers to form the curved soffit of the crossheads. Having access to the specially fabricated equipment has allowed us to maximise the effectiveness of our standard products.”
BahrainT: +973 1738 2724E: [email protected]
QatarT: +974 4465 3034E: [email protected]
UAET: +971 6 553 4173E: [email protected]
www.rmdkwikform.comSaudi ArabiaT: +966 13 896 8665E: [email protected]
OmanT: +968 244 96037E: [email protected]
![KAIA Project Management Plan[1]](https://img.pdfslide.us/doc/110x75/588112bb1a28ab22368b79c1/kaia-project-management-plan1.jpg)
