darmagazine i5issue 5, 2013 Staying the Course: Dubai Remarkable Come Back // Solutions to Complexities: Managing the Design Process for the King Abdullah Financial District // An Impressive Mix // setting the stage As lead A-E-C consultants, Dar Al Handasah (Shair & Partners) works with individual firms, established consultants and specialized designers to manage our clients’ mega projects. This issue of the DarMagazine centers around the unprecedented project design and delivery scales that are being achieved through sound design management and project integration in our industry today. The right leadership, the engagement of a multitude of investigators and a large community of experts through collective work, the utilization of new technologically-inspired tools and common standards achieve high levels of success for the construction of large (medium and small) scale projects. Over many years we have built a solid expertise leading the management of mega-size projects through partnerships, knowledge management, and visualization. Our objective has always been to produce an end project that is valuable for society and useful to many and this issue of the magazine is a glimpse of how we do it. ‘Staying the Course’ is a feature article about Dubai’s remarkable recovery it showcases four recent projects signed in 2012. ‘Solutions to Complexities: Managing the Design Process for King Abdullah Financial District’, is an article about KAFD’s highly complex project that dictated advanced management activities, methods and skills to optimize and run design processes. A unique opportunity to achieve highly successful outcomes based on best design management practices backed up by our solid experience managing large scale projects, regional insight and international exposure, KAFD ranks among our most challenging projects over the last decade. ‘An Impressive Mix’ we present some of our integrated core values, strategic choices and insight for solid and durable success. In May 2012 Dar Al Handasah concluded a deal with the international firm Currie and Brown, DarMagazine features an interview with Sari Gedeon Director of the Project Management and Contracts Department who played a role making C&B part of our Group. The article ‘The Ondjiva Paradox’ relays our flood experts’ solution to tame a flood that constitutes threat and livelihood for the residents of the Angolan city of Ondjiva. Our commitment to E-P-C project delivery especially in large scale industrial projects necessitating particular expertise is presented in ‘The Challenges of Equipment Procurement in Industrial Projects’. Finally, ‘The Unsymmetrical Precast Pre-tension beams for PNU’s APM’ is an overview of a technical paper submitted by our Structural Department and presented during the 2011 Prague fib Symposium. Rawiya Bikhazi DarMagazine Editor-in-chief contents 02// the unsymmetrical precast pre-tensioned beams for the apm bridge at pnu by Essam Ayoub, Senior Bridge Engineer; Gamal Helmy, Bridge Department Head; Charles Malek, Director of Structures Department 07// the challenges of equipment procurement in industrial projects by Lara Al Amm, Senior Project Engineer 10// staying the course: dubai remarkable comeback 12// dar al handasah at dia: two new concourses 28// the pointe 32// dragon mart 34// pearl jumairah 36// an impressive mix 36// joined up execution 38// an interview with sari gedeon 40// the ondjiva paradox by Joelle Makhoul, Environmental Engineer 45// solutions to complexities: Managing the design process for the king abdullah financial district 1 minimizing distortion | pnu’s apm unsymmetrical beams The Unsymmetrical Precast Pre-Tensioned Beams For The Apm Bridge At Princess Nora Bint Abdulrahman University by Essam Ayoub, Senior Bridge Engineer; Gamal Helmy, Bridge Department Head; Charles Malek, Director of Structures Department Figure File • Alignment length: 12.1 km • Precast concrete elements • Cast in situ concrete elements • Concrete volume: 146,500 m3 • slabs: 7,500 m3 with total • Foundations: 43,000 m3 • Construction period: number of ≈ 8650 units • Piers: 18,500 m3 • Pre-casting = 8 months • C beams: 23,000 m3 with total • Topping slab & stitching: 24,500 m3 • Construction = 8 months number of ≈ 660 units • Concrete sleepers: 12,000 m3 • Guideway Bridge • Segments: 6,500 m3 with total • Pre-stressing and ordinary reinforcement • Straight sections: 8,800 m number of ≈ 810 units • Pre-stressing reinforcement for all elements: 1,750 t • Curved sections: 3,300 m • Parapets: 11,500 m3 with total • Ordinary reinforcement for all elements: 32,000 t number of ≈ 8500 units Main image The APM’s box girder bridge and piers. Inset, view of the APM and the Central Plaza, in the background minarets of the main mosque 2 pnu’s apm unsymmetrical beams | minimizing distortion When subjected to gravity loads such as eliminating lateral displacements, the The premise: their own weight, doubly unsymmetrical pre-stressing strands should be arranged sections are subjected to vertical and so that under their own weight, and pre- Minimizing distortion for doubly transversal displacements. Moreover, stressing forces (case of load transfer) unsymmetrical beam sections under pre-stressing, loading the same the final lateral displacement across the kind of displacements and the possibility beam is minimal. This can be achieved of axial displacements can also occur. if, at transfer, the final orientation of the To minimize distortion (bowing), only neutral axis is horizontal at all critical allowing for vertical camber and beam cross sections. 3 minimizing distortion | pnu’s apm unsymmetrical beams The day King Abdullah Bin AbdulAziz Al Saud, Custodian of the Two Holy Mosques, inaugurated the Princess Nora Bint AbdulRahman University (PNU), he rode the Automated People Mover (APM) demand-responsive transport system designed to take students around the 800-ha campus safely, securely and with the least strain on the environment. PNU, east of Al-Riyadh, is the vision of the Custodian of the Two Holy Mosques to advance education in the Kingdom of Saudi Arabia. Completed in a record breaking two and a half years covering design and construction – the King himself laid the foundation stone on the 29th of Shawwal, 1429 (October 30th, 2008), just as he was the one to inaugurate the campus on the 12th of Jumada II, 1432 (May 15th, 2012). The driverless dual-track APM transit system running smoothly at a total 14 stations. The plan calls for an easily constructible and quietly on continuously welded steel rails is PNU’s center and cost-controlled design of the 12-km alignment guideway piece. Visible from all areas of campus, it rises on a pre-tension with straight and curved segments. Sticking with the 25-months C-beam guideway 13-m above the academic plinth providing grueling time schedule was a project requirement but delivering a lookout point from which students can gaze at the canopy- on looks and uncompromising soundness of design is that of the shaded green piazzas connecting the academic buildings and team of bridge engineering designers’ own commitment to design runs on overlapping routes to the residential quarters stopping and execution. 1 5 2 3 6 4 1 Assembling of the two precast unsymmetrical C-beams on site 2 On site connection of the two C-beams through stitching concrete 3 Erection of the 10 cm precast slabs 4 Cast in situ of the 15 cm R.C deck slab 5 Final stage elevation and cross section of the 36 m straight span 4 pnu’s apm unsymmetrical beams | minimizing distortion 7 Closet box section type guideways were chosen for the entire (75 % straight 25 % curved) alignment requiring a precast concrete technique of construction. For the straight sections, the box girder was executed using unsymmetrical precast pre-tensioned C-beams assembled together using stitching concrete. At transfer, the unsymmetrical precast pre-tensioned beam was 8 studied to avoid distortion that could characteristically occur with unsymmetrical beams. The cast-in-situ R.C. deck slab was then constructed using precast slabs resting on the formed box girder section. No formworks were needed for the whole bridge box section construction because of the efficiency gained from the use of precast beams and slabs. For the curved APM parts, a precast post-tensioned segmental construction was considered. This article summarizes the findings of a technical 9 paper accepted by the International fib Symposium and presented by Dr. Essam Ayoub in Prague 2011. The authors present the efficiency obtained using precast construction technique for the PNU elevated APM guideway. The paper also discusses the pre- tensioned strands arrangement for unsymmetrical precast C beams (straight parts) to minimize distortion occurring at transfer due to the unsymmetrical characteristics of the precast beams. 10 Guideway straight parts precast C-beams The straight parts of the APM’s guideway were constructed using doubly unsymmetrical precast pre- tensioned C-beams with several span lengths adopted. These include 22-27, 30 and 36 m simple spans each with two precast C-beams assembled to form the final box girder section of the APM guideway. The sequence of construction resulted in the most efficient box girder section construction with a 45 MPa concrete grade. For the 36-m span straight bridge 75 strands, five are located 11 at beam top and adopted for each of the two precast unsymmetrical pre-tensioned beam. The pre-tensioned strand has an ultimate strength of 1770 MPa and an area of 150 mm2. Ten strands are de-bonded