Concrete Report 2020

A supplement of:

CONCRETE REPORT

An Agile Operator BASHAR ABOU MAYALEH DISCUSSES THE CHALLENGES FACING THE CONCRETE INDUSTRY Embracing the Future HOW 3D-PRINTING CONCRETE CAN REVOLUTIONISE THE INDUSTRY

Adapting to the times

BIG PROJECT ME LEARNS HOW THE CONCRETE INDUSTRY IS ADAPTING AND EVOLVING IN CHALLENGING CONDITIONS In association with:

Experience the Progress.

Liebherr Middle East FZE Jebel Ali Free Zone (South), P.O. Box 2540 Dubai United Arab Emirates E-Mail: ali.kassem@liebherr.com www.liebherr.com

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WELCOME

Introduction A supplement of:

02 Group MANAGING DIRECTOR Raz Islam raz.islam@cpitrademedia.com MANAGING PARTNER Vijaya Cherian vijaya.cherian@cpitrademedia.com Editorial GROUP EDITOR Gavin Davids gavin.davids@cpitrademedia.com +971 4 375 5480 JUNIOR REPORTER Angitha Pradeep angitha.pradeep@cpitrademedia.com +971 4 375 5479 SUB EDITOR Aelred Doyle aelred.doyle@cpitrademedia.com

Staying strong

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Advertising COMMERCIAL DIRECTOR Jude Slann jude.slann@cpitrademedia.com +971 4 375 5714 HEAD OF KEY PROJECTS Andy Pitois andy.pitois@cpitrademedia.com +44 7816 843610 Design ART DIRECTOR Simon Cobon simon.cobon@cpitrademedia.com DESIGNER Percival Manalaysay percival.manalaysay@cpitrademedia.com

elcome to the 2020 edition of the Concrete Report and much like every other industry, this has been a tumultuous time. Over the course of this report, I think you’ll see that the people and companies that operate in this sector aren’t ready to quit just yet – much like the material they work with, they’re built tough.

We hear from companies at the leading edge of concrete technology, while we also talk to established entities that are determined to keep evolving and adapting, no matter the external challenges around them.

Enjoy this special report, and remember to stay safe and maintain social distancing!

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Photography PHOTOGRAPHER Maksym Poriechkin maksym.poriechkin@cpitrademedia.com Marketing MARKETING AND EVENTS EXECUTIVE Aysha Sultan aysha.sultan@cpitrademedia.com +971 4 375 5498 ADMINISTRATION EXECUTIVE Zaara Khan zaara.khan@cpitrademedia.com +971 4 375 5470 Circulation & Production PRODUCTION MANAGER Vipin V. Vijay vipin.vijay@cpitrademedia.com +971 4 375 5713 DISTRIBUTION MANAGER Phinson Mathew George phinson.george@cpitrademedia.com +971 4 375 5476 FOUNDER Dominic De Sousa (1959-2015)

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The publisher of this magazine has made every effort to ensure the content is accurate on the date of publication. The opinions and views expressed in the articles do not necessarily reflect the publisher and editor. The published material, adverts, editorials and all other content are published in good faith. No part of this publication or any part of the contents thereof may be reproduced, stored or transmitted in any form without the permission of the publisher in writing. Publication licensed by Dubai Development Authority to CPI Trade Publishing FZ LLC. Printed by Al Salam Printing Press LLC. CPI Trade Media. PO Box 13700, Dubai, UAE. +971 4 375 5470 cpitrademedia.com © Copyright 2020. All rights reserved.

Gavin Davids

GROUP EDITOR

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gavin.davids@cpitrademedia.com @MECN_Gavin MEConstructionNews me-construction-news

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IN PROFILE

Bashar Abou Mayaleh

An Agile Operator BIG PROJECT ME MEETS WITH BASHAR ABOU MAYALEH, MANAGING DIRECTOR OF CONCRETE INDUSTRIES COMPLEX, TO HEAR ABOUT HOW THE GROUP IS ADAPTING AND PREPARING ITSELF FOR A POST-COVID19 FUTURE

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IN PROFILE

s the new year rolled in, things were looking quite rosy for Concrete Industries Complex (CIC), the Dubai-based umbrella organisation for three concrete solution providers – Hard Precast Building Systems, Hard Block Factory, and Emirates Beton. Despite challenging market conditions, the company had managed to post financial figures close to what it had achieved in 2018 – the best year on record for the group, but things were looking quite promising for the coming year.

Not only was the firm doing turnover bigger than its budget, but it was also primed to take over a larger share of the market thanks to several of its competitors exiting the fray.

As Bashar Abou Mayaleh, managing director of CIC explains, although he was cautious about projected figures, he was still optimistic.

Adapting to the unknown Bashar Abou Mayaleh says that the COVID-19 pandemic has forced CIC to revise its expectations and plans for 2020.

2018

Best year on record for the group

However, in the wake of the COVID19 pandemic sweeping its way across the world and wreaking havoc with the global economy, those expectations and figures have had to be revised, and Abou Mayaleh tells Big Project ME. “With an excellent first quarter behind our back and the COVID19 pandemic hanging over our heads, the future holds a lot of uncertainty, thus requiring continuous adaptation to the situation. All I can say at the current moment is that we are experiencing something beyond expectations.

Everything in the future will further

depend on the resilience of the world economy, and specifically the UAE construction industry towards this unforeseen situation,” he says during an exclusive interview at CIC’s offices in Dubai Investment Park.

“Given the current situation, wherein Expo 2020 Dubai is being postponed, I can foresee it having a ripple effect within the UAE economy. The event was a forerunner in boosting investor confidence within the UAE economy, and the large scale of the event, with massive international participation, created a host of business opportunities within various sectors.

“However, with the recent crash of the oil prices and the hindsight of another global recession, I believe that a lot of government backed investments (mainly from participating countries) may now be held back, delayed or postponed, which in turn might create a gap in the UAE economic plan. Even local developers and investors are quite wary of the situation, and this can be easily observed with the plethora of ongoing and planned projects being suspended or even permanently terminated,” Abou Mayaleh states, though he adds that he remains confident that the UAE leadership will be leaving no

You don’t make any business unless you make a profit. Most of our competitors have been making losses for several years, and now the snowball has become very large” Concrete Report 2020 | MEConstructionNews.com

IN PROFILE

stones unturned in order to ensure that the Expo is an event of a lifetime.

Furthermore, he adds that CIC has been making plans to enter new markets and territories, particularly with regards to Egypt, where the state-backed investment into real estate and infrastructure projects is creating many opportunities for construction firms.

“We are having some serious studies about Egypt right now. To start with, we are looking at some block factories there, and we believe that if that goes smoothly, we might be able to start something else as well. We are studying the market very careful – I have even sent a team of my general managers twice to Egypt to establish several communications with people, and to study the situation there. We are very positive about that market.”

Of course, this is all dependent on how the global pandemic pans out, as Abou Mayaleh acknowledges.

“The impact of the Coronavirus within our industry will mainly

depend on the severity and duration of the current economic lockdown.

We anticipate mostly three different business scenarios: a Mild Impact, where revenue losses are 15% to 20%, wherein the recovery follows a V-curve and there is effective pandemic control and economic stimulus; a Severe Impact, where revenue losses are at 25% to 40% and wherein the recovery follows a U-curve and there are prolonged effects of the virus on the UAE economy; and finally a Catastrophic Impact, where revenue losses are a minimum of 60% to 70%, wherein the recovery follows a L-curve and there is a failed pandemic control and widespread bankruptcies and credit defaults in the market.

“I currently foresee CIC being in the Mild Impact category, but we are ready to deal with more severe scenarios if things become more difficult.”

However, Abou Mayaleh is keen to stress that while the pandemic is likely to have an impact on the

20%

Revenue losses in a ‘Mild Impact’

Bottom of the chain Subcontractors face huge problems due to their position at the bottom of the payment chain, Abou Mayaleh says.

Egypt in focus CIC is looking at the Egyptian market with serious consideration and has sent teams to study the opportunities in the market there.

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economy and the industry, it is only exacerbating problems that already exist in the subcontracting sector of the construction industry, particularly in the precast business.

“In general, I believe that the biggest problem facing subcontractors is low margins and their positions in the payment chain.

“They are situated at the bottom of the payment chain and are faced with a lot of complicated procedures and contracts. Payment certificates, NCRs, being connected to the main contractor (directly or indirectly) and to all the risk that comes with that. They’re tied to their completion certificate, and as a result, a lot of subcontractors are going through very long payment cycles.

“In the precast industry, we enter the project in the beginning, and we finish the concrete works and exit.

The contractor could then spend another one and a half years to finish the project, and yet the subcontractor will be kept connected to their

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IN PROFILE

handover certificate. Sometimes, you get it after three years!

“And originally, the margin is very small. Many subcontractors are making big losses, and due to their system, they don’t recognise these losses for one or two years, because they keep using the money for new projects to pay for the old ones,” he explains.

Therefore, CIC’s strategy has been to stay aggressively profitable and not compromise on that principle, Abou Mayaleh says. As a result of this stance, the group has been one of very few precast manufacturers and suppliers to make a profit, a fact borne out by the company’s financial figures in 2018, 2019 and the early months of 2020.

“You don’t make any business unless you make a profit. Most of our competitors have been making losses for several years, and now the snowball has become very large in their business. That’s why, in the last year, you’ve seen several precast and ready-mix companies going technically bankrupt. That’s

40%

Revenue losses in a ‘Severe Impact’

Low-Touch Economy As construction moves towards a low-touch economy, services like off-site manufacturing and automation will see increased demand.

Aggressively profitable CIC has committed to only taking on business that will allow the company to see a profit.

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what’s helping us take more share in the market, while the volume of the market has been shrinking.”

Being able to have a top-down view of the market is quite advantageous, especially if, as many experts predict, the coronavirus pandemic will force a shift towards adopting less labour intensive methods of construction, such as off-site manufacturing, precast and 3D-printing, amongst others.

“I strongly agree with and support such a prediction. As we head towards a ‘Low-Touch Economy’, we can anticipate certain strict measures being put in place, maybe by the authorities themselves, wherein things like Social Distancing will become a norm of any industry. Although we would like this kind of mindset to happen within the construction industry as well, there are far bigger factors that will drive this shift.

“First and foremost, the liquidity in the market has to allow for the high initial costs that come with any offsite construction process. Secondly,

the client and the consultant’s views towards the use of such technology within their projects has to gain confidence that offsite technology can serve and cater to all their architectural and structural requirements. Lastly, the government has to support this industry in a way wherein we can offer more and more sustainable and commercially viable options to the market by easing our cost burdens (for example, by providing subsidised labour visa costs to such companies),” he outlines.

Having undergone several expansions over the last three years, CIC is now in a position where its assets are being utilised to the maximum. As such, there are no plans at present to further grow the company’s asset base (including machinery, factories, and production lines). However, this does not mean he doesn’t have an eye on the future.

“What we’re doing now is bringing talented, fresh graduates.

They’re really giving us – even

IN PROFILE

The future holds a lot of uncertainty, thus requiring continuous adaptation to the situation. All I can say at the moment is that we are experiencing something beyond expectations” beyond our expectations – very high-quality outcomes. They’re very much involved in contributing to squeezing the most out of each and every sub-item in our cost.

“The older generation really miss a lot of skills and competencies of the newer generations. They are much cleverer than us in several things.

One is in communication – they have high communication skills, and if you direct their skills to be more strategic, then they are wonderful, even with analytical thinking. Their relationship with data is much better than the older generation as well.

They are highly skilled in computers, and their understanding of IT and of new concepts is much more mature.

“These are the main skills, and if you add to them the values of the organisation and the attitude of a person, which is something we don’t compromise on – attitude comes first. But we have found that all these fresh graduates are very enthusiastic here at CIC, when they find out that it’s a progressive environment and that they are encouraged. They really add huge value,” he asserts fondly.

Furthermore, across the group, there has been significant investment in technology, with BIM becoming a standard across their precast projects.

Abou Mayaleh is keen to point out that technology has become so essential to how CIC operates, he jokes that the design department can’t even contemplate going back to the old way of doing things, such is their level of productivity and delivery.

“The second big advantage is that we’re now connecting the design department with our operational software, which was developed here. We call it ELM and it’s a total precast operational software that the design department is totally connected to as the second stage of this software. All the output of

Back stronger Bashar Abou Mayaleh says that CIC’s strategic investments will see it come back much stronger in the post COVID-19 era.

70%

Revenue losses in a ‘Catastrophic Impact’

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the BIM designs are communicated directly with all the other departments in the company, with a lot of very useful statistics and data.”

All of these investments into the future of CIC will stand the organisation in good stead in times of crisis. This belief in the work he and his team have done till date is what he holds on to as he looks towards a post-COVID19 future.

“Our focus on the market has now been intensified, with each opportunity being looked at and reviewed from different aspects. Due to the imminent disruptions to our supply chain, we are also looking for new and locally available alternatives, which in turn can benefit us in the long term.

“Finally, I would just like to say that I trust that the UAE, ASGC and CIC are going to emerge much stronger after passing these difficult times. We [at CIC] have built a very sustainable business. With our investment into all our business differentiation advantages, there is no doubt that, while we are managing in these challenging times, we are also strategically investing in all the non-seen opportunities, so as to become much stronger in the post-COVID-19 era. We are truly very optimistic. ” he concludes.

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TECHNOLOGY

Precast Concrete

An Ideal Method MIDDLE EAST

Elematic’s Curt Lindroth shares his views about the regional precast concrete industry and the advantages of precast construction

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ccording to a leading research firm, the global precast concrete market size is expected to reach $146 billion by 2027, with an annual compound growth rate of 6.3%. An increase in awareness regarding the quality and convenience of precast concrete is expected to contribute to this growth, ResearchAndMarkets. com’s report says.

“In the UAE, Qatar and Bahrain, there are several very capable precast concrete factories able to meet the industry’s current demand.

Nonetheless, the market

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share for precast concrete construction is rising, and there are opportunities for expansion,” says Curt Lindroth, area sales director for Middle East and Europe at Elematic.

“Meanwhile, in Saudi Arabia, the capacity is not enough. Precast concrete companies in the Kingdom have faced economic challenges, however, it’s not due to lack of projects. It’s related to managing their operations and channelling projects from contractors,” he says, adding that the government is now looking at utilising the existing capacity more efficiently.

In an exclusive interview with Big Project ME, Lindroth goes

into detail about the demands of the regional precast concrete industry as well as the benefits of precast construction.

On the Middle East region, he notes that slowdown in projectrelated cash flow is a common issue, which adds economic pressure in meeting deadlines.

“Moreover, cheap labour flattens out the cost difference between building methods in the Middle East. In-situ construction projects, which require far more manpower than precast does, could still be quite cheap. However, in these cases, faster construction time and better quality have turned some projects into precast.”

TECHNOLOGY

“Even with the COVID-19 pandemic affecting most businesses worldwide, construction work is continuing, and precast concrete factories are supplying despite the pandemic,” says Lindroth. “However, sustainability, safety and digitalisation have become vital as a result of the pandemic.

For example, safety has been prioritised, and distance working has increased the need for remote access to sustainable projects.”

To that end, he adds that there is an increasing demand for sustainable construction from governments, citizens, and global communities. He says that compared to cast-in-situ construction, it is well known that precast uses less water, less steel, less cement, and less time.

“The current development presents a good opportunity for the precast industry to be a forerunner in this field. With cement forming up to 70% of the total CO2 load in precast production, it is important to optimise that content through efficient compaction.”

“Hollow core slab production using our extruder machinery makes it possible to use 100 kg less cement per cubic meter of concrete compared to other types of machinery. Not only that, precast concrete buildings also meet the standards and requirements in terms of seismic durability, moisture and fire resistance, and the buildings have a long structural life span,” Lindroth states.

Hollow core slabs are pre-stressed concrete products which have a constant cross-section and

are manufactured using a particular casting machine. He adds that hollow core factory production can be labour intensive or highly automated, depending on the level of technology in automation and production machinery.

He explains: “Factory digitalisation may sound expensive, but it’s actually not, when considering the payback through increased cost-efficiency, product quality and reduced human mistakes.

By calculating and comparing the production cost element by element, one can organise the work based on actual data and notice production bottlenecks in advance.”

“Digitalised production planning creates a basis for further digitalisation of the whole hollow core production process. Using a manufacturing execution system, for example, Elematic’s FloorMES, it is efficient to supervise and plan hollow core slab production.

Factory digitalisation may sound expensive, but it’s not costly when considering the payback through increased costefficiency, product quality and reduced human mistakes”

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It is also possible to re-plan or adjust the production schedule quickly.”

“The system automatically monitors all processes and compares it to the original plan.

One of the most efficient ways to cut down on production costs is to implement efficient production planning.

Through the digitalisation of the hollow core slab production, cost-efficiency of the factory is enhanced.

It also means that the end customers are better served.”

Moreover, Lindroth notes that automated processes are an ideal method to ensure consistent quality throughout the chain of precast concrete production.

“The benefits are not only limited to precast concrete factories as the whole construction project can be digitalised, from original designs to construction sites and beyond, to the entire lifecycle of the building,” he concludes.

Consistent quality Automated processes are an ideal method to maintain consistent quality, says Curt Lindroth (pictured above).

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ENGINEERING

Asset Protection

Stop Talking Rot MIDDLE EAST

Dr Samir Dirar, Dr Dexter Hunt and Professor Peter Robery of the University of Birmingham, discuss why the Gulf region poses distinct challenges to protecting steel reinforcement in concrete assets

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orrosion of steel reinforcement remains the most prevalent form of deterioration to concrete infrastructure assets in the Gulf region. Contributory causes are diverse, including: • variable quality of imported raw materials (aggregates, cementing materials); • high ambient temperatures, affecting mixing, transporting and placing concrete; • lack of an experienced and trained workforce, resulting in areas of low cover, poor compaction and a lack of adequate curing; • hardened concrete surfaces that are more porous than intended, due to incomplete cement hydration.

Compared with Europe, the exposure environment continues to present the most

significant challenges, with high rates of carbonation occurring under dry, elevated temperatures; chloride ion contamination from windborne salt spray; groundwater; and a desire to build in ground with Sabkha salt encrustation.

In this region, as we push our technology with ever more ambitious and complex structures but with only limited long-term experience in this environment, and without universal durability codes and guidance, problems continue to occur.

WHAT’S GOING WRONG?

We know steel structures have to be protected from corrosion by paint systems, whether on our bridges or our cars. The amazing benefit of putting steel reinforcement in concrete, established in the early 1900s,

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ENGINEERING

was the passivating effect of strong alkali that occurs naturally in hydrated Portland cement. To the unwary, a pH of over 12.5 means direct skin contact can cause burns in a matter of an hour.

This means corrosion of reinforcement is immediately inhibited by the concrete that encases it, forming an oxide film. But two principal culprits in the environment fight against this protection.

CARBONATION

With time, atmospheric carbon dioxide, an acidic gas that is all around us, will lower the pH of the concrete. This is called carbonation. When the pH reduces, general corrosion of the steel can begin, as concrete protection has diminished.

The volume of the corrosion product is larger than that of the steel consumed by corrosion, generating stresses in the surrounding concrete. This leads to cracking, spalling and

delamination of the concrete protecting the steel, called the concrete cover. Through thickness losses due to general corrosion, strength and ductility of the steel reinforcement will reduce, which can lead to sudden and catastrophic brittle failure.

worse, the corrosion product may not be expansive and can occur undetected beneath the concrete cover without specialist survey techniques to detect these corrosion sites.

DO WE HAVE ANSWERS?

CHLORIDE IONS

Chloride salts, which either penetrate the concrete or sometimes are already present due to the use of chloridecontaminated materials during mixing, cause even more severe reinforcement corrosion. Unlike carbon dioxide, chloride ions break down the protective passive oxide layer around the steel reinforcement and cause rapid galvanic corrosion.

Chloride-induced corrosion cells produce pitting corrosion with rapid loss of steel section, even in wet conditions such as the splash zone of a pier.

The loss of steel section due to pitting corrosion can also lead to sudden failure. Even

Environmental problems Dr Samir Dirar (pictured above) explains that the regional environment continues to have a detrimental effect on steel reinforcement.

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As we push our technology with ever more complex structures but with only limited long-term experience in this environment, problems continue to occur�

Research at the University of Birmingham is addressing the issue of steel reinforcement corrosion through a multifaceted strategy. For existing concrete structures, while research on corrosion management is well advanced, without extensive breakout and repair of concrete, the losses in steel thickness and the consequent weakening of the structural element cannot be reversed.

We are looking at the use of non-corrosive fibre reinforced polymer (FRP) composites to increase, or reinstate, the loadcarrying capacity. This work, funded by the UK’s Engineering and Physical Sciences Research Council, has clearly demonstrated that externally

ENGINEERING

bonded FRP strengthening systems are effective in strength enhancement of corrosiondamaged concrete structures.

However, the effectiveness of the FRP strengthening systems decreases with increasing corrosion level.

WHAT ABOUT NEW BUILD?

For new concrete structures, a multi-scale study funded by the UK’s Royal Society is exploring the use of emerging aluminosilicate materials, sometimes called geopolymers, as novel coatings for improving the corrosion resistance of steel reinforcing bars in concrete.

The collaborative project between the University of Birmingham team and Dr AngeTherese Akono of Northwestern University in the US is optimising the corrosion resistance of geopolymer coatings: • at the microscopic scale, examining the chemistry and processing procedure; • at the macroscopic (visible) level, measuring the corrosion potential of geopolymer-coated steel rebars in simulated marine environments; • at the structural level, quantifying any changes in the bond performance of uncorroded and corroded geopolymercoated steel rebars, and measuring the impact of the geopolymer coating on the durability of reinforced concrete structures.

Improving resistance The UK’s Royal Society is exploring the use of emerging aluminosilicate materials as novel coatings for improving the corrosion resistance of steel reinforcing bars in concrete.

campuses in Dubai and the UK. In particular, the credit-bearing Structural Engineering PD courses offered at the Dubai campus, which are conveniently designed to be upgradable to a full MSc in Civil Engineering, explicitly cover critical assessment of the structural condition of existing concrete structures subjected to corrosion damage, as well as proposing appropriate repair strategies.

SUSTAINABILITY AND DURABILITY

To leave a more favourable long-term legacy concerning the buildings we construct, both sustainability and resilience should be integrated into new-build design at the earliest stages of decision-making processes. Material selection in the region forms a significant part of these decisions, not least for domestic buildings, where

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the choice to use concrete has critical implications for the carbon cost of construction.

The selection of alternative materials with lower carbon costs (including those classified traditionally as waste) can provide necessary resource streams, transforming them into highervalue materials for construction and other manufacturing industry applications.

In conjunction with Green Building Regulations and Green Rating Systems (see list), accreditation of these improved levels of performance can help showcase the region as a world leader in this field.

• Estidama – Pearl Rating System • Al Sa’fat – Dubai Green Building Evaluation System • Barjeel – Ras Al Khaimah Green Building Regulations • LEED – Leadership in Energy and Environmental Design • BREEAM – British Research Establishment Environmental Assessment Method

FEEDING BACK KNOWLEDGE

This research is also shaping the postgraduate and professional development (PD) programmes that the University of Birmingham offers at its

Integrating sustainability In order to leave a favourable long-term legacy, both sustainability and resilience should be integrated into new-build design at the earliest stages of the decision-making processes.

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Ancient legacy The Grand Egyptian Museum will hold thousands of artefacts and treasures recounting Egypt’s history and culture.

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CASE STUDY

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Grand Egyptian Museum

Preserving History EGYPT

CCL provides a case study detailing how it delivered the post-tensioned elements of the Grand Egyptian Museum

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or centuries, people have been fascinated by the culture and achievements of the ancient Egyptian civilization. Along with a legacy of art, science, spirituality and engineering, the ancient Egyptians also left in their wake a global trade in artefacts, many of which have been taken from their native Egypt over the centuries for both private collections and public display.

Now, for the first time, Egypt is set to counter that legacy of lost treasures by creating the most comprehensive collection of Egyptian antiquities in a single museum anywhere on the planet. Due to open in 2020, the Grand Egyptian Museum will be the largest archaeological museum in the world, with more than 100,000 artefacts in its collection. It will also display the full Tutankhamun collection in a single location, with many of the 3,500 pieces on view to the public for the first time.

But it’s not only the exhibits within the museum that have caused excitement around the world. Located in Giza, the museum building itself has already become a landmark ’must visit’ attraction. The project was the subject of an architectural competition, which received 1557 entries from 82 countries, with a winning design by Irish architectural practice, Heneghan Peng, selected for the project. The building’s chamfered triangle shape references the iconic pyramids, while creating a striking, contemporary structure that accommodates a huge, open-plan main hall.

The museum’s unusual silhouette has been achieved thanks to engineering from the project’s structural engineer, Arup, which relies heavily on the structural capabilities of post-tensioned concrete. The building’s design includes a roof with a total construction area of 10,000m2 of post-

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CASE STUDY

tensioned folded plates, along with post-tensioned edge beams and a cantilevered wall. The post-tensioning element of the project was delivered by CCL, the specialist in engineered solutions for structures, and the company’s partner in Egypt, CSS. The two companies worked together to provide the materials, equipment and expertise required on site.

FOLDED PLATE ROOF

Aesthetically, the folded plate roof continues the chamfered triangle design theme to the roof of the building. Technically, achieving this look involved considerable challenges.

The roof structure is composed of post-tensioned folded plates with different inclinations and spans varying between 18m and 30m. Arup requested that CSS supply CCL post-tensioning tendons containing 19 strands to provide the significant amount of PT forces required for lateral

Specialist solution CCL was appointed to the project at Arup’s request and helped deliver specialised engineered solutions for the museum, in tandem with the company’s Egyptian partner, CSS.

stability and seismic loads.

Other design factors also influenced the design of the post-tensioning, including the removal of some of the lateral beams originally designed into the roof structure, which increased the amount of PT forces required.

The relatively slim concrete thickness of the folded plates – just 275mm - and the varying inclinations also

Technical challenges The design of the roof structure posed a number of technical challenges to the project team, which were resolved in tandem with the engineering team and the client at the shop drawing stage.

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created buildability challenges, because it made it difficult to accommodate the live-end and dead-end PT anchors at the intersection of the angled plates.

This was addressed at shop drawing stage by the CSS team, who suggested an increase in the thickness of the concrete cover at the intersection of the folded plates from the upper part of the roof. This solution provided the increased thickness needed

for the PT anchors in a location where it will not be visible and was approved by both the engineering team and the client.

BEAMS

The structural design for the Grand Egyptian Museum building also includes six post-tensioned beams, with spans ranging from 14m to 38 m, located parallel to the folded plate roof.

These beams support the structural loading of the roof and manage the deflections.

Each of these beams was constructed with three tendons and installed using the CCL XM60 anchorage system.

The building also features a 22m long cantilever wall, which is 8.65 metres deep. This wall performs the role of a deep beam and was designed with six tendons, each incorporating 19 strands, using the CCL XM60 post-tensioning system.

Once again, the CSS team had to address buildability challenges in the design of the wall at shop drawing stage for the PT installation, due to the narrow 45cm width of this cantilever wall/deep beam.

CASE STUDY

Ahmed Zaky, CEO of CSS explains: “The live-end and dead-end PT anchors for the CCL XM60 system require a minimum concrete thickness of 50cm but the wall had been designed to provide a slim, elegant aesthetic, which could have been compromised by increasing the thickness of the concrete for structural reasons.

“To resolve the problem without altering the visual appeal of the wall/beam, we proposed increasing the width gradually over the course of around one meter of its length.

This solution ensured the thickness of the concrete was sufficient to accommodate the PT anchors at the relevant points in the structure, without detracting from the slenderness of the architectural design.”

The availability of experienced personnel was critical to ensure there was no possibility that the post-tensioning works could cause delays to the wider programme”

around the world, including a number of showpiece projects in North Africa, and our PT anchorage system holds ETA and UK CARES certification.

Consequently, we were able to offer the client the level of quality assurance they required along with local PT experts through our partner in Egypt, CSS.” CSS provided the shop drawings for all the PT works on the Grand Egyptian Museum project and technical support throughout the design development and construction process. CCL supplied all the strands and anchorages for the

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programme, according to the design team’s specification, and also worked with CSS on the installation of the PT on site for the folded plates, edge beams and cantilever wall, stressing the tendons using the CCL Multistressing Jack (4000 MG) and CCL Hydraulic Pump (SR5000). Finally, the CSS/ CCL team was also responsible for grouting the tendons to complete the PT works.

The PT elements of the project have now been completed and the Grand Egyptian Museum is due to open its doors to the public for the first time in 2020.

Crucial partner CCL was not involved with the Grand Egyptian Museum at the design stage, but its expertise was crucial in developing the buildability of the design and delivering the project.

PROVEN EXPERTISE

Unlike many of CCL’s projects around the world, the company was not involved in the Grand Egyptian Museum at design stage, but the involvement and expertise of CCL and CSS were critical in developing the buildability of the design and delivering the project on site.

Explains Tedy Chakhtoura, COO MENA/Africa at CCL: “During the tendering phase, the client’s primary concern was identifying a post-tensioning specialist that could complete this element of the project to the highest quality standards.

Speed of project delivery and the availability of experienced personnel was also critical to ensure there was no possibility that the post-tensioning works could cause delays to the wider programme.

“CCL’s PT system and expertise has been proven MEConstructionNews.com | Concrete Report 2020

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TECHNOLOGY

3D Printing

Embracing the Future MIDDLE EAST

Matthew Tribe, executive director at CallisonRTKL, talks to Big Project ME about how 3D printing concrete structures can revolutionise the industry

Why is 3D printing a viable and effective tool for the future of construction?

3D printing is an effective tool for the construction industry as the potential commercial savings are substantial. This is significant because according to a report

by McKinsey & Company, large projects across asset classes typically take 20% longer to finish than scheduled and are up to 80% over budget, highlighting the growing need for disruptive solutions that challenge the status quo and present greater ROI. We do not have to look far to see how 3D printing can revolutionise the future of the industry. For example, the 3D printed ‘Office of the Future’ in Dubai has achieved savings of 30-60% on typical construction waste, and labour reduction costs from 50-80%.

Concrete Report 2020 | MEConstructionNews.com

With time sighted as a reoccurring issue for the industry, one of the greatest advantages of 3D printing is speed. In fact, it was possible to build a 37sqm home in Russia, Apis Cor, from scratch in just 24 hours. This advantage is critical in times where we require immediate and rapid responses to dealing with the COVID-19 pandemic.

Whether it is to construct temporary hospital extensions or shelters after a crisis, the speed of 3D printing in construction is very valuable.

With the advancement in technology and ease of fabrication, it is possible that 3D printing in some form could exist in every construction project in the future, resulting in a reduction in construction waste while achieving efficiency in the design and construction process.

Discuss the pros and cons of 3D printing concrete structures as compared to utilising the traditional concrete frame and pour methods?

3D printing concrete reduces the amount of typical wet construction, which also reduces waste and dust on site. If the 3D printing is completed offsite and then transported to the final location, the quality control of the end-product and performance will be higher, especially in relation to façade systems. Complex and more sophisticated geometries might be easier to build and design if the right matrix for the concrete is developed, 3D printing would reduce the need for complex mould systems in traditional construction.

Of course, there are repercussions to any new

TECHNOLOGY

disruptive technology. 3D printing would require less labour, which would mean many redundancies in a typical construction project.

3D printing is still relatively new so there will always be a longer learning curve to get to the same level of sophistication of traditional concrete frame and pour methods.

The reinforcement of concrete for heavier and taller construction is currently a challenge.

How cost effective is the technology compared to current methods?

Why should the concrete industry embrace it?

What really separates 3D printing from traditional construction is the pace and low-cost nature of the process, which means the technology can also provide social solutions. Despite the advantages, there are only thought to be about 20 commercial buildings around the world that have been built using 3D printing to date.

The first being the COBOD international building in Copenhagen in 2017. Advocates say that the overall construction lifecycle is cheaper than current methods. However, it will take time and research for 3D printing to reach the level of maturity of the current methods before it is readily accepted.

Inertia is high in the construction sector and as profit margins are less, contractors will be less willing to embrace radical technology that could cause delays due to learning curves and general infancy.

For the construction industry to do better, the McKinsey report also discusses how the sector needs to embrace four basic principles including; transparency and risk sharing in contracts, return on investment orientation,

3D printing concrete reduces the amount of typical wet construction, which also reduces waste and dust on site.

If the 3D printing is completed offsite and then transported to the final location, the quality control of the end product and performance will be higher�

New prospects Because 3D printing technology is highly flexible, it opens up new prospects of creativity for designers and architects.

simplicity and intuitiveness in the design of new solutions and change in management.

What will manufacturers have to do to adapt to a 3D printed future?

Through this region’s visionary governments, there is an expectation that municipalities are constantly taking on a proactive and technology-first approach to urban progress. However, the implementation of 3D printing has been met with challenges centred around its affordability, availability and compatibility.

Prior to the implementation of 3D printing within the manufacturing processes, smarter and more innovative frameworks need to be progressively implemented to ensure that the technology is commercially viable.

With the move towards 3D printed designs fast approaching, manufacturers need to move towards testing and optimising properties. Training employees,

19

investing in research and development and embracing Building Information Modelling will also be at the core of steps taken by manufacturers to prepare for a 3D printed future.

What impact will 3D printing have on real estate and design?

As a global leader in the development of smart technologies, Dubai has taken steps to embrace regenerative construction processes to create scalable, smart developments that respond to demographic, social and economic change. As part of the visionary local initiatives, the UAE government has set a target of at least 25% of Dubai’s new buildings are 3D printed by 2030.

The disruptive nature of the technology is highly influencing the way that real estate is being built. Deploying 3D printing in the industry would mean that the construction process would be speedier, regardless of the simplicity of the design. This will allow more complex designs to surface due to the efficiency and consistency of the technology.

3D printing will also allow for designers and constructors to use existing materials more effectively, utilise new materials and implement pre-fabrication and modular building techniques.

As the technique is highly flexible, it opens up new prospects of creativity for designers and architects and allows large commercial projects to be more readily available and cheaper.

Due to the efficiency and costeffectiveness of constructing properties, the real estate market could become more affordable.

Still, the reduction in the cost of real estate can only be made possible with economies of scale.

MEConstructionNews.com | Concrete Report 2020

20

LAST WORD

3D Printing

Three Dimensional Printed Buildings MIDDLE EAST

Matt Smith, associate head of the School of Energy, Geoscience, Infrastructure and Society at Heriot-Watt University in Dubai, shares insights into how 3D printing techniques can transform how the construction sector operates

A

cross the UAE innovative structures are coming together in an effort to increase the speed of execution and completion of buildings in record time. 3D printing is a methodology in construction that ultimately should reduce costs and labour.

The process works by layering a construction fluid material along a predetermined route mapped by a computer. The mineral infused liquid then solidifies into ‘concrete’. In a sense it directly converts our digital model into a realised build.

BENEFITS OF MANUFACTURING 3D PRINTED BUILDINGS

3D printed building promises many benefits, they include the reduction of waste, the reducing of CO2 emissions and the possibility of having total freedom over the structural design.

According to EcoMENA, Dubai alone produces nearly 5,000 tonnes of construction and demolition waste every day, which constitutes for 70% of the

Concrete Report 2020 | MEConstructionNews.com

total solid waste generated on a daily basis. With these staggering figures, the construction industry seeks to take measures in waste reduction to meet the UAE’s national agenda, Vision 2021 which targets a sustainable environment in infrastructure.

The 3D printing solution is viable for this sustainable effort.

In particular, 2019 saw Dubai lay down the foundations of the future of 3D printed buildings after unveiling the largest 3D printed building ever made.

This project was a turning point in the construction sector, as it saw a significant reduction in costs and a high probability in solutions to demographic challenges by reducing the number of construction workers.

3D PRINTED BUILDING TECHNOLOGY TO TRANSFORM THE CONSTRUCTION SECTOR

Under the national agenda of the UAE, it has been announced that the Dubai 3D Printing Strategy is to construct 25% of Dubai’s new buildings by 2030.

Together, the benefit of efficiencies from 3D printing

will ultimately reduce costs, create a positive impact on the environment and it is estimated that there will be a total of 60% in the reduction of construction cost, according to the Dubai Municipality.

3D PRINTING IN THE UAE

The Dubai Government have set a 3D printing technology initiative, which will aim to exploit technology to promote the status of the UAE and Dubai as a leading hub of 3D printing technology by the year 2030. The strategy adopts emerging technology that will help cut cost in many sectors, especially the construction sector.

The technology will restructure economies and labour markets and redefine productivity. 3D printing builds are certainly a step towards an effective and efficient form of construction, furthermore the UAE construction market is expected to register a CAGR of 5.5% over the forecast period, 2019-2024. The growing demand for construction activity can be met and exceeded with the use of 3D technology in a cost-effective way.

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