Contents • Foreword • Khalifa Port’s strategic location • The new gateway port to Abu Dhabi • Facts and figures • Environmental breakwater • Offshore port island • The port’s causeways • Emirates Aluminium platform, causeway and cooling water intake • Highways and bridges • Dredging and reclamation • Khalifa Port and Marine Consortium • Halcrow
Foreword And along the way, Halcrow helped ADPC receive its
as consultants on the Shahama port project just
first international award. In 2008, ADPC was given a
outside Abu Dhabi, where they will help ADPC build
Diamond Award by the American Council of Engineering
a bustling marina.
Companies (ACEC), its highest honour, at the ACEC 2008 Engineering Excellence Awards gala in New York.
We hope that Halcrow employees who visit Khalifa Port
Halcrow won the Diamond Award for its excellence in the
in the future will feel that it is just as much a part of their
category of studies, research and consulting engineering
work as that of ADPC.
services in relation to the Khalifa Port Master Planning
am proud to say that Khalifa Port fully
project. The award was given to ADPC for creating
opened on 1 September 2012 with the
“a major new port with minimal environmental impact”.
official completion of Phase One of the project.
Tony Douglas As anyone can see, Halcrow has played a big part in the
I would like to thank our colleagues and stakeholders
success story of ADPC, part of the visionary team that
who have helped us reach our milestone opening. One
looked far into the future to help us build Khalifa Port.
of our long-serving consultants is Halcrow, who have
Chief executive officer
Abu Dhabi Ports Company (ADPC) ADPC is a leader in the development of world-class
been with the Abu Dhabi Ports Company (ADPC) since
We have now come full circle with the opening of
ports and industrial zones. Established in the Emirate
those far off days in 2005, when some of the first
the port and we would like to offer sincere thanks
of Abu Dhabi in 2006, its mission is to create the right
detailed sketches for the port were made.
to the experts at Halcrow who helped us, and our
environment to spur the economic expansion and
many multi-national teams, form strong alliances to
diversification of Abu Dhabi. ADPC operates and
Halcrow undertook an initial master plan and delivered
build the Khalifa Port and Khalifa Industrial Zone
develops commercial ports in Abu Dhabi and is the
the full master plan in 2007, paying particular attention
Abu Dhabi megaproject.
Emirate’s port authority.
to protecting the Ras Ghanada coral reef, lying adjacent
to the port. The dredging team, the Khalifa Port Marine
We are glad to say that Halcrow continues to work
Consortium, then asked Halcrow to undertake the
with ADPC, creating this year the port’s operational
environmental management plan, and continuing
Khalifa Port’s strategic location S
erving the Emirate and beyond, Abu Dhabi’s
access to global markets. Companies based in
Khalifa Port has been strategically located to
Abu Dhabi have access to nearly three billion
meet the growing demands of global trade.
consumers within four time zones, and with a well-connected transport system, the quick
As a dedicated enabler for the adjacent Khalifa Industrial
and efficient movement of passengers and
Zone Abu Dhabi (Kizad), the port offers unrivalled
goods to and from Abu Dhabi is assured
Ras Ghanada Reef
Al Maktoum International Airport
Abu Dhabi International Airport
With a population of around two million, *
* source: Statistics Centre – Abu Dhabi
Hong Kong Bangkok
Brisbane Sydney Hobart Dunedin
Abu Dhabi is the capital of the United Arab Emirates and the largest of the seven emirates
Rio de Janeiro
Khalifa Port Karachi
Salvador Al Ain
St Petersburg Hamburg
The new gateway port to Abu Dhabi K
halifa Port is the jewel in ADPC’s crown.
With a semi-automated container and general
Hailed as a magnificent engineering achievement
cargo facility handling bulk liquids, dry bulk, roll-
and beacon of technical excellence, Khalifa Port’s
on and roll-off cargo, Port Khalifa is one of the
engineering statistics are truly impressive. As Abu
most modern facilities of its kind in the region
Dhabi’s largest-ever construction project, the ongoing building of the port is a major undertaking. The sheer
size of it is staggering - its scale, state-of-the-art
9 5 10
facilities and handling capacity have secured its place
amongst the world’s advanced marine ports.
Port causeway (north)
Port causeway (South)
Highway and utility bridges
Built over 4.5km offshore to protect the adjacent Ras
Offshore port island
Ghanada coral reef, the port is being developed in five
planned stages over 20 years. Phase One, completed in
Ras Ghanada reef
September 2012, will see an initial capacity of 2.5 million
Wave attenuation breakwater
TEUs (twenty-foot equivalent units) of container traffic
and 12 million tons of general cargo annually. By 2030, as
Emirates Aluminium platform
subsequent phases come on-stream, it is expected that it
Emirates Aluminium causeway and water intake
Kizad Zone A
Kizad Zone B
will be able to handle 15 million TEUs and 35 million tons of general cargo per year.
Facts and figures
KHALIFA PORT AND KIZAD will be
2/3 the size of
4 times bigger than
Abu Dhabi island
1/4 THE SIZE OF
Environmental breakwater Khalifa Port was
oasting the only cactus coral along Abu Dhabi’s mainland coast, Ras Ghanada coral reef is known for its biodiversity
and reef development. Teeming with life and with a plethora of
for one reason
yellow and orange corals of all shapes and sizes sprout from the
alone: to protect the 20km
Ras Ghanada coral reef
colours, the reef is integral to the Gulf’s marine ecosystem. Pink, sea floor, providing shelter to the many species sharing this unique environment. Port Khalifa’s 8km-long environmental breakwater protects this vitally important underwater world. Built at a cost of US$240 million, the breakwater rises 4m above water. It has two main sections – an inner breakwater to protect the sensitive coral reef from contamination, turbidity and unwanted temperature fluctuation caused by port operations; and an outer breakwater to reduce the wave action within the port area. The reef’s foundation is core material, covered with a strong synthetic geotextile like heavy canvas, covered in turn by rock originating from Ras Al Khaimah that has been cleaned to prevent contamination. The outer section has an extra layer of acropod blocks – man-made unreinforced concrete structures designed to resist the action of waves
Built at a cost of US$240 million, the breakwater rises 4m above water
ABOVE: Revetment showing rock and acropod blocks. MAIN LEFT: Wave attenuation and environmental breakwaters. TOP and LEFT: The Arabian angelfish (Pomacanthus asfur) can be found in the Gulf. Its habitat includes sheltered coastal reefs with hard and soft corals, rocky reefs, crevices and the mouths of caves. It is timid, which makes it difficult to observe.
Offshore Port island L
ocated 4.2km offshore, Khalifa Port has been constructed on a 2.7km2 reclaimed port island.
With a platform, causeways and revetments formed from 45 million m3 of dredged materials, and designed to meet stringent seismic criteria, the port island is large enough to host some 340 football pitches. It is joined to the shore by the north and south causeways and the 1km-long road and utility bridge. Rising some 24m from their foundations on the sea bed, the quay walls are equivalent in height to six double-decker buses. Formed from 12 blocks, with a maximum weight of 71 metric tonnes each, around 4m of quay wall is visible above the water line. With ABOVE: Placing of quay blocks.
stringent specifications for block placing tolerances of +/- 20mm, the wallâ€™s foundations vary in depth to accommodate a range of geotechnical conditions. The portâ€™s container yard features six ship-to-shore quay cranes, 30 automated stacking cranes and 20 shuttle carriers. The onshore port area, which connects the port with Kizad, will host customs, immigration, container freight, inspection and security facilities
Rising some 24m from their foundations on the sea bed, the quay walls are equivalent in height to six double-decker buses
ABOVE: Cross section of quay wall. RIGHT: Quay wall and automatic stacking cranes.
The port causeways The seaward part
Formed as a solid bund for most of its length, the
of the causeway
that the water quality within the port basin is
causeway’s bridges allow water to circulate – ensuring
leading to the port
maintained through a process of natural water
island is armoured
quality around Abu Dhabi Water and Electricity
movement and flushing. It also ensures that water Authority’s intake to the south of the port, and the Ras
with rock, with
Ghanada coral reef to the north is maintained. There are areas of sea grass behind the port, and the open
bridge sections allow the flow of the tide to maintain
material as its core
water quality over the grass beds
The offshore port island is joined to the mainland
LEFT: The port causeway’s highway and utilities bridges.
by the 3.2km north and south causeways and the
RIGHT: Main causeway showing EMAL bridge and berth
1km-long road and utility bridges. The southern causeway at the landward side is armoured with rock on both side and filled with land-sourced material. The seaward part of the causeway leading to the port island is armoured with rock, with marine dredged material as its core.
on far right.
Emirates Aluminium’s platform, causeway and cooling water intake E
mirates Aluminium’s (EMAL) complex is a state-
The 810m quay wall is formed from sections comprising 15 blocks,
of-the-art smelter supplying the world with high-
each weighing around 73 metric tonnes. These are topped with
quality metal. It’s one of the largest industrial projects in
bridge showing conveyor gallery.
pre-cast capping blocks, each weighing 108 metric tonnes.
the UAE outside the oil and gas sector and one of the key initiatives leading the diversification of the
A vacuum ship unloader transfers coke and alumina (the
primary raw materials for aluminium production) onto a wharf belt conveyor system. Once on the conveyor, the material is
EMAL’s dedicated berth became operational in November
transported 4.6km along the trestle bridge and causeway running
2010 and receives four million tons of raw material cargo
from the wharf to the shore, before being delivered directly to
a year. The facility plays a key role in meeting the global
EMAL’s storage facility.
demand for aluminium. The causeway’s core was formed from land-based fill to a 4m Based in Kizad at Al Taweelah in Abu Dhabi, EMAL’s plant
contour, with dredged materials used for the remainder. Rock
is the largest single site greenfield smelter in the world. It
and concrete armours have been used to protect the core
produces 750,000 tonnes of aluminium annually, with an
materials from erosion.
expected increase to 1.3 metric million tonnes by the end of 2014 as a result of continued investment.
RIGHT: Typical section of EMAL’s trestle
EMAL’s 1.6km trestle bridge is the UAE’s longest bridge, whilst the seawater cooling facility for the aluminium smelter, which
EMAL’s dedicated berth is 3.5km offshore. With space for
runs through a dredged channel, includes 13km of 2.6m
two 60,000 ton ships, it rises 23.7m from the sea bed.
diameter pipe – wide enough to drive a large SUV through
TOP RIGHT: EMAL berth during platform construction. BOTTOM RIGHT: EMAL’s berth and conveyor system.
EMALâ€™s plant is the largest single site greenfield smelter in the world
Highways and bridges P
ort Khalifa’s highways and bridges connect the
Each structure is built to last for 100 years and was designed to
main operational areas with the mainland.
withstand full exposure to adverse sea conditions, whilst requiring the minimum amount of maintenance. To comply with local
The port’s three bridges were built with minimum casting
environmental regulations each crossing is designed to maintain
in situ within a relatively short construction contract. With
tidal flows around the causeways
no access through land all manpower and materials were transported by sea.
Highway and utility bridges
The 28.9m wide highway bridge carries three lanes of
Width (highway): 28.9m
Width (utility): 27.5m
Number of piers: 84
Number of piers: 156
Weight of piers: 110 tonnes
Weight of piers: 115 tonnes
Number of pier caps: 42
Number of pier caps: 104
Weight of pier caps: 125 tonnes
Weight of pier caps: 115 tonnes
Number of girders: 205
EMAL’s 1.64km-long, 19.5m-wide trestle bridge connects
Number of girders: 700
Weight of girders: 90 tonnes each
Weight of girders: 90 tonnes each
ABOVE: Port causeway’s highway
Deck slab and parapets
and utility bridges.
vehicular traffic as well as a 2m walkway in each direction, while the adjacent 27.5m wide utility bridge carries pipelines and services. A dedicated traffic lane provides access for
the company’s offshore terminal to a causeway leading to its onshore facilities. It has a 10m wide road as well as a heavy-duty bulk conveyor gallery.
Deck slab and parapets
EMAL trestle bridge Length: 1.64km
Each structure is built to last for 100 years and is designed to withstand full exposure to adverse sea conditions
Dredging and reclamation I
n October 2007, ADPC awarded the Khalifa Port
levels and weather conditions. Specialists using a dedicated
Marine Consortium (KPMC), a team comprising
monitoring vessel worked to ensure that water quality
Boskalis, Archirodon and Hyundai Engineering and
was maintained and undertook regular dive inspections
Construction, a contract to undertake the multi-
of the coral reef.
faceted design, procurement and construction of the construction of the port.
Computer modelling was used to predict the turbidity and suspended sediment concentrations around the
The commission included dredging for a 12km access
work areas. This information was used to minimise the
channel, 250m wide with a 16.5m draft; the 800m by
environmental impact of the dredging operations.
3.6km port basin with a 16m draft; land reclamation; rock protection works; breakwaters and quay wall construction.
Surveys conducted throughout the project indicated the
In all, some 45 million m of material was dredged. The port
impact of construction on the sea grass and the coral
platform was delivered on 31 July 31 2010, 18 months
reef was minimal.
ahead of the contracted schedule.
To protect the precious Ras Ghanada coral reef, the project team employed an extensive monitoring programme
ADPC has won many international awards for the In order to minimise the impact of the construction works on
Environmental Breakwater. In 2011, it received the
water quality and to protect the precious Ras Ghanada coral
Environmental Protection Award at the prestigious
reef, the project team employed an extensive monitoring
International Bulk Journal Awards held in Belgium.
programme. Fifteen fixed monitoring stations were used to
The award recognises ADPCâ€™s commitment to protect
provide real-time data on turbidity, waves, currents, water
the Ras Ghanada coral reef
Port basin and reclamation area enclosed by breakwater and revetments
The Khalifa Port Marine Consortium I
n 2007, the Khalifa Port Marine Consortium (KPMC), a team comprising Archirodon
Construction (Overseas) Co SA, Boskalis
Archirodon is one of the leading international contracting
Boskalis is a leading global services provider operating
Westminster Middle East Ltd and Hyundai
groups. With a 50-year record of worldwide diversified
in the dredging and earthmoving, maritime infrastructure
Engineering and Construction as awarded the
experience offering a full range of services in engineering
and maritime services sectors. The company provides
contract to undertake the multi-disciplinary design,
and construction of major civil, industrial and marine
creative and innovative solutions to infrastructure
procurement and construction works for marine
projects and has a special focus in the Middle East and
challenges in the maritime, coastal and delta regions of
structures, dredging and reclamation of the first
the world including the construction and maintenance of
phase of Khalifa Port.
The commission included the reclamation for the
and riverbank protection. boskalis.com
port platform and its protection by rock revetments, breakwaters, causeways and bridges to provide access to the port platform, dredging of the access channel and port basin, quay wall construction and
Hyundai Engineering and Construction is one of the
EMALâ€™s offshore facilities.
worldâ€™s leading global engineering and construction companies, seizing the initiative in the field of next-
Through innovative design concepts and leadership,
generation green growth.
KPMC has completed the works 18 months ahead
ports and waterways, land reclamation, coastal defence
A CH2M HILL COMPANY
Khalifa Portâ€™s principal consultant In 2005, Halcrow was commissioned by the ADPC, to undertake a pre-master plan for the development of a new port. A year later, the company was asked to undertake the detailed studies needed to develop a master plan. Including a marine infrastructure impact assessment report, site investigations and an environmental impact assessment, the master plan for Khalifa Port was delivered to the client in July 2007.
alcrow delivers planning, design and management services for developing
infrastructure and buildings worldwide. It contributes to the construction, operation and maintenance of the built environment, and the protection, enhancement and maintenance of
Halcrow is part of US-based CH2M HILL, the employeeowned consulting, design, design-build, operations, and program management firm. Combining world-class experience with local presence, CH2M HILL and Halcrow are more than the sum of their parts. Their combined capability provides more
The company takes on the big issues that affect us
infrastructure development around the globe.
to live and work.
opportunities to make a positive contribution to
contractor, the Khalifa Port Marine Consortium to perform the detailed design to Phase One,
the natural environment.
all â€“ water, transportation, energy, and creating places
In the same year, Halcrow was retained by the
consisting of the marine structures, bridges, reclamation and dredging. Halcrow continued to support the project after its main commission was completed in 2010, and in 2012 was responsible for the portâ€™s operational
environmental management plan
Construction of the offshore and onshore port