slow down check point - sarooj · majis industrial services company was ... cast-in situ concrete...

SAROOJ CONSTRUCTION COMPANYQuarterly Newsletter Volume 8, Issue 4 OCT - NOV - DEC 2016

IN THIS ISSUE : SC 111 & 112 - THE PROJECT - THE CHALLENGES - EARTHWORKS

CONCRETE AND CBM - ASPHALT WORKS - BUILDINGS & SHEDS

STEELWORKS - MEP WORKS - HSE AND QUALITY - THE TEAM - PROJECT

GENERAL FEATURES - SAROOJ NEWS - THE GROUP IN MEDIA

SLOW DOWN...CHECK POINT

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THE GROUP IN THE MEDIA

SAROOJ NEWS

THE TEAM

HSE AND QUALITY

STEEL WORKS

BUILDING AND SHEDS

ASPHALT WORKS

CONCRETE AND CBM

EARTHWORKS

THE CHALLENGES

THE PROJECT

CONTENTS

Dear Colleagues,

Two decades ago, precisely in 1995, the Sultanate of Oman published its vision 2020. Several 5- year plans were inspired by it and aimed at achieving its national objectives. A pillar of the infrastructure strategy was the construction of the Sohar Industrial Port (SIP). Since then this port kept growing in capacity, efficiency, and quality of its services. Very quickly it attracted many industries to its zones. Steel smelters, refineries petrochemical complexes, aluminum smelters, fabrication yards, power and desalination plants. Majis Industrial Services Company was formed to supply customers with utilities – Oman International Container Terminal Company built their first container yard inside the port.

What further enhanced the growth of SIP is the Royal Decree that restricted commercial activities in port Sultan Qaboos in Muttrah to tourism and leisure and move all other activities to Port Sohar, particularly container handling. The operators of the port and their service providers had to accommodate this sudden surge in the demand.

OICT embarked on Phase II of their yard. SCC were invited to participate to this Tender and were selected by the owner as the preferred bidder. Delivery on time and to specification was of essence.

This contract is another manifestation of our strategy to become the preferred local and regional partner for many international companies.

Simon KaramDirector

Message from the...

PROJECT GENERAL FEATURES

MEP WORKS

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SC 111 & 112 - SLOW DOWN! ... CHECK POINT

OVERVIEW:

The Project: Container Yard and Main Gate at Sohar Port The Client: Oman International Container Company (OICT)

The Consultant: Tebodin

The Contractor:Sarooj Construction Company

The Location:Sohar Industrial Port

The Duration:18 Months

Project Manager:V.C.Pandian

The Contract Value:34 Million US Dollars

Container Yard

Reefer Gantry

Pouring Concrete

Cantilever Cranes


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The ProjectOICT are a specialized company that build and operate container yards in various ports. Containers are constantly off-loaded from ships, transported by traveling cranes and stacked in a yard before they are transported to final destinations by road transport. The scope consisted of major earthworks and soil improvement, of casting reinforced concrete sleepers taking the containers’ loads, of asphalt access tracks capable of taking heavy loads, of roads for trailers, and of spreading aggregate between sleepers.Furthermore, the construction of a main gate housing security and control activities under shaded area was part of the scope of works. Provision of reefer gantries, external lighting, and the building of several sub-stations were to be included. Several ancillary activities such as fencing, provision of weighbridges, parking areas for trailers were also carried out.

Cantilever Cranes

Container Yard

Ready to Operate

Reefer Gantries

Traveling Cranes

Closer Look

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Whilst technical problems were relatively easy to solve considering the repetitive nature of the works, the real challenge was to complete the works on time and achieve the various milestones when working in a restricted and busy environment. This necessitated sustained efforts to obtain approvals, permits, no objection certificates (NOC), and gate passes. Existing services had to be located, exposed, protected, and reinstated.The management of the procurement of local materials proved challenging. In order to ensure constant supply of aggregate sub-base materials, hot mix asphalt, ready mix concrete, single size aggregates for spreading and cement bound materials (CBM), we had to mobilize our own resources to the area. Several long lead imported items had to be procured from abroad on time requiring thus constant monitoring and follow-up.

The Challenges

Congested Worksite

Live Site

High Structures

Existing and New Services

Confined Areas

Complexity of Finishings


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Unsuitable Soil

Encouraging SMEs

Disposal

Soil Improvement

Sub-Base Materials

Manholes and Chambers

EarthworksThe site is on the sandy beach. It has to be leveled and then reduced by 600mm to remove the sand and replace it with granular fill materials as a general improvement of ground performance. The real loads come from the stack of containers that rest on ground beams. Special treatment was applied for areas under the beams. Additional layer of aggregate base course is applied before the concrete is poured. Interstices are filled with clean aggregates. The movement of vehicles bringing materials from outside sources was organized in such a way that no truck/trailer would travel without being loaded. Coming in they would carry imported materials, going out they would carry unsuitable materials and sand. This opportunity was explored not only to optimize resources and improve efficiency, but also it proved suited to award large parts of the scope to local small and medium size enterprises (SMEs).

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Cast-In Situ Concrete Sleepers

Casting Roof Slab

Concrete Ducts

Steel Reinforcement

Finishing Top of Concrete

Sleeper Beams

Concrete WorksConsistent with our commitment to encourage small and medium size enterprises, we have decided to procure our ready-mix concrete from a local supplier in Sohar. However, in order to ensure continuous delivery when needed on site, we preferred to use our own concrete transit mixers and concrete pump. The major concrete works were to be done on ground beams (sleepers) carrying containers and on traveling-crane lanes. Considering the repetitive nature of the works, it was decided to use steel moulds and panels to form the beams and hold the concrete when it is still wet. Reinforcing steel was cut and bent on site. Several other places and structures required concrete on the project: service ducts, surface drainage channels, hardstandings, pole foundations.


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Fresh Concrete

Steel Reinforcement

Concrete Blinding

Steel Shuttering

The specifications called for the use of a layer of cement bound materials (CBM) to be placed under the asphalt in areas of heavy loads such as the mobile traveling cranes. This technique requires the use of a special wet mix plant to mix granular materials with controlled gradation together with cement in a defined ratio. These materials had to be placed by aggregate spreader to achieve exact gradient and thickness. The layers would be compacted by vibratory rollers. The surface would eventually be cleaned to receive bituminous prime coat which seals its surface.

Concrete and CBM (Cont’d)

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Rubber Tyred Roller

Laying of CBM

New Area Ready for CBM

Aggregate Spreader Machine

Compacting Around Structures

Compaction

Finished Product

Steel Roller


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Traffic Arrows

Bird’s View

Compaction On-Going

Thermoplastic Paint

Intermediate Lane

Asphalt Finisher

Asphalt Works

In the container yard, circulation areas for trailers, vehicles, maintenance pick-ups, and trucks had to be provided between the stacking zones. Two challenges: the supply of hot mix asphalt and the discontinuity in laying. We decided to obtain the asphalt from our plant in Suwaiq despite the distance (about 100 km) and to plan laying of bituminous base course and wearing course in such a manner as to reduce the number of mobilizations of resources. A well-engineered road marking system was implemented giving direction to users and ensuring safety of operations.

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Prime Access

Numbering of Zones

Interlock Pavement

Road Marking

Driving Lanes

Working around Structures


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Isolated Footings

Concrete Frame

Floor Ducts

Curing Stud Columns

Roof Slab

Scaffolding

Building and ShedsThese are specialized buildings: three booths, substation sheds, and shaded areas. The project included the construction of a main gate controlling access to and from the port. Security personnel at the check point work from gate houses and inspect vehicles stopping under shaded areas. Trucks enter, go through buildings to be inspected by Royal Oman Police. The majority of these structures consist of steel frame and insulated cladding. Sub-station buildings, on the other hand, are designed as concrete structures that are air-conditioned to protect equipment from excessive heat which many jeopardize their performance.

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Concrete Protection

Superstructure for Sub-Station

Sub-Station

Main Gate Filter

Booth

Inspection Shed

Sub-Station Building

Simple Architecture


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Several steel structures had to be manufactured and assembled on site. This task was assigned to our sister company Synergy Petroleum International (SPI). A prominent part was the building of reefer gantries. These structures carry containers that act as cold stores. Therefore, they have to be provided with power and give access to operators. Other structures such as canopies, provided shaded areas at the new entrance gate to the Port.

Steel Works

Steel Erection

Access Stairs

Ready to Receive Cold Stores

Connecting Power

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Men at Work

Reefer Gantries

Steel Shell

Balustrades

Canopy

A Row of Reefers


16Generators

Sub-Main Distribution Boards

High Mast MV Cable Lighting Poles Cable Drum

Medium Voltage Switch Gear

Industrial Sockets

MEP Work

A new 11kv sub-station fed from the Sohar Industrial Port (SIP) network was built in order to provide power to the traveling cranes as well as to feed the reefer gantries with necessary electrical supply. Three new security booths were serviced with HVAC, power, firefighting system and domestic lighting. The container yard is lit with a series of high masts (25m) carrying flood lights and aviation lights. Special connections and power outlets were provided to the reefer gantries as these carry cold stores containers. An external firefighting system consisting of pipes and hydrants was integrated with the overall system available in the Port. All installations were properly earthed using copper bars, cables, and rods placed in earth pits. Weighbridges were installed at each gatehouse.

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Reefer Gantries at Night

Transformers

Power Engine

Indoor Transformers

Reefer Gantry Lit

Terminations

Cable Trays

Cold Store Containers


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Our client, OICT, put the management of HSE matters high on their agenda which coincides with Sarooj’s commitment to conduct their business without causing any harm to people, their health, and the environment they work and live in. Of particular importance was the management of hazards deriving from (i) the existing services and their protection (ii) the fact of working near live operations. Permit to work system and clear interfacing mitigated the risks. Consequence management scheme in parallel with a recognition and reward programme, enhanced safety performance.

HSE and Quality

HSE Meeting

Tool Box Meeting

Team Ready to Work

Barricade

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In-Situ Test

Concrete Cubes

Gradation Test

Inside the Laboratory

Testing Compaction

Concrete Slump Test

Testing Joints

Reading Temperature


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A solid HSE plan was drawn and implemented considering the heavy loads to be handled and stored. A strict quality control plan had be adhered to in order to ensure good performance of foundation layers, CBM layer, and asphaltic courses. Furthermore, special attention was given to the concrete sleeper beams.

Inside Site Laboratory

Weighing the Cube

Personal Protective Equipement

Site Laboratory Unit

Column of Sieves

Crushing Concrete Cubes

HSE and Quality (Cont’d)

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V.C. Pandian (Project Manager)

Nayef El Akouri (Electrical Manager) Joseph Bouty (Site Engineer - Civil)

Jad Fadel (Site Engineer - Electrical)

Charbel Ayoub (Electrical Supervisor) Bakhos Maatouk (Civil Supervisor)

Assem El Haj Diab (Site Engineer - Civil)

Asif Mohammed (Site Manager)Jean Pierre Feghali (Site Engineer - Mechanical)

Sandeepa W.K. (QS)

The Team


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Farhan Hamid Ansari(HSE Lead)

Adnan (Assistant Surveyor)

Chockalingham Velu (Site Accountant)

Fadi Ayoub (Concrete Foreman)

Said Mohammad Al Maamari (HSE Officer)

Midhun E.M.(Draftman)

Ramachandran Kaliyath (Earthwork Foreman)

Muhammad Yousaf(Steel Foreman)

Anvarbhi Mansuri(Earthwork Foreman)

Waseem Tariq(Surveyor)

Parvinder Singh(Lab Technician)

Bhumaiyya(Building Foreman)

David Dibb(Plumbing Foreman)

Chandrika Sharma (Carpenter Foreman)

Ragunath Persiyasamy(Project HSE Team Lead)

Sajesh Sadananthan(Surveyor)

Sajid Raza(Lab Technician)

Anbu Kaliyaperumal (Concrete Foreman)

Amjad Hussain (Supervisor)

Georges Chahine (Supervisor)

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Praveen(Time Keeper)

Shaju Veluthedath(Camp Boss)


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Project General Features:

Volume of Cut : 285,000 m3

Volume of Granular Fill : 146,000 m3

Concrete Sleeper Beams : 593 No

Concrete Pavement : 6,153 m3

Reinforced Concrete : 22,000 m3

Cement Bound Materials : 28,000 m3

Asphalt Pavement : 72,000 m3

Interlock Pavement : 23,000 m3

Reefer Gantries : 16 No

Sub-Station Buildings : 3 No

Electrical Cables : 44 Km

Security Booth Buildings : 5 No

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SAROOJ NEWS

• Majid Al Futtaim Corporation has awarded package one of the prestigious ‘Mall of Oman’. Although the project is

very challenging, our construction team, led by Mr. Mansour El Akouri have decided to embark on it with confidence.

• P hase II of the Oman International Container Terminal (OICT) in Sohar Industrial Port (SIP) has been successfully

completed and commissioned by VC Pandian and his team.

• Final Discussion with Petroleum Development Oman have led to signing Service Contract C311622. Elyas Rouhban

already has started mobilization in terms of training personnel, upgrading equipment, planning and putting the team together.

• Elie Nammour has successfully completed his project in Sur. The Reverse Osmosis Plant has been commissioned

and the production of desalinated water started. In this respect Elie has added SIDEM to the long list of Sarooj satisfied customers. The project was completed without any lost time injury (LTI).

• Wassim Karam, a Senior Project Manager with SNE of Lebanon with whom we worked closely on marine

works in ‘The Wave’ Waterfront Project, has joined our team to work as a Project Manager on the ‘Mall of Oman’. He is welcome to Sarooj family.

• Masirah International continue progressing on their revetment works in the port of Khassab. They are also

renovating the floating pontoons. It is a major contract which they have secured directly with the Ministry of Transport and Communications.

• Sarooj CEO, Mr. Jad Karam and his charming wife Deema were blessed with a new girl in their young family. Lea is

her given name. We congratulate her parents and her sister Danni for this happy arrival.

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THE GROUP IN MEDIA

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THE GROUP IN MEDIA

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Sarooj Construction Company LLC

Oman - Main OfficeP.O.Box 1413 , Postal Code 112 - Ruwi - Sulatante Of Oman

Telephone : (+968) 24 59 60 01 / 02 / 03 - Fax : (+968) 24 59 60 11

Dubai - UAE OfficeJumeirah Lake Towers - Gold (AU) Tower, Office 16B

P.O.Box 625789 - United Arab EmiratesTelephone : +971 4 431 1723 - Fax : +971 4 431 1543

Abu Dhabi - UAE OfficeDana Offices Suites - United Arab Emirates

Telephone : +971 50 3969755 - Fax : +971 4 431 1543

Doha - Qatar OfficePalm Tower, B Wing - 15th Floor, West Bay - Qatar

Tel : +974 403 42044 - Fax : +974 403 42020

www.sarooj.com

CONSTRUCTINGEXCELLENCE

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slow down check point - sarooj · majis industrial services company was ... cast-in situ concrete...

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