Upgradation and Expansion of an existing industrial port of Aluminum Bahrain (ALBA).
Client has inaugurated the Marine Jetty Extension in a ceremony that was held on 30 August 2021. The ceremony marked the successful completion of a master project that aimed to upgrade the existing Marine facility and expand its capacity to meet the Company’s increased production following the commissioning of Reduction Line 6, which boosted Alba’s overall output by more than 50%. As part of this project, the North Jetty at Alba’s Marine was extended by 24 metres to accommodate bigger ships such as 60,000 tonnes Panamax alumina vessels and be able to receive more than 3 million metric tonnes of alumina per annum. Moreover, the Jetty was equipped with a state-of-the-art Dual-Purpose Vacuum Ship-Unloader which will enable the Company to faster discharge its raw materials and gain additional days for routine maintenance work on site. In addition to the upgrades made at the Jetty, a new 50,000-tonne alumina concrete storage silo was built at Alba’s Marine bringing the total alumina storage to 3 silos on-site with a total built-in capacity of 150,000 tonnes. A new Truck Loading Station was added on top of the existing one at the site. The Marine Terminal upgrades were necessary to be on the very top, meet Alba’s additional requirements and support the business operations round-the-clock. The Marine Jetty extension project was constructed over a period of 2.5 years and maintained the highest safety standards by achieving 1.6 million safe working hours without a single loss time injury (LTI).
On the 20th February 2021, Fata has successfully completed the Performance Tests for the project. The new facilities enable ALBA to receive and store the increased quantities of alumina and CPC (calcined petroleum coke). This increase has been necessary to feed the new Line 6, now in full production, which has almost doubled ALBA’s aluminium production capacity. The upgrade of the port facilities performed by Fata on an EPC basis, comprises on-shore as well as off-shore (marine) facilities. With the achievement of this important milestone only the Final Acceptance Certificate to be issued at the end of the Defect Liability Period is still outstanding.
Nass Corporation has been awarded a sub-contract for the silos construction works on this scheme.
Construction of an Alumina Silo 50,000 Ton Capacity (42 mtr Diameter, and 43mtr Height)
Silo Pile cap foundation included 227 numbers of 1.0 meter diameter piles
Silo is constructed on 1.4 meter Thick Pile cap foundation and area of foundation is 1878 Sqm
860 Tons of reinforcement steel fixed and 2470 Cum of concrete poured for the foundation
500mm thick and 42mtr height Silo wall constructed using Slipform method
Slipform sliding completed along with lifting of 400 Ton of load (270 Ton of Fully Assembled Roof and 130 Ton of temporary works, equipments, etc.…)
42 Mtr height Slipform wall construction completed with 830 Ton of reinforcement steel and 3100 Cum concrete in 23 Days of time
Alumina storage Silo wall is post tensioned with 150 tons of Strands and approx. Length of Post Tensioning Ducts is 10,000 meter.
Construction of a Calcined Coke Silo (CPC) 20,000 Ton Capacity (30 mtr Diameter and 62mtr Height)
Silo pile cap foundation included 116 numbers of 1.0 meter diameter piles
Silo is constructed on 1.6 meter Thick Pile cap foundation and area of foundation is 882 Sqm
470 Tons of reinforcement steel fixed and 1540 Cum of concrete poured for the foundation.
Construction of 600mm thick elevated slab 6.00m above from Ground level. 380 Tons of reinforcement steel fixed and 485 Cum of concrete poured for the slab
Construction of 1850mm thick elevated slab 14.00m above from Ground level. 560 Tons of reinforcement steel fixed and 1455 Cum of concrete poured for the 1850mm thick slab
Lower level and elevated level floors constructed prior to start Slipform silo wall for Electrical and Mechanical equipments
500mm thick and 62.0 mtr height Silo wall constructed using Slipform method
Slipform sliding completed along with lifting of 270 Ton of load (170 Ton of Fully Assembled Roof and 100 Ton of temporary works, equipments, etc.…)
8 Mtr height Slipform wall construction completed with 575 Ton of reinforcement steel and 2510 Cum concrete in 21 Days of time
CPC Silo wall is post tensioned with 100 tons of Strands and approx. Length of Post Tensioning Ducts is 7,400 meter.
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