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h Pipes for the Abu Dhabi Presidential Palace Decades of Experience for the President of the UAE
PipeLineContents
1 I h Pipes for the Abu Dhabi Presidential Palace
3 I Development Calls for h Pipes, UAE
4 | HOBAS Gulf
5 | h - XXL through Sand and Groundwater
6 | 30 Years Jacking Experience
8 | h Jacking Pipes - State of the Art Technology for Your Benefit
Special Edition United Arab Emirates
HOBAS GRP Pipes were first employed in the late 1950s in Switzerland. Always striving for high quality and technically challenging projects the very first HOBAS Project was a hydropower pipeline which is still in per-fect condition today.
In the years to follow HOBAS Pipes conquered Europe and the United States and in the early 1980s also the Arabian Peninsula: With a special installation method called pipe jacking, that requires no open trench to install a pipeline, HOBAS Products were utilized in Iraq. In Baghdad, the GRP pipes in man-entry diameter range were installed in open trench for the establishment of interceptors. One of the contractors proved far-sight-ed and installed a part of his section – 500 m of HOBAS GRP Pipes, DN 1800 – by jacking. The result was so encouraging that a further 1,050 m of GRP DN 1200 pipes were jacked for this construction project. Back then, over 100 km of GRP pipes were installed alone in Baghdad.
High quality products, state of the art produc-tion technologies and a proven track record that spans decades convince authorities, private in-vestors and business partners around the globe.
One of HOBAS´ clients in a project currently under construction is the Executive Committee for the Presidential Palace Project the Ministry of Presidential Affairs (MOPA) in Abu Dhabi, UAE. In the course of the construction HOBAS Manholes ensure safe stormwater discharge.
Located on the Ras al Akhdar pensinsula right next to the Emirates Palace Hotel, the new Presidential Palace will house the offices of H.H. The President, H.H. The Vice President, H.H. The Crown Prince, and the Ministers and it will serve as the primary governmental facility for receiving visiting dignitaries.
The Greek firm Consolidated Contracting Engi-neering & Procurement S.A.L. (CCC) has been selected by the UAE presidential affairs ministry for the main construction contract. US-based RW Armstrong is the project manager, while the local firm Ewan Architectural & Engineering
Consultancy is the appointed architect. The engineer is UK-based WSP Group and the cost consultant is Bahrain-based Haj Gulf.
Due to the specialty and the criticality of the project nothing but polycrete and CC-GRP structural stormwater man-holes were specified. HOBAS Gulf was awarded for the engineering, manu-facture and delivery of GRP structural stormwater manholes including the benching, cover slabs, shaft, ladder, port fixing, future ports’ fixing and all the other accessories.
h PipeLine | Special Edition UAE | Page 02
Year of construction
2012
Total length of pipeline
300 m
Diameter
Structural Manholes
DN 1500, DN 1800 & DN
2000
Pressure Class
PN 1
Stiffness Class
SN 10000
Installation method
Open trench
Application
Stormwater discharge
Client
The Executive Commit-
tee for the Presidential
Palace Project; Ministry
of Presidential Affairs
(MOPA), Abu Dhabi UAE
Consultant
RW ARMSTRONG
Contractor
Consolidated Con-
tracting Engineering
& Procurement S.A.L.
-Offshore
Advantages
Approved high quality,
quick installation, high
corrosion resistance,
proven track record, pre-
vious project references
in the Gulf region
As per the project manager, RW Armstrong “HOBAS Gulf was selected as it fully complies to the ADSSC (Abu Dhabi Sewerage Services Company) and the ADM (Abu Dhabi Municipality) latest specifications, engineering calculations, project references, submitted certifications and the manu-facturing process”. HOBAS Gulf provided the manhole wall thicknesses and all the design details. The calculations were based on the engineer-ing standard design loading as required by the ADSSC / ADM / project specifications.
“The diameter size DN 2000 was the first ever commercial pipe or man-hole shaft production in the history of HOBAS Gulf in Abu Dhabi. We paid every bit of attention to the technical details and the top most care during the production. This is the current largest size here,” says Philip Plumb, general manager at HOBAS ANABEEB. “Due to the extended depths of up to 10 meters and the specially made benching, we had to order special transport trucks. HOBAS Gulf provided the training and an approved meth-od statement to the contractors (CCEP) team to construct the concrete works in the base unit and the cover slab.”
Fmd: [email protected]
h PipeLine | Special Edition UAE | Page 03
Development Calls for HOBAS PipesRecent Projects in the UAE
Massive construction projects in the UAE call for equally extensive development of underground utilities. One of the most recent projects realized with HOBAS Gulf GRP Pipes includes 1 km pipe DN 300 to 450 and no less than 800 inspection chambers and manholes DN 800 to DN 1500 in diameter for a sewer system for Al Sila’a Gharbia Emirati housing development in February 2012. Desert is here developed, there-fore soil conditions and high ground water levels are the challenges the client and contractor are confronted with when it comes to choosing pipe material. Thanks to the proven track record of HOBAS Gulf GRP Pipe Sys-tems in the UAE as well as pre-qualification documents and an approval by the ADSSC (Abu Dhabi Sewerage Services Company) the client opted for HOBAS Gulf Pipes.
In 2011, with the support of the Abu Dhabi Government, Waha Land started developing a prime six square kilometre plot of land, located some 20 km from Abu Dhabi which has been earmarked as a mixed-use flagship project ALMARKAZ. The master plan outlines an integrated mixed-use development with premium workforce accommodation, light industrial facilities, and larger land parcels zoned for warehousing and storage. Providing a comprehensive work and living environment with modern infrastructure that addresses the needs of the industrial sector, ALMARKAZ will be a first of its kind in Abu Dhabi. For the establishment of an underground sewer system, 20 kilometers HOBAS Gulf GRP DN 200 to DN 1200 Gravity Pipes have been installed in open trench. Difficult soil conditions as well as high groundwater levels were an issue to be considered also in this project. Most importantly, the material needed to be of approved high quality. Quick deliveries of various diameters were essential as regards the time, dates and periods specified in the agree-ment. Upon completion, the development will be locally unrivaled, as the emirate is eager for more available options in the mixed-use, light industrial sector. “This project is instrumental to growth. Due to the high importance of the project and the tight and pressing delivery schedules,
we all are very alert and on toes to continuously monitor the produc-tion, the varying sizes and delivery requirements” says J. Mathew, production manager at HOBAS-ANABEEB.
Al Sila’a GharbiaYear of construction
2012
Product mix:
1 km pipe, 800 inspection
chambers & manholes
Specifications:
DN 300 - 450, PN 1,
SN 10000
Installation method
Open trench
Application
SewerLine
Client | Contractor
Abu Dhabi Sewerage
Services Co. (ADSSC) |
Al Husam General Con-
tracting Est.
Waha LandYear of construction
2011
Product mix:
20 km pipe
Specifications:
DN 200 - 1200, PN 1,
SN 5000 & SN 10000
Installation method
Open trench
Application
Stormwater, sewage
Client | Contractor
Waha Land LLC
h PipeLine | Special Edition UAE | Page 04
Property developer Aldar Properties started converting Yas Island, one of Abu Dhabi’s largest natural islands into a lush recreational setting, complete with a Formula One race track, seven hotels, one already func-tioning and one constructed marina, and the 200,000m² Ferrari World theme park complexes. An international-standard links golf course – a first for the Middle East – and fully landscaped areas round out the development, creating a verdant oasis within easy access of both Abu Dhabi and Dubai. For stormwater drainage and duct works the client utilized 12 kilometers HOBAS Pipe DN 200 to 1800 including structural manholes. Once again quick deliv-eries of various diameters as well as approved quality were the essence of the pipe project. With reliable underground structures Yas Island will be an attractive recreational resort for many decades to come.
Fmd: [email protected]
Yas IslandYear of construction
2008
Product mix:
12 km pipe and structural
manholes
Specifications:
DN 200 - 1800, PN 1,
SN 5000 & SN 10000
Installation method
Open trench
Application
Stormwater, duct works
Client | Contractor
Al Dar Properties
E GulfNews and Standards
In 1996 HOBAS-ANABEEB and its sales office HOBAS Gulf started pro-duction and business serving mainly the UAE market. Due to the rapidly developing construction market on the peninsula as well as the steadily growing customer base of HOBAS GRP Pipe Systems, the initial two-feeder-facility was gradually upgraded to a six-feeder-factory, which makes HOBAS-ANABEEB today one of the largest HOBAS Production Facilities in the world. Its approximately 170 dedicated employees take well care to meeting and exceeding stringent European, national and international standards, for instance the WRAS Potable Approval and BS Kitemark, as well as product requirements set by internal and independent institutions. From planning through pipe design to production and finally delivery, every bit of attention is paid from the basics to the technical details to ensure top quality and utmost client satisfaction.
To find out more about the various trenchless application fields of HOBAS GRP Pipe Systems in GCC Countries and around the world visit us at Trenchless Middle East 2013 in Dubai, March 18 - 19. We would be glad to welcome you at our booth and supply you with all the information you need. Together we can live by our motto and “Make things happen.”
Fmd: [email protected]
5
h PipeLine | Special Edition UAE | Page 05
Year of
Construction
2009 - 2010
Construction Time
21 months
Total Length of Pipeline
7.1 km
Diameter
De 3000
Pressure Class
PN 1
Stiffness Class
SN 40000 - 64000
Application
Sewer
Client
Waterworks Warsaw
Contractors
PBG Group:
Hydrobudowa 9,
PRG Metro and KWG;
POL-AQUA, Sonntag
Baugesellschaft mbH
Special Features
Jacking with very large
pipes, low weight of
HOBAS Products, very
smooth outer surface,
high stiffness, precise
routing in sandy soil
3 meters are a little more than the average ceiling height of a flat, yet one can hardly be speaking of something “average” when talking about a 3 m pipe diameter – however, this has become routine for HOBAS…
The project to establish a collector leading to the new wastewater treatment plant Czajka in Warsaw was broken down into three sections. The first is 5,714 m long and was realized with HOBAS Jacking Pipes De 3000 which were installed along the right side of the Vistula river, while 1,400 m HOBAS Pipes De 3000 pipes were laid within the second part and on the left river bank. The pipelines meet in the third section with two lines DN 1600 inserted in a 4.5 m diameter concrete tunnel traversing beneath the Vistula.
The contractors Hydrobudowa 9, PRG Metro and KWG (all members of the PBG Group) worked as consortium on the first project section. Worthwhile mentioning is the 840 m long part of the first section where the pipes were supposed to be jacked from both ends meeting in the middle. However, installation with HOBAS Pipes can be conducted so pre-cisely that the section could be jacked with one single drive and from one side only despite the sandy soil and high groundwater levels reaching 4 to 8 meters above. The smooth and even outer surface and high stiffness of the relatively light-walled HOBAS Pipes were signifi-cant for this success. Piles by Larsen were set up around the thrust pits and jet-grouting was added to prevent too much water from pouring in. Despite the small friction and low forces needed to jack HOBAS Pipes, the contractor followed the project plan and erected an intermedi-ate station every 100 m. None of these but the last was put into service to make sure that also the last drive at 1,200 tons would run smoothly. After completing the works the intermediate stations were replaced by HOBAS Tangential Manholes and reused for different sections in the project.
For the consequent stage, pipes were jacked beneath the main road of the district Białołęka. An open trench would not have been possible here since the construc-tion works would have impaired the traffic on this important road (3 lanes in each direction). The pipeline route runs beneath the middle, the green line, of the road and a single drive over 910 m broke the record of longest single drives in the project.
Within the second part of the project, the contractors POL-AQUA and Sonntag Baugesellschaft mbH layed 1,400 m HOBAS Pipe De 3000 almost unnoticed by the population and also via jacking on the left side of the Vistula.
Fmd: [email protected]
h - XXL through Sand and GroundwaterPipes De 3000 Jacked beneath Warsaw, Poland
Corrosion and seawater resistant HOBAS Pressure Jacking Pipes De 1720, PN 6, SN 140000 were installed beneath the Lido sandbar for an environmental project in Venice, Italy.
HOBAS Jacking Pipes De 3000 for the Czajka Project in Poland even won the prestigious No-Dig Award by the International Society for Trenchless Technology (ISTT) in 2011 (see page 5 for project description).
HOBAS Pipes in various diameters and pres-sure classes master difficult environmental conditions on Maui and Oahu. In Honolulu, for example, 671 m of De 1219 mm HOBAS Pres-sure Jacking Pipes were installed beneath the harbor, the area’s busiest port docks and a coastal highway. Considering the seawater, the environment and raw sanitary sewer as medium, corrosion resistance is very important and reliability was paramount due to an installation depth of up to 11 m.
In Basel, Switzerland, HOBAS Pressure Jacking Pipes De 1499, PN 10, SN 160000 were installed in a depth of 32 to 28 m (high groundwater table of over 20 m) just 6 m below the river Rhine. Neither the uphill drive of 4 m over the entire length of the pipeline of 433 m nor the jacked curve with a radius of 1000 m
presented a challenge for the HOBAS Pipes.
h PipeLine | Special Edition UAE | Page 06
30 Years Jacking ExperienceHundreds of Satisfied Clients around the World
In Melbourne, Australia, HOBAS GRP Pipes have been jacked in 15 to 19 meters depth. The high groundwater level and difficult geological conditions as well as the small clearance between the pipe, the stream
bed above and the settlement area along the pipeline route have been easily mastered with HOBAS Products.
In the early 1980s, HOBAS Jacking Pipes DN 1800 and 1200 have been installed in Baghdad, Iraq. The pipes were hydraulically jacked and the spoil was manually removed with shovels and wheelbarrows.
At the HOBAS Gulf Factory in Abu Dhabi, UAE, HOBAS Jacking Pipes DN 200 to DN 2000 are produced to very strict external and internal standards and are approved by numerous facilities and institutions.
h PipeLine | Special Edition UAE | Page 07
h PipeLine | Special Edition UAE | Page 08
© E Gulf LLC
P.O.Box 46231 | Abu Dhabi | UAE
T +971.2.58 68 100 | F +971.2.58 25 892
[email protected] | www.hobas.ae
Responsible for texts, layout & graphics: Alexandra Dobnigg, Sabine Friesser | Publishing Date: 01/2013
All rights reserved. No part of this document may be reproduced or utilized in any form or by any means without our prior written permission. All informa-
tion in the document is correct at the time of going to press. However, we reserve the right to make changes without notice, in particular to technical data.
The data given is not binding and must therefore be checked in each individual case and revised as appropriate.
h Group Worldwide
HOBAS manufactures and markets HOBAS CC-GRP Pipe Systems. The HOBAS Network
includes HOBAS Production Facilities and Sales Organizations in Europe and throughout
the world.
h Jacking PipesState of the Art Technology for Your Benefit
Centrifugally cast GRP jacking pipe systems by HOBAS have proven their worth in trenchless projects over decades and around the globe. The first project implemented with GRP jacking pipes and remote-controlled jacking machines was carried out as part of a research project in Hamburg in 1982 where 2,980 mm-long pipes with an outside diameter (De) of 752 mm and a wall thickness of 50 mm were safely installed. Within a matter of a few decades, GRP jacking pipes have gained a firm foothold in trenchless technology and today HOBAS manufactures jacking pipes for pressure as well as gravity applications with diameters ranging from 250 to 3600 mm.
HOBAS GRP Pipe Systems are made of unsaturated polyester resins (UP), chopped glass fiber (GF) and reinforcing mineral materials. In a rotating mold, the pipe wall is built up layer by layer from the outside inwards. Once all the materials have been fed into the mold, the speed of rotation is increased. Spinning at a pressure of 30 to 70 bar presses the material against the mold wall, which removes the gas, com-pacts and cures it. This innovative production process (centrifugal casting) ensures that the pipes are circular, the wall thickness uniform over the entire length and that the material displays corresponding compressive strength properties for each individual project.
Given their high stiffness and smooth, almost non-absorbent outer surface, CC-GRP Pipes are also suitable for long drives, saving on intermediate stations and installation time. For the 2011 No-Dig Award winning project “Czajka” in Poland, for instance, pipes 3000 mm in diameter have been jacked in sandy soil on a single 900 meter-long drive. Even curved routes are no obstacle utilizing the right material: Pressure jacking pipes were e.g. pushed on a curve with a radius of 1000 meters beneath the River Rhine in Switzerland.
Thanks to the three-dimensional chemical bonding of the resin, the pipe as a thermoset retains its stability even in very warm environments. One of the benefits of composite material technology is that the pipe's strength properties can be cus-tomized to suit the specific load directions required. The sandwich construction of the wall thus ensures that HOBAS Pipes can also withstand high loading without any trouble and boast a particularly long service life. Moreover, the small roughness coefficient of the outside pipe walls reduce friction and ensure precise pipe routing. Installation progress up to 20 meters per day, comparably low jacking forces, lower equipment costs, less excavation material, high corrosion resistance and insensitivity to sulfuric gases, excellent hydraulic properties and a long service life of more than 50 years, are only few of the main advantages associated with the light-weight, high strength CC-GRP pipes produced by HOBAS.
Short and longterm product tests at approved HOBAS internal as well as independent laboratories and institutions make sure that our clients receive only top quality. Alongside the many tests we put our products through, more than 30 years of experience in the trenchless sector and a proven long track record speak for themselves.
Fmd: [email protected]
