Cooling Tower SAFCO IV, Jubail, Saudi Arabia

In March 2004 DYWIDAG Saudi Arabia (DSA), a 100 % branch of DYWIDAG International, was awarded the contract for the execution of the first cooling tower with forced ventilation in Saudi Arabia by Uhde Arabia Ltd. The project in Jubail is part of the expansion program of the Saudi Arabian Fertilizer Company, SAFCO.

After pouring of the base slab, the shell of the cooling tower is constructed using a DOKA climbing formwork system. The height of each climbing section amounts to 1.50 m.

Delivery of formwork panels, concrete and reinforcement is done by 3 tower cranes and 1 mobile crane.

The exterior and interior formwork elements (maximum length around 5.50 m) form a unit with climbing brackets and the suspended platforms. The installation of the individual formwork elements in the next working position will take place with the crane.

A typical working cycle for the cooling tower is as follows:
- Opening of form anchors and loosening of form
- Lifting of exterior formwork element by crane in next
working position
- Cleaning, adjustment and fixing into new position
- Placing of reinforcement
- Lifting, adjustment and fixing of interior
formwork element
- Start pouring concrete
- Repeating of a.m. sequence

The climbing formwork is designed for a fresh concrete pressure of 50 KN/m². The anchoring of the formwork makes us of DYWIDAG DW 15 tie-rods. The climbing brackets and the inner working platform will be fastened to the embedded anchor parts, from which the anchor rod will remain in the concrete. The installation of these embedded anchor part is always one concrete stage ahead.

The embedded anchor parts are designed statically and structurally to be able to transmit easily the loads appearing in the specified early strength of the concrete. The installation of the climbing formwork in the next section will not take place until the concrete has reached the required strength. This is guaranteed by concrete test cubes.

The verticality, diameter and circumference of the shell shall be checked with a thoedolith located inside of the cooling tower (basin slab).

A coating system and cathodic protection will be applied on fresh concrete and be used as curing compound for the concrete of the tower.

After completion of the shell and dismantling of the climbing formwork, the inlet structures will be finished. The scope of works comprises all related civil, mechanical and electrical works, i.e. earthing, form and concrete works, structural steel works, cathodic protection, application of coating system, mechanical and electrical works. All necessary tests will be performed to guarantee that the plant operates satisfactorily.

All works are executed in accordance with the corresponding safety policy placing highest importance and priority on safety, health and protection of the environment and will be supervised, checked and documented on the basis of the DSA quality management system.

The project is executed on a turnkey basis and will be handed over to Uhde in April 2005.

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