CIVIL CONSTRUCTION INFATIMA FERTILIZER COMPANY LIMITED

AAGTE (Civil)

CONTENTS:

Project Overview Civil Construction and Fatima

Fertilizer My Working Areas

○ Roads and its Structures○ Weigh Bridge○ Nitro Phosphate (NP) Plant

Project Overview:

Salient Features:Start of Land Acquiring in Year 2005.Total Land Acquired 800 acres.Estimated Cost in Rs. = 8,000 millionStart of project phase in April 2007 (NA plant).Total no of plants/supporting areas are 50+.Four Types of Fertilizer Products/Plants having

design capacity.

1. Urea 1500 MTPD

2. CAN 1400 MTPD3. NP 1200 MTPD4. NPK 1000 MTPD

Project Overview:

Salient Features:Other Supporting Plants having design capacity

1. Ammonia 1500 MTPD

2. Nitric Acid 1500 MTPD3. Offsite & Utilities 50 MW

Gas consumption of 75 MMCFDCivil Contractors

1. CNCEC China2. IPL Pakistan

Civil Designers1. NESPAK Pakistan2. A & A Pakistan

Civil Construction and Fatima Fertilizer:

Civil Engineering role in the establishment of any kind of project is not ignorable.

The project like Fatima Fertilizer, its importance is more.

Fatima Fertilizer have structuresFrom simple pumps foundations to complex pile

foundation under Prilling towers and Ammonia Tank.From steel structures of Urea, CAN, Bulk Storage &

Ware houses to concrete structures of Cooling Tower, Raw water Reservoir, Bagging, NA and NP plants.

From Technical building, CCR I & II, Substations to Strom water drains, water pits, area development and network of roads.

Civil Construction and Fatima Fertilizer:

In Fatima Fertilizer, basic form of structure is frame structure .

Frame Structure is a combination of beams and columns and load is transfer through this system to design foundation.

Two types of frame structures are used.1. Steel Structures2. Concrete Structures

Steel Structures:

Steel structures are basically composite structures having substructure of concrete and superstructure of steel e.g.• Ammonia & Urea Plants• CAN & NPK Plants• Bulk Storage (Phase-I)• Ware houses, Pipe Racks etc.

Concrete Structures:

Concrete structures comprise of both substructure and superstructure of concrete e.g.• Raw Water Reservoir and Treatment Plant• Cooling Tower & Urea Prilling Tower• Bagging (Phase I & II)• Bulk storage (Phase II)• NP Plant• Substations CCR I & II and Equalization Basin• Workshop, Technical Building, Laboratory, etc

Pictorial View of Civil Construction in FFCL:

Construction View ofUrea Prilling Tower and Plant

Nitric Acid Plant

Foundation of Ammonia Storage Tank

Construction View ofCooling Tower

Raw Water Reservoir andWater Treatment Plant

Construction of CAN Plant

Construction of Ammonia Plant

Construction of Bagging (Phase – I)

Construction ofBulk Storage (Phase – I)

Bagging (Phase – II)under construction

NP Plantunder construction

My Working Areas:

In Fatima Fertilizer during my Trainee period of 1 year, I worked on Roads and its Structures, Construction of Weigh Bridge and also play a vital role in the construction of NP plant.

Job Responsibilities:

Study of Drawings Design Reviews Survey of roads Quality Control at site ( Formwork, Steel &

Concrete) Inspections before concrete Checking of Bar Bending Schedule Checking of Bills

Roads and its Structures:

Salient FeaturesTotal length of Roads = 17.484 kmCompleted Length of roads = 8.301 kmRemaining Length of roads = 9.183 kmRoads have Strom water drain and walkway

on one side, and shoulders on both sides.Designer = Akbar & AssociatesContractors = IPL, Farhan Munir

& Company, AHCC

Type of Pavement = Rigid PavementDesign Capacity = 90 Tons

What is Rigid Pavement?

Rigid pavements are generally constructed of a reinforced concrete slab or more recently a continuously reinforced concrete road base.

The pavement structure deflects very little under loading due to the high modulus of elasticity of their surface course.

A rigid pavement structure is typically composed of a PCC or RCC surface course built on top of either○ the sub-grade or ○ an underlying base course. 

Rigid Pavement:

Typical Cross-section of a Rigid pavement

Why we (FFCL) preferred Rigid Pavement instead of Flexible Pavement (Carpet Road)?

Rigid Pavement lasts much, much longer i.e. 30+ years compared to 5-10 years of flexible pavements.

In the long run it is about half the cost to install and maintain. But the initial costs are somewhat high.

Rigid pavement has the ability to bridge small imperfections in the sub grade.

Less Maintenance cost and Continuous Traffic and Flow.

Low thermal variation as compared to Flexible Pavement.

Rigid Pavement has one draw back in terms of its repair i.e. we have to remove 2-3 panels instead of damaged portion as in case of Flexible pavements.

Pictorial View of Roads in FFCL

KLP Road under construction

Roads in the Plant Area

Weigh Bridge: Salient Features:

Total No of Weigh Bridges = 4Weigh Bridges constructed= 2Located near Gate # 1 or KLP Gate.No of Load Cells = 8Design Load measurement capacity = 120

TonsDesigner○ Mechanical= Mettler Toledo○ Civil = Akbar & Associates

Contractor = IPL

View of Weigh Bridge in FFCL

Nitro Phosphate (NP) Plant

Nitro Phosphate (NP) Plant:

NP plant started from Prilling Tower in 2009.

Estimated Civil Cost in Rs. = 279.1 million Civil Designer = NESPAK Civil Contractor = IPL 80% of Civil work completed. Remaining 20% include Refrigeration area

and Lime Drying unit, paints, brick masonry, and finishing works.

Nitro Phosphate (NP) Plant:

NP Plant is divided into four partsPrilling Tower & Lift WellMain BuildingSubstationCN & AN Section, Refrigeration Area,

and Lime Drying Unit

Salient Features:

Prilling Tower supported on 72 piles of length 27m. Prilling Tower has height of 67.9m and diameter of

19m. Lift Well has height of 70.1m, supported on 900mm

thick raft foundation. Main Building has dimensions of 67.5m x 27.5m x

37.3m supported on raft foundation. Main Building comprise of 10 floors max on line 1-2. Substation comprise of 2 floors supported on isolated

foundation.

Special Techniques adopted at NP Plant:

Prilling Tower and Lift Well concrete done by using Slip Form Method.

Strengthening of Columns has to be decided.

Slip Form Method:

The most common method adopted for the construction of an RCC outer shell/prilling tower is by using the ‘slip form method’.

In this method the form work for the concrete literally slips up cm by cm to produce an integrated concrete column in the form of wall.

Continuous pouring of concrete ensures a joint free construction.

At a rate of 0.3 meters per hour, this is consider as fast construction method.

Components of Slip Form Method:

Slip form method is comprise of a complicated system of jacks and radial screws.

Radial steel yokes, which have an inverted “U” at both ends, support the slip form shuttering all around the shell/prilling tower.

Walers strengthen and keep the shuttering in place. The working deck and scaffolding is supported from the

walers and yokes. The yokes are supported on hydraulic jacks, which move on

jack rods embedded in the concrete. As the concrete pouring progresses the jacks lifts up the

yokes, together with the decks and slip form. Screwed on pieces extend the jack rod as the work progresses. The entire system of decks and shuttering appear as if floating

on top of the tower.

NP Prilling Tower

Top View of NP Prilling Tower

Strengthening of Columns: To increase the capacity of NP Main Building

columns from 3500 Tons to 5500 Tons, the procedure that is used called Strengthening of columns.

Why Strengthening of columns needed?Continuous changing of mechanical design of

Cfit of NP main building, load on columns increased from 3500 Tons to 5500 Tons.

To counter this problem, columns has to be strengthened by using concrete and steel jacketing.

Lift Well

Main Buildin

g

View after Completion of Lift Well and Prilling TowerMain Building and CN Section under construction

Prilling Tower

Sub Station

CN, AN Section and

LD Unit

Any Questions????