tel: riyadh metro project mneefah goes...

Guest Editorialby Peter Graham

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Riyadh Metro Project

"Mneefah"From Assembly to

Launchingp.9

A Look inside Almabani's

Design Department

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Central Equipment

FacilityAn Insight into the

Fabrication Divisionp.20

Q&A with Wadih FaresPMV Department

Managerp.24

Events2015 AUB, LAU and

NDU Annual Job Fairs and Exhibitions

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Issue No.10 . April - May 2015

Almabani HeadquartersAlmabani Building

Hail Street, Ruwais DistrictP.O.Box. No. 2781

Jeddah 21461Kingdom of Saudi Arabia

The Almabani [email protected]

Tel:(+966 12) 614 7800

ext: 2822 / 2706Fax:

(+966 12) 651 9180

www.almabani.coAlmabani General Contractors

Almabani Media Department PublicationAlmabani General Contractors . All Rights Reserved ©2015

BACS Top Management Sites Tour

Mohammad Al Qahtani Almabani's General Counsel"I am sure that the sum of expertise present in the leadership of this company is sufficient to drive Almabani to a higher position."

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Riyadh Metro Project "Mneefah" Goes Live

Event: KAIA Development Project Scientific Meeting p. 28

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HSE is an integral part of Almabani. It is a part of our daily routine life at the projects and in offices. It effects everyone in our company.

IOSH “Managing Safely” course designed for senior managers and engineers has been successfully conducted and completed by Almabani’s trainer Mr. Kashif Muneer.The result will be announced in August and successful candidates will be awarded with UK Certification.Congratulations must go to all the Top Management who not only took part in the IOSH “Directing Safely” course but also achieving 100% passing result which also demonstrates the leadership’s commitment towards health and safety in our company.

Moving forward, engineers and supervisors training program will begin from June. “Supervising Safely” will be an internal training program which will be conducted by the Regional Managers with the help of the Training Manager.

We will now also be looking at carrying out our planned internal audit schedule for all major projects to assess how much we have improved in regards to HSE and the ongoing goal of OHSAS 18001:2007 international certification. Meanwhile, we will continue to “deliver excellence in health, safety and environment in the way we behave and work”.

Peter GrahamCorporate HSE Manager

2The Almabani Journal . Issue No. 10 . April - May 2015

Guest Editorial Next Issue HSE: Where We Are Preview

Project UpdateWork Progress Report

Insight Coverage, Filming & Reports

Racing Time

King Abdulaziz UniversityProject

KAIA Project

TPMR Project

FIRE DRILL TRAINING


Riyadh Metro Project"Mneefah" Goes Live

HRH Prince Faisal bin Bandar Al Saud, Head of the High Commission for the Development of ArRiyadh and president of the committee supervising the implementation of the King Abdulaziz Project for Public Transport – Metro & Buses, launched the work on "Mneefah", the first BACS Tunnel Boring Machine (TBM), on Wednesday, May 20, from its start point on the Blue Line (Batha – Olaya streets), south of Najd National Schools in Olaya District. The ceremony was attended by a number

of ADA key personnel, in addition to high-profile representatives of BACS Consortium.In a statement to the media, HRH Prince Faisal expressed his happiness on the launch of "Mneefah", a name chosen by the local community of Riyadh in an earlier competition organized by ADA to give names to the TBMs, pointing out that this ceremony comes within a scheduled plan to launch other TBMs in the near future.HRH Prince Faisal added that the TBMs used in the

- Riyadh, KSA -

DR. AMJAD BANGASH PRESENTING THE CEREMONIAL KEY OF "MNEEFAH"

"MNEEFAH", THE FIRST BACS TUNNEL BORING MACHINE (TBM) WENT LIVE ON MAY 20, 2015.

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Riyadh Metro Project (RMP) represent the latest worldwide technology in the field of boring deep tunnels, employing high-tech tools in its various functions, in order to contribute in facilitating the work, thus in the timely achievement of objectives.At the end of his speech, HRH Prince Faisal expressed his thanks and appreciation for the efforts deployed by the High Commission for the Development of ArRiyadh in pursuing the execution

of the RMP according to the highest standards, praising H.E. Mr. Ibrahim Sultan, Member of the High Commission for the Development of ArRiyadh and President of ArRiyadh Development Authority, along with all the ADA team working on accomplishing the objectives of this project according to the set plans.Immediately after the screening of a short presentation about "Mneefah"’s assembly and

JOSEPH DAHER, CEO OF ALMABANI & RALPH HASSELBACHER CEO MOBILITY TURNKEY SOLUTIONS FROM SIEMENS

HRH PRINCE FAISAL (RIGHT) LAUNCHING THE TBM, WITH H.E. MR. IBRAHIM SULTAN, PRESIDENT OF ADA (LEFT)

The Almabani Journal . Issue No. 10 . April - May 2015



tasks, HRH Prince Faisal pressed the control button that gave the green light for the TBM to start boring.It is worthwhile mentioning that "Mneefah" is the first of four TBMs to be launched by BACS Consortium, whereby the machines will be simultaneously executing several tasks, including:

30m-depth excavations and tunnel boring, transport of soil and production of tunnel walls. The TBMs have a length of 90-120m, a weight of 2,000t (equivalent to four fully-loaded Boeing 747) and a total estimated capacity of excavation (per machine) reaching 200 trucks per day.

SOUVENIR PHOTO WITH THE TBM TEAM

BACS BOARD MEMBERS AND SENIOR LEADERSHIP TEAM

ELIE CHRABIEH, PIERRE MOURANI & MIKE ADAMS

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Riyadh Metro ProjectBACS Top Management Sites Tour

ELIE CHRABIEH, BACS DEPUTY PROJECT DIRECTOR WITH ALMABANI'S CEO JOSEPH DAHER


- Riyadh, KSA -

ON THE SIDELINE OF THE TBM LAUNCHING CEREMONY, BACS TOP MANAGEMENT PAID A VISIT TO VARIOUS CONSTRUCTION SITES, WHEREBY THEY WERE BRIEFED BY SITE MANAGERS AND SITE ENGINEERS ABOUT THE PROGRESS MADE AND CHALLENGES FACED.



Nassim Arabi: How many sites did this tour cover?George Mouawad: We have visited the following sites: Tunneling Segment Precast Factory, Al Fahd Underpass New Scope (CN#33), Grade Station 2G1 (East Line 2), East Depot, Cut & Cover Tunnel 2-2 (East Line 2), Sheikh Jaber Al-Ahmad Al-Sabah Intersection (East Line 2), Cut & Cover Portal 2-1 (East NATM Tunnel), Olaya Iconic Station.

NA: What is the importance of such tours in the presence of all the BACS Executives?GM: The tour was conducted to give an idea to the BACS Executives on the progress and the constraints we are facing.

NA: How do you assess the overall progress in the BACS package of the Riyadh Metro Project?GM: Although it is not as planned but lots of improvements occurred this month. We have now 88 active sites and we are catching up. Lots of changes requested by the client are affecting the progress yet we are dealing with them. With the engineering progressing better now, I believe we will be on track within the coming four to six months.

NA: What can you tell us about the launch of "Mneefah"?GM: It was a very successful launch and it will give a good momentum. After all tunneling is one of the major activities of the project. We hope the remaining three launches go as smooth as the first one.

NA: After the "Mneefah" event, what is the upcoming milestone that you are looking forward to achieve?GM: Many important milestones are approaching, mainly the start of the excavation of the deep underground stations, the launching of the first viaduct and the start of the construction of surface and elevated stations.

IN THIS REGARD, THE ALMABANI MEDIA DEPARTMENT TOOK THE OPPORTUNITY AND HAD THIS SMALL CHAT WITH MR. GEORGE MOUAWAD, STATIONS DIRECTOR.

Interviewed by: Nassim Arabi

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BACS TOP MANAGEMENT IN A SOUVENIR PHOTO

FROM LEFT TO RIGHT: JOSEPH DAHER, PIERRE MOURANI & GEORGE MOUAWAD

TONY ABI NADER GIVING A WORK PROGRESS BRIEF



Riyadh Metro Project"Mneefah": from Assembly to Launching

TBM S904, also known as the orange TBM, is from now on called "Mneefah", a name suggested by one of the Saudi capital’s local residents, who participated in the “What to name it” competition organized by ArRiyadh Development Authority.

OverviewA Tunnel Boring Machine (TBM) is a machine used to excavate tunnels with a circular cross section through a variety of soil and rock strata. It typically consists of several gantries connected to each other.TBMs brought to bore the RMP tunnels are manufactured by Herrenknecht, a German

worldwide market leader in mechanized tunneling technology and the most recognized manufacturer of tunnel boring machines of all sizes.Mneefah is an Earth Pressure Balance (EPB) type, with a total length of 105m and an excavation diameter of 10.35m. Its various segments were delivered to site as 64 bulk items and 12 open-top containers.

Cutter HeadThe first segment of the TBM is the cutter head, a rotating cutting wheel which does actually most of the excavation work. The cutter head is 24/7 operational and rotates in both directions.

- Riyadh, KSA -

NASSIM ARABI FROM THE MEDIA DEPARTMENT INTERVIEWING ENGINEER HADI SALMAN

IN ORDER TO DRAW A BROADER IMAGE ON THE TUNNEL BORING MACHINES’ ACTIVITY IN THE RIYADH METRO PROJECT, THE ALMABANI MEDIA DEPARTMENT, GUIDED BY ENGINEER HADI SALMAN, TOURED EVERY SINGLE INCH OF THE NORTH SHAFT, WHERE "MNEEFAH" WAS LAUNCHED, AND CAME BACK WITH THE FOLLOWING REPORT.

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ASSEMBLY AND WELDING OF THE BLUE TBM CUTTER HEAD - PRECAST SEGMENTS BEHIND

SHIELD BORING INTO THE GROUND, FOLLOWED BY GANTRY 1


It consists of hard rock disc cutters that break rock chips from the tunnel face by rotating and applying high contact pressure.

Front ShieldThe front shield, which contains the muck storage area, the motor of the TBM (Main Drive) which consists of 10 motors 350 KW each, pressure sensors and provisions to supply foam, water, air, bentonite… as required. The excavated material is taken up by the screw conveyor which is a mechanism that uses a rotating helical screw blade to transfer muck which is then dropped into a funnel, from there into the conveyor belt all the way up to the surface muck pit .

Earth Pressure Balance (EPB)One of the most important features of Mneefah is called EPB. It is a mechanized tunneling method in which spoil is admitted into the TBM via the screw conveyor arrangement which allows the pressure at the face of the TBM to remain balanced. Thus, the EPB Machine controls the stability of the tunnel face and subsidence of the ground surface by monitoring and adjusting the pressure inside the cutter head to achieve a balance with the pressure in front of the cutter head.This allows soft, wet or unstable ground to be tunneled with maximum speed and safety.The machine can also operate on Open mode, which is faster but only works in dry and stable ground conditions.



Middle ShieldThe front shield is connected to the middle shield through articulation cylinders which plays important role steering of the machine. The middle shield contains as well the Thrust Cylinders (between Middle shield and Tail Skin) which is mainly used for pushing the TBM forward and supporting the segments as well until they become self-supported. A total of 15 thrust jacks are fixed circumscribed along the middles shield whereas, every two thrust jacks support a segment.

TailskinThe tailskin is the rear section of the shield skin and resembles the interface between the TBM and the tunnel. The diameter of the tailskin is larger than the diameter of the tunnel, thus encircling it. The tailskin also accommodates the segments erector.The erector is a remote-controlled, movable vacuum manipulator used to position the segments, assembling them piece by piece, during ring building.Those segments are supported by the thrust jacks, each segment at a time, until the whole ring is self-supported. Among the main tasks of the tailskin is also to produce grease during advance of the TBM. The pumped material provides a perfect seal against water and slurry whereby grout is used to stabilize

and secure the area at the exterior side of the segments, ensuring a highly effective tail seal during TBM advance.

GantriesFour gantries support Mneefah: three are already assembled while the fourth will be assembled right after the advance of the TBM 30 m inside the tunnel.The first gantry houses the control stand. Through this chamber-station, all the work of the machine will be operated and monitored.Gantries are also equipped with an arrangement of foam tanks, water tanks, air tanks and bentonite tanks. All those additives are injected ahead of the face to increase the stability of the ground, to ensure that the spoil remains sufficiently cohesive and to restrict water flowing through. In addition, electrical rooms and supplies, ventilation supplies and the refuge chambers are provided from the gantries as well.

Power SupplyMneefah’s power supply is provided through six MV generators (1,500 kVA), thus a total of 9,000 kVA. In addition, three LV generators (4,500 kVA) were deployed to support the conveyor belts, cooling towers, grouting plants and other supporting items. 12 MV generators

TEMPORARY CONVEYOR BELT IN BLUE, COOLING TOWERS AND GROUT SILOS TO THE RIGHT

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GANTRY #3 (REFUGE CHAMBER, CABLES AND DUCTS), CONVEYOR BELT AT THE SIDES


and 6 LV generators are already connected to the distribution and totalizing panels, transformers and switch gears in order to supply both the orange and the blue machines that are starting from this site.

Instrumentation and MonitoringA highly-challenging task is to monitor and maintain that the tunneling process does not damage any existing foundation or generates noises above the acceptable levels all the way of excavations, taking into consideration that any careless vibration might result in a catastrophe. For instance, Mneefah’s boring line passes adjacently to the pile foundation of the Kingdom Tower. In this regard, sensors are spreaded all over the alignment and will measure any violation to the triggers limits and give the following signals: Green (proceed), Amber (proceed with caution) and Red (Stop and reevaluate).

TUnIS Navigation TBMLaser

Mneefah is boring at 30m depth, therefore no landmarks or control points are available. For this purpose, TUnIS Navigation TBMLaser system was installed.This system is a product of VMT, a German best-seller of navigation systems in tunneling worldwide. Based on a total station and a target unit installed within the TBM shield, it determines the current advance position. Thus, the machine

position is continuously calculated relying on signals provided by the laser detectors, providing temporary 3D navigation through the thrust cylinders.

Multi-Service Vehicles (MSV)Intelligent logistical support in tunneling is prerequisite for a continuous and efficient construction progress. The key advantage of the MSVs is their excellent all-terrain mobility even on steep inclines and declines.MSVs are man-operated wheeled units. They will supply Mneefah with segments, grout, pipes, lubricants, tools and disc cutters. In addition, the MSVs are equipped with a spacious cab to transport site personnel quickly and safely (in case of emergencies)

TBM RefugeTunneling underground, fires and ground settlement during the construction phase can represent potential hazards to personnel. In case of emergency, a gantry-mounted TBM Refuge chamber offers premium safety features (air conditioning, air lock, chamber flood protection, CO & CO2 scrubbing, etc.). It can accommodate up to 20 persons for more than 24 hours which is maximum number of people who might be present underground.



ManpowerMneefah was assembled under the supervision of Herrenknecht Dogus, one of Turkey’s largest construction companies and globally known for having a hand in the largest tunneling projects, are in charge of both assembling and operating the TBM work. Up to now, Dogus has employed a workforce of 100 personnel that are working in the North Shaft and the Segment Yard. 200 more are expected to arrive as soon as they get their visas to enter and work in the Kingdom.

ChallengesMneefah’s launching site is located on King Fahd Road, one of the highly congested roads in Riyadh. Trucks are only allowed to pass through this road between 10 PM and 5 AM.One TBM is going to excavate up to 2,000 m3

per day. Taking that every truck has a maximum load of 24 m3 , this means that a total of 165 trucks are going in and out of the site every day, in addition to 20 trailers that are shipping the segments to the site.In order to deal with this challenge, BACS Management went through negotiations with the Municipality of Riyadh that resulted in releasing

permits for BACS trucks to operate for up to 18 hours per day. This will guarantee that the site will be working properly. Mneefah is launched from Jreisy and will go southward to Station 1C4, where it will be extracted after boring a total length of 4 km. Concerning the Blue TBM, it is currently being assembled: welding of the cutter head have started, under the supervision of the manufacturer. It will take between six and eight weeks to be fully assembled, and therefore the launch is expected to take place from this site as well (going northward) by July.

ConclusionEngineer Salman takes pride in delivering the shaft and assembling the TBM in such speed. “It is a huge responsibility because the tunneling team is currently the most active team in BACS. We delivered the shaft on time and handed it over to Dogus without any major problem or constraint. This achievement will motivate us and gives us a push forward to proceed with assembling the three remaining TBMs”, says Salman, before concluding: “We are hopefully expecting to finish the whole 16km tunnel by October 2016”.

CONVEYOR BELT

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Guest of the JournalMohammad Al Qahtani, Almabani's General Counsel

- Jeddah, KSA - Interviewed by: John El Khoury

John El Khoury: Thank you Mr. Qahtani for giving us the chance to interview your good self, at the beginning of this interview, we would like you to introduce yourself to the readers…Mohammad Al Qahtani: Welcome to the Legal Department of Almabani. I graduated from King Saud University in 2005 and joined Almabani as a fresh graduate. When I came here, we started working on establishing a legal department for the company, building its organizational structure that was divided into two sections: Licenses Section, Contracts and Legal Affairs Section. The work of Almabani’s Legal Department as an executive unit responsible for all the company’s legal affairs has officially begun at the beginning of 2006.The tasks entrusted to me involve overseeing and identifying the legal issues in all departments and their interrelation, as well as the company’s relation with the Saudi legal authorities in terms of labor law, contracts, legal procedures, licenses, certificates, etc. Those are the main tasks that the Legal Department handles since its establishment.

CONSIDERED AMONG THE SIGNIFICANT SAUDI YOUNG FIGURES OF ALMABANI, GENERAL COUNSEL MR. MOHAMMAD AL QAHTANI IS THE GUEST OF THE JOURNAL OF THIS ISSUE. IN THIS INTERVIEW, MR. AL QAHTANI INTRODUCES THE LEGAL DEPARTMENT OF ALMABANI, TALKING ABOUT THE DEPARTMENT’S DUTIES, RELATIONSHIP WITH THE TOP MANAGEMENT, RELATIONSHIP WITH THE SAUDI LEGAL AUTHORITIES, AND MORE…


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JK: Being the General Counsel of one of the Kingdom’s big players in the general contracting field, you have a high volume responsibilities on your shoulders. What can you tell us about your key achievements in your position? And what about the letdowns?MQ: Alhamdulillah with the guidance, shoulder to shoulder policy and hard work of the Top Management we have always reached success. Even when we do not reach our desired ambitions, we consider this a strengthening experience and not a failure. Alhamdulillah I can say that Almabani does not have any outstanding claim or case against us. All our licenses, contracts and other legal proceedings are let under the Saudi law. We are always keen to be proactive in all our projects, whether delivering a project to governmental bodies or private sector. Due to the serious measures we take, we do not face any legal problem. At the contrary, we always fulfill the prerequisite paperwork concerning our licenses, certificates and classification in a manner that keeps Almabani out of problems’ way. Alhamdulillah we have never had any problem.

Taking into consideration the company’s current status in the market, I can say that it is a pure achievement that we do not have any legal problem. In addition, the timely completion of all our applications and transactions is also considered among our significant attainments. This does not mean that we rush in our job. At the contrary, we take our time in studying all the documents in our hands, identify our target, take action and deliver our job on time.

JK: Would you please give us an idea about the whole legal team of Almabani?MQ: The most senior member of the legal team is the veteran General Counsel Mr. Souheil Haddad, whose long experience has greatly aided us on all levels. Moreover, the Legal Department has representatives who, under my supervision, are responsible for the licenses, certificates and other legal matters in both Riyadh and Khobar offices.

JK: How do you assess the relationship between the Legal Department and the Top Management of Almabani?MQ: Almabani’s Top Management and the Board of Directors are very strict about the company’s legal reputation. We are always pushed to develop ourselves and the department under the direct supervision of H.E. Mr. Nehmé Tohmé. We always rely on the guidance of the Chairman and our senior executives. All the mentioned above takes place in a smooth manner and family atmosphere. We all work here as a complimentary unit where all the tasks are distributed properly and this is why we never face any serious problem.

JK: Do you consider this to be a distinguished feature in Almabani?MQ: Of course. We always set our eyes on clear targets and we strive constantly to meet and exceed excellence. We always keep in our mind that Almabani’s position shall be reflected in all our daily tasks and corporate behavior. Those innovative names present in the Top Management and their creative solutions are the main drive of the company’s reputed quality.


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JK: If we want to move outside the company’s internal relations, how do you summarize Almabani’s relationship with the legal authorities of Saudi Arabia?MQ: Alhamdulillah we have maintained a good working relationship with the governmental authorities due to our interest and serious handling of all the matters related to our licenses and certificates. This special relationship has always been a focal point in our department’s strategy.We always work on improving this relationship of trust with the official authorities by abiding to the labor law and regulations. This flexibility is the result of our dedication and commitment to all facets of company-government relationship, and is a key element to the Legal Department’s success and to the company’s honorable classification.

JK: As a General Counsel of an expanding general contracting company in the Kingdom, what are some of the legal challenges you face in this industry?MQ: Challenges lie in the unexpected matters that impose on us the need to take instant action. However, the sense of togetherness and collaboration with the Top Management has always helped us in our times of need, and this is why we were always able to resolve issues when they arise.

JK: What are the current high-priority tasks undertaken by the Legal Department?MQ: Most of our job is related to the maintenance of Almabani’s reputable legal status. At the beginning of each year, we launch a process of reviewing our contracts and reorganizing all our licenses and certificates. We also work on the renewal of certain licenses in addition to the commercial registration. Moreover, we start our annual expansion studies by preparing all the documents that we need in order to draw a development plan for our Department.

JK: Construction Week Magazine has ranked Almabani in the third position among all the general contracting companies working in Saudi Arabia. How do you see this result?MQ: This achievement is the direct result of continuous planning of the Top Management and its permanent keenness on the development of all the company’s departments and facets. Advance planning and clear targets characterize our company’s corporate values and this has always been the main reason behind our current respectable status.I am sure that the sum of expertise present in the leadership of this company is sufficient to drive Almabani to a higher position.

JK: How do you see the future of Almabani, in light of all the regional disturbances that have direct impact on the business market of the Gulf Region?MQ: Alhamdulillah the situation in the Kingdom of Saudi Arabia is stable and the urban development is constant. We have witnessed a huge urban development in the last 10 years under the reign of the late King Abdullah and Incha'allah we're on the fast track of witnessing another new era of development with H.R.H. King Salman. This stability in the Kingdom has always been the reason for the success and urban development of this country.In this regard, Almabani, being a major contributor to the Kingdom’s infrastructural development, has worked on organizing and developing its legal status, showing eagerness to meet all the Kingdom’s



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legal regulations in a way that maintains Almabani’s reputation in its field of expertise.Given the projects executed by Almabani in the recent years, the company has developed its Human Resources Department, hiring talented manpower to fulfill the project's different posts in the highest level of professionalism. This makes Almabani distinctive and we are proud of that. The political stability in the Kingdom is the key drive for the proper execution of development projects in the country. The set of goals and plans drawn by the government over the past years is the major force that boosted this diversity of development projects. Thus, do not fear the situation in the Kingdom and do not fear the future of Almabani.

JK: I will take the chance now and thank you for your time, would you like to add anything at the end of this interview?MQ: First allow me to thank you for this interview. Second, I would like to thank H.E. Mr. Nehmé Tohmé and Mr. Youssef Tohmé for their trust and infinite support.Our legal department is proudly contributing to the success story of Almabani General Contractors. Insha'allah with our joint efforts we will maintain our excellent reputation.One last message to all my colleagues: "Adhere to the regulations of the Kingdom of Saudi Arabia, and be always aware of the labor law regulations to avoid any legal issues.I wish Almabani all the best of growth and prosperity.


MOHAMMAD AL QAHTANI, GENERAL COUNSEL OF ALMABANI


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A Look inside Almabani Design Department

ALMABANI DESIGN TEAM, FROM LEFT TO RIGHT : GEORGE NASSIF, HEAD OF THE INFRASTRUCTURE PROJECTS DIVISION. TONY JABBOUR, HEAD OF THE STRUCTURAL DEPARTMENT. CAMILLE MAYO, HEAD OF THE ARCHITECTURE PROJECTS DIVISION & LUTFI AHMED, CORPORATE DESIGN MANAGER

Overview

The Almabani Design Department has always been an embedded part of a respective project team. Major projects in most cases have design support fully mobilized on site. Certain projects, due to their circumstances, rely on design services that are being conducted remotely at the Almabani Head Office. The Design Department team comprises disciplines of:

Architectural, Civil Infrastructure, Structural, Electrical for Buildings, Electrical Infrastructure, Mechanical Infrastructure, Mechanical for

Buildings, Special Airport Services and Apron Stand Equipment.

Each of these departments function under its Department Head supported by experienced engineers, draftsmen and CAD operators.

Major tasks that are being conducted in the Design Department include the technical evaluation of tenders, complete in-house design, value engineering studies, review and management of all the design activities that are outsourced,


- Jeddah, KSA -

ALMABANI’S MOST PRECIOUS CREATIVE SEEDS ARE PLANTED HERE. THROUGHOUT THE YEARS, A VAST ARRAY OF PROJECTS WERE DESIGNED IN THIS DEPARTMENT. IN THIS REGARD, THE ALMABANI JOURNAL GIVES THE READERS A BROADER IMAGE OF THE ALMABANI DESIGN DEPARTMENT, THROUGH A CHAT WITH MR. LUTFI AHMED, ALMABANI’S CORPORATE DESIGN MANAGER.

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A Look inside Almabani Design Department

PROFILE LUTFI AHMED, CORPORATE DESIGN MANAGER

1991: OBTAINED A BACHELOR OF SCIENCE IN CIVIL ENGINEERING FROM BOGAZIÇI UNIVERSITY – ISTANBUL, TURKEY1993: OBTAINED A MASTER’S OF SCIENCE IN CIVIL ENGINEERING FROM BOGAZIÇI UNIVERSITY – ISTANBUL, TURKEY1994: JOINED A CONSULTING FIRM IN SAUDI ARABIA AS AN ASSISTANT STRUCTURAL DESIGNER ENGAGED IN DESIGNING COMMERCIAL AND RESIDENTIAL CONCRETE BUILDINGS.1995 - 1997: JOINED ALMABANI AS A SITE STRUCTURAL ENGINEER FOR KING ABDULAZIZ INTERNATIONAL AIRPORT, MODIFICATIONS OF THE SOUTH TERMINAL PROJECT.2000 - 2003: ASSIGNED A ROLE OF PLANNING ENGINEER FOR DIR’H AL-JAZIRA PROJECT WHILE SUPPORTING THE TEAM IN STRUCTURAL DESIGN.2000 – 2006: HAD SEVERAL ROLES SERVING PROJECTS SUCH AS JIZAN AIRPORT PROJECT, YANBU AIRPORT PROJECT, SAUDI-YEMENI BORDER DEMARCATION PROJECT, PRIMARY HEALTHCARE CENTER AND COMMUNITY CLINICS PROJECT, ETC. IN THE FIELD OF PLANNING AND STRUCTURAL DESIGN.2006: APPOINTED DESIGN & ENGINEERING MANAGER FOR KAIA AIRFIELD PROJECT.2014: PROMOTED TO THE POSITION OF CORPORATE DESIGN MANAGER.

construction drawings preparation, material submittals and technical reports’ preparations and reviews.Over 30 staffs are engaged in delivering the services of the Design Department while, at the same time, executing construction site activities.

Challenges

Performing design services in design-build contracts has always been a challenge to us due to time constraints in achieving deliverables that meet the construction schedule. The circumstances become more challengeable when the contract requires a third party design services that necessitates our team to manage the design process while at the same time be ready to step in to ensure the project schedule is met. However, “the multitasking capabilities of our team that were acquired through years of experience have been one of the key factors in overcoming these challenges”, states Mr. Ahmed.

Design Engineers: Prerequisites and Qualifications

According to Mr. Ahmed, self-motivation, dedication, perseverance and teamwork are the fundamental cornerstones for design engineers to be successful. It is a teamwork spirit that always yield a common result. Design engineers have to be in parallel with the evolving engineering technologies through self-studies, seminars, workshops and certifications whenever possible.

Design Department - Top Management

Mr. Ahmed considers the relationship of the Design Department with Almabani’s Top Management “beyond excellent”.Almabani’s Top Management has always been a direct support to the Design Department. It is Almabani’s Top Management initiative that encouraged, facilitated, advised and supported the in-house capabilities and growth of design engineers who constitute today an engineering wing of the Almabani family.


“In a competitive construction industry market, we have to maintain and continue to be cost effective while achieving the best. We have to be in parallel with technology and the latest tools with the aim to deliver quality works that are above the standards” – Lutfi Ahmed.

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Central Equipment FacilityAn Insight into the Fabrication Division

- Bahra, KSA -


THE ALMABANI MEDIA DEPARTMENT PAID A TWO-DAY VISIT TO THE CENTRAL EQUIPMENT FACILITY OF ALMABANI, GATHERED INFORMATION, PHOTOS AND VIDEOS, AND CAME BACK WITH THE FOLLOWING REPORT AND INTERVIEW WITH MR. WADIH FARES, ALMABANI’S PMV DEPARTMENT MANAGER.

Fabrication Division Jobs

Decoration Jobs

Aluminum Cladding (Flat, Curved & Spherical)

Stainless Steel Wall & Column Cladding

Stainless Steel Louvers

Stainless Steel Handrails

FABRICATION DIVISION DECORATION JOB AT NAJRAN AIRPORT DEVELOPMENT PROJECT

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An Insight into the Fabrication DivisionCentral Equipment Facility

INSPECTION OF DEEP CANS, INSPECTED BY A THIRD PARTY

DUCTS FABRICATION SECTION


Deep Cans - Airfield Lighting

Ducts

Air Field Lighting Deep Cans (Deep Base & Elevated / Single Piece & Multiple Sections

Rectangular Galvanized Steel Ducts with Accessories

Flange Rings

Rectangular Stainless Steel Ducts with Accessories

Spacer Rings (Galvanized Steel, Stainless Steel & Aluminum)

Spiral Galvanized Steel Ducts with Accessories

Elevated Light Fixture Bases

Spiral Stainless Steel Ducts with Accessories

Stainless Steel Earthing Rods with Accessories (Coupling Dowels, Driving Heads & Spikes)

Inset Structural Covers

Galvanized Steel Handrails

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Central Equipment FacilityAn Insight into the Fabrication Division


NEW ASPHALT PLANT DRYER

PCC SHUTTERING

Molds

Shuttering

Asphalt & Concrete Batching Plants

Horizontal Slab Molds

Shuttering

Cement Storage Silos (300 t)

Walkways & Stairs

Circular Molds (Inner & Outer)

Vibratory Screeds

Elevated Microsilica Silos

Bitumen Tanks

Rectangular Molds (Inner & Outer)

Slotted Solid Bars / Straight Wedgelocks / Curve Wedgelocks

Dismantling & Erection

MC1 Tanks

Circular Blockouts for Circular & Rectangular Manholes

Conveyor Belts

Diesel Tanks

Filler Towers

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An Insight into the Fabrication DivisionCentral Equipment Facility


TRUCKS CHASIS FITMENT

PRE-ENGINEERED STRUCTURE ERECTION

Structural Steel

Trucks

Full structures (columns, beams, rafters, trusses) for airport terminal

Tipper Boxes & Hydraulic Kits (Fabrication & Installation)

Parking Lot Sheds

Canopies

Trailers (Fabrication & Repair)

Fuel Loading Station Structures

Domes

Truck Chassis (Repair & Modification)

Sliding Gates

Ice plant towers (Structural Steel Water Basins, Side Structures, staircases, walkways)

Water Tanks (Fabrication & Installation)

Scaffolding Bracings

High-mast Lightings & Antennas Structures

Pump Houses

Flatbeds (With/Without Drop Sides)

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Central Equipment FacilityQ&A with Wadih Fares, PMV Department Manager

Nassim Arabi: Good day Mr. Fares. This is the second exposure of the Central Equipment Facility.We would like to focus today on the Fabrication Division, but first give our readers a brief about this facility.Wadih Fares: Almabani’s Central Equipment Facility (CEF) is located in Bahra area, halfway between Jeddah and Holy Makkah, 50 km east of Jeddah. Our area is around 60,000 m2. It serves two main activities: a labor camp with all its related services and the Almabani Central Equipment Facility.The Central Equipment Facility houses:- The Fabrication Division on which today’s focus will be.- The PMV Department management and operations, in addition to a workshop, an equipment lay-down area, warehousing capability and archives.

NA: What is the manpower employed at the Central Equipment Facility?WF: Currently our head count is slightly under 80.

NA: What can you tell us about the history and the major milestones in the Fabrication Division?WF: The Fabrication Division grew from within the Central Equipment Facility.The CEF was started in 2006 with a nucleus of 24 people and a limited workshop capability. The scope was limited to overhauling and putting back to work major equipment items. As the number of machines grew and the depth of intervention increased, we had to increase our manpower and tooling and had to include all kinds of metal working to rehabilitate our machines.

Having done a lot of heavy metal fabrication and assembly in the course of rehabilitating large machines, we introduced in 2008 metal fabrication as an activity on its own as opposed to being complementary to machine rehabilitation, to support Prince Abdul Majeed bin Abdulaziz Domestic Airport Project in Al-‘Ula with steel structures. The outcome turned out very successful, generated savings while fully complying with the project standards. We then extended the structural steel fabrication to cater for Najran Regional Airport Project which needed over 700 t of heavy steel structures. We invested heavily in qualified manpower, machines, training, certification and inspection.

We managed to cater for all the structural steel needs of Najran Project, thanks to a very close cooperation with the Design Department, Najran Project’s management and workforce, as well as the outstanding dedication of the whole Fabrication Division team headed by our Production Manager Mr. Ahmad Maayouf. At the same time, we started considering many metal items in other niches that were being subcontracted to external suppliers that we found out that we could fabricate them in-house if we hire the right people and get the needed machines.


THROUGH OUR TOUR, MR. WADIH FARES GAVE US A THOROUGH INSIGHT INTO THE CENTRAL EQUIPMENT FACILITY.

Interviewed by: Nassim Arabi

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The feasibility studies showed that the saving on a single project would outweigh the additional investment needed. Mr. Joseph Daher, then EVP-Operations, encouraged us to embark on those ventures and set the goals:“Give maximum support to our projects, with timely delivery, belts quality of products, rigorous implementation of standards and catering for projects’ emergencies”.This meant fabrication, assembly, finishing, as well as installation. In addition to this, we also do the batching plants erections and relocations.On later stages, I can summarize our milestones as follows:- 2010: Start of the stainless steel production.- 2011: Aluminum cladding was added.- 2012: Introducing the pre-engineered beams (fabricated beams) as opposed to standard section beams.- 2013: Developing the Air Field Lighting (AFL) line.- 2014: Launched the HVAC duct manufacturing. Two production lines were installed: one for rectangular ducts and another one for the round spiral ducts.- 2015: Powder coating capability was added.

To go more into details, we asked Mr. Fares to talk extensively about certain jobs, starting with the STRUCTURAL STEEL

Structural steel production has been ongoing since 2008. We have covered requests from:- Prince Abdul Majeed bin Abdulaziz Domestic Airport in Al-‘Ula- Najran Regional Airport- King Faisal Air Base in Tabuk- Jeddah Flood Control Project- Prince Nayef bin Abdulaziz Regional Airport in Buraydah- King Abdulaziz International Airport in Jeddah- King Khalid International Airport in Riyadh- Riyadh Air Base- Prince Sultan Air Base in Al-Kharj- King Abdulaziz University- King Faisal Naval Base in Jeddah

In line with our internal requirement laid out in the beginning, compliance with the American Welding Society (AWS) standards has always been a must and applies to the certified welders as well as the approved processes and machines. No matter the size of the job, it will still be up to worldwide approved structural steel standards.

ENGINEER AHMAD MAAYOUF, PRODUCTION MANAGER


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The applications ranged from conventional steel structures to fabricated steel beams structures, to heavy vehicles superstructures, silos, stationary tanks in all configurations, guardrails, chassis rebuilds, load-bearing AFL enclosures, stackable shuttering molds in all sizes and shapes, car park shed structures to large span hangars. Unlike the commercial steel structure factories, we added the erection of steel structures to our scope to achieve the “turnkey solutions”.

STAINLESS STEELOur stainless steel products cover the following lines:- Decoration products- Structural products- Food facilities productsIn 2010 we started the decorative stainless steel that was used in the terminal of Najran Airport, ranging from indoor stainless steel cladding and decoration to stainless steel structural elements.

ALUMINUMIn 2011 we made our first steps in the aluminum cladding. The jobs started with flat wall cladding in Najran Airport’s Cargo Building and Administration Building, and went to curved cladding in the Fire Station Building, to culminate in the spherical shapes in the dome of the Royal Pavilion.

AIRFIELD LIGHTINGGiven the vast array of airports’ projects that Almabani has undertaken, Air Field Lighting is a repetitive item in all the airports’ projects. In 2013, we developed the AFL line where we certified Almabani’s Airfield Light Bases (deep cans) along with their accessories (spacer rings, extensions, flange rings, pavement dams, shallow bases, elevated light bases). All these items have been made out of mild steel and stainless steel with finishes of epoxy coating, powder coating and galvanizing as per each specific requirement.

HVAC DUCTSThe Fabrication Division supplies the KAIA Apron 6 Project, KAU Project and Tabuk Project with all sorts of HVAC ducts: rectangular ducts, single wall & double wall, galvanized steel & stainless steel, as well as circular spiral ducts, mainly double wall stainless steel with diameters up to 160 mm. In addition, all the accessories needed for air distribution are manufactured here.


AGREGATE FEEDER FOR DRYER

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ADDITIONAL ITEMSAlmabani’s Fabrication Division is covering a large number of different types of products that would not be found under one roof in a commercial factory. Keeping in mind that our mission is to “give the best support to projects”, we had to be ready to deliver different products and services with the same manpower. We stressed from day one on cross-trade qualification for our staff. The aim was to eliminate any idle time due to some types of jobs not being needed by the projects. We had not any single idle worker since 2008. The operation has been recovering all its expenses in addition to the investment in machines and generating savings that have been growing steadily to reach 2.5 million SR in 2014.

IN THE NEAR FUTURE…Since our main objective is to cater for projects’ needs, any future addition will rely on the projects’ demands. The criteria on which we base the decision are:- The volume of items needed.- The repetitiveness of these items.- The extra resources needed.

However, among our plans are:- HVAC ducts mass production, taking into consideration the fast growing demand- Enlarging our coating and painting capability- Adding a portable building (portacabin) production capability.


RECTANGULAR DUCT PRODUCTION LINE

28

EventsKAIA Development Project Scientific Meeting


A number of company representatives, aviation authority representatives and civil engineering society members gathered at Jeddah Hilton hotel on May 19 to participate in the KAIA Development Project Scientific Meeting that was jointly organized by the Saudi Society for Civil Engineering and the General Authority of Civil Aviation.

The meeting included a panel discussion that tackled the following:- Development of King Abdulaziz International Airport (Phase One)- Development of King Abdulaziz International Airport Runways

- Jeddah, KSA -

ON BEHALF OF ALMABANI, WHICH CONTRIBUTED AS THE DIAMOND SPONSOR TO THE EVENT, PROJECT MANAGER MR. WISSAM CHEHAB RECEIVED A TOKEN OF APPRECIATION FROM THE ORGANIZERS.

FROM LEFT TO RIGHT: MOHAMMAD ABU RAYA, WISSAM CHEHAB, ANTOINE SAMARANI & MARC BECHARA

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Events2015 AUB, LAU and NDU Annual Job Fairs and Exhibitions


- Lebanon -

SARAH HAJJ CHEHADE AND MARIE EL SAIFI FROM THE ESTIMATION DEPARTMENT (LEBANON OFFICE) REPRESENTED ALMABANI.

JOUD FARAJ FROM THE OPERATIONS DEPARTMENT, FADI SALIBI AND SARAH HAJJ CHEHADE FROM THE ESTIMATION DEPARTMENT (LEBANON OFFICE) REPRESENTED ALMABANI.

Almabani’s presence in the job fairs and exhibitions organized by Lebanese leading universities has been a constant source of exposure to a wide range of potential candidates and young talents.

For this purpose, Almabani participated this year in the following events:

2015 Lebanese American University (LAU) Byblos Career Fair (April 22)

2015 American University of Beirut (AUB) Annual Job Fair-Exhibition (April 23 – April 24)

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Events

In the News

2015 AUB, LAU and NDU Annual Job Fairs and Exhibitions

Riyadh Metro Tunneling Work Begins on Six Lines


GABRIEL ABBOUD AND MARIE EL SAIFI FROM THE ESTIMATION DEPARTMENT (LEBANON OFFICE) REPRESENTED ALMABANI.

2015 Notre Dame University – Louaize (NDU) Job Fair (May 27 – May 28)

Tunnel boring work has commenced on the $22.5bn Riyadh Metro project in Saudi Arabia.Seven bespoke and purpose-built machines are currently being used to burrow beneath the Saudi capital as contractors construct six interconnecting lines to help carry commuters around the city.The seven TBMs will create tunnels up to 35 km long at around 30 metres under the capital. The 178 km-long system will have 85 stations in total, including underground, ground level and elevated stations.[…] ADA awarded the design and construction contract of the Riyadh metro to three consortiums BACS, ANM and FAST, in August 2013.The BACS consortium includes Bechtel, Almabani General Contractors, Consolidated Contractors Company and Siemens. The consortium is led by

Bechtel and will design and construct the Blue and Green lines.It will also be responsible for the train cars, signalling, electrification and integration of the lines to the metro network. The contract value is $9.4bn about $10bn.

Related link: http://www.constructionweekonline.com/article-33503-riyadh-metro-tunneling-work-begins-on-six-lines/

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In the News

In the News

Riyadh Metro Operations Prequalification

Top Projects feature at Saudi Arabia Transport Expo


Major transportation projects, including mass transport systems and high-speed rail, were featured at Saudi Transport 2015 as the exhibition opened yesterday (May 31) in capital.The exhibition was inaugurated by Hathlool Hussein Alhathlool, Deputy Minister for Roads, on behalf of Engineer Abdullah bin Abdulrahman, Minister of Transport, Saudi Arabia, at the Riyadh International Exhibition Centre. It will run until June 3rd. The opening ceremony was attended by key officials from the ministry along with representatives from various sectors and government entities. The event also drew the presence of project leaders in Saudi Arabia’s transportation sector, as well as heads of regional and international companies that have played instrumental roles in projects that

Arriyadh Development Authority has invited interested parties to prequalify for operation of the metro, with a deadline of June 1.Work is progressing on

the six-line network. The Governor of Riyadh Prince Faisal bin Bandar officially activated the first tunnel boring machine for the Riyadh metro project at Riyadh Air Base on April 30. TBM Dhafrah is one of two TBMs being used to bore the 12·9 km north-south Line 5, connecting Riyadh Air Base and King Abdul Aziz Historical Centre. It is expected to cover an average of between 75 m and 100 m per week.

Related link: http://www.railwaygazette.com/news/news/middle-east/single-view/view/riyadh-metro-operations-prequalification.html

are currently being implemented and are involved in potential future projects.

Related link: http://www.tradearabia.com/news/IND_283186.html

www.almabani.co

tel: riyadh metro project mneefah goes...

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