Projects 

Ducab VCV Towers

Article Details

  • SYSTEM Climbing Formwork
  • PRODUCT Tru-Lift
  • STRUCTURE TYPE Hi-Rise, Industrial
  • REGION MENA

The new Tru-Lift system was used in the Middle East for the first time for the construction of a specialist 151metre concrete cable tower for Dubai Cable manufacturer, Ducab’s brand new manufacturing facility. Located just outside Dubai, the multi-million dollar factory will produce high voltage cable for the distribution of electricity. Due to the size of the cables a specialist tower was needed to assist with the cable winding packaging process.

Commenting on the project, Arul Raja, RMD Kwikform Sales Manager for Dubai and NE said: “Being the first time ever we have used the new Tru-Lift system, we have had to work very closely together with the whole Khansaheb team, to understand the job and how we could help from both an engineering and practical site support perspective.

“Our engineering team have worked hand in hand with the Khansaheb project team to design in specific site related safety to the system and ensure it met the needs of the project. For example for the first 100m the tower wall thickness is 700mm. For the remaining 40m the thickness is reduced to 400mm so the system itself had to be flexible enough to adapt to these changes.

“Interestingly enough this is one of the most complex types of tower you can construct and therefore a huge first test for the Tru-Lift system in the Middle East. Essentially the tower itself is a very large core with restricted access, meaning the slabs are formed inside the structure once the tower itself is cast. This was why when we introduced Khansaheb to the Tru-Lift self lifting system, they immediately saw its potential to help them with the job.
Having reached the full height, the tower, which is situated next to the busy Sheikh Zayed road, has already become a major landmark and thanks to the speed of its erection Khansaheb’s client, Ducab is extremely happy with its progress. Commenting on its use of Tru-Lift and working with RMD Kwikform, Khansaheb Project Manager N. Venkatesan said: “We had a major challenge for this project and a very competitive tender. We were awarded the contract because we were able to bring down the construction time for the project substantially.

“Having never constructed a tower of this type, size and scale before the make or break for the project was the selection of the right self climbing core forming system. Having looked at competitor systems and worked with RMD Kwikform throughout the tender stage, we felt the Tru-Lift system was definitely right for the application.
Initially we were looking at taking 4 days to complete a 4 metre pour, but due to the time constraints of the project, we looked to RMD Kwikform to help us reduce this programme time.

Through working with the engineering team, we explored a range of potential solutions and by understanding the tolerances of the system, opted for a special self-compacting concrete. By working 24 hours a day, we were able to bring down the time from pour to striking and moving from 4 to 2.5 days, a dramatic difference.

“The only way this could be achieved was by working hand in hand with RMD Kwikform staff. For every pour and every lift they supported us with a team member onsite, no matterwhat the time of day, 3am in the morning or 10pm at night.

“RMD Kwikform’s engineering team also supported us well supplying every single drawing required in a timely fashion. But what really made a difference was the site supervisors RMD Kwikform provided. This was instrumental in getting the teams on the ground up to speed. With erection training, checking and general support, we were able to come to grips with the system very quickly which was again crucial to programme delivery. This is one of the most complex types of tower you can construct and therefore a huge first test for the Tru-Lift system.”

“We have worked with RMD Kwikform now for many years and we recognise that they invest a great deal of time to support our business. Whether it is throughout a project of this type, at the very conceptual stage or just keeping us informed of what is going on in the market, the relationship we have is very valuable. Both businesses benefit and I think the professional way we work together is a true reflection of how delivering growth together can work, no matter where you are in the world.”

Concluding, Paul Williams, Managing Director – Arabian Gulf and India said:“By working closely together throughout the project, the RMD Kwikform and Khansaheb project teams have been able to push the boundaries of construction and in particular programme time delivery, in what is a very competitive market.

This first test of Tru-lift, following its recent launch, proves that through engineering development and working in partnership with our customers, we can provide them
with an innovative core formwork solution, bringing an important new addition to our product range. We now have a much greater understanding of how we can help to deliver complex core formwork projects in what are challenging environments, on time and on budget.”

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