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Category: Precast in Perlite

Published: Monday, 08 June 2015 14:56

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Tunnel Wall

Construction of Toheed Traffic Tunnel and lining its wall with prefabricated segments is also an innovation by Perlite. This tunnel was designed and built by Iranian engineers and experts within 30 months, a record in execution time. This project is beautiful civil structure and an icon in the city, ranked as one of the top ten world tunnels by relevant authorities. 

Toheed Tunnel

Resalat Tunnels

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Category: Precast in Perlite

Published: Monday, 08 June 2015 14:56

Written by Administrator

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Design, manufacture and installation of pipe racks in Bandar Abbas refinery project

As pipe supporters, pipe racks are among most important and accurate structures of the refinery. These elements are manufactured in large numbers to hold the pipes which will all be laid on them with different diameters.

Highly humid climate of Bandar Abbas provides very corrosive condition. In addition, the expatriate engineers had designed pipe racks, foundations, columns and part of beams to be built as in-situ concrete structures for fire protection.

However, construction of the skeleton by in-situ concrete pouring with base plates in the formwork were difficult, considering high precision required. Moreover, pipe rack columns some of which were 14 m high and had to be joined with the beams at 6 different levels, should have been concreted 6 to 7 times. This would leave concreted parts as pour planes during sequence of concrete pouring, allowing chloride ions to penetrate the structure and cause gradual corrosion. Also, columns with pour planes would not expose a good looking structure.

Perlite studies by its competent experts lead to a valuable innovative procedure to manufacture high quality parts at high speed. This procedure consisted of manufacture of columns and beams as prefabricated parts which were joined together by special steel connections before grout injection.

The project Consultants (Snam Projeti and Chiyoda) did not initially approve this procedure, but after explanations given by Perlite and tests made, not only were convinced but after completion they announced it as a valuable procedure. They also suggested that it may be put to work in similar projects in other parts of the world.

Production and installation of precast concrete pipe racks included 2700 beams and 1300 columns, all fabricated in 13 months. Thus, pre-casting of all pipe racks in a refinery in Iran were done by Iranian experts of Perlite and secondly, this short period of time was a record in itself.

Construction of Bandar Abbas Refinery by Iranians proved intelligence, innovation and qualifications of Iranian engineers and experts.

Pipe Rack

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Category: Precast in Perlite

Published: Monday, 08 June 2015 14:56

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Manufacture and installation of precast parts in the outfall pipe project at South Pars - phases 9 and 10

This project is located in Assaluyeh region of Bushehr Province. It was aimed to transport refinery waste water through 56 inch polyethylene pipe 6 km long on the 10 m deep sea floor.
Considering the nature of the project and previous experience in manufacture of precast concrete part, and also availability of well-equipped prefabrication unit of Perlite in the area, production of all concrete parts were considered to be precast. Also, "flex-mat" for the first time precast concrete covers were used over the pipe laid on the sea floor, instead of soil and rock embankment.

Steam curing was used during production cycle of precast parts. This caused the parts to reach 70% of their 28th day of strength through 10 -12 hours of steam curing.

The following include some advantages of stem curing:

• Need for less formworks and reduction of daily cost
• Saving time due to reduction in curing time
• Reducing the area needed for the operations.

The following table gives the total number of precast parts in the project: 

Flexible Armour Shield

Sinking Weight

Manhole Coverage

Diffuser Anchor Block