ALBA Pot Line 6 – Vertical Direct Chill Excavation and Pit Concrete Construction

Client: Aluminum Bahrain B.S.C.

Consultant: International Bechtel Co.

Location: ALBA, Bahrain

Project Overview:

The ALBA Pot Line 6 project represents a significant advancement in aluminum production technology, spearheaded by Aluminum Bahrain B.S.C. and guided by the expertise of International Bechtel Co. This transformative initiative focuses on the meticulous construction of two Vertical Direct Chill (VDC) Pits at the project site, showcasing a commitment to innovation and excellence in the aluminum manufacturing sector.

Brief Description:

The project entails the comprehensive construction of two critical components:

1. Slab Pit:
   • Dimensions: Approximately 10.45m by 8.3m with a depth of 16m below ground surface.
   • Features: Includes an approximately 2.85m diameter bored hole with grouted-in steel casing extending below the pit base.
2. Billet Pit:
   • Dimensions: Approximately 10.55m by 6.9m with a depth of 14m below ground surface.
   • Features: Incorporates an approximately 2.55m diameter bored hole with grouted-in steel casing extending below the pit base.

Scope of Works:

1. Mobilization and Demobilization:
   • Efficient deployment and withdrawal of contractor’s equipment and facilities to and from the project site.
2. Survey and Set Out:
   • Precision surveying and layout to ensure accurate positioning and alignment of excavation and construction elements.
3. Excavation Area Clearing and Grubbing:
   • Thorough clearing and grubbing of the excavation area to prepare the ground for construction activities.
4. Concrete Construction:
   • Implementation of comprehensive concrete, reinforcement, formwork, and waterproofing for the construction of the pits.
5. Dewatering Works:
   • Implementation of dewatering measures if required to maintain optimal working conditions during construction.
6. Steel Caisson Installation:
   • Expert installation of steel caissons to provide structural support and integrity to the pits.
7. Water Leak Test:
   • Rigorous testing procedures to verify the watertight integrity of the constructed pits.
8. Grouting Works:
   • Precise grouting works to ensure the stability and durability of the embedded items and structures.
9. Embedded Items:
   • Installation and integration of embedded items essential for the functionality and operation of the VDC pits.