| During the hottest part of the year, temperatures in Oman can reach up to 122 degrees Fahrenheit (50 degrees Celsius), and dry winds can make it seem even hotter. Such conditions can lead to unusual problems—and unique solutions—on a big construction job.
At the Sohar smelter, the 580 main structural support columns for the potroom structure are 10 feet (three meters) high and about 6.5 feet (two meters) across. To cure the concrete in the columns evenly, it’s important to keep the concrete the same temperature inside and out. Traditionally, curing has been done using water held against the concrete with a combination of burlap cloth and plastic sheeting. But that method requires constant maintenance, and when the weather is really hot, water evaporates quickly—a big problem at Sohar, where water for curing must be brought nine miles (15 kilometers) by truck.
Bechtel engineers solved the problem by developing thermal panels made of polystyrene foam bonded to soft timber framing. Affectionately called nappies (diapers), the panels are bolted together to enclose the columns. The system doesn’t require maintenance or water, and the panels can be reused.
“We estimate that this method saves over 10,000 job hours and an immense amount of burlap and plastic sheeting,” says Bechtel Civil Superintendent Shane Topp.
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