1. AA
GTE (Civil)

2. CONTENTS:
 Project Overview
 Civil Construction and Fatima Fertilizer
 My Working Areas
○ Roads and its Structures
○ Weigh Bridge
○ Nitro Phosphate (NP) Plant

3. Project Overview:
 Salient Features:
 Start of Land Acquiring in Year 2005.
 Total Land Acquired 800 acres.
 Estimated Cost in Rs. = 8,000 million
 Start of project phase in April 2007 (NA plant).
 Total no of plants/supporting areas are 50+.
 Four Types of Fertilizer Products/Plants having design
capacity.
1. Urea 1500 MTPD
2. CAN 1400 MTPD
3. NP 1200 MTPD
4. NPK 1000 MTPD

4. Project Overview:
 Salient Features:
 Other Supporting Plants having design capacity
1. Ammonia 1500 MTPD
2. Nitric Acid 1500 MTPD
3. Offsite & Utilities 50 MW
 Gas consumption of 75 MMCFD
 Civil Contractors
1. CNCEC China
2. IPL Pakistan
 Civil Designers
1. NESPAK Pakistan
2. A & A Pakistan

5. Civil Construction and Fatima Fertilizer:
 Civil Engineering role in the establishment of any
kind of project is not ignorable.
 The project like Fatima Fertilizer, its importance is
more.
 Fatima Fertilizer have structures
 From simple pumps foundations to complex pile
foundation under Prilling towers and Ammonia Tank.
 From steel structures of Urea, CAN, Bulk Storage & Ware
houses to concrete structures of Cooling Tower, Raw water
Reservoir, Bagging, NA and NP plants.
 From Technical building, CCR I & II, Substations to Strom
water drains, water pits, area development and network of
roads.

6. Civil Construction and Fatima Fertilizer:
 In Fatima Fertilizer, basic form of structure is
frame structure .
 Frame Structure is a combination of beams and
columns and load is transfer through this system
to design foundation.
 Two types of frame structures are used.
1. Steel Structures
2. Concrete Structures

7. Steel Structures:
 Steel structures are basically composite structures
having substructure of concrete and superstructure
of steel e.g.
• Ammonia & Urea Plants
• CAN & NPK Plants
• Bulk Storage (Phase-I)
• Ware houses, Pipe Racks etc.

8. Concrete Structures:
 Concrete structures comprise of both substructure
and superstructure of concrete e.g.
• Raw Water Reservoir and Treatment Plant
• Cooling Tower & Urea Prilling Tower
• Bagging (Phase I & II)
• Bulk storage (Phase II)
• NP Plant
• Substations CCR I & II and Equalization Basin
• Workshop, Technical Building, Laboratory, etc

9. Pictorial View of Civil Construction in
FFCL:
Construction View of
Urea Prilling Tower and Plant

10. Nitric Acid Plant
Foundation of
Ammonia Storage Tank

11. Construction View of
Cooling Tower
Raw Water Reservoir and
Water Treatment Plant

12. Construction of CAN Plant
Construction of Ammonia Plant

13. Construction of
Bagging (Phase – I)
Construction of
Bulk Storage (Phase – I)

14. Bagging (Phase – II)
under construction
NP Plant
under construction

15. My Working Areas:
 In Fatima Fertilizer during my Trainee period of
1 year, I worked on Roads and its Structures,
Construction of Weigh Bridge and also play a
vital role in the construction of NP plant.

16. Job Responsibilities:
 Study of Drawings
 Design Reviews
 Survey of roads
 Quality Control at site ( Formwork, Steel & Concrete)
 Inspections before concrete
 Checking of Bar Bending Schedule
 Checking of Bills

17. Roads and its Structures:
 Salient Features
 Total length of Roads = 17.484 km
 Completed Length of roads = 8.301 km
 Remaining Length of roads = 9.183 km
 Roads have Strom water drain and walkway on one
side, and shoulders on both sides.
 Designer = Akbar & Associates
 Contractors = IPL, Farhan Munir &
Company, AHCC
 Type of Pavement = Rigid Pavement
 Design Capacity = 90 Tons

18. What is Rigid Pavement?
 Rigid pavements are generally constructed of a reinforced
concrete slab or more recently a continuously reinforced
concrete road base.
 The pavement structure deflects very little under loading
due to the high modulus of elasticity of their surface
course.
 A rigid pavement structure is typically composed of a PCC
or RCC surface course built on top of either
○ the sub-grade or
○ an underlying base course.

19. Rigid Pavement:
Typical Cross-section of a Rigid pavement

20. Why we (FFCL) preferred Rigid Pavement instead
of Flexible Pavement (Carpet Road)?
 Rigid Pavement lasts much, much longer i.e. 30+ years compared
to 5-10 years of flexible pavements.
 In the long run it is about half the cost to install and maintain.
But the initial costs are somewhat high.
 Rigid pavement has the ability to bridge small imperfections in
the sub grade.
 Less Maintenance cost and Continuous Traffic and Flow.
 Low thermal variation as compared to Flexible Pavement.
 Rigid Pavement has one draw back in terms of its repair i.e. we
have to remove 2-3 panels instead of damaged portion as in case
of Flexible pavements.

21. Pictorial View of Roads in FFCL
KLP Road under construction

22. Roads in the Plant Area

23. Weigh Bridge:
 Salient Features:
 Total No of Weigh Bridges = 4
 Weigh Bridges constructed= 2
 Located near Gate # 1 or KLP Gate.
 No of Load Cells = 8
 Design Load measurement capacity = 120 Tons
 Designer
○ Mechanical = Mettler Toledo
○ Civil = Akbar & Associates
 Contractor = IPL

24. View of Weigh Bridge in FFCL

25. Nitro Phosphate
(NP) Plant

26. Nitro Phosphate (NP) Plant:
 NP plant started from Prilling Tower in 2009.
 Estimated Civil Cost in Rs. = 279.1 million
 Civil Designer = NESPAK
 Civil Contractor = IPL
 80% of Civil work completed.
 Remaining 20% include Refrigeration area
and Lime Drying unit, paints, brick masonry,
and finishing works.

27. Nitro Phosphate (NP) Plant:
 NP Plant is divided into four parts
 Prilling Tower & Lift Well
 Main Building
 Substation
 CN & AN Section, Refrigeration Area, and Lime
Drying Unit

28. Salient Features:
 Prilling Tower supported on 72 piles of length 27m.
 Prilling Tower has height of 67.9m and diameter of 19m.
 Lift Well has height of 70.1m, supported on 900mm thick
raft foundation.
 Main Building has dimensions of 67.5m x 27.5m x 37.3m
supported on raft foundation.
 Main Building comprise of 10 floors max on line 1-2.
 Substation comprise of 2 floors supported on isolated
foundation.

29. Special Techniques adopted at NP Plant:
 Prilling Tower and Lift Well concrete done by
using Slip Form Method.
 Strengthening of Columns has to be decided.

30. Slip Form Method:
 The most common method adopted for the construction of
an RCC outer shell/prilling tower is by using the ‘slip form
method’.
 In this method the form work for the concrete literally slips
up cm by cm to produce an integrated concrete column in
the form of wall.
 Continuous pouring of concrete ensures a joint free
construction.
 At a rate of 0.3 meters per hour, this is consider as fast
construction method.

31. Components of Slip Form Method:
 Slip form method is comprise of a complicated system of jacks
and radial screws.
 Radial steel yokes, which have an inverted “U” at both ends,
support the slip form shuttering all around the shell/prilling
tower.
 Walers strengthen and keep the shuttering in place.
 The working deck and scaffolding is supported from the
walers and yokes.
 The yokes are supported on hydraulic jacks, which move on
jack rods embedded in the concrete.
 As the concrete pouring progresses the jacks lifts up the yokes,
together with the decks and slip form.
 Screwed on pieces extend the jack rod as the work progresses.
 The entire system of decks and shuttering appear as if floating
on top of the tower.

32. NP Prilling Tower

33. Top View of NP Prilling Tower

34. Strengthening of Columns:
 To increase the capacity of NP Main Building columns
from 3500 Tons to 5500 Tons, the procedure that is used
called Strengthening of columns.
 Why Strengthening of columns needed?
 Continuous changing of mechanical design of Cfit of
NP main building, load on columns increased from
3500 Tons to 5500 Tons.
 To counter this problem, columns has to be strengthened
by using concrete and steel jacketing.

35. Lift
Well
Main
Building
View after Completion of Lift Well and Prilling Tower
Main Building and CN Section under construction
Prilling
Tower
Sub
Station
CN, AN
Section and
LD Unit

36. Any Questions????