Dubai based advanced composites manufacturer is the first contractor to complete roof installation at any of the four Haramain Railway Stations.
The Haramain High Speed Railway project links the holy cities of Makkah and Madinah via Jeddah and King Abdullah Economic City. The work was planned in phases and includes the construction of four passenger stations. The project is driven by the Saudi Railway Organization involving a 450km rail link between Mecca and Madinah.
All stations have a common planning strategy but each has its own distinctive design and building envelope to represent the cities that they serve.
PCT was awarded the contract to build the Concourse Roof at the Madinah station in February 2012. The scope of work for PCT included all elements of design engineering, manufacturing, delivery and installation of the advanced composite cladding for the concourse roof at the Haramain railway station at Madinah.
With a built up area of 172,000sq.m, the Madinah station contains facilities and services for passengers designed in accordance with the best international standards of high speed train stations. The station's facilities include a main building of the station which houses the arrival and departure concourses, a mosque with a capacity of 600 worshipers, a center for civil defense, helipad, pavements for trains, car parking with a capacity of 1,000 parking spaces which are divided into short and long-term parking and VIP lounges. The station has also been linked with the Public Transportation System through the provision of appropriate parking area for buses, and linking the station via pedestrian pathway with the Light Train Station which is planned to be implemented on King Abdul-Aziz Road.
Designed in a JV between Foster+Partner and Buro Happold, the Madinah Station is built in a unique design of umbrellas with green tiling giving it a remarkable and eye-catching appearance. The concourse roof design consists of a highly repetitive pattern that is made up of 41 panels that fit together to make one large square module 27 x 27 meter. Each panel is required to be structurally lightweight, fire resistant, immune to extreme temperatures and weather conditions, and easy to install.
Working alongside Foster + Partners and Buro Happold, PCT developed an advanced composite solution that would meet all requirements.
The roof is structurally built using a fire resistant composite of glass fibre and epoxy resin combined with lightweight foam core and is finished with glass mosaic coloured tiles. PCT produced 1,312 of these panels to complete the 26,400m2 surface area of the Madinah station roof.
The structure has been designed to use as much natural light as possible. For this purpose the roof panels have unique diamond shaped skylights incorporated into the design. The composite roof has a suspended inner ceiling made of green anodized aluminium segments with a special embossed perforated pattern and fixed anti-glare lamellas to help achieve high reflectivity (a minimum of 95%). The glass skylights are dropped into the moulded recess after the roof is assembled and are equipped with anti-glare system to enhance the light distribution inside the station.
Installation started in October 2013. PCT is the first contractor to successfully complete the installation of all roof panels at the Haramain Rail Madinah station.
A modular approach to the design with a high degree of prefabrication meant that all FRP parts were produced at the PCT facilities in Dubai Investment Park. Installation and final sealing operations were done on site.
On the ground, four panels were pre-assembled to form a segment of approx. 100sq.m weighing almost four tonnes. Adjustable footing in three directions allows for easy on-site installation and fixation to the main steel structure. With no secondary structure in place, the largest span is 13.5m.
Each module is able to move independently with movement joints sealing the gaps between the modules. The movement joints are covered using FRP SS clad capping which also serves as maintenance walkways.
The entire operation has been carried out at expedient levels whilst maintaining focus and due consideration to health and safety procedures.