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Products and solutions, 2005-02-23, 01:00 AM

PeinigerRöRo involved in construction of new Grand Mosque in Abu Dhabi

Corrosion protection and concrete coating at world`s third largest mosque

Gelsenkirchen/Abu Dhabi, february 2005 Peiniger International, subsidiary of Gelsenkirchen-based PeinigerRöRo, is involved in a prestigious project of a special kind. On the outskirts of Abu Dhabi, United Arab Emirates, the Sheikh Zayed Bin Sultan Al Nahyan Mosque - the world`s third largest Islamic house of worship when completed - is being built in honor of H.H. Sheikh Zayed Bin Sultan Al Nahyan who died at the end of 2004. Project management and coordination are in the hands of the Halcrow Group and Hill International. For the current phase of intricate finishing work, a joint venture has been formed by Six Construct, a subsidiary of the Belgian Besix, and the Arabian Construction Company (ACC). Al Mazroui & Peiniger International, a subsidiary of Peiniger Inter­national from Gelsenkirchen, is responsible for the concrete coating and for corrosion and fire protection.

The mosque, which is estimated to cost approx $700 million to build, is due for completion in November 2006 and will hold 40,000 people. The building has a footprint of over 22,000 square meters. About 210,000 cubic meters of concrete and 33,000 metric tons of steel reinforcement have gone into the building`s shell. The inner walls are to be clad with gold plate and Italian marble, with a cavity remaining between the marble and the gold. Using laser cutting technology, scriptures from the Koran will be cut into the marble so that, with backlighting, the viewer will be able to read six pages of the Koran in golden letters on the walls. Each page will be 22 meters high and 20 meters wide.

With such lavishness and attention to detail, the very highest standards are naturally demanded of the building`s long-term preservation. This is where the experts from PeinigerRöRo take their cue. Peiniger International is one of the biggest coating service providers in the Middle East and has been a familiar name in the region for over 25 years. Project Manager Axel Bub says: "When it comes to meeting deadlines and quality workmanship, our Company is usually the first that springs to mind. And compared with local firms, what we have to offer is practically out on its own as we can provide several trades in a single package."

This was also what clinched the contract in Abu Dhabi. Because, in addition to coating the concrete, the mosque also required anti-corrosive coatings on the load-bearing steel columns and F90/F120 fire protection for certain load-bearing elements and the entrance areas. The total of 5500 square meters of steel elements were sand-blasted with garnet abrasive from India and subsequently painted with zinc primer and several coats of topcoats.

The concrete coating, however, made up the bulk of the work. A total of 165,000 square meters of the shell were cleaned by high-pressure water jets and subsequently painted with a migratory corrosion inhibitor as the concrete coating. A precisely defined quantity of the colorless coating was applied per square meter. This was followed by coating in a shade of white. "A coating thinned with water is problematical in this climate", explains Peter Sneyd, Operations Manager of Peiniger International in Abu Dhabi. "The water evaporates too quickly in strong sunlight and the coating bubbles up like an egg in a frying pan." This is why the experts used a coating adapted to application conditions. Regular measurement of the concrete surface`s temperature is therefore essential if damage is to be prevented.

The sun and the heat are in fact the overriding factors affecting the coating. In the summer months the most strenuous jobs are reserved for the morning and evening hours, while the midday period with peak temperatures is used for preparations for later tasks or for cleaning the tools. The climate repeatedly dictates unusual procedures. During the blasting and jetting work in the building`s interior, virtually the entire mosque had to be enclosed because of the gusty drafts caused by the dramatic difference in temperature between inside and outside. Owing to the high level of evaporation during water jetting, the humidity in the mosque was also very high. "You have to expect the occasional sandstorm as well", Sneyd adds.

Despite or perhaps precisely because of the taxing conditions, PeinigerRöRo - like all the other companies involved in the project - is tied to precise procedures for the various steps and has to document them meticulously in the construction report. Every week, progress is checked by the client, and only then does the latter give his personal go-ahead for further work. In the case of PeinigerRöRo for instance, this meant a precise check of substrate preparation before protective coating work was allowed to start. And this applied to every single building element.

Background information

When the British withdrew from the Gulf in 1968, H.H.Sheikh Zayed Bin Sultan Al Nahyan, as he was known in full, the ruling Prince of Abu Dhabi at the time, had a major hand in the founding of today`s United Arab Emirates. At the end of 1971, he was elected the first head of state of the new union and remained in office until his death in November 2004. Because of his generosity and diplomacy, he was a highly esteemed personality in the whole world. The Arabs therefore consider the completion of his mosque after his death a matter of honor.

<small>PeinigerRöRo is a leading German and international industrial services provider operating in the scaffolding, corrosion prevention, concrete repairs, and complete maintenance segments. This group of companies belonging to ThyssenKrupp Services AG, based in Düsseldorf, is represented throughout Germany and has an international network of offices in the Benelux countries, Scandinavia, the UK, the USA, the Middle East, and Asia. The PeinigerRöRo Group provides services for the (petro)chemical industries, the steel and shipping sectors as well as the energy industry, generating sales of 700 million euros in fiscal 2002/2003 with an 8,300-strong workforce. The Management Board consists of Rolf-Bernd Maas, Georg Kürfgen and Hans-Rudolf Orgs.</small>


ThyssenKrupp Services
Ulrike Grönefeld
Tel: +49 (0)211-967 5792

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