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| Project Summary |
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History of cement
production in Iran
Iran's first cement factory was built in Shar-e
rey, situated in south of Tehran, when cement consumption had already
started to gain momentum both in Iran's construction industry and
globally. The Ray cement factory had a daily production capacity of 100
metric tons. Prior to the triumph of the Islamic revolution, several
cement factories were built in various parts of Iran, including Fars,
Tehran, Doroud, Isfahan, etc. During the ensuing years, some of these
factories set up new production lines, thereby increasing their output.
During 1970s, new companies were established and the old ones carried out
expansion plans designed to boost their output. However, most of the new
production actually came online between 1978 and 1981.
According to statistics available, Iran is currently the world's 13th
largest cement exporter and its annual production, wich currently stands at
43 million
tonnes, is the highest in the Middle East. According to existing
estimates, over the next five years, Iran, India and China will account
for 34%. of the increase in world cement production. Iran's Cement
production capacity is expected to rise to more the 70 million tonnes by
2010, the last year of the five-year economic development plan. |
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Project Location
The Saveh Grey Cement Factory is located 16 km
southwest of Saveh White Cement Factory and 60 km from Saveh, a city in
Markazi province in central Iran. Limestone, the main material used in
Saveh Grey Cement Factory, will be acquired from the huge Doshakh quarry
located only 4 km away from the project site. Also, 400 hectares of
uncultivated land surrounding the factory will be devoted to planting
trees, shrubs and other greeneries, thus providing a pleasant scenery
and minimizing the factory's negative impacts on the environment. |
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Basic Information
Client: Saveh White
Cement Company
Building Consultant:
Archen Consulting Engineers
Technical Consultant:
Bounyad Sanaat Company
Equipment Manufacturer:
FL Smidths Company
Type of Contract:
Construction
Contract Period: 27
months
Site Mobilization: 4 months |
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Scope of Work
Kayson's scope of work involves the civil
works of Saveh Grey Cement Factory's production lines, including cut and
fill operations, concrete pour of above- and under-ground structures, 2
construction of limestone plant, raw material storage bunkers, raw
mills, two nine-stage 110- meter high preheaters, coolers, ESP
(Electrostatics) dedusting units, cement silos, clinker silos, packing
and loading plant, blending silo, masonry work, building construction,
structural steelwork, etc. |
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Key Statistics
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Concrete:
145,000 cubic meters. |
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Reinforcement:
18,000 tonnes. |
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Ordinary and sliding formwork:
250,000 square meters. |
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Heavy steelwork:
4,000 tonnes. |
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Earthwork:
220,000 cubic meters. |
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| Project Site Plan |
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Objectives
The Saveh Grey Cement Factory pursues a
two-pronged objective aiming at driving Iran's national growth plans,
and a business objective aimed at meeting the increasing demand for
cement, currently standing at over 45 million tonnes per annum and
expected to exceed 80 million tonnes within the next five years.
Specifically, the plant is designed to meet the cement requirements of
Tehran and its nearby provinces. |
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Specifications of
site mobilization
According to the schedule set forth in the
contract, site mobilization was to be completed within four months. All
the necessary facilities, comprising 6500 square meters of floor space,
were completed and utilized as planned. The sleeping quarters were
divided into three types, namely for laborers, technicians and
engineers. All sleeping quarters were situated outside of the project
area, a short distance from the construction site. Water and electricity
were supplied by the client and distributed by means of an intra-site
network. In case of emergency, the site's water requirement was supplied
by an elevated water tank, with a capacity of 20,000 liters. Also,
emergency electricity supplies were provided by five electric generators.
A waster disposal facility was built a short distance from the
construction site, where the waste was stored, burned and the ashes used
as fertilizer.
It is to be noted that the design and construction of administrative
buildings and sleeping quarters were done with a view to enable the
client to use them for its personnel once the factory became
operational. |
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| Cement Plant Structures and Specifications
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Row |
Building |
Concrete
(m^3) |
Formwork
(m^2) |
Reinforcement
(tone) |
Steel Work
(tone) |
Height
(m) |
|
1 |
Limestone Crushing and
Gallery |
4000 |
6900 |
500 |
10 |
21 |
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2 |
Kaolin Stone crusher |
1500 |
3200 |
300 |
- |
20 |
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3 |
Secondary Stone
Crusher |
600 |
1200 |
100 |
- |
10 |
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4 |
Limestone Silo |
3400 |
7800 |
600 |
- |
40 |
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5 |
Feed Bunkers |
3700 |
8500 |
400 |
300 |
50 |
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6 |
Raw Mill (Line1) |
2900 |
6000 |
300 |
310 |
35 |
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7 |
Raw Mill (Line2) |
2900 |
6000 |
300 |
310 |
35 |
|
8 |
Raw Mill ESP (Line1) |
1000 |
2300 |
300 |
- |
20 |
|
9 |
Raw Mill ESP (Line2) |
1000 |
2300 |
200 |
- |
20 |
|
10 |
Raw Meal Silos (Line 1) |
6400 |
12400 |
200 |
35 |
55 |
|
11 |
Raw Meal Silos (Line 2) |
6400 |
12400 |
1000 |
35 |
35 |
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12 |
Preheater Unit (Line 1) |
8300 |
15300 |
1000 |
330 |
103 |
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13 |
Preheater Unit (Line 2) |
8300 |
15300 |
1100 |
330 |
103 |
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14 |
Kiln Feed (Line 1) |
1100 |
2100 |
1100 |
- |
25 |
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15 |
Kiln Feed (Line 2) |
1100 |
2100 |
2100 |
- |
25 |
|
16 |
Kiln Support (Line 1) |
1600 |
1400 |
2100 |
45 |
10 |
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17 |
Kiln Support (Line 2) |
1600 |
1400 |
100 |
45 |
10 |
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18 |
Cooler and ESP cooler
Department (Line 1) |
1800 |
4000 |
100 |
- |
15 |
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19 |
Cooler and ESP cooler
Department (Line 2) |
1800 |
2400 |
200 |
- |
15 |
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20 |
Clinker Transport (Line1) |
1900 |
2400 |
200 |
100 |
45 |
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21 |
Clinker Transport (Line2) |
1900 |
2400 |
200 |
100 |
45 |
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22 |
Clinker Silo (Line 1) |
8300 |
9500 |
1100 |
290 |
45 |
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23 |
Clinker Silo (Line 2) |
8300 |
9500 |
1100 |
290 |
45 |
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24 |
Cement Mill Feed |
5500 |
12700 |
700 |
- |
35 |
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25 |
Cement Mills |
6500 |
15600 |
800 |
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26 |
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26 |
Cement Silos (Line 1) |
9200 |
14600 |
1300 |
45 |
60 |
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27 |
Cement Silos (Line 2) |
9200 |
14600 |
1300 |
45 |
60 |
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28 |
Packing and Loading
Plant |
3200 |
14600 |
400 |
880 |
30 |
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29 |
Clinker Transport |
600 |
1500 |
100 |
- |
- |
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30 |
Other Structures |
6000 |
10000 |
1000 |
- |
- |
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Sum |
120000 |
222000 |
20100 |
3500 |
- |
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