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Dome designs for challenging environments

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World Cement,

Star Cement, UAE

Ras Al Khaimah is a large cement-producing region, with output that has helped develop the country and spur the infrastructure of neighboring Dubai and Abu Dhabi. To continue this growth, Star Cement, a company of the ETA group, built a new world-class cement plant in RAK with a capacity of 7000 tpd of clinker.

The biggest challenge was the enormous nature of the limestone stockpile. A week’s worth of limestone amounts to 34 000 t and has a diameter of 92 m. Star Cement's civil and structural consultant, FLSmidth Designs Pvt Ltd, India, drafted a performance specification that included all dimensional and loading requirements for the stockpile cover. It was required to allow ample clearance for the stacker-reclaimer system, provide an opening for the incoming conveyor, as well as four entrances for off-road vehicles, and include space for a traffic lane inside the dome around the ring rail of the reclaimer.

Crucial to the schedule was Geometrica's ability to accommodate the stacker-reclaimer and the conveyor gallery while building the structure. Once the structure was complete, the second pour of the concrete edge beam was completed and the cladding installed. The cladding used for this structure consists of simple rectangular panels of “Star Cement Blue” laid out in a 12-slice arrangement.

Translucent fibre-reinforced plastic panels form chevron-shaped skylights that make interior artificial light unnecessary during daylight hours. Notably, the desert sand added its own hue to the blue cladding.

See more photos here.

Ras Al Khaimah Cement, UAE

The Ras Al Khaimah Cement Company is a world class manufacturing plant utilising prime quality raw materials to supply cement to the people of the United Arab Emirates. Geometrica was hired to provide coal storage and installed a longitudinal dome dedicated to sustainability. The plant is designed to meet the most stringent European standards for environmental protection.

The vault extends an impressive 140m in length and was installed over concrete walls that contain the coal stockpile. The dome design included natural ventilation and lightning protection systems to help control the potential fire and explosion hazards associated with storing coal.

Cimento Sanayi ve Ticaret, Turkey

Cimento Sanayi ve Ticaret added a limestone storage dome spanning 68 m to its facilities in Kayseri to further meet the demands of both domestic and overseas customers in several sectors. As a leading producer of cement and ready-mix concrete, sustainability was a concern. Geometrica designed a circular stockpile cover to prevent runoff and particulates from harming the environment.

Geometrica also designed two 68 m blending domes for Cimsa's Mersin plant. Cimsa has been a leader in the Turkish cement sector for more than 40 years. The domes helped achieve sustainability and environmental objectives.

Adapted from press release by

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