MANAUS, BRAZIL, August 2013 – Located 1500 km from the sea, in the middle of the Amazon rainforest, Manaus is where the Rio Negro and Rio Solimões run together to form the Amazon, the world’s largest river. It is also the capital of the Brazilian state of Amazônia, and was the center of the natural rubber boom at the beginning of the 20th century. Now, with its Free Economic Zone, it is an important part of Brazil’s economy and a finance center with global trade relationships. Manaus, with what is said to be one of the world’s most beautiful stadiums, will be the host of 4 matches during the upcoming 2014 FIFA World Cup. For the construction of Manaus’s “Arena da Amazonia” stadium, three different companies – Andrade Guitierrez, ENTEC, and Tomiasi, combined their expertise and Terex equipment to work on one of the world’s most innovative stadiums. They used Genie® aerial working platforms and Terex® tower, crawler, all terrain, rough terrain and truck cranes.
An energy efficient design masterpiece
With a maximum capacity of 45.000 spectators, design cues symbolizing its location in the Amazon and under a banner of a sustainable world cup, the “Arena Da Amazonas stadium” in Manaus features multiple innovative design features and will be a LEED certified building. The stadium’s most striking feature is its roof, a structure made with mutually supporting cantilevers whose steel hollow core girders function simultaneously as large gutters to drain the 2.200 mm of rain water that fall on average during the year. To cope with the average temperature of over 30 C° and 80% of relative humidity in Manaus, the stadium’s roof will be covered with translucent PTFE (Teflon) membranes that reflect heat and at the same time let light through. Additionally, ventilation is provided by movable vanes within the roof structure that allow the wind to flow through or can be configured to use convection as a mean ventilation on non-windy days.
Together with a Sambodromo, athletic facilities, swimming venue, shopping center and other sports facilities, the stadium will be part of the “Complexo Esportivo Amazonas”, a sport and leisure complex expected to be used daily after the World Cup. The project was designed by “GMP Architekten” a German architecture firm and the same firm that designed the Commerzbank arena in Frankfurt for the 2006 FIFA World Cup.
Construction activities of the Arena Amazonas stadium started with the demolition of the Vivaldão Stadium that stood where now the new stadium is being built. During this stage, the lawn was reclaimed and stored for future use and a large percentage of the material from the old stadium was recycled for use in the construction of the new stadium.
When the old stadium was demolished, construction of the stadium’s basic structure began. For this phase, foundations and supporting structures were laid, and two Terex SK 575-32 hammerhead tower cranes were erected to lift and place precast concrete components. The cranes had heights of 60 and 52 meters and jib lengths of 54 and 59 meters respectively. The cranes have a maximum lifting capacity of 32 tonnes and were mounted on bases on rails over 100 meter long. “These cranes had to pick and placed hundreds of pre-cast pieces that assemble the seating tiers. We chose the SK for its robustness and lifting capacity,” said Thiago Bezerra, Construction and Equipment Engineer, Andrade Gutierrez S.A. “The setup we chose is very efficient, as we can cover a large surface with only two tower cranes, this saves costs and time when comparing erecting multiple towers.”
Assembly of the last row of the upper tier of the Arena da Amazonia was completed on May 30, 2012. With this phase complete, the focus shifted to the finishing stage of the stadium’s structure and to the construction of the facade and roofing structure. The Head of the Public Projects Management Bureau for the World Cup (UGP-COPA), Miguel Capobiango Neto, pointed out that according to the schedule, the end of the assembly of the stands was anticipated in two days. “With this step, we will concentrate on the more sensitive and complex process of the work, that’s the roof/façade system,” he said.
During the construction of the stadium’s basic structure, the two SK 575 tower cranes performed the majority of the lifts, but when more mobility and versatility were needed, the lifting duties were assumed by Terex AC 200-1 and AC 350/6 all terrain cranes, an RT 280 rough terrain crane and a TC 780 truck crane.
The all-terrain and truck cranes belong to the local Manaus based lifting and rental company ENTEC Longhi S.A. and were used for multiple kinds of lifting, from loading heavy steel components to placing pre cast components in difficult and hard to reach places. “For this kind of work, we needed cranes that could handle the variety of different lifts, such as heavy lifting and long radii lifts. The cranes also needed to move from place to place relatively quickly and be able to be set up equally fast. We chose an AC 200-1 and an AC 350/6.” Said Reinaldo Longhi, Operational Director, Entec. “We had the cranes on site with maximum counterweight and just the main boom. The boom length and capacity of these machines without attachments are very solid, no attachment meant faster set up times for each new lifting location. These two (cranes) handled most of the lifts around the stadium. We also brought a TC 780 when we needed to step up the number of lifts within the restricted timeframe. We get a lot of rain here, over 2000 mm per year on average, so we really need to be precise and efficient to keep to schedule.”
The cranes were on site for 6 months and carried out over 90 lifts. Some of them at 25 meters height, 24 meters radius and lifting 28 tons. Thiago Bezerra, Construction and Equipment Engineer, Andrade Guitierrez commented “Of the eleven cranes working on site, eight were Terex. I was impressed by the reliability of all of them, this provided me with peace of mind that operations and timing wouldn’t be jeopardized because of equipment failure.”
During the finishing process, Genie® products from the Terex Aerial Work Platforms business segment assumed a prominent role at the work site. Andrade Gutierrez utilized Genie GS 2646 electric scissor lifts to mount fixtures and general finishing work. “The GS 2646 was designed to meet demanding needs of the aero industry. Here we are on an extremely tight deadline, we can’t afford to lose time. That’s why we decided on this extremely reliable and maneuverable platform.” said Bezerra.
The Stadium’s Crown: The Roof
The roof of this stadium is unique, it provides functionality, moderating temperatures and draining immense quantities of water, and it provides the arena its unique style. The design cues were inspired by local flax basket weaving made by indigenous Amazonas inhabitants. The self-supporting roof is anchored to the stadium structures via tie bars and made from over 200 pieces of steel weighing over 6670 tons all together with the largest components 22 meters long and weighing 30 tons.
With most of the routine pre cast assembly work behind, the construction of the unique roof started. The journey of the parts that compose the roof’s structure started 7.000 km away in Portugal, where the company Martifer S.A. produced them. The parts were shipped by boat directly to the Port of Manaus. After being unloaded, the parts were loaded to semi-trucks with the help of a Terex TFC 45 reach stacker.
The construction of the steel roof structure is by far the most complex part of the stadium. The construction was divided into eleven phases, including the erection of prefabricated structures, building and placing temporary support structures to bear the weight of the structure during construction, and the final phase, when the top pieces (compression stress) are placed. Once completed, the structure becomes self-supporting and the temporary supports can be removed.
Once the parts arrived at the jobsite, the work was coordinated almost like an assembly line. Boats arrived from Portugal periodically with the parts, the parts were unloaded and transported on site where Terex all terrain cranes, previously used for pre-cast lifting duties, lifted individual parts of the structure to form sub-assemblies, which in turn were lifted and placed with a Terex CC 2400-1 crawler crane belonging to Tomiasi Logistica Pesada. Finally, construction workers welded them together with the help of Genie Z 80/60 booms.
“The Genie booms were perfect for this project. The structures were very complex, as you can see in the photos, and the ample freedom of movement of the Genie Z boom allowed us to work efficiently and safely” according to Thiago Bezerra, Construction and Equipment Engineer, Andrade Guitierrez. “The technological advance of construction machines like these allow the increasingly complex and innovative to happen.” added Bezerra.
Before being joined together, the sub-assemblies needed to be lifted. This was the task of the CC 2400-1 belonging to Tomiasi ingenieria. “We are one of the biggest heavy lifting companies in the north region, and the CC 2400-1 is one of our most used “tools”. For this job we configured it with a 84m main boom, SH/LH configuration, and vario superlift. We had to lift sub-assemblies weighing up to 92 tons. In the beginning, we were working at 20 meters radius or less and we didn’t need to use the additional superlift counterweight, but when we had to place the roof trussed well inside the stadium, the radius was much larger so we connected the vario superlift.” said Marcelo Vinhote da Silva, Commercial Analyst, Tomiasi Logistica Pesada. “We are very well in schedule, and expect to be on site till the end of the year.”
Once the roof structure is finished and is self-supporting, the last step is to install the PTFE membrane. This is expected to occur towards the end of 2013.
About ENTEC Longhi & Cia.
Founded in 1979, headquartered in Manaus and with a fleet of 38 cranes, most of them Terex, ENTEC is specialized in heavy transport, rental and equipment installation. With almost 35 years of experience and a vast portfolio of services to cater customers all over the Amazon region, ENTEC is an industry leader in the region. To maintain this position, ENTEC believes in constantly investing to expand and renew its fleet and invest in team member training. More information at:www.entecmanaus.com.br
About Tomiasi Logistica Pesada
With 23 Terex cranes, from RT 780 to AC 500-2, Tomiasi Logistica Pesada is one member of the Grupo Chibatao. Situated in Colonia Oliveira Mechado in Manaus, Tomiasi links the most modern equipment technology with a team of qualified professionals. Its extensive portfolio of services include heavy lifting, transport, container logistics and more. During the duration of construction, TOMIASI supported its customers Andrade Gutierrez and Martifer. As the largest logistics company in northern Brazil built over 20 years they have accumulated an extensive portfolio that endorses their performance in business logistics. They were present in the work of the stadium from the outset offering to Andrade Gutierrez knuckle boom cranes for transportation of pre-molded concrete and the cranes AC 140, RT 130 and LT 1070 in lifting pre-cast concrete panels. In the assembly and disassembly, they also made available two SK 575 tower cranes and used a AC 350-1 with jib. During the pre installation of metal by Martifer, they provided two AC 200-1, a AC 140 and a RT 780. Finally, for the lifting of metal weighing up to 100 tons within a radius of 28 meters they will use a CC 2400-1 crawler crane.
More information at www.tomiasi.com.br
About Andrade Gutierrez
Grupo Andrade Gutierrez is one of the largest infrastructure conglomerates in Latin America, active in Brazil and abroad. Founded in 1948, in Belo Horizonte (Minas Gerais), Andrade Gutierrez has renowned expertise in heavy construction and reaps the results of successful investments in the fields of telecommunications and concessions – the two fields of activity the Company decided to bet on when it first decided to diversify its business portfolio, starting back in the 1990s. Across all business areas, the order of the day is to promote growth coupled with profitability.
About the Terex SK 575 hammerhead tower cranes
Designed for easy maintenance and reliable performance for excellent uptime, the models of the Terex® SK hammerhead tower crane series offer jib lengths from 35 to 80 meters (114.83 to 262.5 feet) for maximum load capacities of 16 to 32 tonnes (17.6 to 35.3 US tons). Their range of freestanding heights reaching up to 75.8 meters (248.7 feet) makes them well-suited to lifting heavy loads on high-rise construction sites. Fully compatible with Terex CTT and CTL tower cranes, the SK series provides excellent maneuverability and load moment precision. They are equipped with comfortable ergonomic cabs, time-saving counterweight set-up, high-performance load diagram, and built-in safety features. In addition, Terex tower cranes are known for their time-proven design quality and components that are engineered to deliver safe, reliable, cost-effective performance for long working hours. As the largest model in the Terex SK series, the SK 575 offers a maximum lifting capacity of 32 tonnes (35.3 US tons) for 3.9 tonnes (4.3 US tons) capacity at a maximum jib length of 80 meters (263.5 feet) and 75.8 meter (248.7 foot) freestanding height.
About The Terex CC 2400-1 lattice boom crawler crane
The Terex® CC 2400-1 lattice boom crawler crane has a maximum lifting capacity of 400 tonnes and a maximum load moment of 5168 tonne meter ([email protected]). Equipped with main boom, luffing jib and superlift the CC 2400-1 is one of the most powerful cranes in its class. With additional wind turbine erection equipment like the light fixed jib LF2 in 12, 24 or 36m in combination with two reinforced boom sections the crane scopes with the majority of 1,5 to 2 MW wind turbines up to 130 m tower heights. For petrochemical and infrastructure we offer a variable superlift system which allows easy change of superlift radii. This gives customers the opportunity to minimize transport costs for counterweight. The superlift can be combined with a telescope stinger system or a self-propelled counterweight wagon.
About the Terex AC 200-1 all-terrain crane
With a total length of 14.1 meters (46.1ft), the Terex® AC 200-1 all-terrain crane is the shortest five-axle crane in the 200-tonne (220 US t) capacity class. Its standard main boom reaches up to 67.8 meters (222.4ft), for a maximum reach of 100 meters (328 ft) when equipped with its main boom extension and variable extension. Four outrigger settings improve jobsite access while its state-of-the-art IC-1 control system with touchscreen color monitor, makes the AC 200-1 all-terrain crane particularly user-friendly to operate. A 390 kW (530 hp) carrier engine provides a powerful and cost-effective drive mechanism and is complemented with an automatic 16-speed transmission that is designed to provide high performance and excellent gradeability while reaching speeds up to 85 km/h (53 mph). Its independent superstructure engine provides an output of 170 kW (228 hp). Combining power with high maneuverability, four of the five axles (five of the six axles at AC 200-1P crane) are steering axles, to enable the AC 200-1 all-terrain crane to turn within a radius of 11.05 meters (36.25 ft).
About the Terex AC 350/6 all-terrain crane
One of the most compact 6-axle all terrain crane in the 350-tonne (400 US-t) capacity class currently available on the market, the Terex® AC 350/6 boasts exceptional lifting capacity and operator safety. Featuring a state-of-the-art fall arrest system for safe access during work at height and patented Terex Easy Luffing Jib Rigging System, the AC 350/6 all terrrain crane enables fast, easy rigging and safety. Offering a maximum telescopic boom length of up to 64 meters (210 ft) for an impressively compact maximum system length of 125.7 meters (412.4 ft), this powerful, versatile 6-axle crane can out-lift the performance of larger cranes in the 400-tonne (440 US-t) capacity class in a number of jobsite situations. Additional attachments can be loaded onto conventional trucks within a width of 8.4 ft (2.55 m).
About The Genie® GS™-2046, GS™-2646 and GS™-3246 Self-Propelled Electric Scissor Lifts
Designed to be compact and easy to position, the Genie® GS™-2046, GS™-2646 and GS™-3246 Self-Propelled Electric Scissor Lifts boast a 3 ft 10 in (1.17 m) profile and a 7 ft 6 in (2.29 m) turning radius. Combined with their front-wheel drive capabilities, these units offer operators exceptional maneuverability in tight spaces like congested construction sites, elevators and narrow aisles and easily pass through standard double doorways. The GS™-2046 works to a height of 26 ft (8.10 m) and boasts a lift capacity of 1,200 lbs (544 kg). The GS™-2646 has a working height of 32 ft (9.92 m) with a lift capacity of 1,000 lbs (454 kg). The GS™-3246 boasts a working height of 38 ft (11.75 m) with a lift capacity of 700 lbs (318 kg). The GS™-2046 and the GS™-2646 have a 30% gradeability, and the GS™-3246 has a 25%.
About the Genie® Z™-80/60 Self-Propelled Articulating Boom
The Genie® Z™-80/60 Self-Propelled Articulating Boom features a telescoping jib and 360° continuous turntable rotation for fast, easy positioning of the boom. This unit is designed with an innovative reverse-articulating secondary boom for 29 ft (8.83 m) of up and over reach with zero front arm swing to reach applications inaccessible by a traditional jib. The platform hydraulically rotates a full 160° and stays level throughout the entire range of motion. The Z™-80/60 also is engineered with four-wheel drive with full-time positive traction to handle the roughest ground conditions. This unit works up to 86 ft (26.38 m), reaches up to 60 ft (18.28 m), clears up and over objects up to 29 ft (8.83 m) and has a lift capacity of 500 lbs (227 kg).
Terex Corporation is a diversified global manufacturer of a broad range of equipment that is focused on delivering reliable, customer-driven solutions for many applications, including the construction, infrastructure, quarrying, mining, shipping, transportation, refining, energy, utility and manufacturing industries. Terex reports in five business segments: Aerial Work Platforms; Construction; Cranes; Material Handling & Port Solutions; and Materials Processing. Terex offers financial products and services to assist in the acquisition of equipment through Terex Financial Services. More information can be found atwww.terex.com.