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World Cup’s Manaus Stadium under Construction with Terex Cranes

MANAUS/BRAZIL, October 17, 2013 - 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.

The stadium for the FIFA World Cup 2014

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. | photo: Terex

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.

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.

First Phase

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. 

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. 
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.

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.

Before being joined together, the sub-assemblies needed to be lifted. This was the task of the CC 2400-1 belonging to Tomiasi ingenieria.
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.