Project Overview
Stadium 974 is a groundbreaking venue located near Doha Port and Hamad International Airport. Built for the FIFA World Cup, this 40,000-seat stadium is the world's first demountable and transportable stadium. It features a modular construction using repurposed shipping containers and prefabricated steel elements — setting a global precedent for sustainable sports infrastructure.
A key structural challenge was anchoring the massive steel roof to the reinforced concrete foundation using large base plates and dense bolt configurations. This required a deep-pour grout solution that could flow through tight spaces, remain dimensionally stable under extreme loads, and control heat generation to prevent thermal cracking.
Task at Hand
This task demanded a precision-engineered, deep-pour grout capable of:
- »Flowing through narrow, congested bolt configurations
- »Achieving monolithic bonding in deep layers (600 mm)
- »Maintaining dimensional stability under high structural load
- »Controlling heat during curing to avoid thermal cracking
The grouting operation was on the critical path, as the steel roof erection depended on the successful, time-bound curing of grout in the shear key zones.
KingKrete Solution
KingKrete recommended KingGrout BP80, a specialized high-performance, non-shrink precision grout engineered for heavy-duty and deep-pour structural applications. It offered exceptional flowability and structural performance, ideal for deep pours, high bolt densities, and significant structural loads.
System and Execution Approach
Before site implementation, mock-up trials were conducted to accurately assess grout behaviour, thermal characteristics, bonding integrity, and setting times under simulated conditions.
Carefully staged pours in three distinct layers, each with a 90-minute interval to manage heat build-up effectively. This allowed partial thermal dissipation and ensured a monolithic bond across layers, crucial for structural integrity.
To maintain consistent flowability through narrow and densely packed anchor bolt configurations, the grout mix excluded aggregates — essential for thorough encapsulation of complex reinforcement arrangements.
Rigorous on-site monitoring ensured precise placement, consistent flow, complete encapsulation, and defect-free curing — critical to structural integrity and long-term performance.
Results
The careful selection of KingGrout BP80 and a meticulously planned phased application fulfilled the project's stringent structural and timing requirements. The grout achieved:
- »Monolithic, high-strength encapsulation of all base plates and anchor bolts
- »Exceptional load transfer performance, essential for the stadium's structural integrity
- »Zero instances of thermal cracking or dimensional instability
| Product Supplied | Quantity |
|---|---|
| KingGrout BP80 | 5,000 bags × 25 kg |