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Big Ben
IN MAKKAH
Overall tower height: 610m/2,001 ft
Composite cladding: 45,000m2/484,376 ft2
FINIAL: Spire
Mosaic tiles: 100 million (13,000 gold)
LEDS (light-emitting diodes): 700,000 Carbon/epoxy
structure
(no steel substructure)
Composite design makes possible the world’s largest clock and tallest clock tower. Helicopter control tower 160m/525 ft
Solar panels
R
ising above Islam’s holiest city, the 610m/2001-ft tall Makkah PCT’s managing director, Hannes Waimer, credits the failure-free
Clock Royal Tower is the focal point for the nearly complete performance of these structures, in part, to detailed design and test- Composite cladding
Lunar
panels over steel Observation
Abraj Al-Bait hotel complex opposite the Grand Mosque of ing performed by the SL-Rasch/PCT team. Paired on many projects, spaceframe, with
Observation
deck Center
Makkah (Mecca) in Saudi Arabia. A key part of the Development beginning with the sliding domes in 1988, PCT and SL-Rausch nev- mosaic-tile overlay
of King Abdul Aziz Endowment (DOKAAE) project, devised to ertheless faced some unusually large challenges in this massive tower.
upgrade the mosque environs, the clock tower is the world’s largest Because it is rectangular — the east and west faces are slightly more
Comosite
— almost five times the size of London’s Big Ben. narrow (38m/125-ft wide by 43m/141-ft tall) than the north and dome and
When Premier Composite Technologies (PCT, Dubai, United south faces (43m/141 ft square) — PCT would have to fabricate two glass/epoxy-clad
Arab Emirates) was tasked by lightweight-architecture specialists different pairs of clock faces, each assembled from hundreds of dif- corner tower
SL-Rasch (Leinfelden-Echterdingen, Germany) to build and install ferently shaped panels, which would be drilled to accommodate a to-
43m/141 ft
the clock, it came well prepared. Previously, PCT had fabricated tal of 700,000 light-emitting diodes (LEDs) for night-time illumina-
composite protection flaps for mechanized umbrellas (see “Learn tion. Further, the clock would be crowned with a 22m/72-ft diameter,
Lightning arrestor deploys
More,” p. 48) and, earlier, 27 fiberglass sliding domes for the Holy 160m/525-ft tall, crescent-topped finial (see drawing, p. 47), which Hour hand from each corner of clock face)
Mosque of the Prophet in Al-Madinah (Medina), Saudi Arabia, as (23m/75-ft long by
would house a Lunar Observation Center. Compounding the diffi-
3m/10-ft wide) Arcade (glass/epoxy w/
well as composite domes up to 42m/138-ft in diameter for show- culty, the hotel was already under construction when Saudi King Ab- mosaic-tile overlay)
piece buildings elsewhere in the Middle East and Asia. dul Aziz decided that its main tower should be crowned with a clock Top of original 76-
— the original 76-story structure was not designed to story hotel tower
Source | Premier Composite Technologies
sufficient laminate stiffness and strength in a structure plied by DIAB International AB (Laholm, Sweden), because it met arrestors into the composite cladding. Further, in each of the tower’s
compromised by thousands of LED ports. mechanical and fire requirements and was compatible with the wet four corners, 3m/10-ft telescoping steel lightning arrestors deploy
automatically during storms (see drawing, this page).
CT o c t o b e r 2 0 1 0
“We … had to integrate [the] LEDs into this sub- lay/vacuum bag process.
This close-up of one of
structure and then extend them through the cladding Used in all of the clock tower cladding, the PET core thickness
the four massive Makkah
to be visible from the exterior,” says Waimer. Gurit’s varies from 15 mm to 20 mm (0.6 inch to 0.8 inch) for most panels Sandwich-construction cladding
Clock Royal Tower clock
FEA determined both the local and global effects that to as thick as 50 mm/2 inches in the clock tower corners. “We ana- The cladding panel skins, 2 mm to 3 mm (0.08 inch to 0.12 inch) in
faces (note the man in lower
left corner for scale of the through-holes would have, and PCT verified the lyzed every part of the building,” says Waimer, “to put in precisely thickness, were mostly 800 g/m2 (23.5 oz/yd2) and 1000 g/m2 (29.4 oz/
structure). predictions via testing. what material was needed, but no excess, in order to save weight.” yd2), stitched E-glass quadraxials with balanced construction. Small
The clock tower’s scrollwork and other com- Next, he recounts, “We needed to develop an economical meth- quantities of unidirectional and stitched 0°/90° reinforcements were
plex, three-dimensional (3-D) ornamentation tested od for attaching the panels, which averaged 20m [66-ft] long and also used locally where additional properties were needed. Suppli-
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Engineering Insights
Lightweighting the hands of time speed production, multiaxial fabrics made from Toray Industries’
More heavily loaded than the cladding panels and each equipped (Tokyo, Japan) T700 carbon fiber.
with roughly 3,000 LEDs, the clock faces’ minute and hour hands “The finial was actually not as difficult to mold because it was
(3m/10-ft wide, 26m/85 ft and 23m/75 ft long, respectively) needed larger with more gentle curves,” Waimer recalls. “The scrollwork and
to be stiff and lightweight to prevent excessive deflection and vibra- other decorations on the clock faces required using thinner fabrics
tion during service. Heat generated by the LEDs and absorbed by because we could not get the heavier textiles into and around the
the predominantly black tiled finish in the sun demanded a higher corners, so this slowed fabrication.” Because the finial was wet-layed,
design temperature (85°C/185°F) than the clock faces. the same low-temp Divinycell P100 foam used in the cladding was
The clock hands are sandwich structures. Skins feature an outer sufficient. Ultimately, the finial adds only 12 metric tonnes/26,456
layer of prepregged glass cloth, backed by three to nine plies of Gu- lb to the building load.
rit’s WE91-2 prepreg, made from large-tow carbon fiber manufac-
tured by Zoltek Inc. (St Louis, Mo.) and SGL Technologies GmbH Analysis, testing and installation
(Wiesbaden, Germany). The core is Gurit Corecell T-foam, a styrene During the past 18 months, PCT has built more than 18,000m2
acrylonitrile selected because it offers greater rigidity and strength (193,750 ft2) of molds and already has fabricated 60 percent of the
than PET and resists temperatures up to 100°C/212°F. Core density project’s 45,000m2 (484,376 ft2) composite cladding. Approximately
varied from 80 kg/m³ to 130 kg/m³ (5 lb/ft3 to 8lb/ft3), and thickness 100 million Italian mosaic tiles have been epoxy-bonded to the tower
ranged from 20 mm/0.8-inch to 30 mm/1.2-inch, with another three exterior — including 13,000 made from gold. The reflective tiles not
to nine plies of prepreg on the inner skin. To connect the hands to only provide continuity with Middle East architectural styling, but
their steel hubs, 26 plies of prepreg were laid to form a solid laminate also reduce panel surface temperature and, reportedly, will provide
up to 21 mm/0.83 inch thick. The clock hands were cured under 100-year protection from UV degradation, under which, Waimer
vacuum bag at 80°C/176°F. contends, “no paint will last even 10 years.”
Designed as a self-supporting structure to minimize weight, the As CT went to press, all clock tower panels and segments had
finial was driven by a high stiffness-to-weight requirement. “The been fabricated and shipped to the construction site. Waimer hopes
compositesworld.com
client wanted to use the inside space, so we could not use a steel to complete installation by the first quarter of 2011. With the finish
substructure here,” Waimer points out. “It would have occupied too in sight, Waimer says, “This has been an extremely challenging proj-
much room.” The laminate combines unidirectional, biaxial and, to ect, but also a once-in-a-lifetime project.” | CT |
Contributing Writer
Ginger Gardiner is a freelance writer
Read this article and view additional construction photos of the Makkah and regular CT contributor based in
clock and PCT’s umbrella project online | http://short.compositesworld. Washington, N.C.
com/qUD9kZt8. ginger@compositesworld.com
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