MAN Enterprise is in the process of executing a high-end construction project using the latest state-of-the-art technologies. Located in the heart of downtown, the prestigious Beirut Terraces project has a total built-up area of 97,000 m2.

This landmark, designed by the renowned Swiss architect Hertzog & de Meuron, is based on a transparent shell with a full glazed façade, large spans, and small diameter columns. In order to manage these architectural requirements, the adopted design was based on composite steel W beams embedded in reinforced concrete columns. The implementation of composite columns is a new concept being utilized in Lebanon. The circular reinforced concrete columns with a steel W beam core provide the ideal small diameter required by the design concept. These steel sections are not available off the shelf nor are they easily found on the worldwide market. Therefore Tecman Industry, the manufacturing arm of the group, is handling the execution of this delicate and distinct metallic package that has to be imported from Luxembourg specifically for the Beirut Terraces project.

The beams in question are referred to as wide beam flanges to the American Standard and they have been especially extruded for Tecman Industry. The beam dimensions are 90 - 125 mm flange thickness and 50 – 80 mm web thickness and measure 445mm x 569 mm. The weight of the beams varies between 800 to 1000 kg per linear meter, and their average length is 9.00 meters. These beams were cut to the dimensions as per the specifications required. A dedicated band saw was specially purchased by Tecman Industry for this task. It takes 45 minutes to cut a beam of 445 mm x 569 mm. Moreover, these beams had to be drilled for splice plate connections. Hence, heavy duty magnetic drills equipped with specialized coring bits imported from Germany were used. It takes an average of 40 minutes to drill a 125mm thick flange due to the liquid cooling time required to avoid overheating and breakage of the coring bit.

The intricate practice of stud welding to the beams, shown in the photos below, was undertaken specifically for this project. This one of a kind activity took place at the Tecman Industry fabrication shop. Specialized Nelson stud welding machines, along with all required accessories, were imported from the United States. Qualified Tecman welders completed a training series in order to ensure that the stud welding was to the required norms of strength. The stud is welded to the beam using a ceramic ferrule to hold the molten metal in place until the bind is formed. This produces a dense weld as strong as the fastener and the beam. Welding currents are from 200 to 2,400 amps, and weld cycles are from 0.1 to 1.5 seconds depending on the diameter of the fastener and the material being joined.

At the site where the beams are erected in a vertical position, special couplers are fitted to the studs and the rebar is connected to the other side of the coupler, thus achieving a homogenous, continuous reinforced metal frame for concrete pouring and strength.