The challenge
Stadium 974 is a 40,000-seat stadium near Doha Port and Hamad International Airport, built for the FIFA World Cup. It is a demountable stadium built from repurposed shipping containers and prefabricated steel. The steel roof is anchored to the reinforced concrete foundation with large base plates and dense bolt groups. The grout had to flow through narrow, congested bolt patterns, bond as one mass in 600 mm deep layers, stay dimensionally stable under high loads and control curing heat to avoid thermal cracking. Grouting was on the critical path, because roof erection depended on the grout in the shear key zones curing on time.
The DCP solution
DCP recommended Flo-Grout BP800, a high-performance, non-shrink precision grout for heavy-duty and deep-pour structural work. It offers high flow and structural performance for deep pours, dense bolt layouts and high loads. Mock-up trials checked grout behaviour, heat, bond and setting time before work started. The grout was placed without added aggregate so it could flow through the dense bolts, and heat was managed by pouring in layers.
DCP products used
How it was applied
- Run mock-up trials to check flow, heat, bond and setting time.
- Pour Flo-Grout BP800 in three layers, with 90 minutes between layers to let heat dissipate while keeping a monolithic bond.
- Leave out aggregate to keep flow through bolt groups of up to 14 bolts of 40 mm per plate.
- Monitor placement, flow, encapsulation and curing on site throughout.
The result
The grout fully encapsulated all base plates and anchor bolts at 600 mm depth without added aggregate. It transferred the vertical, shear and bending loads from the roof, and no thermal cracking or dimensional instability occurred.
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