The walls that they are a component of are not constructed on-site and they are not built by the owners of the building they are a part of, in the case of the warehouse being built in Jebel Ali, the acoustic barrier being built for a new road in the Jebel Ali area, the facade being built for the hotel being built in Jebel Ali… They were produced in a factory, cured under a certain mold and delivered to a flatbed for lifting. Why not, Precast Concrete Wall Panels are now one of the most widespread building systems in UAE. This guide will cover the offerings of precast concrete wall panel suppliers in UAE, the different types of precast panels, what to expect from a precast panel supplier and the specification to installation process.
The UAE Has Seen a Boom in Precast Concrete Wall Panels as the Preferred Material for Building, But Why?
Precast Concrete Wall Panels have become the option of choice for building in the UAE, but why?
Precast concrete wall panels are a wall component which is cast and cured in the precast plant before being taken to and installed at the project site. Panels can form structural and/or load-bearing elements of the main structure of a building system or can be used as the non-structural architectural envelope attached to an independent structure.
These are the elements that are attractive in the UAE. The dense smooth finish of the panels is not a result of site casting, but rather a result of casting in a controlled environment in the factory, which is an advantage to site-cast or block-and-render walls in an area where moisture will penetrate walls, fungus growth and salt-laden coastal air may be a problem. Typically, a period of 28 days is used for curing to ensure the concrete achieves a compressive strength that will enable it to meet its performance requirements in the UAE field.The curing period is usually 28 days with the idea that the concrete will reach the compressive strength needed to perform satisfactorily under UAE field conditions.
The other important consideration would be the speed of construction. Site built walls are slow and require special skills to construct, and must be formed on site and cured. Prefabricated panels are delivered ready to be lifted up and put in place, which helps projects to the subsequent trade much more rapidly. That discrepancy can quickly add up when it comes to bigger commercial and industrial jobs, where time is the currency and money is the factor.
Precast Concrete Wall Panels Come in a Variety of Different Types
There are several types of Precast Concrete Wall Panels available in UAE.
Not all panels are suitable for a project and choosing the wrong panel can be a disastrous mistake to make in the middle of a construction project.
Solid Panels
They are used for walls within buildings either as load bearing walls or as non-load bearing walls, typically 80mm up to 350mm (and more) thick, depending on the structural requirement. Simple and affordable, when insulation is not a critical factor.
Sandwich Panels
The sandwich panel is composed of a core material, typically sandwiched between two concrete faces, and typically has a thickness of about 200 mm-350 mm or greater, and can be used as a load-bearing material or as a cladding material. These are now listed for the external wall (where there is thermal performance required) as the built-in insulation will help to reduce heat gain into the building, which is a crucial factor in UAE energy codes and the climate.
Cladding Panels
Cladding panels are installed on an existing structure (insulated or non-insulated) and do not share the structure’s load. These panels are typically 100mm to 300mm or more, and are often the focus of architectural detailing such as textures, patterns and anything unique on the building’s façade that people see.
Acoustic and Barrier Panels
These panels are generally used in situations where noise control and sound separation are the main priority, like highway construction or along the periphery of projects and panel design is not primarily intended to be an architectural detail but rather a noise control item. There are still many panel manufacturers that continue to offer texture and colour options.
Decorative & Architectural Panels
Facing the exterior of the building as well as for commercial interiors and residential projects where appearance is critical, decorative wall panels come in a variety of textures from brick, stone, wood-grain and geometric finishes to UV-resistant coatings and custom colours.
To Choose a Wall Panel Supplier in UAE, You Must Also Take into Account the Following Factors
There is a good pool of suppliers of precast wall panels in the UAE. There are a few things to get right before you can make a decision regarding which one of the two is the correct one for your project.
The Mix Design of Heat Resistant is Mentioned Here
Emphasis will be placed on the UAE’s climate, which is really harsh for concrete. Again on the potential supplier, always inquire about their mix design, how they have designed it to address thermal cycling, cure conditions and long term crack resistance in high summer temperatures. When reflecting on such a thing, if a supplier is hesitant to discuss it, then it is a supplier that isn’t worth considering.
Structural Requirements vs. Non-Structural Requirements
If the panel has been requested to be designed to be load bearing it is a necessity that this is done early, as it will be a very different panel thickness, reinforcement and cost to the one being designed as cladding only. This should be explained to you by the supplier and not assumed to be a panel type that is simplest for them to make.
Certifications and Quality Control
Locate suppliers who make certified products to known quality standards, including ISO 9001, and have a quality assurance and quality control system to provide quality during the process. This is significant for wall panels, particularly when compared to nearly all other precast products in which defects are not nearly as evident once installed.
Avoiding Delays in the Curing Process or Delivery
If the proper curing is a requirement for panel strength, ask for the curing time as part of the supplier’s production schedule, and if the supplier’s quoted production lead time does not include the curing time, but is incorporated into it.
Customisation Capability
If a special texture, colour, integrated logos or non-standard size is required, make sure the supplier has the design and mould making facility and not subcontracted the work or it may be expensive and time consuming.
Installation Support
There are some suppliers who provide panels only and other suppliers who provide a full erection package including cranes and a team of experienced erectors. Otherwise, if it’s a bigger project, it’s a better idea to have the panels installed by the manufacturer that produced them; this will reduce the coordination issues when they are on site.
The UAE is Home to a Number of Reputable Precast Concrete Wall Panel Suppliers
1. KKK Precast Concrete Industry LLC
KKK Precast is a manufacturer of precast concrete wall panels, which are used in a range of projects including residential, commercial, and agricultural and industrial infrastructure throughout Dubai, Abu Dhabi and Sharjah for a variety of site and structural needs.
2. Solid Rock Concrete Works (SRC Precast)
Based in Umm Al Quwain, SRC Precast employs a team of highly skilled designers and project managers and has the latest manufacturing equipment, delivering customised solutions for all projects, including corporate headquarters, hospitality buildings and residential complexes.
3. Gulf Precast
One of the UAE’s oldest precast manufacturers, Gulf Precast produce solid wall panels, sandwich wall panels, external wall panels and internal wall panels all with ISO 9001 quality assurance. The company can be easily recognized in large-scale commercial and infrastructure projects because of the scale and decades of experience.
4. Abu Dhabi Precast (ADP)
Since 2001, Abu Dhabi Precast has earned a reputation for supplying precast and pre-stressed wall panel solutions, spanning from solid panels, sandwich panels and cladding panels, engineered for load bearing or architectural panels in a wide range of thicknesses and finishes, in the UAE market.
5. Exeed Precast
Exeed Precast runs on a large scale facility utilising an automated production system that produces large quantities of work to a high dimensional accuracy and, where required, has an in-house design team to cater for the bespoke production of wall panels on expensive projects where appearance is the key.
6. Hard Precast Building Systems (HPBS)
With a manufacturing base in Dubai, HPBS is a specialist in precast concrete wall panels, among a wide array of products, and is capable of large scale production and fast delivery for its products.
7. RAK Precast LLC
RAK Precast is known for its innovative and high-quality wall panel solutions for commercial, industrial and residential projects that have a long usage life and can be customised as per the requirement, in addition to delivery and installation services in Dubai, Sharjah and Abu Dhabi.
The Process of Installing Wall Panels
An understanding of the process—from order to finished wall—will assist in planning a project realistically.
Design and Specification
The panel type, thickness, reinforcement and finish are verified with project drawings and structural requirements, and the engineering team from the supplier verifies the load requirements of the structural panels.
Manufacturing and Curing
Panels are cured, at full design strength, for approximately 28 days on a factory floor prior to texturing, coating or painting to the finished product.
Delivery
Completed panels are loaded onto flat bed trucks for delivery to site and then laid to the site sequence, and access.
Lifting and Installation Precast Concrete Wall Panel Suppliers UAE
Panels are raised with a crane and placed on the structural frame/foundation and experienced erection crews ensure alignment and fixings are under observation when panels are being erected.
UAE Approvals and Regulations for Precast Concrete Wall Panel Suppliers UAE
When installed structurally and facadely, Dubai Municipality, Department of Municipalities and Transport (DMT) Abu Dhabi, Sharjah Municipality or any other relevant municipality approval will be required in addition to the Building permit process for Precast Wall Panel installations. The structural panels should also conform to the requirements of the UAE building code regarding thermal performance and energy efficiency, particularly of the exterior wall systems.
A reputable supplier should be able to have knowledge of this sign-off process and structural calculations and material details for the municipal sign-off.
Conclusion on Precast Concrete Wall Panel Suppliers UAE
From the manufacturers with decades of scale, like Gulf Precast and Abu Dhabi Precast, to the design-focused suppliers, like Exeed Precast and SRC Precast, specialising in bespoke architectural elements, the UAE’s precast market is diverse and varied. KKK Precast, HPBS and RAK Precast are an ideal balance of product for any size project, irrespective of finish.
The most important part of choosing the right supplier is to find out whether their mix design, certification and customisation are suitable to your requirements for structure and aesthetics of your project. Before ordering ask the mix design, inquire if the curing schedules are being reduced and seek references of other similar size projects before deciding on a supplier as the panel will be a structure for many years and the supplier you select will make it last or fail.