One of those building elements where you simply cannot get it wrong – and it just costs too much money to have it corrected and it is totally unsafe to leave it. Having uneven risers, inconsistent tread widths, or a structure that was not engineered and designed to handle the loads it is subjected to is an issue that you don’t want to find after installation. The reason why precast concrete staircases are the choice of most UAE construction projects is because there is not much of a difference between the stairs produced in the factory and even those produced on site, with the exception of the elimination of most of the variability that the on-site concrete casting process brings. Here is a guide to the variety of stairs precast in UAE, what to expect before picking the manufacturer and what the process entails from shop drawings to installing the precast steps.
Why Precast Concrete Staircases Are Preferred in UAE Construction
There are numerous reasons for the preference for precast concrete stairways in the UAE’s construction industry.
A precast concrete staircase is produced as a whole staircase (or individual flights and landings), in a factory facility and then installed on site using a crane. Unlike a cast-in-place staircase, which must be accurately formed on site, reinforced in an awkward geometric shape, and allowed to cure prior to removal of the formwork and use of the staircase, this method requires no formwork to be built to exacting specifications on site, no special reinforcement, and no curing time before it can be used.
For staircases, precision is more important than for virtually any other structural component. If a staircase is not a consistent height and depth from riser to riser, it will not feel safe and comfortable for a user to use, and they will notice the differences right away. This consistency is available from the factory, batch by batch, and is much harder to achieve on-site with formwork. In addition to precision, precast stairs are also delivered as either a complete or near-complete structural component, which can save substantial time over the in-place, sequential, and weather-dependent stair construction.
A UAE-specific factor that needs to be taken into account: The coastal environment in the UAE is very aggressive on the durability of concrete. When the concrete mix, water-cement ratio and reinforcement cover are not correctly designed for the exposure conditions, salt-laden air can speed the corrosion of reinforcement. This is a detail that should be addressed directly with any staircase manufacturer because it is the only way to see issues with durability of the structural element in this environment that are related to failure of the reinforcement will become apparent years into the future, rather than immediately apparent.
Types of Precast Concrete Staircases Available in the UAE
In the UAE, Precast concrete stairways are offered in different types, including:
The way stairs are arranged will vary according to the building layout, structural needs and architectural design of the project.
Straight Flight Staircases
The most basic setup is two rows of seats in a single straight line between two levels of the floor and is often the most popular when space is an issue and simplicity is preferred.
Dog-Leg (Return) Staircases
Two flights connected by a landing, turning 180 degrees, which is a common layout for both residential and commercial buildings where the space between the floors should be utilized efficiently.
Quarter Turn and Half Turn Staircases
A 90-degree or other rotation, accomplished by a landing, is a type of staircase that is sometimes used in buildings where the use of a particular stairway direction from entry points or circulation paths is required.
Spiral Staircases
Going beyond these was more architecturally interesting configuration, which necessitated more complex precast engineering and mould design and, as a consequence, were often employed in UPSCALE residential and commercial buildings, as a feature staircase in lobbies and atriums.
Fire Escape / Emergency Staircases
Precast stairs designed specifically for life safety egress needs that satisfy structural and fire resistance requirements for emergency escape stairs of commercial buildings and high rise structures.
Custom-Engineered Staircases
Specifically developed for architectural drawings that deviate from standard configuration in order to meet the unique requirements of the project for a building’s layout or design intent, necessitating greater interaction between the manufacturer’s engineering team and the architect and structural consultant for the project.
Factors to Consider When Choosing a Precast Staircase Manufacturer in UAE
When it comes to choosing the suitable precast staircase manufacturer in UAE, one needs to consider several factors.
The importance of stairwells in building operations and life safety makes the process of supplier vetting in this instance worthy of attention.
Shop Drawing Coordination
A good precast supplier will give you detailed shop drawings reviewed with your structural drawings prior to production. This eliminates the risk of unexpected problems and expensive mistakes on-site, and if a supplier doesn’t do the coordination step, it’s a definite red flag.
Concrete Mix Performance Under Coastal Exposure Conditions
Ask for the mix design and durability test reports. The type of cement, water cement ratio and reinforcement cover should all be suitable to the concrete in the UAE where the air is salty, especially external or semi-exposed staircases.
Track Record in Your Specific Building Type
A manufacturer with a track record in business bay high rises may have a different idea of how to handle a high rise in a warehouse facility compared to a manufacturer with a track record in JAFZA, and vice versa. Compare the experience they have shown in their projects to your building type.
Logistics of Transport and Crane Installation
They are best delivered by a specialist and installed by crane and they are large precast staircase units. Be sure that the manufacturer can supply the appropriate logistics, as staircase units may be awkwardly shaped and sized compared to more standard precast units.
Structural Certification and Compliance
Request to see documentation that meets relevant UAE structural codes and, if applicable, a Certificate of Conformity from Dubai Central Laboratory for projects in Dubai.
Complete Fire Rating and Quality Documentation
If staircases are on the life safety egress path of the building, verify that a fire rating is documented and achieved and the finish quality is stated for visible tread and riser surfaces.
Leading Precast Concrete Staircase Manufacturers in UAE
1. KKK Precast Concrete Industry LLC
KKK Precast’s structural precast concrete staircase line includes staircases specifically designed for the project layout and structural needs of residential, commercial and industrial projects in Dubai, Abu Dhabi and Sharjah.
2. Abu Dhabi Precast (ADP)
Abu Dhabi Precast has more than 20 years of experience in the UAE market, and produces staircases as part of their extensive structural product portfolio, with their experienced QA/QC, structural design and project management team taking care of the standard and architecturally complex staircase structures.
3. Dubai Precast
With a 400,000 sq foot factory at Jebel Ali, Dubai Precast has a wide range of technical expertise and project experience that can be applied to wall panels, slabs, beams, columns and staircases, across commercial and residential building types.
4. Exeed Precast
Exeed Precast, which was established in 1986, is one of the biggest precast production operations in the region with two manufacturing sites in Abu Dhabi, producing staircases as well as hollow-core slabs, columns, boundary walls and GRC products, across the residential, commercial, industrial, governmental and infrastructure sectors.
5. United Precast Holding (UPH)
United Precast Holding, with decades of manufacturing experience across the GCC and over 95,000 square metres of manufacturing facilities, provides staircases as part of their full precast product range in Bahrain, Dubai and Abu Dhabi.
The Design and Installation Process of Precast Staircases
The sequence is essential to be understood for a project that relies on precast staircase units for realistic planning.
Shop Drawing Preparation
Detailed shop drawings are drawn and verified with the structural drawings of the project to ensure that riser heights, tread depths, landing dimensions and connection details are correct before manufacturing.
Manufacturing
Staircase units are cast and cured in the factory, which has a close control on the dimensional accuracy and finishing quality of the units due to the precision required to ensure safe and comfortable use of the stairs.
Transport
Staircase units are normally delivered by a specialist transport company that is able to transport oversized or awkwardly shaped precast loads.
Crane Lifting and Installation
Flights and landings of stairs are hoisted into place and fastened to the building’s structural frame, ensuring careful attention is paid to alignment and level at each point of connection.
UAE Approval and Regulations for Precast Staircases
As part of the structural and fire safety design submission for a project, precast staircases must meet the appropriate emirate authority’s structural and Civil Defence requirements: both Dubai Municipality and Dubai Civil Defence, Abu Dhabi’s Department of Municipalities and Transport and Abu Dhabi Civil Defence; Sharjah Municipality or equivalent bodies in other Emirates.
Any manufacturer who has experience in producing staircases for use in the UAE should have detailed knowledge of this documentation and should be able to assist the structural consultant and fire safety engineer with the structural and life safety approval process for a project.
Summary: Precast Concrete Staircase Manufacturers UAE – The Ultimate Guide
In addition to the larger structural manufacturing scale UAE precast suppliers, such as Abu Dhabi Precast, Dubai Precast and Exeed Precast, as well as the emerging UAE precast players such as KKK Precast, are available for the precast staircase market in the UAE. This is not a category where price should come into play, due to the importance of staircases in the day to day use of a building, safety, and overall longevity in such a difficult coastal environment.
If drawings are not yet checked, do not let the manufacturing process proceed until drawings have been checked; ask for mix design and durability documentation relevant to UAE exposure conditions; ask the manufacturer if they can transport and install the crane at your site if there are access restrictions. When properly designed and properly installed, a precast staircase is one of the most quietly successful structural components in a building, where no one ever thinks about it, and will be safe, comfortable and durable for decades.