Until things go wrong, staircases are not often thought of again. If the stairs are not constructed properly, they may squeak, crack or even be a serious hazard in the worst cases. Precast concrete staircases have become favourite among developers, contractors and engineers in the UAE because of its boldness to be built and its high quality standard.
Whether you are based in Dubai or elsewhere in the UAE, this guide will answer the key questions about precast concrete staircases, including what they are, why they’re so effective, the different types available, and the manufacturing standards of the best UAE precast concrete manufacturer.
Precast Concrete Staircases Manufacture are what?
Precast concrete stairs are stairs that are pre-formed in a concrete plant and then transported to the construction site. They are highly durable, require minimal maintenance, and are an economical option for residential, commercial, and industrial projects.
The idea behind the process is simple: each step of the staircase is cast at a factory in steel moulds, under controlled conditions, reinforced with steel bars and cured in optimal environmental conditions. The final product is shipped to the site and installed rapidly once delivered. Precast stairs may be single steps or entire flights of stairs with integrated landings, cast separately, or cast together as a single flight with integrated landings. In fact, much of the work has already been accomplished before your product arrives at your construction site.
Why UAE Developers and Contractors Prefer Precast Staircases
This preference is supported by a number of good arguments. Traditional cast in place stairs are both very labor intensive and expensive: make formwork, pour concrete, allow days to cure, strip formwork, and hope it is done correctly, then repeat for each floor. But it’s not effective in the market where build times are short and labour costs are high.
Precast concrete stairs help to save a lot of construction time. Straight and even curved or even helical stairs can frequently be fitted within a day or two, and are often fitted in conjunction with the actual structural ground. In-situ stairs, on the other hand, can take weeks after casting, curing, stripping and finishing are all considered.
These benefits are further accentuated in the UAE construction sector. The difficulty of on-site concrete curing becomes real in the summer’s extreme heat, which is eliminated in production at the factory. Precast also minimizes exposure to safety hazards, and the general disruption in the worksite, since fewer workers have to be on site. As all the elements are produced under controlled quality conditions, precast staircases are consistently produced to specification, and are frequently significantly stronger than in-situ or blockwork alternatives.
Precast concrete stairs come in a variety of styles
Not all precast staircases are created equal. The following is a list of the various options you can expect to find:
The most common staircases are straight flight stairs with or without a mid-landing; they are one continuous flight of risers and treads. Monolithic top and bottom landings eliminate onsite formation of landings and advanced mechanical connections shorten installation time without propping.
An L-shaped and U shaped staircase are used when the staircase must turn a quarter turn between floors. These are usually made as individual flight and landing components, and assembled at the installation location.
Curved and helical staircases are installed rapidly, designed to build fit requirements, and help to speed up construction time while minimizing onsite time. These more complex forms can also be used to carry a substantial structural load, using precast and prestressed materials.
Stairways with open-risers provide a more architectural appearance and have an open riser design, which gives a lighter effect. These make for great use in high-end residential developments and commercial lobbies, as appearance is as important as function.
The stairs are constructed from weatherproof concrete, which is widely used in the UAE for outdoor applications, such as in industrial, warehouse and utility access environments.
Precast staircases can be neatly connected to steel-framed and concrete structures and are tied to the floors with projecting reinforcement to form a fully integrated part of the construction.
Precast Concrete Stairs in Dubai, UAE, offer numerous advantages, such as:
The first thing you notice is that this is weather independent. Installations can take place in any weather conditions and smaller units can be installed in as little as an hour, with minimal disruptions to foot traffic and the overall construction schedule.
Off-site manufacturing also offers precision, as dimensions and tolerances are precise to the required requirement and are especially crucial when each floor height must match the structural drawings.
Fire resistance is built-in. Further, precast stairs are incombustible, and generally have a minimum 1 hour of fire resistance thus enhancing the overall fire safety rating of a building, which is a very significant factor given the level of fire safety regulation in the UAE.
Another benefit is the removal of temporary steps. Precast stairs are extremely strong and relatively maintenance free, eliminating the necessity of using temporary access stairs during construction, while also providing safe vertical access immediately upon installation and a stable base for finishes to be installed later on.
Reusable steel moulds and precision off-site construction also contribute to cost efficiency, as it cuts labor, eliminates site delays, and provides project teams with greater budget predictability.
The added advantages include design flexibility, as precast stairs can be designed to fit various design and dimensional specifications for a multitude of project applications.
Application of precast staircases in UAE Construction
The UAE’s precast industry is well developed and fully mature and the industry’s capabilities go beyond the small scale. UAE precast manufacturers are established with huge and well-equipped modern factories, manned by committed engineering teams that can manage complex staircase configurations, irrespective of their scale, range or purpose, ranging from prestigious designs for the hospitality segment, to large-scale staircase layouts for mixed-use towers, to industrial settings. The production capacity and technical support has made precast the norm for the vertical circulation portion of ambitious projects throughout Dubai, Abu Dhabi and the rest of the Emirates.
The Design of a steel structure with a 1.4-meter span
Regulatory compliance is not a choice in the case of any project in Dubai. To ensure compliance of manufacturers’ compliance by the Ready Mix Concrete plants, Precast Concrete plants and Central Batching Units with approved quality rules and specifications, Dubai Municipality issued Administrative Decision No. (316) of 2012 governing these plants.
Dubai Municipality has stipulated that all precast concrete factories must have a Certificate of Conformity from the Certification and Quality Control of Products Section (DCLD-CQPS) of Dubai Central Laboratory (DCL). If the precast staircase manufacturer is not certified, they are not able to sell their products for Dubai regulated construction. Always check the DM conformity certificate before ordering a quotation.
Relevant provisions of the Dubai Municipality building code apply to precast staircases and other structural components requiring them to be adequately tied at support points as per the relevant approved code provisions. These connection requirements should be clearly though out and communicated through shop drawings for precast staircases in Dubai for the structural engineers to review. At a more general level, Dubai’s construction industry is pushing the modular and off-site production techniques which are essential for quicker construction time, lower costs, and more consistent quality, which are easily employed by precast stairs.
What to Look for in a Precast Staircase Manufacturer in the UAE
The right manufacturer could be the difference between a smooth project and one that’s stressful. What’s really important:
The Dubai Marina Authority Certification is a vital certification for any project in Dubai and is a good indicator of quality throughout the seven emirates of Dubai.
The internationally recognised standard for quality management systems, ISO 9001, demonstrates a manufacturer’s commitment to maintaining the same good quality control during design, manufacture and erection of precast components.
Custom mould capability is important as each project will have its own floor-to-floor heights, tread dimensions and landing configurations. A good manufacturer will create a mould specifically for your drawings, rather than requiring you to change your design to fit into a mould that they have.
The higher quality suppliers will provide shop drawings and engineering support. A good precast partner will first give you detailed shop drawings and verify them with your structural drawings, so that you don’t find yourself with unpleasant surprises on site.
The delivery logistics are also important to consider as large precast staircase units need special attention to delivery and installation using a crane. Look up a manufacturer’s reputation for projects that fit your specific requirements such as a high rise tower in Business Bay or a warehouse facility at JAFZA.
The UAE has a very tough coastal environment which is why durability and mix design is important. The type of cement, water-cement ratio and cover of reinforcement must be adequate to satisfy concrete faced with salt-laden air. Request mix design documentation and durability test reports prior to committing.
Final words on precast concrete Staircases in UAE
Precast concrete stairs continue to be a convenient option for builders in the UAE, especially within residential and commercial buildings. They are time-savers and risk minimizers, and ensure quality and meet Dubai Municipality and other regulatory requirements.
The use of precast concrete flights and landings is one of the most efficient and professional ways of building stairs today. The construction works can be prepared concurrently to receive the manufactured stair flights and landings when they are built on the construction site, which saves time and costs throughout the project.
This is the perfect blend of speed, reliability and regulatory compliance that today’s fast-paced UAE construction market requires. The easiest way to keep your staircase from becoming another project concern is to select a staircase manufacturer who is qualified and make sure they are early enough in the process to get your drawings when your structural engineer requires them.
References: Dubai Municipality (dm.gov.ae) – Administrative Decision No. (316) of 2012, and precast concrete certification requirements; KKK Precast (original content and internal pages).
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