As soon as you step onto a construction site in the UAE where something is being built, you will see it: A crane hoisting a long cured concrete member into place between two column structures, without the formwork, curing wait or falsework that a cast-in-place structure would require. That’s a precast concrete beam in its element, supporting floor and roof loads and rapidly putting a building’s structure in place. This guide details what precast concrete beam suppliers of the UAE actually provide, the various types and sizes of precast concrete beams, things to look out for when selecting a precast concrete beam supplier and the process of precast concrete beam design and erection.
Understanding what is Precast Concrete Beams and why they rule the UAE construction industry.
A precast concrete beam is a horizontal structural component that has been cast in a controlled environment in the precast factory and then delivered to the site where it is lifted to its final position as a component of a building structure. The counterpart to columns, which are used to transfer loads vertically to the foundation, are beams which transfer loads horizontally from a column or wall, and from floor or roof to a column.
This is a huge benefit compared to cast in place construction, and is very well appreciated throughout the UAE construction industry. A conventional site-built beam needs formwork to be erected, the reinforcement to be attached, the concrete poured and then a curing period during which the formwork can only be struck — a slow process with weather dependence. All of this can be avoided from the critical path altogether with precast beams. All curing is done at the factory prior to delivery, eliminating the curing delay on site, and connection of columns to beams is generally achieved with both grouted sleeves and bolted joints where required, and is an efficient method of connection. That is a key reason why precast has become the industry standard for so much of the UAE’s quick-track construction industry as it becomes more and more multi-storey.
In the UAE, temperature control is more important in the manufacturing process than in many markets. A good manufacturer will actively monitor the concrete placement temperature for casting – this is achieved by means of flaked ice in the mixing water, a chiller to chill the mixing water and light coloured plant equipment to minimise heat absorption, as an excessive placement temperature can affect the strength and durability of the concrete in the long term. A point of manufacturing that is specific to the UAE and a question that should be asked of any potential supplier.
The variety of precast concrete beam types offered in UAE are:
The selection of beam depends on the span, load and type of the structural system.
Rectangular Beams
The most common beam profile; most applications where the span and loading do not require a more specialised shape.
L beams and Inverted T beams.
Used under floor slabs or hollow-core slabs that sit on a ledge along the length of the beam – typically in multi-storey buildings where the beam must sit flush with or below the floor level that it supports.
Double Tee Beams
A wide and structurally efficient profile that features two vertical webs with a flat top flange, commonly used for long spans in parking structures, warehouses and industrial buildings where less supporting columns are required.
Pre-Stressed Beams
The load capacity and span potential are highly superior to a normal reinforced beam with the same dimensions, typically required for longer span structural applications such as bridges, parking structures, and large commercial buildings, due to the internal tensioning used in the manufacture of the beams which enable them to support load before it is applied.
Custom-Engineered Beams
Typically, a model generated to the requirements of the project and its structural consultant, as opposed to standard beam profiles, and a stronger level of engineering coordination between the supplier and project team.
When deciding on a precast beam supplier in the UAE, one must take into account numerous factors.Several factors need to be considered when selecting a precast beam supplier in the UAE.
The selection of suppliers is as important as it is for any other primary structural component because beams are an integral part of the structure.
Certifications & Regulatory Compliance
Request documentation for compliance with Dubai Municipality Standard Specifications and Administrative Decision requirements and DCL Conformity Mark as relevant. This is the minimum amount of documentation a good precast beam company in UAE should be able to provide without hesitation.
Heat Control in the Manufacturing Process.
Instead of assuming that the standard practice is followed, you should ask the supplier how they control the temperature of the concrete during casting in UAE conditions.
Connection Design
Ensure that the connection between the columns and beams is confirmed as per the design, either by grouted sleeve, bolted connection, or both, and determine if the design fits the project erection sequence and structural needs.
Span and Load Capacity
Size of beams should be appropriate to the span and load of the structural design. A supplier’s engineering team should be able to verify suitability by checking against your structural drawings and not supplying a generic beam size for any application.
Manufacturing Capacity and Delivery Scheduling:
If the project has a critical erection schedule, double-check the supplier’s ability to work with you on your sequence of construction, which may not otherwise be a constraint.
Transport and Site Logistics
Beams are big, heavy structural components. Ensure the supplier has a good delivery and transportation system in place that helps you get the precast to your site, before the delivery process fails to take advantage of precast’s pace benefit, to begin with.
Leading Precast Concrete Beam Suppliers in UAE
The first company was KKK Precast Concrete Industry LLC.The first was KKK Precast Concrete Industry LLC.
KKK Precast is a structural precast concrete beam manufacturer that supplies precast concrete beams for residential, commercial and industrial projects of different spans and loadings in Dubai, Abu Dhabi and Sharjah.
2. Gulf Precast
Gulf Precast has multiple manufacturing facilities in the UAE and is certified with Dubai Municipality Standard Specifications enabling the company to obtain the Dubai Conformity Label (DCL) Conformity Mark, which is a good sign of compliance to regulatory requirements for supply of structural beams.
3. Dubai Precast
Dubai Precast is a part of the ASCORP Holdings group and as such, their relationship with Eastern Pretech, one of the largest precast plant operators in Southeast Asia, provides international technical expertise to the structural beam and column production for UAE projects from Jebel Ali Industrial Area.
Abu Dhabi Precast (ADP)
Abu Dhabi Precast has more than 20 years of experience in the UAE market, producing beams, columns, slabs and stairs within its structural product portfolio, which is complemented by an experienced QA/QC (quality assurance/quality control), structural design, and project management team, which covers standard and complex structural scopes.
5. Solid Rock Concrete Works.
SRC Precast is located in Umm Al Quwain and produces beams, columns and structural elements as well as its extensive precast product offering, understanding how to work closely with contractors and developers for medium-sized projects with quality expectations.
6. UCES Middle East
UCES Middle East is ISO 9001:2015 certified and ADNOC compliant, and has a special achievement in the field of oil and gas and heavy industrial precast structures.
The Precast Beam Design and Erection Process
Knowing the sequence is important when planning a project that is dependent upon precast structural beams.
Structural Design and Detailing
Beam size, reinforcement and connection design are verified in accordance with the structural drawings for the project, working closely with the project’s structural consultant, who is the engineering team of the supplier.
Manufacturing
Beams are cast and cured in the factory with a monitored temperature for the casting of the concrete, and connection points (sleeves, bolted fixings or a combination) are created during the casting process, and are compatible with the UAE climatic conditions.
Transport and Delivery
Beams are brought to site on flatbed in preparation for being erected in accordance with the sequence of the project and any site restrictions for larger structural elements.
Lifting and Erection
Crane lifts beams into place and joins them to the columns or walls as per the connection method and verifies their alignment and level before placing the next structural beam.
Precast Beams Approval and Regulations in UAE
Precast beams are considered primary structural components and should be capable of meeting the requirements of the structural code applicable to the emirate in question (Dubai Municipality, Department of Municipalities and Transport, Sharjah Municipality or equivalent elsewhere) as part of the project’s structural design submission. Compliance documents include the Certificate of Product Conformity as per Dubai Municipality Standard Specifications.
A supplier who has real experience in structural works in the UAE should be familiar with this documentation and be able to assist in the approval process, in conjunction with the project’s structural consultant.
Final Thoughts on Precast Concrete Beam Suppliers in UAE
The UAE precast beam market consists of established structural manufacturing companies with decades of scale such as Gulf Precast, Abu Dhabi Precast and Dubai Precast, alongside a few new regional entrants, such as KKK Precast and SRC Precast, and specialists in heavy industrial applications, such as UCES Middle East. The selection of the right one depends upon the scale and complexity of the project structure.
Ask for compliance documents, ask specifically about how they manage the temperature when producing and ask the supplier if they can deliver and transport the material to match your project erection schedule before you commit. If a precast beam is specified and produced right the first time, it becomes a building component of which you never think — doing its job for years without a second thought.