Gulf Precast Concrete Company LLC, the largest precast manufacturer in the United Arab Emirates, announces the completion of its 2069 Villas’ Precast project, including 190 kilometres of Boundary Wall, on time. This project is part of the Al Falah Community Development which, when completed, will provide 4,857 villas to Emirati Families, on a 12.5 million square meter area.

Gulf Precast started the manufacturing of Precast Villas for the Al Falah Development in June 2010, and their 190 kilometres of Boundary Wall in October 2010. To sustain the project requirements of 5 villas per day, Gulf Precast produced 319,000 cubic metres of Precast Concrete, 740,350 square metres of Hollowcore Slabs and 7,600,000 kg of GFRC. After less than 2.5 years of work on one of the largest housing projects in the region, Gulf Precast has completed on time the handing over of the precast superstructure works of the 2069 villas.

Sami Saab, Factory Operations Director, recalls: “This project was the largest ever undertaken by Gulf Precast. Not only did it mobilise a significant part of our 6 factories, but in addition we had to install a production facility directly on site. The scope of Gulf Precast included all of the 18 different types of villas of the master development. Due to differences in site ground levels as well as layout specificity of each villa land area, the 94,000 elements of the 190 kilometres of Boundary Wall comprised 11,000 different types of columns and panels.” Rani Talih, Projects Director, commented on the challenges of the erection works: “As all trades were progressing together on site, the logistics coordination was incredibly tricky. At some point in time, Gulf Precast was operating more than 65 site cranes concurrently. The site erection team received up to 91 trailers sent by our 7 factories on a single day. It was one of the most challenging projects of my career.” Mohamed Abdul Wahid, Gulf Precast’s Quality Control Director, mentioned that “product quality remained a top priority for Gulf Precast throughout the project execution, at every single step of the production, transport and site installation of every single element. The Client’s expectations in term of tolerances exceeded by far those specified in any Precast International Standard.”

Another major focus of the development, both for the Main Contractor and for Gulf Precast, was Environment, Health and Safety considerations. Sean Antonie, EHS Manager for Gulf Precast, recalls that “performance in this regard was not only dependent on the internal performance of each Contractor involved, but also on the constant coordination of all involved parties.”

Elias Seraphim, Chief Executive Officer, concluded that “the talent, experience and commitment of our employees was the corner stone of Gulf Precast’s success in this challenging project, which is one of the most outstanding achievements of our 28 years of service in the UAE construction industry.”

Although Gulf Precast has completed its 2069 villa scope, the company still operates in the Al Falah Community Development, as its noted success has triggered the award of additional scope of work, such a further 90 kilometres of Boundary Wall in a different part of the development, and the production and erection of the Sheikh Khalifa Mosque at sector 8 of the same development, which are currently still on going.

For more information consult www.gulfprecast.ae or email to estimation@gulfprecast.ae

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