Manufacturing

Design

At ABS, we are committed to excellence in the design and production of precast concrete structures. Our design discipline is founded on innovation, precision, and sustainability, ensuring that every project meets the highest standards of quality and efficiency, our design team utilizes the latest CAD and BIM technologies to create detailed and accurate models of our precast concrete components. This approach allows for seamless integration with other building systems and ensures precise fabrication and installation, we understand that each project has unique requirements. Therefore, our design process is highly customizable, allowing for a wide range of architectural and structural configurations. This flexibility enables us to meet the specific needs of our clients while maintaining structural integrity and aesthetic appeal.

Mould Preparation

Mould preparation is of vital importance in the manufacturing of precast concrete, alfanar Building Systems has its own mould shop. The mould must be very precise, sturdy, watertight and not prone to deformation.

The mould is composed of wood, steel, synthetic rubber or polyester, depending on the complexity and the number of identical pieces to be cast.

Architectural design and Decorative precast is made of synthetic rubber or polyester, such as emblem, complex designs in form liner shapes, etc.

Reinforcement

A key concern for owners and designers when planning a construction project comes from the possibility of corrosion of reinforcement

Corroding reinforcements can cause significant long-term deterioration that goes unnoticed until extensive damage has occurred. However, techniques used to design and install reinforcement in all precast concrete applications inherently prevent this from happening.

When designing the reinforcement of the elements, alfanar Building Systems will take into account each phase of production and handling, with special attention on the demolding process.

Quality control and adequate cover for reinforcement guard against corrosion.

When applicable, prior to layering on the approved mold, air blow is executed to ensure that dust, accumulated dirt, rust, has been removed from the reinforcement prior to usage.

alfanar Building Systems uses varieties of concrete reinforWhen designing the reinforcement of the elements, alfanar Building Systems will take into account each phase of production and handling, with special attention on the demolding process.cements such as: Epoxy Coated (FBE) and Mill Finished of all sizes, Low relaxation strands (9.5mm, 12.7 mm, 15.2mm), Wire mesh, Fiber etc.

Composition of Concrete

Composition of concrete is the guarantee of a quality finished product. The types of cement most commonly used by alfanar Building Systems are; Ordinary Portland Cement, Sulfate Resistant Cement and White Cement. In addition, Alfanar is utilizing sustainable cement replacements such as micro silica, silica fume and GGBFS.

All aggregates, including fine aggregates, coarse aggregates and architectural aggregates, must comply with the local and international standards referred from various project specifications.

alfanar Building Systems carefully selects the aggregates & sand to assure the quality of products.

Mixing Water used is within the acceptable limits as per the local and international standards New generation concrete admixtures (polycarboxylate) are applied on the mixed concrete.

Pouring & Casting

alfanar Building Systems has a fully automated casting systems from the concrete mixing, transported on a concrete shuttle, and in no time transferred to the casting bucket then directed to the approved casting mold.

It is ensured that no concrete segregation will appear as gap between application is with utmost consideration.

Each mold is built in with a table vibrator, and with the aid of needle vibrator uniform concrete distribution is achieved.

Concrete Ordering is validated from the request, mixing till the concrete reached the actual approved casting mold

All concrete components are based on various testing from independent testing laboratory to manifest acceptance as part of alfanar Building Systems product control measures.

When casting the concrete, compaction is done mechanically on tables equipped with high frequency vibration motors.

Curing

Upon casting the concrete elements are covered with a tarpaulin in order that the moisture is retained and there is no exposure to any dry winds. The pallets are transported to custom-built curing chambers and arranged to ensure equal distribution of curing.

The pallets are then left covered for 8 to 14 hours in order to ensure that the minimum design strength of 15 N/mm2 is obtained before progressing to demolding.

Each of the production bays are equipped with state-of-the-art curing facilities

Demoulding 

After confirmation that the minimum strength has been achieved from the Q. C. Department, the pallets are removed from the curing chamber, the covers are removed from the elements and all shutters carefully demoulded.

The elements are directly lifted from their moulds with a special tilting mechanism. The elements are carefully stacked on to a special storage wagon. From here the elements are moved to our finishing area on rails by pulling.

When casting the concrete, compaction is done mechanically on tables equipped with high frequency vibration motors.

Automation

Alfanar Precast automated batching plant is with four silos of different cement and having a capacity of supplying 770 m3/day of concrete by means of user controlled transport shuttle to the required location, which ensures the precise dosing and mixing of the concrete.

Cement and aggregates are loaded through a conveyor from the storage bins and cement inlet pipes directly to the designated silos.

Storage

The finished precast elements will be stored in the yard in a neat, tidy, safe and a manner that will ease the loading process.

Particular attention is be paid to ensure no damage is occurred to the final unit and also that there is easy identification of the pallets.

Precast Elements are placed on a Steel Stocking frame and arranged vertically to ensure that will not be damaged until requested for site delivery.

Final QC check

When the Q.C. department is fully satisfied that the finished element has been manufactured in accordance with the approved shop drawings they will stamp it as such, indicating that it is ready for dispatch to site.

If for any reason the Q.C. is not satisfied then it will take steps to isolate the element and arrange for repair or re-cast

Transportation

When the site is ready to receive the finished product, the pallets will be carefully loaded onto a suitable trailer.

The units will be securely strapped and transported to the appropriate site where our highly trained erection staff will take over.

Installation

Using precast concrete improves the speed of construction, depending on the complexity of the layout and detailing in the specification.

Precast concrete allows parts of the structure to be released, forming an immediate working platform that allows other trades to conduct work.

This can take place while the rest of the frame is erected. alfanar Building Systems has well trained and experienced erection crews to carry out the site work with utmost satisfaction of the customer.

“Quality is always the result of high intention, sincere effort, intelligent direction and skillful execution”

alfanar Building Systems ensures that in-house inspection are well executed, regardless the availability of any project protocols, alfanar Building Systems is guided by the general Inspection and Test Plan which is applied on the entire scope of the project.