Beaver Gulf Precast Concrete parks near epicenter of U.A.E. building boom

Beaver Gulf is one of the largest precast factories in the region, with a capacity to produce over 2.5 mio. m² of precast panels per year, located in Dubai. Beaver Precast Gulf called upon the precast consultant and international manufacturing capability of MCT Italy for a plant modernization, supported by the local partnership of Philip Tabone International.

Beaver Gulf is a leader in providing techno-economical solutions to government, semi-government and major private establishments for multi-million dollar projects. Beaver Gulf is a turnkey contractor with full-fledged in-house civil construction, oil and gas EPCC, electro-mechanical, structural steel, aluminum & glazing and precast concrete products divisions with its headquarters in Dubai, UAE. Over the years, Beaver Gulf has maintained and ensured maximum possible transparency and quality criteria coupled with customer satisfaction and this disciplined approach assisted in placing Beaver as one of the leading multi-million turnover business groups across the region.

Beaver Gulf Precast Concrete division is one of the largest precast factories in the world. Formerly known as Mammut Technocrete was formed in 2005. Nowadays Beaver Gulf offers full precast/prestressed systems for labor accommodation, villa complexes, sub-stations and other building systems.

The factory

It is one of the largest precast factories in the region, with a capacity to produce over 2.5 mio. m² of precast panels per year, located at National Industries Park Jebel Ali, Dubai.

The precast concrete plant has state-of-art machinery including cut & bend machine, mesh machine, batching plant, machinery, small tools, lifting and transporting platforms, cranes, including a shutter robot, computerized mold plotters, welding machines, concrete distributors and curing chambers.

Precast concrete products can be modulated in structures or systems with endless array of sizes and configurations, architectural or decorative purposes as well.

 

Product range offered are as below:

Precast concrete frame buildings,

Prestressed hollow core slabs,

Prestressed beams & band beams,

Facade elements / architectural precast,

Concrete prestressed beams non-load bearing cladding panels,

Precast concrete boundary walls,

Precast concrete staircases and landings,

Precast concrete load-bearing walls and

Precast concrete load-bearing insulated walls.

 

In 2017, the factory has been deeply reorganized and for this new large challenge, Beaver worked together with top expertise engineers. To achieve such remarkable success in quality and speed on this prestigious task, Beaver Precast Gulf called upon the precast consultant and international manufacturing capability of MCT Italy, supported by the local partnership of Philip Tabone International.

MCT Italy was selected for, and entrusted with fulfilling the major precast plant by Beaver, after detailed studies of its equipment, efficiency, reliability, after sales service support and experience throughout the Emirates region.

 

Technology developed by MCT Italy

The factory is composed of five production halls and two independent batch plant with fully automatic concrete distribution system through high-speed flying buckets and automatic casting machines. The first batch plant, equipped with 2 x 2250/1500 planetary mixers and 1 x 1500/1000 mixer, can support the production of grey and colored concrete for concrete panels and walls.

The second plant, equipped with 2 x 3000/2000 planetary mixers, delivers concrete to 17 beds of prestressed hollow core slabs and molds for the casting of structural precast elements, beams, staircases and boundary walls. The double mixer plant is able to guarantee a concrete production of 100 m³/h during peak time; an automatic ice dosing system ensures also the possibility to cast concrete during the hottest hours. Rapid, reliable and fast delivery is carried out by the latest version of Marcantonini Concrete Technology flying buckets: 240 m/min
is the speed achievable.

The plant supplied to Beaver Gulf Precast includes one of the latest releases of Compumat, MCT Italy‘s in-house developed software, taking the precast production to a new level. MCT‘s new system for concrete production and casting process management keeps growing along with the requirements of quality control and verification that nowadays, more than ever before, almost worldwide are becoming more common and strictly controlled by authorities.

The new software control system, together with the technologies developed by MCT, enables our customers to achieve the most efficient precast production, minimizing mistakes, waste and reducing costs.

Several new features have been implemented in our software aiming to considerably reduce the manual work of the operators, meanwhile guaranteeing the best results. MCT added a proactive support in order to be able to prevent any possible fault and to monitor the status of the plant from the headquarter almost real-time. A plethora of data can be easily extracted from the software to feed any ERP, BI suite or any other data-analysis system.

 

Better safe than sorry

The concrete transport system is a central part in Beaver precast production facility. All modifications done with factory upgrade have been specifically approved, guaranteeing a safe industrial environmental based on MCT risk assessment chart.

MCT Italy has created a risk assessment chart that includes suggestions and actions for eliminating the possible wide-ranging risks. The methods for eliminating the risks vary: at the lowest risk level, simply informing and educating workers might be enough; at the highest level MCT Italy installed automatic gate to prevent the entrance to danger zone (flying bucket washing and maintenance areas) and the power is switched off automatically when the gate is open.

 

Playing a major role in the Middle East

MCT Italy is well established and known as one of the major players for the supply of customized precast mixing plant & concrete distribution systems across all the Middle East countries.

“Based on our extensive experience in the sector, we are able to offer our client customized turnkey services starting from designing plant layout to plant operation and erection on site. The whole process involves consultation, project planning, production, operation, installation, and after-sales services,” Gabriele Falchetti, Middle East Sales Director for MCT Italy, said.

“I think the Dubai market still has a long way to go. Yes, it has matured, and I don’t expect the market to grow like before—100 % or 200 %. The demand for housing cannot be met using traditional building systems and can only be addressed by using precast building systems produced in modern and computerized precast plants. This will minimize the labor requirements and project duration while increasing product quality” Falchetti added.

Rajesh Kumar Krishna, formal Chairman and CEO of Beaver Gulf Group, affirmed: “Our driving force, undoubtedly, has been the trust our clients have placed in us and the versatile team of committed and qualified professionals who stood by us as we shaped the city’s skyline. We are proud of our new precast facility and supplier MCT Italy which will help us to increase our success in all segments of project management, construction and precast concrete products, across the Emirates. We have faced many challenges in our journey to excellence and MCT Italy gave us competence to surpass them thanks to their robust techniques, skilled support & encouraging our team members through innovation and knowledge.”

Continuous product development is our main target which MCT strongly believe. The role of software and automation is on the rise, the company always optimizing the concrete production process and analyzing relevant data becomes intuitive with the new Compumat. Remote control makes updates, checks or even managing the whole production process extremely easy.

CONTACT
Beaver Gulf Precast Concrete FZE
P.O. Box: 31835
Dubai/U.A.E.
+9714 8804442
 
Philip A. Tabone International
Dubai/U.A.E.
+356 21346632
 
MCT Italy S.r.l.
Via Perugia 105
06084 Bettona (Perugia)/Italy
+39 075 988551

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