Bahrain Precast Concrete Company (BPC) has been riding high on the wave of new construction projects that have been launched in Bahrain during the past year or so.

Over the past few months it has also been playing a pioneering role in promoting the advantages of using precast concrete in high-rise construction.
“We have done remarkably well in 2006 in the precast industry, not only in conventional precast elements such as hollowcore slabs, insulated and solid panels (in grey and colour concrete) but also ventured into total precast buildings,” says Goran Hogberg, general manager of Bahrain Precast Concrete Company. “We have seen a 25 per cent increase in turnover over the past year and are set to embark on major expansion plans to cope with the anticipated demand.”
Besides the increased volume of work that the buoyant Bahrain market has generated, Hogberg attributes BPC’s success to the fact that it is a “total solutions provider, and not just a product supplier.
To this end, Hogberg has worked incessantly to popularise the concept of total precast solution in Bahrain for high-rise buildings, and his efforts have already borne fruit.
“Precast structures have so far been limited to ground-plus-three-storey buildings. It is time that the concept of total precast is adopted for multi-storey buildings. Total precast buildings are faster and cheaper to erect, look elegant and reduce future maintenance costs. They offer a quality product, enable early utilisation of building and hence early earnings. I hope very soon total precast buildings will be seen throughout the island,” he comments.
The precast structures system (PSS) was launched in Bahrain last April and initial interest and response has been overwhelming, he says. BPC has already received orders for 11, 13 and 18-storey buildings entailing the full superstructure in precast including beams, columns, shear walls, slabs and staircases and several other buildings are under negotiations.
The 13-storey building, located in Hoora, will accommodate a four-star hotel. “This building, which will also feature external load-bearing walls, will be the first high-rise structure to be built totally of precast concrete,” he points out.
Elaborating on the advantages of the PSS system, Hogberg says: “Customers have opted for this solution mainly because of the time and manpower savings offered by the system, which are becoming predominant factors in selecting a construction system. Developers are keen to reduce the construction period – precast concrete offers the possibility to do so by cutting the construction time by as much as 40 per cent, and thus earn rent or sales income much earlier than if the building was cast in situ. The reduced construction period translates to cost savings as the financing period will be significantly reduced, offering a direct saving on the project’s overheads and other savings such as labour and crane rental costs.
“While on paper initially it may appear that cast in situ construction is cheaper, in effect when looking at the overall project, PSS can result in cost savings of up to 15 per cent.”
Precast concrete also helps address the manpower shortage – especially of experienced and skilled labour – that is becoming an increasing problem throughout the GCC. “When choosing PSS, the contractor leaves the building erection to BPC and can utilise his manpower elsewhere and generate further revenues,” he says.
BPC has allocated and trained personnel to deal specifically with PSS projects.
This apart, PSS also offers the advantages of enhanced safety, being resistant to wind speeds of up to 45 m/s and seismic resistance as per zone 2A.
In the long term, maintenance costs are also reduced as precast concrete facades only require to be washed down after five to seven years.

Hollowcore slabs
Meanwhile, the demand for hollowcore slabs has “never been as good as during 2006,” because of the numerous private and public sector housing construction projects launched during the year, according to Hogberg.
“BPC has done very well and continues to dominate the hollowcore slabs market, thanks to the good service and quality of its product. BPC is the only precast company in Bahrain to offer such a wide range of hollowcore slabs in thickness of 150, 200, 265, 320, 400 and 500 mm,” he claims.
The 500-mm-thick hollowcore slabs were recently introduced to meet the requirements of an upcoming shopping complex in Seef district.

Projects
Among the most prominent projects BPC is currently engaged with are the Bahrain Chamber of Commerce (BCCI) headquarters in Seef and the Sheikh Khalifa Sports City in Isa Town.
At the  20-storey BCCI headquarters, erection is in progress of curved precast elements, which are supported on a steel structure. A solid 80 mm skin with a 150 by 150 mm frame all around will replace the traditional beam/block wall around the periphery of this building.
The Sheikh Khalifa Sports stadium is being extended by the addition of a main grandstand, a swimming pool hall and a multipurpose hall. BPC, which has designed and produced bleachers, beige coloured panels, steps, staircases and precast copings, is now in the process of erecting them at the site.
Elaborating on the challenges of this project, Hogberg says: “The placement of cladding panels on the inner side of the building has posed a challenge for the erection crew as the panels have to be fixed under the already cast beams. To erect them, the panels must first be lifted from the trailer using a small beam with slings and placed between the walls on side of the beam joining the two walls and secured temporarily. The slings are then unhooked from the panel and the small beam is replaced with a bigger one, to which the panel is attached and slowly lifted and guided to position. As the space is limited and the panel swings when lifted, the crew has to take lot of care as any excess swing will result in the panel hitting the adjoining wall and getting damaged.”
BPC is currently working on an 11-storey precast building in Um Al Hassam, having erected 25 per cent of the beams, columns and panels. The company expects to complete the building within five to six months.
The firm is now completing the erection of pigmented insulated cladding panels and hollowcore slabs for the extension of the Al A’ali shopping complex in Seef District. The panels were designed and produced to match the colour and shape of the existing panels.
BPC is looking optimistically ahead at 2007 with a healthy order book, which shows a “300 per cent increase in orders compared to the same time last year,” according to Hogberg. The company has some other major projects on its design desk including:
• A multiple building complex for National Guards includes a headquarters; accommodation building, watch tower, stores and multi-purpose building;
• A 13-storey and 18-storey PSS hotel buildings; and
• A spare parts building for Toyota in Tubli.
Among the projects completed by BPC are two projects for the Ministry of Education, including 10 computer laboratories, which are precast structures consisting of load-bearing, insulated panels and hollowcore slabs where all the services are embedded in the precast; and three three-storey academic blocks calling for staircases, columns, beams, 250-mm-thick external insulated load bearing panels, 150 mm internal panels and 240 and 150 mm hollowcore slabs.
Over the past year, BPC has also completed work on a sports stadium in Umm Al Hassam, for which it designed, produced and erected precast concrete beams (seat supports), bleachers, blocks and 150 and 200 mm thick slabs; and the Muharraq Municipality building, which involved the production and erection of 270-mm-thick insulated panels and 240 mm hollowcore slabs as well as a 2,400 by 2,400 by 200 mm fountain slab in beige coloured concrete with calligraphy.