Bahrain Precast Concrete Company (BPC) – which is on the threshold of its 30th anniversary celebrations – is jubilant about its performance over the past year, having surpassed all its previous records in terms of value and volume.

“We were able to achieve almost double production with the same equipment and manpower, thanks to a dynamic team effort, better planning and motivation of staff,” says general manager Goran Hogberg.
Given the increasing demand for BPC’s precast concrete products, the company has now decided to build a new factory in Maameer industrial area opposite Alba's (Aluminium Bahrain) smelter. 
“Our present production facilities in Salmabad cannot cope with the growing requirements for precast elements and does not allow room for expansion – hence the decision to build our new factory in Maamer,” he explains.
The new factory will feature state-of-the-art technology and equipment and its layout is planned in such a way as to promote a smooth flow of men, material and machinery, thus saving on time. It will be bigger and more spacious and will include provisions for expansion, if required in the future.
BPC has completed a number of high-profile precast projects last year and has several others in hand which will keep it busy.
“Our recently-launched precast building system has met with extraordinary success,” Hogberg comments. “High-rise buildings constructed with total precast elements – once unheard of in this part of the world – have now gained wide acceptance and BPC is currently handling many multi-storey precast buildings projects including a 24-storey twin tower, an 18-storey and a 13-storey building which are in various stages of construction.”
While the twin tower is still in the design stage, erection work has begun both on the 18-storey and 13-storey precast buildings.
Among the major projects that are in advanced stages of construction and are to be completed soon include:
• Royal College of Surgeons in Ireland-Medical University of Bahrain (RCSI-MUB), a six-storey building coming up in Busaiteen next to King Hamad Hospital. BPC’s scope of work on the project includes design, production, supply and erection of  pigmented acid-washed insulated cladding panels, external load-bearing panels, external elements, beams, column cladding and 150, 200, 265 and  400 mm hollowcore slabs. Around 50 per cent of the elements have already been erected on the job, which is scheduled to be completed by March.
• Ali Kanoo Health Centre, a precast building being set up by Ali Kanoo Group in Nuwaidrat.  BPC’s work on the development includes design, supply, delivery and erection of 250-mm-thick external insulated load-bearing panels, 150-mm-thick external panels, 120-mm-thick side parapet panels,  precast concrete columns, circular columns, beams, staircases,  boundary wall and 150 and 265 mm hollowcore slabs. Most of the panels have already been erected on the three-storey project, which is scheduled to be completed shortly.
• A series of 14 low and mid-rise totally-precast buildings in Hidd. On this fast-track contract – which was required to be completed in 11 months – BPC’s responsibility was to design, produce, deliver and erect sandblasted white and grey load-bearing panels, beams, staircases and prestressed hollowcore slabs.  The project will be completed in the first quarter of this year.
Meanwhile, last month BPC completed the erection of the final precast elements on the prestigious Shaikh Khalifa Sports City, where it undertook the design, supply, delivery and erection of 120-mm-thick light beige-coloured concrete cladding panels, staircases and bleachers seats for the main grandstand, a multipurpose hall and swimming pool hall.
Another landmark project completed by the company last July is the Bahrain Chamber of Commerce and Industry headquarters, where it has erected 250-mm-thick curved precast elements on the 20-storey building in the Seef District. The building is now close to completion. Among the challenges posed by the project were the large size (3.5 m by 5 m) and the curvature of the panels and the tight programme stipulated – which was nine months from design to installation of panels.
“The precast elements are curved and supported on a steel structure. Here, a solid 80-mm skin with a 150 by 150 mm frame all around has replaced the traditional beam/block wall around the periphery of the building,” he explains.
Apart from precast building systems, BPC has also gained considerable success with hollowcore slabs, which achieved record sales last year, thanks to the comprehensive range of slabs it produces in thicknesses of 150, 200, 265, 320, 400 and 500 mm.
“We have obtained approval from Saudi Aramco for hollowcore slabs, following rigorous tests and inspection over three months and have so far supplied the organisation with more than 10,000 sq m of 400 mm and 500 mm-thick slabs,” Hogberg says.
“In addition, we are completing an export order for 400 mm hollowcore slabs to Saudi Arabia,” he adds.
In Bahrain, BPC is supplying hollowcore slabs to main contractors GPZ and Bokhowa for the construction of more than 60 per cent of the villas being built under phases one and two of the Durrat Al Bahrain resort development.  It has also completed erection of 500 mm hollowcore slabs at the Bahrain City Centre.
“We expect 2008 to be very good year for hollowcore slabs as a lot of major projects are in line for execution,” he says.
Innovation is a watchword at BPC, which has tried to offer the market a new product every year.
“In 2006, we launched the precast building system, last year we offered a wet room solution, and in 2008…. we will offer some more innovative solutions,” promises Hogberg, without revealing details.
Commenting on the precast industry, Hogberg says: “The construction boom in the Middle East has generated good opportunities for all the companies. However, this boom has also brought its own share of problems – the most severe of which is the shortage of trained precast personnel. While the precast industry is offering increasing job opportunities, there is a shortage of qualified and experienced personnel. BPC is facing problems in recruiting trained staff.”
Next month, BPC completes three decades of operations in Bahrain and has been lined up a number of events throughout the year – both fun and educational – to mark the occasion.
“These include a staff party in March, printing and distribution of a history folder to customers, a party for customers and organising lectures on precast concrete at the Bahrain Society of Engineers and University of Bahrain to attract student talent,” Hogberg says.