Mammut Technocrete has commissioned the largest precast concrete factory of its kind in the world, with its first phase having an annual capacity of 2.5 million sq m of precast concrete elements, according to the Dubai-based company.

Sales and marketing manager Poul Soegaard Nielsen says Technocrete is already working on plans not only to expand the facility and bring the capacity to 5 million sq m, but to include new products, such as pre-stressed precast concrete in its existing range.
“It is our long-term strategy to include innovative and competitive precast concrete systems and concepts in the product programme, and become the single preferred supplier and sub-contractor when it comes to precast concrete,” he adds.
Nielsen says what sets Mammut Technocrete apart from the competition are the massive capacity, the precast concrete technology and the extensive product range offered for the construction industry.
“Our factory is fully automated and equipped with state-of-the-art technology like computerised mould robots, full automatic mesh welding machines and cut-and-bent shop, computerised concrete distributor, automatic power floating stations, and computer controlled steam-curing chambers,” he continues.
Nielsen says the production process is done in a rotating circulation system and at each station a single repeated process is carried out, similar to the optimised way cars are manufactured on robot assembly lines. The engineering department is equipped with cutting-edge design software tailor-made for the computers and factory robots.
“Production information and data is transferred directly from the engineering department to the factory which reduces the need of old-fashioned production drawings and manual work to an absolute minimum,” he adds. “Production drawings are only used for the purpose of quality traceability and documentation and to provide as-built drawings.”
Explaining as to how the new technology will help the construction sector, Nielsen says the traditional benefits of precast concrete are already known to the local construction industry. The introduction of precast concrete has helped in cutting down the project completion time by typically 25 per cent to 35 per cent, which translates into early returns and reduced financial cost for investors and developers. Apart from cutting down time and cost savings, precast concrete is providing a higher quality than conventional on-site construction, as the precast concrete is produced in a closed and controlled factory environment.
“Our automated set-up differentiates us from traditional precast concrete companies. Our plant is the most reliable in the market, as we are not dependant on labour performance and availability. Elimination of human error, accuracy, uniformity and quality also enhances the lifespan of construction investments,” he maintains.
The new production facility is also beneficial to contractors who are always under pressure to complete projects within tight schedules. “We are offering support to contractors by doing the conventional concrete structures as precast concrete, so they can allocate their often limited labour force to other tasks on the project. Contractors can also subcontract the concrete structures to Mammut Technocrete so they have the opportunity to take on more jobs without in-creasing their own labour force,” he adds.
The company has introduced two new main products – Mammut Plank and Mammut Twin Panel – which combine the benefits of precast concrete and in-situ concrete. “The composite concept, also known as half-precast, Filigree or Omni slabs and double walls, offers precast benefits such as elimination of form, reinforcement and plaster works, and in-situ benefits such as structural continuity and integrity,” he indicated.
The company has received a positive response from the market and has already completed projects at the prestigious Burj Dubai Development and is involved in projects with blue-chip clients including Emaar Properties, Emirates airlines, Al Futtaim Carillion, Al Naboodah Contracting, Al Ghurair Group, Al Rostamani Group, Al Jaber Group, Al Ahmadiah Contracting, and System Construct.
The future outlook for the company – which is part of the Mammut Group of Companies – is bright. With the second-to-none reliability and additional benefits Technocrete offers, the company is set to grow at a fast pace, he says.
“I believe the whole concept of industrialising and optimising the construction processes goes hand-in-hand with the visions and plans set out for Dubai and the rest of the UAE. The reduction of the labour force required in the construction industry is of immense interest to local experts. We hope Dubai will adopt the same model of reducing the labour force through pre-cast concrete usage that Singapore had picked up when it was booming. The construction in-dustry has been blamed for decades for lack of innovation. We think it’s about time to change that, and with the establishment of Mammut Technocrete we are on the right track and the front runners,” he concludes.