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Case Study: 4,100 Precast Villas at Al Falah: Presented By: MAX E. JORDAN Fluor Mideast Limited Date: 15 MAY 2012

This case study summarizes the construction of 4,100 precast villas at Al Falah housing development in Abu Dhabi. The developer, ALDAR PJSC, aimed to provide housing for Emirati citizens using a master plan of 12 million square meters divided into 5 residential villages. Three general contractors were selected to build the villas, with two using precast construction and one using cast in situ concrete. The precast construction method allowed the villas to be completed four years ahead of schedule and with only one fourth of the on-site manpower compared to cast in situ construction. The success of this project demonstrated that precast construction can efficiently deliver large numbers of residential units on time and on budget.

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125 views25 pages

Case Study: 4,100 Precast Villas at Al Falah: Presented By: MAX E. JORDAN Fluor Mideast Limited Date: 15 MAY 2012

This case study summarizes the construction of 4,100 precast villas at Al Falah housing development in Abu Dhabi. The developer, ALDAR PJSC, aimed to provide housing for Emirati citizens using a master plan of 12 million square meters divided into 5 residential villages. Three general contractors were selected to build the villas, with two using precast construction and one using cast in situ concrete. The precast construction method allowed the villas to be completed four years ahead of schedule and with only one fourth of the on-site manpower compared to cast in situ construction. The success of this project demonstrated that precast construction can efficiently deliver large numbers of residential units on time and on budget.

Uploaded by

VîkÅš VìČký
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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CASE STUDY: 4,100 PRECAST VILLAS AT AL FALAH

Presented by: MAX E. JORDAN


Fluor Mideast Limited
Date: 15 MAY 2012
CASE STUDY: 4,100 PRECAST VILLAS
2
IT’S ONLY
VILLAS
AL FALAH FACTS:

• Housing Development for the Government of Abu Dhabi

CASE STUDY: 4,100 PRECAST VILLAS


• Developer: ALDAR PJSC
• Project Management Consultant: Fluor Mideast Limited
• Lead Design/Masterplan: GHM Design, Ltd

3
Master Plan

CASE STUDY: 4,100 PRECAST VILLAS


• 12,000,000 m2 site in 6 villages

• 5 Residential Villages contain 4,856 Villas

• 3 General Contracts for Villas

- 2 Using Precast

- 1 Using Cast in situ Concrete

• Contract Award: January 2010

• First Handover: 1000 Villas – 1 April 2012

• Last handover: December 2012 (Planned)

4
HISTORY

CASE STUDY: 4,100 PRECAST VILLAS


• Project launched in 2006 – To provide housing for Emirati Citizens
• General Contracts Awarded – August 2009
• Project Approvals Received – January 2010
• Notice to proceed – January 2010
• First handover of 1,000 villas – 1st April 2012
• Last handover – December 2012 (Planned)

5
PROJECT APPROVAL PROCESS

Factors Related to a 4 year Approval Process

CASE STUDY: 4,100 PRECAST VILLAS


• Unique Masterplan Concept
 Narrow Street Right of ways
 Curved Road Design
 Distributed Access Around
Perimeter
• Evolving Planning Process
 UPC was New
 First Major Project through UPC
• Economic Boom followed by Distress in
the market

6
DESIGN DECISIONS

3 STYLES

CASE STUDY: 4,100 PRECAST VILLAS


GULF HERITAGE ANDALUSIAN

• 3 sizes – 3,4 and 5 • Standard and Mirror


Bedroom Villas Image
• 18 Villa Repeated • 4,856 Total Units

GULF MODERN

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DESIGN DECISIONS

CHALLENGES

CASE STUDY: 4,100 PRECAST VILLAS


 The design did not use factory
components – a waste on a
repetitive project like this
 The structural design was not
efficient
 The budget was set in 2006
 Villa projects were not attractive to
contractors with a high rise
mentality
 How do we manage the logistics of
all of the tradesmen required on
site

8
CONTRACTING PROCESS

CASE STUDY: 4,100 PRECAST VILLAS


ORIGINAL DESIGN
 Conventional Concrete frame
 Masonry and Plaster infill
 Concrete Piers
 Slab on grade

ISSUES
 The foundation was not the
right choice
 The budget was set in 2006
 Shrinking construction market provided opportunity
to improve the outcome
 Approval delays provided time to improve the
outcome
9
MARKET DRIVEN STRUCTURAL DESIGN
• ALDAR accepted the recommendations to investigate alternative structural
systems

CASE STUDY: 4,100 PRECAST VILLAS


• Certain things were non-negotiable
 Longevity
 Must feel solid
 Must follow the architectural style
 Must fit the budget

10
CONTRACTOR SELECTION

• At least eight contractors priced

CASE STUDY: 4,100 PRECAST VILLAS


the villas
• Three contractors were selected
• All had the same price per square
meter
• All three brought different
solutions
 Precast Solution
 Original Design (Quickly
changed to Precast Solution)
 Cast in situ solution

11
EXECUTION

CASE STUDY: 4,100 PRECAST VILLAS


• Design a mat foundation
• Precast companies took on
design liability for the
structural
• Distributed precast production
– Five main firms – 10 plants
• The Magic is in the Shop
Drawing Coordination with
Mechanical/Electrical
Contractors

12
COMPARISON TO CAST IN SITU STRUCTURE

Precast: 4126 Villas – 24 months

CASE STUDY: 4,100 PRECAST VILLAS


Cast in situ: 730 Villas – 20 months
Cost: Same – By Contract
Precast: One fourth of the on site manpower
Precast: Cleaner operations on site
Precast: Exterior work off of lifts, not scaffolding
Precast: Ready to paint

13
CASE STUDY: 4,100 PRECAST VILLAS
14
CASE STUDY: 4,100 PRECAST VILLAS
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CASE STUDY: 4,100 PRECAST VILLAS
16
CASE STUDY: 4,100 PRECAST VILLAS
17
WHAT WOULD WE DO DIFFERENTLY?

• Design precast from the start

CASE STUDY: 4,100 PRECAST VILLAS


• Tweak the design to accommodate the panel layout
• Fully modularize the drivers units
• Replace some GRC components by casting them with the panels
• No cutting precast to make chases
• All precast components
• Joint sealants are better than grouted joints

18
WHAT SURPRISED PEOPLE?

• They really look GREAT!

CASE STUDY: 4,100 PRECAST VILLAS


• The precast panel joints look great
• The painted hollow core ceiling with exposed joints look great
• The precast industry rose to the need for Attractive Efficient Villas

19
CASE STUDY: 4,100 PRECAST VILLAS
20
JOINT DETAIL
CASE STUDY: 4,100 PRECAST VILLAS
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JOINT DETAIL
CASE STUDY: 4,100 PRECAST VILLAS
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CEILING JOINT
WHERE DO WE GO FROM HERE?

Full Modularization

CASE STUDY: 4,100 PRECAST VILLAS


23
CASE STUDY: 4,100 PRECAST VILLAS
24
DISCUSSION
CASE STUDY: 4,100 PRECAST VILLAS

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