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Masonry

Al Ghurair Construction - Masonry 1

2 Al Ghurair Construction - Masonry
Introduction
Al Ghurair Construction - Masonry (formerly known as Arabian Concrete Products) has been
manufacturing concrete blocks since 1976. Since that time our plant has undergone through
a constant process of modernisation to embrace the very latest technology the industry has
to offer. Fully computerized German machineries have allowed us to dramatically increase our
capacity and to produce innovative new products such as insulated styrol blocks, lightweight
blocks and interlocking paving stones. We are fully ISO certified in both quality management and
environmental management systems - with an additional OHSAS 18001 (Occupational Health &
Safety Assessment Series). All our incoming raw materials are strenuously tested to the highest
international standards and our finished products are tested rigorously before deliveries are made.

We invite you to explore our capabilities further

Sincerely

Al Ghurair Construction – Masonry

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Contents
Corporate Profile

Plant Equipment

Materials

Product Range

Pavers Required for Composite Paving

Special Products

Production & Quality Control

Personnel

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Corporate Profile
Al Ghurair Construction - Masonry was established as a manufacturer of concrete blocks in 1976,
and since then over 300 million concrete blocks have been successfully manufactured and delivered
to various construction projects in the UAE. In 1994, we commissioned the most modern German
plant which is fully computerized, and one of the most sophisticated of its kind in the world. With
this plant AGC Masonry’s production capacity was tripled to over 15,000,000 blocks per year, as well
as diversifying to new products such as insulated styrol blocks, light weight blocks, and inter locking
paving stones.

Certificate of Product Conformity

from Dubai Municipality
The first block factory (in UAE) to obtain the Certificate
of Product Conformity “Factory Assessment”
certification license from Dubai Municipality in
November 2011 by demonstrating its commitment
to quality, product excellence and dedication. Al
Ghurair Construction Masonry LLC have been
assessed in accordance with DCLD Document Ref.
No. RD-DP21-2001 (IC) “General Rules for Dubai
Municipality third party product certification through
factory assessment” and the system assessment
relevant Specific Rules, in conformity with the standard
specification DMS 1:PART 1:2011

Integrated Management System

Certification
AGC Masonry has always been best known for the
unique standard of its product quality, and service.
In July 1997 AGC Masonry has successfully obtained
ISO 9001 certificate of approval from TUV CERT
for its quality management system and in 2008 it has
obtained ISO 14001 & OHSAS 18001.

Set-up in Dubai Industrial City

Jebel Ali
To support construction works at Jebel Ali Airport
City and surrounding major developments, AGC
Masonry has set up a new manufacturing facility in
Dubai Industrial City at Jebel Ali which is 55km
away from Al Quoz at the Abu Dhabi border, also an
ideal location to serve Abu Dhabi market. Annual
production capacity of the new facility exceeds 8
million blocks, and pre-cast concrete lintels of various
sizes and lengths.

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Plant Equipment
Mixing plant - Al Quoz
Fully automatic computerized plant with a capacity of over
50 m3 per hour. The plant has two state of the art Teka
mixers; one 2250/1500 liters for back mix, and one 750/500
liters mixer for face mix which is used for interlocking
paving tiles to obtain the highest quality surface finish. All
ingredients are batched by weight for maximum accuracy,
with computerized devices for free water and chemical
measurements.

Cement Silos
2 Nos. : Capacity 100 tons each

Overhead Bucket Conveyor System

2 Nos. : 1.5 m3 and 0.5 m3 capacity, fixed to twin rail
system for transporting concrete from mixing plant to
block machine hoppers.

Block and Paving Tiles Machine - Al Quoz

Fully automatic Henke machine, weighing over 30 tons
and built on a rigid steel framework with both back mix
and face mix systems. Output in over 4 cycles/min. for
blocks and over 3 cycles/min. for paving tiles, using 1.4m x
1.00m steel pallets.

The machine utilized the latest and most sophisticated

vibration and production systems, fully controlled by an
automatic Siemens computer control system.

Pallet Transfer Carriage

Fully automatic, electronically controlled for transferring
empty pallets from the dry line to the block machine.

Pallets De-stacking System

A unique vacuum device for feeding pallets to the block
machine.

Pallet Weighing Devices

For efficient quality control.

Direct Washing Device

For exposed aggregate finish.

Automatic Stacker (Elevator)

18 tons capacity, stacks two full pallets up to fourteen
storeys at the end of the wet line.

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Transfer platform with Finger Car
18 tons capacity, fully automatic, equipped with laser
distance products from the stacker to the curing
chambers, and cured products from the curing chambers
to the de-stacker.

Curing System
Cold water mist curing system is used from Concure,
U.S.A (The first of its kind in the Middle East).

Curing Chambers
12Nos: With automatic roller shutter doors, capable of
holding 4704 pallets.

Automatic De-Stacker (Lowerator) - 18 tons capacity, de-

stacks pallets from the finger car to the dry line.

Slat Conveyor
Transports production cubes outside the plant.

Delivery Fleet
6 Trucks with trailers of 35-ton capacity, each having a 3.5
ton crane for convenient unloading on site, and 8 Nos: 18-
ton trucks with crane.

Front end Loader

2 Nos

Forklift Truck
3 Nos: 5-ton capacity each.

Catchers
7 Nos: Each of 5-ton capacity.

Block Making Machine - Jebel Ali

02 Nos SACME (ITALY). For Hollow and concrete
polystyrene sandwich masonry insulating blocks, with all
supporting equipment & facilities.

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Materials
Al Ghurair Construction - Masonry uses only the best
available material complying to BS specifications. Cement
used is supplied by National Cement Company (NCC/
Dubai), one of the best cement manufacturers in U.A.E
where all types of cements are produced strictly to
BS & ASTM specifications.Various natural and crushed
coarse/fine aggregates are used to suit the customer’s
requirements and product type. For all these materials,
regular in-house and independent laboratory tests are
carried out. For water, potable water from Dubai Electric
& Water Authority is used. For chemicals, different types
are used, from reputable manufacturers, such as BASF to
improve strength, cohesion, and reduce water absorption
of certain products.

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 Product Range
Normal & Light Weight (Lava Pumice) Concrete Blocks
(Hollow, Solid, Hourdi & Thermal Insulated Block)

DIMENSIONS (mm)
TYPE SIZE (inch)
LENGTH WIDTH HEIGHT
10 400 250 200
8 400 200 200
8 400 190 200
8 390 190 190
6 400 150 200
Hollow Block
6 400 140 200
6 390 140 190
4 400 100 200
4 390 100 190
4 390 90 190
8 400 200 200
8 390 190 190
6 400 150 200
Solid Block
6 390 140 190
4 400 100 200
4 390 100 190

8 400 200 200

Styrol Insulated
Blocks
10 400 250 200

6 420 - 380 150 200

8 420 - 380 200 200
8 400 - 360 200 200
10 420 - 380 250 200
Hourdi Blocks 10 400 - 360 250 200
12 420 - 380 300 200
12 400 - 360 300 200
13 370 - 350 340 200
14 420 - 380 350 200

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Product Range
Concrete Paving Blocks

TYPE OF PAVER WORK SIZE (mm)

Uni - Coloc 100

80
Uni - Shape
60

80
Uni - Starter
60

200 x 100 x 80
Rectangular
200 x 100 x 60

80
Behaton
60

80
Quadro (I) shape
60

80
Octagon
60

80
Rhombus
60

80
Cube
60

Heel Kurb Stone 600 x 150 x 75

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Pavers Required for Composite Paving
Paved Surface, approximate Nos./m2

Laying Patt. Ref

No.
Quadro (1) Octagon Cube Rhombus
A 51
B 25 12.5 12.5
C 25 25
D 17.5 17.5 17.5
E 59.5
F 50
G 34 20
H 25 12.5 12.5
I 21 8 8 17.5
J 42 42

A B C

D E F

G H I

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 Special Products
Lava Pumice Lightweight Concrete Blocks Specification
Information & Technical Data

The Material
VOLCANIC PUMICE was used initially by the Greeks and the Romans. Many of the ancient
magnificent Grecian and Roman structures are still to be seen. Since 1952, LAVA has been operating
a large Pumice quarry at Yali Island near Rhodes Island producing different grades of Pumice,
mainly for concrete and blocks production, and exporting to Europe, U.S.A., and recently to
U.A.E. Pumice is produced by volcanic action and its cellular structure is created by the formation
of air bubbles or voids, when the dissolved gases in the lava are released on cooling. LAVA Pumice
has been formed 200,000 years ago, after the explosion of the volcano at Nissiros Island. It is of
an extremely low density of-white colored clean rock, expanded in its molten state by entrained
gases, thrushing up from the volcanic core.The volcanic gases have effectively turned the lava, into
foam, and it is this multitude of enclosed air channels that give LAVA Pumice such a low density
(ranging from 600-800 Kg/m3).

The Blocks
When LAVA Pumice is used in concrete masonry units, it can be utilized in its “natural” state,
requiring only crushing and grading to size. Unlike manufactured and by-product aggregates, LAVA
Pumice does not require critical control processes that make room for errors and non-uniformity.
LAVA Pumice has been a chemically and physically stable material over the last 30 years. Having a
high degree of elasticity, excellent thermal insulation, light color and 99% clearance, LAVA Pumice
is a very popular aggregate for light-weight concrete blocks all over the world. The Light-weight
concrete blocks produced are generally 50-60% of the weight of normal concrete blocks, giving
structural designers a great opportunity to reduce concrete sections and/or steel reinforcement
etc. This is particularly desirable, and cost-effective in high-rise buildings.

Advantages of Lava Pumice Light-weight Block

s 7%)'(4SAVINGS: LAVA Pumice masonry units are substantially lighter in weight resulting to
savings on in-situ costs.
s ,/7%2(%!4LOSS: LAVA Pumice masonry units have a better thermal transmission coefficient
“U-Factor” than other types, attesting to the effectiveness of reduced thermal conductivity.
K 0.20 – 0.4 / W/M °C
U 0.40 – 2.20 W/M2 C
For a typical 8” Hollow block, concrete blocks made with Pumice reduce the U-value of the wall
by 34%, providing superior insulation properties to the building.

Sound Absorption
Usually the denser (heavier) a material is the better it functions as a “sound barrier.” Nevertheless
with Pumice, because of its unique internal structure similar results are obtainedto other normal
weight blocks made with limestone or other heavy aggregates. The S.T.C. (Sound Transmission
Coefficiant) for a plastered Pumice block wall has been measured at 54 db.

Better Fire Rating

Surpassing other types, LAVA Pumice masonry units fully meet the requirements established by
the official laboratories, carrying a four-hour fire rating for a 200mm wide hollow core unit.

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Strength Factor
LAVA Pumice masonry units have a high strength-to-weight ratio, 3.2N/mm2 is easily achieved for 8”
hollow block, BS 6073:198 specifies an average crushing strength _> 2.8 N/mm2 for non-load bearing
masonry block-walls.

Faster Nailing and Sawing

Extensive tests have revealed the LAVA Pumice masonry units readily accept and hold nails. Easy
grinding also saves labor.

Greater Resilience
The excellent resilient property of the aggregate makes LAVA Pumice masonry units more shock-
absorptive without breaking or chipping.

More Uniform in Color and Texture

A whitish color and distinctive texture are readily accomplished by controlled blending of the Pumice
aggregate at manufacturing facilities.

List of Available Lave Pumice Light-Weight Concrete Blocks & Hourdi Blocks

Approx. Weight & Density

Approx. Weight & Density of
of Pumice Light-Weight
Block Size Normal Concrete Blocks
Concrete Blocks
Kg. Kg./m3 Kg. Kg./m3
Hollow Blocks
1) 8” (400x200x200) 10.12 630-750 22 - 23 1400
2) 6” (400x150x200) 8.1 670-830 17 - 18 1450
3) 4” (400x100x200) 5.5 - 7 690-880 14 - 15 1800

Hourdi Blocks
1) 6” (420/380x150x200) 8 - 10 750 13.5 - 15.5 1200
2) 8” (420/380x200x200) 10.5 - 12.5 725 17.5 - 19.5 1150
3) 8” (400/360x200x200) 10 - 12 725 17 - 19 1175
4) 10” (420/380x250x200) 11.5 - 13.5 625 20.5 - 22.5 1075
5) 10” (400/360x250x200) 11 - 13 625 20 - 22 1100
6) 12” (420/380x300x200) 13 - 15 575 22.5 - 24.5 1000
7) 12” (400/360x300x200) 13 - 15 625 23.5 - 25.5 1025
8) 13” (370/350x340x200) 14 - 16 625 23.5 - 25.5 1000
9) 14” (420/380x350x200) 15 - 17 575 25 - 27 925
10) 14” (400/360x350x200) 14 - 16 575 24.5 - 26.5 950

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20 Al Ghurair Construction - Masonry
Production & Quality Control
Incoming Raw Material
Aggregates & Sand: All incoming aggregates are checked daily for grading, and on a half-yearly
basis a full range of tests are carried out at an independent laboratory to assess compliance to BS
specifications. For all other materials such as cement and admixtures, manufacturer’s certificates are
supplied regularly to ensure compliance with BS specifications. Finished Products: For all of Dubai
supplies, each delivery is certified by DCL (Dubai Central Laboratory) with its Conformity Mark
which serves as a third party product certification through factory assessment and compliance to
standard specification DMS 1: Part 1: 2011. Furthermore, Al Ghurair Construction Masonry LLC
carries out, in its own laboratory an in-house testing scheme on a daily basis, which ensures that
target strengths and quality are reached for all types of products. The quality system of Al Ghurair
Construction Masonry LLC for manufacture and supply of concrete blocks and interlocking paving
tiles has certified the requirements of ISO 9001 standards.

Personnel
(Over 98 qualified and dedicated staff members)

Our highly experienced and qualified personnel are always available at your service. Attached is a
calling card printed for your convenience, with the names and telephone numbers of all our key
personnel.Please do not hesitate to contact any member of the AGC Masonry team for any further
information or assistance.

Al Ghurair Construction - Masonry 21

 ‫ﻣﻨﺘﺠﺎت اﺳﻤﻨﺘﻴﺔ‬
Masonry

Al Ghurair Construction - Masonry LLC ‫م‬.‫م‬.‫ ﻣﻨﺘﺠﺎت إﺳﻤﻨﺘﻴﺔ ذ‬- ‫ﺷﺮﻛﺔ اﻟﻐﺮﻳﺮ ﻟﻺﻧﺸﺎءات‬
P.O. Box 158, Dubai, UAE ‫م‬.‫ع‬.‫ إ‬،‫ دﺑﻲ‬،!" ‫ب‬.‫ص‬
T +971 4 3502100 / 00971 4 3382886 +%& ' (!)*)) /+%& ' (("*"", :‫ﻫﺎﺗﻒ‬
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masonry@al-ghurair.com masonry@al-ghurair.com
www.al-ghurair.com www.al-ghurair.com