Mabani Steel started its commercial operations in April 2006. Since the Mabani has grown into a significant player in the industry surpassing all others in terms of product quality and service. Mabani steel factory has been built to produce:
-Pre-Engineered Steel Buildings comprising of Built-up members, Secondary Cold formed (C & Z) members and Panels & Panel Accessories.
- Hot Rolled Steel Buildings & Structures comprising of hot rolled members
Mabani Steel's campus occupies a 124,000 sqm site. Our built -to - purpose facilities are the best in the PEB industry,even from the international perspective. No other PEB campus anywhere in the world matches our facilities in terms of functionality, efficiency and simple elegance.
A Pre-Engineered Steel Buildings is composed of two distinct subsystems:
The Pre-Engineered Steel Building Structure
The Panels & Panel Accessories
The Pre-Engineered Steel Building Steel Structures (PEBSS)
The PEB Steel Structure of a Pre-Engineered Steel Building generally accounts for over 80% of the weight of the Pre-Engineered Steel Building. This 80% is an average and may change plus or minus 10% depending on the presence of mezzanines, crane runway beams, type of Panels used and the amount of building accessories that are included in a building. The unit of measure for PEB Steel Structures is metric ton (MT). As a general average, one square meter (1 m²) of PEB Steel Structure weighs 25 kg. Thus one MT of PEB Steel Structure = 40 (1000/25) m² of building foot print. The PEB Steel Structure is made up of frames, secondary members and steel standard buyouts.
Frames in the PEB industry often refer to primary built-up & hot rolled members. Constant depth or tapered depth built-up members generally account for over 90% of the weight of frames while hot rolled members generally account for the remaining 10%
Secondary Members in the PEB industry refer mostly to longitudinal roof and wall members that are roll formed from galvanized coils or press broken from narrow galvanized sheets. The raw material of these members is stocked in five thickness: 1.5, 1.75, 2.2, 2.25 and 2.5mm.
The following building components are considered secondary members.
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Z” sections acting as longitudinal roof purlins and longitudinal wall girts that connect to columns & rafters and support exterior roof and wall panels.
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Eave struts located at the building eaves (corner of roof and wall sheeting along sidewalls also providing bracing for frames and supporting roof and wall panels.
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"C” sections used primarily in framed openings and as a transition member between partial block walls and wall panels.
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Mezzanine Deck (0.7mm thick) used to support concrete slabs in second level flooring.
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Base angles, gable angles, and mezzanineedge angles.
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Valley gutters (0.9mm thick) in Multi Gable Buildings.
Steel Standard Buyouts (SBO): These are items that are required in almost every PEB Steel Structure. They are manufactured by others and stocked by the PEB manufacturer. They include Anchor Bolts, Connection Bolts, Sag Rods and Cable Bracing Components.
The unit of measure of hot rolled structures (structural steel) is the metric ton (MT). Hot Rolled Steel Structures applications include Multi Storey low rise buildings, equipment supporting structures, pipe racks, Petro Chemical Plants, Power Plants, conveyor supporting structures, cement plants, etc.
The majority of hot rolled steel buildings and structures are designed by Consultants and tendered for fabrication, blasting, painting and delivery to the jobsite. The fabricator is responsible for the design of connections and the preparation of shop drawings, erection drawings and Bills of Materials (BOM’s). Occasionally erection is included in the scope of the supplier.
As a general practice, Mabani Steel prefers to undertake the structural design of hot rolled steel structures to ensure that the design is both economical and compliant with latest applicable U.S.A. codes and welcomes the inclusion of design in its scope.
Panels & Panel Accessories include single skin panels, sandwich panels, trims and flashing, panels standard buyouts and building accessories. Although all roofs have panels, walls are often partially or fully open for blockwall, precast panels or access.
Single Skin Panels are trapezoidal ribbed sheets roll formed from thin mill finish or prepainted aluzinc coated steel and aluminum coils and cut-to-length to meet the requirements of a specific building.
Sandwich Panels havea polyurethane foam core sandwiched between two single skin metal panels (or an exterior single skin metal panel and an interior aluminum faced laminate). Mabani Steel does not produce sandwich panels but has an exclusive arrangement, with the largest producer of sandwich panels in the UAE, for the purchase and resale of sandwich panels, to provide its Customers with a single source supply responsibility. The engineering drawings for the sandwich panels are done by Mabani Steel so are the production of trims and the supply of all sandwich panels accessories such as fasteners, bead mastic, purlin tape, etc.
Trims and Flashing include eave trim, eave gutters, downspouts, gable trim, curved eave panels, flashing around building accessories, etc. which are produced from prepainted aluzinc coated steel or aluminum sheets that are bent to the required shape using roll formers, presses, or folding machines. They weather seal the building and contribute to the neat finish appearance of a PEB.
Building Accessories and special buyouts (SBO’s)include sliding doors, rollup doors, personnel doors, fiberglass insulation, sandtrap louvers, windows, ridges ventilators. Some are produced in-house. Some are purchased from suppliers and included in our single source supply.
Panel Standard Buyouts are items that are produced by others and stocked as finished items by the PEB manufacturer. They include sheeting fasteners (carbon steel and stainless steel), bead mastic, pop rivets, foam closures, skylights, etc. These are packed by us for a specific building and shipped to the jobsite with the panels.
Insulation is typically fiberglass blanket of stable and uniformly textured inorganic glass fiber bonded together by a non-water soluble and fire retardant thermosetting resin.
Standard insulation thickness is 50 mm; higher thicknesses (75 mm and 100 mm) are available upon request.
Standard insulation facing is White Metalized Scrim Kraft (WMSK).
The standard nominal insulation density shall be 12 kg/m3 with a thermal conductivity of 0.041 w/mk at mean temperature of 25 0C. Higher densities (16 kg/m3 and 24 kg/ m3) are available upon request.
Personnel Doors
Door leaves are 44mm thick flush-finished. Single leaf doors are 915 mm wide x 2135 mm high. Double leaf doors are 1830 mm wide x 2135 mm high.
Steel Sliding Doors
The frames of horizontal steel sliding doors are manufactured from 1.5 or 2.0 mm (nominal) thick x 200 mm deep cold formed channels and are delivered knocked down packages for field assembly are provided.
Steel Roll-Up Doors
The roll-up door curtain is cold formed from variable thickness white polyester painted galvanized steel. The bottom rail of the door curtain is an extruded aluminum angle guide.
Standard Roll-Up Door Sizes are 3000 x 3000, 4000 x 4000, 5000 x 5000 and 6000 x 6000. In between sizes can be accommodated.
Windows
Window frames are made of powder coated aluminum extrusions in Frost White color only. They are horizontal half slide type (fixed type is optional), 1000 mm high and 1000 mm wide (other sizes are optional). Windows are factory glazed with 6mm thick clear glass and are equipped with latches and removable insect screens.
Sand Trap Louvers
Standard sand trap louvers are 1000 mm wide x 1000 mm high (other sizes are optional). They are supplied with vanes and framing. They are made from 0.7 mm (nominal) polyester painted Aluzinc Coated Steel sheet in any Mabani Steel Standard Colors.
Gravity Ventilators
Gravity ridge ventilators are 3000 mm long with a throat opening of 300 mm or 600 mm. 300 mm (throat opening) ventilators are equipped with dampers and are available in fresh White color only. 600 mm (throat opening) ventilators are supplied without dampers and are available in any standard Mabani Steel Color. Ventilators are installed as either individual units or as continuous (joined) units. The outer skin of both types of ventilators is made from 0.7 mm thick polyester painted Aluzinc Coated Steel. Both sizes are supplied with bird screens and shipped knocked down.
Fiber Glass Roof Curbs
Roof curbs are made of 3 mm thick fiberglass reinforced polyester and coated with a weathering surface on the outside face.
Sidewall roof extensions beyond the building width at sidewall eaves and are generally a simple continuation of the main building roof slope.
Endwall roof extensions extend beyond the building length at endwall gable and are developed by extending the end bay purlins and eave struts of the main building beyond the endwall rafter.
Standard widths for roof extensions are possible but may require heavier framing or additional structural members.
Canopies
Sidewall canopies are cantilevered rafters attached to sidewall columns at any point below the eave. Endwall canopies are cantilevered rafters attached to the endwall wind columns below the gable.
Canopy widths range from 1500 mm to 3000 mm. Wider canopies are possible but may require reinforcement of sidewall or endwall columns.
Fascias and Parapets
Vertical fascias consist of 200mm deep hot rolled or built-up I-section vertical posts supported by brackets attached to sidewall or endwall columns. Cold-formed 200 mm deep “C” section top and bottom channel girts are flush-framed to the vertical fascia posts. An intermediate “Z” girt is supplied to support a modified valley gutter, when required.
Mezzanine Systems
Mezzanines typically require mezzanine support columns, beams, joists, deck and edge angles. Mezzanine columns are usually placed along the existing main building frame lines. They support the mezzanine beams which in turn support the mezzanine joists. Mezzanine joists are normally oriental parallel to the sidewall. Joist spacing varies from 1000 mm and 3000 mm depending on the mezzanine, deck profile and applied loads.
The mezzanine columns, beams and joists are designed to withstand the mezzanine live load, the weight of a 100 mm thick reinforced concrete slab, and the weight of the deck. Additional dead loads, collateral loads and floor finish loads, if present, must be advised to Mabani Steel by the client to be considered in the mezzanine design.
Mabani Steel recommends that the erection of its building is executed by Mabani Steel Certified Builder or by a Specialized PEB Contractor (irrespective of its affiliation).
