First in precast in Egypt! Modern Company for Concrete Products

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First in precast in Egypt! Modern Company for Concrete Products

Modern Company for Concrete Products offers solutions for growing demands of the Egyptian market by making the smartest match in changing business environment.

In 2011, Modern Company for Concrete Products started production at Egypt’s first complete precast factory in Al Sadat City in Central Egypt. The new factory was delivered by Elematic of Finland, and it is located halfway along the highway between Cairo and Alexandria. The new precast factory is able to produce 1 300 m2 of hollow-core slabs daily. It also manufactures façades, wall elements, and staircases as well as complete precast buildings. Elematic delivered to the new plant a hollow-core slab production line consisting of six casting beds, each 150 meters long. The delivery included an Extruder E9 with nozzle modules for production of 160 mm, 200 mm, 400 mm, and 500 mm thick hollow-core slabs and exchange parts to produce 265 and 320 mm thick hollow-core slabs. In addition, four hydraulic tilting table molds, a TT-slab mold, and Comcaster casting machine have already been put in place. The plant is managed by ELiPLAN. “An extension for a battery mold has already been completed and we are expecting to increase the capacity for hollow-core and tilting tables as soon as our business expands,” says CEO Sabbagh Sharabati. Modern Company for Concrete Products, a part of Sabbagh Sharabati Group, serves a wide range of customers: private companies, real estate developers, and various Egyptian governmental projects. “Naturally, we use our products for our own projects, too,” Sharabati concludes. “Our plant is able to deliver industrial and office buildings, housing, schools, hospitals, parking facilities, commercial buildings as well as pre-stressed girders for bridges, and all sorts of miscellaneous precast products,” Sharabati explains. Precast guarantees the best conditions for production Shabbagh Sharabati Group has been, and continues to do business which seems an unlikely way to end up as one of Egypt’s first precasters. After having created during the past forty years one of the leading textile companies in the Middle East and North Africa, Sharabati had to find a way of building high-standard facilities for their textile weaving, spinning, and dyeing business. They needed facilities that would meet the requirements imposed by indoor and outdoor conditions. A natural choice for building technology was precast and the first precast development projects were started in Sharabati’s home market, Syria, already in 1998. “We had high maintenance costs for our steel shed factories because of variation in day and night temperatures in our region. In addition, the steel structures were affected by high humidity during the dyeing process of the textiles,” Sharabati explains. “Furthermore, textile production processes require stable conditions in terms of temperature and humidity. Conditions which precast concrete technology can fulfill. This is very important for maintaining our production standards. In addition, sandwich wall structures offer energy savings by keeping the heat out in hotter climates, which again mean lower maintenance costs for the buildings,” continues Sharabati. Sharabati Group employs currently over 3 500 people. Providing accommodation for the workforce in areas where there is not enough affordable housing available was another challenge for Sharabati and his partners. Precast building also offered a solution to this need. Egypt a natural choice for the expanding textile industry For a textile industrialist in the Middle East specialized in producing material for the most famous brands in jeans clothing, Egypt is a natural choice of location. “The most important raw material in this industry is cotton. The cotton we use is produced locally in Egypt,” says Sharabati. As Sharabati Group had already gained experience as a precaster in Syria for more than a decade, the next step to expand their Egyptian operations into the construction sector was not a difficult one to take. When Sharabati was building production facilities in the Egyptian textile market, precast was the natural and already familiar choice as building technology for the new plant in Al Sadat City. In Egypt, there was also an urgent need to build fast affordable housing for the workforce working in the Sharabati factories. “We strongly believe in the advantages of precast concrete construction because of the high quality, lower maintenance costs, and durability,” Sharabati explains. Strong partner for long-term cooperation Elematic has worked closely together with Modern Company throughout the project, offering consultation and advice regarding all aspects of building a completely new facility and organization in a new market area. “When you are choosing a supplier for a new precast plant, it is essential to choose a strong, experienced firm with a specialized organization for continuous cooperation. After we got up to full speed with negotiations with Elematic, and our technical and consultant engineers supported us in omparing different suppliers, the contract was prepared within six months for the Egyptian plant,” explains Sharabati. “We got excellent feedback from Elematic regarding the business environment. They supported our specialized engineers and consultants in confirming that we have to lead the Egyptian construction industry in offering precast solutions for the Egyptian market,” says Sharabati. Sharabati and his engineers visited some precast plants Elematic had delivered to other customers. They also viewed finalized precast buildings for reference and were introduced to Elematic’s organization in Finland. “All this convinced us that Elematic should be our choice of supplier for Sharabati Group’s first precast plant in Egypt,” explains Sharabati. Adapting to the changing business environment During the planning and construction phases of the project, many things changed in the business environment in Egypt. Now there is an increasing demand for low-cost and rapidly finished housing for the Egyptian growing middle-class. The changing world did not go unnoticed at Modern Company. The business plans regarding the new precast production line were updated to correspond with the new market outlook. “We are expecting that the new Democratic Egypt will do its best to solve the housing problem in this country. Our goal is to be an important contributor in this development as the country continues to develop and its economy strengthens,” predicts Sharabati. “Our new factory focuses on precast concrete construction technology and it offers technical support for all consultant offices in Egypt to further the country’s urban renaissance.” Having plans in place for a precast plant, Sharabati’s team and Elematic made the necessary modifications to the business plan that became necessary in the aftermath of changes in Egypt’s political environment. It was essential to ensure that the new factory was able to benefit from the growing building boom in Egypt. The new plant is located on a large property that leaves room for future development. Partnership that lasts a lifetime Elematic’s area sales director Raimo Juhantalo says that the precast plant Elematic has delivered in Al Sadat City is the first of its kind in Egypt. During the past years, Egyptian society has gone through changes that have had a boosting effect on the construction industry as the new leaders tackle the nation’s problems. “In this part of the world, there is an increasing demand for low-cost housing. Precast technology can offer a good solution for this. At Elematic, we help our customers adapt to the changing environment and new business opportunities throughout a project. Modern Company’s project is an excellent example of this,” Juhantalo explains. He points out that Elematic is able to take the changing requirements of the market environment into consideration already in the pitching phase of the sales process. A precast plant is a long-term investment so there has to be room for flexibility, even in the unknown future. “We want to offer our customers all our industry experience, professional networks, and the most versatile service offering in the industry,” says Juhantalo. These include services that enable customers to renew and maintain their skills, tools, and know-how during the production line’s lifetime. Best matches through proactive evaluations of customers’ needs In order to make the best match of existing and standardized building blocks, Elematic works closely together with its customers. Produced in one location in a fully synchronized process, product specifications can be changed and new products produced quickly. This enables the precaster to maintain high performance levels and to optimize production rates. This also makes it possible to react faster to new orders. In order to achieve the smartest matches of precast technology, production automation, and services, it is crucial to monitor business conditions and consult customers’ needs proactively. “Elematic is the one-stop-supplier in the industry. We are able to match any need in precast concrete building construction with an upgradable production concept,” Juhantalo concludes. Elematic has delivered the following products to Modern Company for Concrete Products (Egypt): • Batching and mixing plant equipment • Concrete distribution system • Hollow-core slab production line • Casting beds 6 pcs, each 150 m long • Extruder E9 with nozzle modules for production of 160 mm, 200 mm, 400 mm and 500 mm thick hollow-core slabs + exchange parts to produce 265 and 320 mm thick hollow-core slabs • Slab saw EL1300 • BedMaster EL400 • + other additionally needed equipment • Hydraulic tilting table molds 4 pcs, 4.5  x 12.5 m • TT-slab mold 3.0 x120 m • Comcaster casting machine • ELiPLAN Still under construction: • Extension of battery mold with 6 slots, 3.1  x 8.1 m

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