AL FAYHA ALUMINIUM FACTORY

PROJECT OVERVIEW

This project involves delivering comprehensive architectural and structural engineering consultancy services for the development of a state-of-the-art Ground + Mezzanine (G+M) warehouse and industrial storage facility for Al Fayha Aluminum Factory (L.L.C). Strategically located near Al Layan 1, Dubai, U.A.E., the development aims to provide highly efficient, durable, and well-planned industrial spaces that perfectly respond to current market demands and logistical needs.

The expert engineering team at Moduline focused on integrating functional layouts with robust structural systems, ensuring maximum long-term operational efficiency, durability, and cost-effectiveness.

PROJECT HIGHLIGHTS

Flexible layouts adaptable to divers storage and industrial uses

Authority-compliant design aligned with Dubai Municipality standards.

BIM-coordinated multidisciplinary engineering approach.

PROJECT OBJECTIVES

Deliver functional and cost-efficient warehouse facilities.
Ensure structural safety, durability, and compliance with local regulations.
Provide flexible warehouse spaces suitable for various industrial and storage uses.
Support efficient circulation, loading/unloading operations, and service access.
Achieve timely authority approvals through coordinated and well-documented design.

SCOPE OF WORK

Architectural, structural, and MEP design for warehouse buildings.
Site planning and layout optimization for industrial operations.
Design of associated external works, including parking areas, loading zones, and access roads
Coordination with all concerned authorities for approvals and NOCs.
Structural design utilizing steel, RCC, and composite systems as required
BIM / Revit-b.ased workflows for coordinated and accurate project documentation.
Compliance with industrial safety standards, fire protection, and civil defense requirements.

KEY DESIGN CONSIDERATIONS

Optimized structural systems suitable for large spans and industrial loading.
Integrated solutions for ventilation, fire protection, and utility services.
Selection of durable materials appropriate for logistics and storage environments.
Efficient site circulation planning for trucks and service vehicles
Use of BIM and Revit workflows to enhance coordination accuracy and minimize design conflicts.

AL FAYHA - DESIGN VISION

Scope of Services:

Comprehensive structural engineering study for the entire building.
Detailed analysis and calculation of gravity, live, wind, and seismic loads.
Design and integration of a steel bridge structural system within the building configuration.
Design and verification of steel connections , ensuring structural safety and constructability.
Advanced structural modeling to evaluate global behavior and load transfer mechanisms.
Compliance with applicable international structural design standards.

Design Development Process:

1 Concept Stage: Initial understanding of project requirements and functional needs of the factory.
2 Structural Strategy: Evaluation of different structural systems, leading to the selection of a steel frame system for efficiency and span capability.
3 Detailing & BIM Modeling: Creation of detailed 3D model and connection design to ensure accurate fabrication and smooth construction.
4 Substructure Design: Development of the foundation system considering soil properties, load distribution, and structural requirements to ensure safe and efficient load transfer.
5 Analysis & Modeling: Development of analytical model using structural software to assess loads, stability, and performance.
6 Interdisciplinary coordination.
7 Clash Detection & Resolution: Using BIM models to detect conflicts between different elements and resolve them before the construction phase.
8 Shop Drawings & Execution Documentation: Development of coordinated construction and fabrication drawings to ensure accurate execution, clear communication, and smooth workflow on site.

STRUCTURAL STRATEGY

Design Standards & Engineering Approach:

We deliver designs fully compliant with international standards and local authority requirements.
Our engineering approach ensures safety, durability, and smooth approval processes.
We provide optimized structural solutions that balance performance and cost efficiency.

Structural System Optimization:

We develop efficient steel structural systems tailored for large-span industrial facilities.
Our solutions maximize usable space while ensuring stability against wind and lateral loads.
We focus on achieving economical and practical structural designs without compromising safety.

Structural Analysis & Section Optimization:

We perform advanced structural analysis to achieve safe and economical designs.
Our team optimizes steel sections to reduce material consumption while maintaining full code compliance.
We ensure all structural elements satisfy strength, stability, and serviceability requirements.

CONNECTION DESIGN EXCELLENCE

We provide accurate and reliable steel connection designs for complex structural conditions.
Our connection solutions ensure efficient force transfer, structural integrity, and ease of execution.
We deliver safe, practical, and cost-effective detailing ready for fabrication and construction.

Steel column and base plate connection design for industrial warehouse by Moduline

Structural steel connection design for complex conditions in Al Fayha project by Moduline Engineering Consultancy

Accurate steel connection detailing and fabrication drawings ready for construction by Moduline

3D steel connection analysis ensuring efficient force transfer and structural integrity by Moduline

ANALYSIS & MODELING

BIM Modeling & Coordination:

We develop fully integrated BIM models with high detailing accuracy.
Our workflow ensures seamless coordination between architectural and structural disciplines.
We provide precise quantity extraction, clash-free models, and smooth project coordination.

Detailed Revit BIM model for precise quantity extraction and smooth project coordination by Moduline

Fully integrated BIM model for seamless architectural and structural coordination by Moduline Engineering Consultancy

High-accuracy clash-free BIM model for Al Fayha project engineering analysis by Moduline

SUBSTRUCTURE STAGE

RCC Substructure Design

After completing the design of the steel structure:

we proceeded to the design of the reinforced concrete (RCC) elements, which include:

- Pedestals
- Tie beams
- Foundations

We design reinforced concrete foundations and substructure elements fully integrated with steel structures.
Our solutions ensure safe load transfer, structural stability, and efficient reinforcement detailing.
We deliver practical foundation systems optimized for project requirements and site conditions.

RCC pedestal and tie beam structural detailing integrated with steel structure systems by Moduline

Reinforced concrete warehouse foundations design for Al Fayha industrial project by Moduline Engineering Consultancy

Reinforced foundation systems designed to ensure long-term structural stability under industrial operational loads.

GUARD ROOM FOUNDATIONS & SERVICE BLOCK FOUNDATIONS:

Detailed RCC foundation system design for the service block at Al Fayha project by Moduline

Reinforced concrete foundation layout for industrial service block ensuring long-term structural stability by Moduline

Structural foundation design and concrete detailing for the guard room block by Moduline

RCC foundation system for the guard room unit at Al Fayha industrial facility by Moduline

BIM COORDINATION & INTEGRATED WORKFLOW

We apply BIM-based coordination to ensure accurate integration between all project disciplines.
Our workflow enhances design accuracy, minimizes clashes, and improves project efficiency.
We provide coordinated and detailed models that support smooth execution and project management.
Effective integration between architectural and structural design to ensure compatibility between the architectural form and structural requirements without conflicts.

Technical architectural elevation drawing for Al Fayha Factory | Moduline Engineering Consultancy

Technical steel frame construction diagram for Al Fayha Factory | Moduline Engineering Consultancy

BIM coordination and integrated workflow for Al Fayha Factory | Moduline Engineering Consultancy

SHOP DRAWINGS & EXECUTION DOCUMENTATION

We produce detailed and coordinated shop drawings ready for direct site execution.
Our documentation minimizes construction errors and improves execution efficiency.
We provide clear and accurate detailing for both steel and reinforced concrete elements.

Engineering design sheets and details for al fayha aluminium factory | Moduline engineering consultancy

Engineering CAD blueprint layout for al fayha aluminium factory | Moduline engineering consultancy

FROM MODEL TO REALITY

Project Outcomes:

Optimized steel sections to reduce material cost.
Efficient structural system for large spans .
Accurate detailing minimizing construction erro.
30%Reduction in coordination conflicts
15%Steel optimization efficiency
100%Authority-compliant workflow

Project Value:

This project demonstrates the consultancy’s capability to deliver advanced structural engineering solutions for architecturally ambitious developments, where nonlinear behavior, seismic performance, and constructability are critical to project success.

Construction site from above in progress - alfayha factory | Moduline consultancy

Industrial construction site for alfayha factory | Moduline consultancy

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Project Information

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