Al Fayha Aluminium Factory Steel & Warehouse Design

al fayha aluminum factory - Moduline Engineering Consultancy

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-based 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.
al fayha structural steel design dubai - Moduline Engineering Consultancy

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.
steel structure connection design al fayha factory 1536x998 1 - Moduline Engineering Consultancy

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.
  • Selection of durable materials appropriate for logistics and storage environments.
moduline structural steel connection analysis - Moduline Engineering Consultancy
moduline steel connection detailing fabrication drawings - Moduline Engineering Consultancy
moduline steel connection design al fayha dubai - Moduline Engineering Consultancy
oduline steel column base plate connection detail - Moduline Engineering Consultancy

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.
moduline bim modeling architectural structural coordination - Moduline Engineering Consultancy
moduline clash free bim model analysis - Moduline Engineering Consultancy
moduline revit precise quantity extraction detailing - Moduline Engineering Consultancy

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 deliver practical foundation systems optimized for project requirements and site conditions.
  • 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.
moduline rcc pedestal tie beam structural detail - Moduline Engineering Consultancy
moduline rcc warehouse foundations design dubai - Moduline Engineering Consultancy
Reinforced foundation systems designed to ensure long-term structural stability under industrial operational loads

Guard Room Foundations & Service Block Foundations:

moduline service block reinforced concrete foundations - Moduline Engineering Consultancy
moduline guard room rcc foundation system - Moduline Engineering Consultancy
moduline guard room foundations structural detail - Moduline Engineering Consultancy
moduline service block foundations design - Moduline Engineering Consultancy

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.
BIM coordination and integrated workflow - Moduline Engineering Consultancy
Technical architectural elevation drawing - Moduline Engineering Consultancy
Technical steel frame construction diagram - 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

From Model To Reality

Project Outcomes :
Optimized steel sections to reduce material cost
Efficient structural system for large spans
Accurate detailing minimizing construction error
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 - Moduline Engineering Consultancy
Industrial construction site alfayha factory 1 - Moduline Engineering Consultancy
Project Details

Project Name :

Al Fayha Aluminium Factory & Storage

Project Title :

(G+M) Warehouse and Associated Works

Location :

Near Al Layan 1, Dubai, U.A.E.

Category :

Industrial Projects

Contact Us Now

Have a project in mind or need expert professional team advise you ?

Call At : +971 4 566 9593

Leave a Message  : info@moduline.ae

Share Project Via

Related Projects