HARD BLOCK FACTORY L.L.

C
A Member Of Al Shafar – ASGC Holdings LLC

Table of contents
Company Profile 3

 ISO 9001:2008 …………………………........................................... 5

Chapter 1  HBF Awards ……………………………………………………... 8

 Full Licenses and Certificate ………………..……. …………….. 10

 Organization Chart ………………………………………………. 15

16
Range Of Products & Technical Information
 Masonry Blocks …………………………………………………… 17

 Paving Blocks ……………………………………………………… 18

 Roof Tiles & Paving Color ………………………………………. 19

 HBF Mix Design ………………………………………………….. 20

Chapter 2
 Technical Data Sheet For Masonry Blocks ……………………… 21

 Technical Data Sheet For Interlocks & Roof-Tiles …..…………. 22

 Technical Data Sheet For 8” Thermal …………………………… 23

 Technical Data Sheet For 10” Thermal………………..…. ……... 24

 Sound Transmission & U-Value …………………………………. 25

 ESTIDAMA Requirements & Approval…………………………. 26

28
Fire Resistance & Civil Defence
 Fire Rating for (Hollow,Solid)…………………………………... 29
Chapter 3  Fire Rating for (thermal)………………………………………… 30

 Certificates………………………………………………….... 31

 Civil Defence Comprehensive Sefty Programme….…………… 38

41
Dubai Municipality Certificates
 Implementation of factory assessment certification……………. 42

 Paving Blocks……………………………………………………... 46
Chapter 4
 Hourdi Blocks ……………………………………………………. 48

 Masonry Blocks…………………………………………………... 50

 Sandwich Blocks………………………………………………….. 52

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 HARD BLOCK FACTORY L.L.C
A Member Of Al Shafar – ASGC Holdings LLC

Quality Systems 58

 Quality Policy ………………….………………………………... 59

Chapter 5  Method Statement ……………………………………………… 60

 Quality Control System …………………………………………. 62

 Interlocks Method Statement ………………….…………. ……. 63

Runing Projects 64

 City Walk – Jumeirah……………………………………………. 65

Chapter 6
 682 Villa Complex & Townhouses………………………………. 74

 Nestlé Manufacturing Facility…………………………………... 75

Landmark Projects 76

Chapter 7  JBR (Jumeirah beach residence tower)………………………... 77

 Al Mas Tower ……………………………………………………. 78

Chapter 8 Consultants Approvals 89

Raw Materials Technical Data Sheets 114

Chapter 9  Cement Certificates…………………………………………… 115

 Aggregates & Sand Certificates……………………………… 117

Hard Block Factory L.L.C

P.O BOX 37642, Jebel Ali Industrial Area,3 Dubai U.A.E
Phone: +971 4 880 1555
FAX: +971 4 880 1400
Email: [email protected] Web: www.hardblock.com

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A Member Of Al Shafar – ASGC Holdings LLC

Chapter 1
Company Profile

 Company Profile

 ISO 9001:2008

 HBF Awards

 Licenses

 Full Certificate

 MOPW Certificate

 Organization chart

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 HARD BLOCK FACTORY L.L.C
A Member Of Al Shafar – ASGC Holdings LLC

Company Profile

“Hard Block Factory LLC” is an elite manufacturing conglomerate established in

UAE to meet the increasing demand for quality products in the booming construction
market.

“Hard Block Factory LLC” (HBF) is a leading manufacturer of all kinds of Masonry &
Hourdi blocks, Paving blocks and Sholin blocks for the construction industry in the region. HBF
has utilized the most advanced machinery in the world and accompanied with the latest up-to
date fully computerized technology to manufacture the best quality products for its clients. HBF
management commitment is to maintain solid and long-term business relationship, not only
with our clients but also with suppliers and consultants. HBF management put quality and
customer satisfaction its first priority. Therefore, the company has invested in the most
advanced in-house testing and quality control facility and quality assurance as well as from
receiving raw material till delivering the final products.

Hard block Factory has a management system certified to ISO 9001-2008. In 2012, the
company received a certificate of appreciation from Dubai Municipality for its continuous
efforts to improve the quality of construction in the Emirate of Dubai. HBF recently represented
United Arab Emirates for the International Award for Technology and Quality. Another
achievement was added to the company’s success story by winning the New Millennium Award
2005 in Geneva, Switzerland.

The company’s products are approved by Dubai Municipality, Public Work

Department, Nakheel Development, Emaar Properties, and many other clients and
international consultants in the region. HBF has supplied its products to many projects in Dubai
specifically and UAE in general. You are kindly requested to log on our website at
www.hardblock.com.

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A Member Of Al Shafar – ASGC Holdings LLC

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A Member Of Al Shafar – ASGC Holdings LLC

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A Member Of Al Shafar – ASGC Holdings LLC

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A Member Of Al Shafar – ASGC Holdings LLC

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A Member Of Al Shafar – ASGC Holdings LLC

INTERNATIONAL AWARD
FOR TECHNOLOGY AND QUALITY

“HARD BLOCK FACTORY LLC” / ‫ هارد بلوك فاكتوري‬/, a member of AL SHAFAR GROUP;

and sister company to Hard Precast Building Systems is one of the largest and most advanced
(fully computerized plants) producers of the masonry and paving blocks in Dubai, has been
recently chosen to represent the United Arab Emirates, and given THE INTERNATIONAL AWARD
FOR TECHNOLOGY & QUALITY in Geneva- Switzerland

International Award for Technology and Quality is an old and strong international prize created
in Switzerland in 1978 to honor companies that pay special attention to giving priority to
constant improvement in technological quality and development in their respective production
processes, a priority that translates into excellence in their products and services.
And, in spite of our very short business age (3 years only), “HARD BLOCK FACTORY LLC” could
prove its strong name and excellence reputation, and get everybody’s trust in the market.

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A Member Of Al Shafar – ASGC Holdings LLC

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A Member Of Al Shafar – ASGC Holdings LLC

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A Member Of Al Shafar – ASGC Holdings LLC

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A Member Of Al Shafar – ASGC Holdings LLC

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A Member Of Al Shafar – ASGC Holdings LLC

Organization Chart

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A Member Of Al Shafar – ASGC Holdings LLC

Chapter 2
Range Of Products & Technical Information

 Masonry Blocks
 Paving Blocks ( INTERLOCKS )
 Roof Tiles
 Mix Design
 Technical Data Sheet
 Sound Transmission – STC
 U-Value for different masonry products
 LEED/Estidama Weighted Mix Design Index
 Recycled & Regional Material Content

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A Member Of Al Shafar – ASGC Holdings LLC

Masonry Dimensions Weight Blocks Strength

Picture
Products (mm) (Kg) per m2 (N/mm2(

8” Hollow 400 x 200 x 200 22.5 12.5 7.5

8” Hollow
400 x 200 x 200 26 12.5 12.5
(Load Bearing)

6” Hollow 400 x 150 x 200 19 12.5 7.5

4” Hollow 400 x 100 x 200 14 12.5 7.5

10” Solid 400 x 250 x 200 45 12.5 7.5

10” Solid
400 x 250 x 200 45 12.5 12.5
(Load Bearing)

8” Solid
400 x 200 x 200 38 12.5 12.5
(Load Bearing)

6” Solid 400 x 150 x 200 27 12.5 7.5

4” Solid 400 x 100 x 200 17 12.5 7.5

420/380 x 200 x Density:

8” Hourdi 200
19 12.5
1200 Kg/m3

420/380 x 250 x Density:

10” Hourdi 200
22 12.5
1100 Kg/m3

420/380 x 300 x Density:

12” Hourdi 200
25 12.5
1000 Kg/m3

8’ Thermal 400 x 200 x 200 24 12.5 7.5

10’ Thermal 400 x 250 x 200 32 12.5 7.5

N.B. For special Products/orders with higher specs/ strength, a separate quotation/ prices will be applied.

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A Member Of Al Shafar – ASGC Holdings LLC

Paving
No. Dimensions Strength Layout
Products

Thickness
1 UNI - SHAPE 50
60, 80 mm

Thickness
2 Uni-Star (Half Uni) _
60, 80 mm

Thickness
3 Uni-Starter _
60, 80 mm

200x100x 60
4 Rectangular 50
200x100x 80

100x100x 60
5 Rectangular Half _
100x100x 80

La Plaza Bishop Hat Thickness

6 _
(Rectangular – Starter) 60, 80 mm

200x200x 60
7 La Plaza – Square 50
200x200x 80

Quadro System - Thickness

8 50
Octagonal 60, 80 mm

Quadro System – Thickness

9 50
I-Shape 60, 80 mm

80x80x 60
10 Quadro System – Cube _
80x80x 80

11 HEEL KERB STONE 600x75x 150 _

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A Member Of Al Shafar – ASGC Holdings LLC

No. Roof Tiles Dimensions Strength Layout

1 Roof Tiles - 40 400x400x40 5

2 Roof Tiles - 50 400x400x50 5

Roof Tiles – 40
3 400x400x40 5
(without Face Mix)

Roof Tiles – 50
4 400x400x50 5
(without Face Mix)

HBF Range of
Paving Blocks & Roof Tiles’ Colors

Grey Red Black

Dark Brown Yellow Green

Beige Orange

NOTE

1. Above colors do not express the real colors, for the real colors please refer to our samples.
2. We are only interested in the production of: Gray, Black, Red, Brown, Yellow, Orange and Beige.

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 HARD BLOCK FACTORY L.L.C
A Member Of Al Shafar – ASGC Holdings LLC

Mix Design

Here by you can find a table of our mix designs, for approx. 1 m3 of concrete:

3/8 3/16 Dune Water

No Product Name Cement
Aggregate Aggregate Sand (Liter)

1 12”, 10”, 8” Hollow 900 900 200 230 160

2 6”, 4” Hollow 900 900 200 210 155

3 10”, 8”, 6”, 4” Solid 900 900 200 200 150

4 10”, 8” Thermal 900 1000 200 220 155

5 12”, 10”, 8” Hourdi 1100 900 200 230 160

Paving Blocks
6 1000 800 _ 450 110
Full Range of HBF

Roof Tiles,
7 1000 800 _ 450 120
with & without face mix

All our aggregates are from RAK, Bartawi and Al-Ghail crushers.

N.B. 1. HBF quality products uses RAK normal OPC for its usual production, unless a special order
that specifies SRC (Sulphate Resistant Cement), then it will be provided by HBF with the same
previously mentioned Mix-Design but on a special rate (to be finalized with the sales
department).
2. No GGBS is used at all in HBF various mix-designs.

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A Member Of Al Shafar – ASGC Holdings LLC

Technical Data Sheet For Masonry Blocks

No Item HBF / DM standards

A Standards Applied: DM Local order #44:1990, BS6073:2008 & ASTM C90

Dimensions: HBF and DM standard dimensions are:

12” Hollow 400 x 300 x 200 mm
10” Hollow, Solid 400 x 250 x 200 mm
8” Hollow, Solid 400 x 200 x 200 mm
6” Hollow, Solid 400 x 150 x 200 mm
4” Hollow, Solid 400 x 100 x 200 mm

12” Hourdi 420/380 x 300 x 200 mm

B 10” Hourdi 420/380 x 250 x 200 mm
8” Hourdi 420/380 x 200 x 200 mm

Tolerance in dimensions: Tolerance max. allowed =  3 mm

12”, 10”, 8”, 6”, 4” Hollow & Solid average compressive
Compressive Strength:
strength = 7.5 N/mm2.
C
Test Method: BS 6073,
12”, 10”, 8” Solid average compressive strength for load
1981 P2 Ap. B AMD4508 : 1984
bearing = 12.5 N/mm2.
Concrete Bulk Wall
Dimensions
Density Density Density
(inch) m2
Kg/m3 Kg/m3
8” Hollow 2240 1406 281
Concrete Density for Masonry blocks not 2190 1500
6” Hollow 225
less than 2000 Kg/m3.
4” Hollow 2120 1750 175
D 10” Solid 2298 2298 520
Bulk Density = block weight / block
8” Solid 2290 2150 450
volume.
6” Solid 2230 2167 325
4” Solid 2150 2125 213

Density for Hourdi blocks (bottom opened) 950 – 1250 kg/m3

Density for Hourdi blocks (bottom closed) 1050 – 1450 kg/m3

Linear Shrinkage (HBF): 0.03% - 0.05%

E Aggregate Chlorides: 3/8” – 3/16” 0.01% - 0.02%
Aggregate Sulphates: 3/8” – 3/16” 0.05% - 0.06%
HBF range of masonry blocks are assessed by “Warrington
Fire” company in UK which is approved by the CD.
F Fire Rating:
Our range of masonry blocks are rated for 4 hours fire
resistant.
HBF : Hard Block Factory LLC.
DM : Dubai Municipality. NOTE: Mix Design & all laboratory certificates, proofs and documents can
CD : Civil Defense. be found in the HBF – Prequalification’s submittal.

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 HARD BLOCK FACTORY L.L.C
A Member Of Al Shafar – ASGC Holdings LLC

Technical Data Sheet For Interlocks & Roof-Tiles

No Products HBF / DM standards

Standard Applied: British Standard: BS 6073.

A

HBF and DM standard dimensions are:

Dimensions: The standard Thicknesses for all interlock
shapes are:
Interlock: different shapes
Varies in dimensions, only 1. 60 mm.
THICKNES is unified. 2. 80 mm.

Roof Tiles 40mm 400 x 400 x 40 mm

Roof Tiles 50mm 400 x 400 x 50 mm

B Tolerance in dimensions: Tolerance max. allowed =  3 mm

Due to molding of interlock, it’s unlikely to have Length

or width changes, but a minor change in height might
rarely happen.

Compressive Strength: Test Method: BS 6073,

(Paving Blocks ONLY) 1981 P2 Ap. B AMD4508 : 1984
C
N.B. due to the irregularity of some shapes or For all measurable interlock compressive
sizes a compression test is NOT applicable in strength, the average is 50 N/mm2.
some cases.

Test Method: BS 7263, 1994 P1 Ap. B

Transverse Strength:
D
(Roof Tiles ONLY) For all measurable Roof Tiles Transverse
compressive strength is 5 N/mm2.

HBF Color Range available is:

Grey, Red, Black, Brown, Orange, Beige &
E Color Range Yellow.

N.B. For colors please refer to SAMPLES.

Dark Gray Color = 26

F SRI: solar reflective index Light Gray Color = 29
White Color < 29

HBF: Hard Block Factory

NOTE: Mix Design & all laboratory certificates, proofs and documents can
DM : Dubai Municipality.
be found in the HBF – Prequalification’s submittal.
CD : Civil Defense.

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A Member Of Al Shafar – ASGC Holdings LLC

Technical Data Sheet For 8” Thermal Block

NAME 8” SANDWICH BLOCK 400 x 200 x 200mm

PRODUCT NO. HBF-Poly200
DESCRIPTION A concrete masonry block with intermediate polystyrene insulation
STANDARDS BS 6073
STORAGE SYSTEM 1 LOT = 10,080 Blocks, 1 LOT = 140 Bundles, 1 BUNDLE = 72 Blocks.
TRANSPORT 6 WHEELS’ TRUCK = 936 Blocks, TRAILER: 1872 Blocks.
PICTURES DRAWINGS

PHYSICAL PROPERTIES
BLOCK DIMENSIONS 400 x 200 x 200 mm. Polystyrene insulation thickness = 60 mm.
DIMENSIONS TOLERANCE ± 3 mm
STRENGHT Average=7.5 MPa (per 10 specimen), Minimum = 6 MPa
DENSITY (WA = 28 Kg) Bulk Density = 1280 Kg/m3, Concrete Density = 2200 Kg/m3
THERMAL CONDUCTIVITY U-value = 0.51 W/m2.K
BLOCK DIMENSIONS 400 x 250 x 200 mm. Polystyrene insulation thickness = 60 mm.

CHEMICAL PROPERTIES
LINEAR SHRINKAGE 0.03 % - 0.05 %
AGGREGATE CHLORIDES 0.01 % - 0.02 %
AGGREGATE SULPHATES 0.05 % - 0.06 %

METHOD STATMENT
1. Prepare wall frame level by applying levelling mortar.
2. Apply mortar on the ground to adhere the blocks on it.
3. Stager the blocks in line (beside each other).
4. Put vertical polystyrene strips of 60mm width. (National Polystyrene, StyroKing24)
5. Apply mortar on the side of the blocks adjacent to the vertical polystyrene strips.
6. Put horizontal polystyrene strips of 60mm width. (National Polystyrene, StyroKing24)
7. Apply mortar on the top of the blocks.
8. Stager the 2nd level of blocks in an interlocking pattern (50% in length edge to edge shift).
9. 1st or last block may need to be split. Choose only designated split block for this job.
10. Repeat the above procedures from 3 to 9 up till you finish building the wall.

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 HARD BLOCK FACTORY L.L.C
A Member Of Al Shafar – ASGC Holdings LLC

Technical Data Sheet For 10” Thermal Block

NAME 10” SANDWICH BLOCK 400 x 250 x 200mm

PRODUCT NO. HBF-Poly250
DESCRIPTION A concrete masonry block with intermediate polystyrene insulation
STANDARDS BS 6073
STORAGE SYSTEM 1 LOT = 10,080 Blocks, 1 LOT = 224 Bundles, 1 BUNDLE = 45 Blocks.
TRANSPORT 6 WHEELS’ TRUCK = 585 Blocks, TRAILER: 1170 Blocks.
PICTURES DRAWINGS

PHYSICAL PROPERTIES
BLOCK DIMENSIONS 400 x 250 x 200 mm. Polystyrene insulation thickness = 60 mm.
DIMENSIONS TOLERANCE ± 3 mm
STRENGHT Average=7.5 MPa (per 10 specimen), Minimum = 6 MPa
DENSITY (WA = 28 Kg) Bulk Density = 1400 Kg/m3, Concrete Density = 2200 Kg/m3
THERMAL CONDUCTIVITY U-value = 0.49 W/m2.K
BLOCK DIMENSIONS 400 x 250 x 200 mm. Polystyrene insulation thickness = 60 mm.

CHEMICAL PROPERTIES
LINEAR SHRINKAGE 0.03 % - 0.05 %
AGGREGATE CHLORIDES 0.01 % - 0.02 %
AGGREGATE SULPHATES 0.05 % - 0.06 %

METHOD STATMENT
1. Prepare wall frame level by applying levelling mortar.
2. Apply mortar on the ground to adhere the blocks on it.
3. Stager the blocks in line (beside each other).
4. Put vertical polystyrene strips of 60mm width. (National Polystyrene, StyroKing24)
5. Apply mortar on the side of the blocks adjacent to the vertical polystyrene strips.
6. Put horizontal polystyrene strips of 60mm width. (National Polystyrene, StyroKing24)
7. Apply mortar on the top of the blocks.
8. Stager the 2nd level of blocks in an interlocking pattern (50% in length edge to edge shift).
9. 1st or last block may need to be split. Choose only designated split block for this job.
10. Repeat the above procedures from 3 to 9 up till you finish building the wall.

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A Member Of Al Shafar – ASGC Holdings LLC

Sound Transmission – STC

Hard Block Factory LLC masonry products have a natural acoustic insulation properties. Blocks are
tested in Material lab as a third party lab for accurate claimed results.

 Third Party Lab: Metrial Lab (al Quoz)

 Lab Project No: P-257
Lab test results measured in “Average STC”:

Without With 16mm

No. Product Report No
plaster (STC) plaster (STC)

1 8” Hollow (400x200x200mm) 212563.SN1/1 56 62

2 6” Hollow (400x150x200mm) 214416.SN1/1 54 59

3 4” Hollow (400x100x200mm) 214415.SN1/1 51 56

4 8” Solid (400x200x200mm) 215984.SN1/1 62 67

5 6” Solid (400x150x200mm) 215983.SN1/1 57 62

6 4” Solid (400x100x200mm) 212562.SN1/1 54 59

U-Value for different masonry products

No. Product Name U-Value No. Product Name U-Value

1 8” Hollow 2.002 W/m2K 2 8” Solid 1.848 W/m2K

3 6” Hollow 2.12 W/m2K 4 6” Solid 2.04 W/m2K

5 4” Hollow 1.75 W/m2K 6 4” Solid 2.18 W/m2K

7 8” Thermal Block 0.51 W/m2K 8 10” Thermal Block 0.49 W/m2K

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 HARD BLOCK FACTORY L.L.C
A Member Of Al Shafar – ASGC Holdings LLC

LEED/Estidama Weighted Mix Design Index

For all HBF masonry products: (12”, 10”,8”,6”,4” Hollow, Solid, Thermal) & Paving Interlocks

Distance Distance from

Weighted Location Location Means
Mix from manufacturer
Weight Weight Distance of Of of
Desigh extraction to site
% (KM) Extraction manufacturer Transport
(KM) (KM)

0-5mm Jebel Ali,

900 38% 200 100 113 RAK Trucks
Agg. Dubai

5-10mm Jebel Ali,

900 38% 200 100 113 RAK Trucks
Agg Dubai

Dune Jebel Ali,

200 38% 200 100 25 RAK Trucks
Sand Dubai

Jebel Ali,
Cement 230 38% 200 100 29 RAK Trucks
Dubai

Jebel Ali,
Water 150 38% 1 100 6 Dubai Trucks
Dubai

TOTAL 2380 100% 287

LEED/Estidama Requirements
for Recycled & Regional Material Content

Recycled Content Regional Material Content

Manufactu 1Pre- 2Post-

Extraction/harvesting Manufacturing distance
Material Name
rer Consumer Consumer distance from site from site
Content Content
Location KM Location KM
(%) (%)
All Types of
Masonry Blocks, Jebel Ali Ind.
Insulated Sandwich Hard Block Ras Al Area,
%0 0% 150 100
Blocks and Factory LLC Kheimah, UAE
Dubai, UAE
Paving Interlocks

1
Pre Consumer Content – Also referred as Post Industrial Content, is defined as materials diverted from the waste stream during the
manufacturing process. Excluded is the reutilization of materials such as rework, regrind or scrap generated in a process and capable of being
reclaimed with the same process that generated it.
2
Post Consumer Content- This is the material generated by the household or by commercial, industrial and institutional facilities in their role
as end users of the product which can no longer be used for its intended purpose.

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A Member Of Al Shafar – ASGC Holdings LLC

Estidama approval listing

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A Member Of Al Shafar – ASGC Holdings LLC

Chapter 3
Fire Resistance & Civil Defence

 Fire Rating for (Hollow,Solid)

 Fire Rating for (thermal)

 Certificates

 Civil Defence/Comprehensive Sefty Programme

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Fire Rating – (Fire Resistance)

Hard Block Factory LLC masonry products have been assessed against the requirements of:
Exova Warrington fire Product Certification Scheme (System 5)
Incorporating the test / assessment / surveillance requirements defined in:
DXB TAS 103 FX – Separating Elements

Test standards:
BS 476: Part 22:1987 - Fire tests on building materials and structures. Methods for determination of the fire
resistance of non-loadbearing elements of construction

Product(s)
Concrete masonry block walls

Certificate of Conformity: No. 02A-11.0006.01-FX.

Product performance and description:

BS 476: Part 22:1987

Masonry walls constructed
using the following blocks
Insulation(minutes) Integrity (minutes)

4” Hollow Blocks 60 120

6” Hollow Blocks 120 180

8” Hollow Blocks 180 240

4” Solid Blocks 90 120

6” Solid Blocks 180 180

8” Solid Blocks 240 240

Description:
1. This certification relates to non-loadbearing block walls consisting HBF Masonry Blocks.
2. The walls shall be constructed in accordance with Code of Practice documents BS 5628-3: 2005.
3. The maximum certified wall height is 3m.
4. Wall widths are unrestricted.
5. Allowance for movement due to shrinkage or thermal movement shall be made such that the number and spacing
of joints allows for the necessary freedom of movement without compromising the integrity and stability of the
construction.

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A Member Of Al Shafar – ASGC Holdings LLC

Fire Rating – (Fire Resistance for thermal blocks)

Hard Block Factory LLC masonry products have been assessed against the requirements of:
Thomas Bell-Wright International Consultants
ACCREDITED by the UNITED KINGDOM ACCREDITATION SERVICE Testing Laboratory No. 4439 & EMIRATES
NATIONAL ACCREDITATION SYSTEM Registration Number: NAL008
Under ISO/IEC 17025:2005 General Requirements for the competence of testing and calibration
laboratories.

Test standards:
BS 476-20:1987; Fire tests on building materials and structures - Part 20: Method for
determination of the fire resistance of elements of construction (general principles)

BS 476-22:1987; Fire tests on building materials and structures - Part 22: Methods for
determination of the fire resistance of non-loadbearing elements of construction

Product(s):
Thermal Blocks, walls made out of Concrete with 60mm Polystyrene insulation and assembled by mortar.

Summary Results:
The Non-Loadbearing Block Wall has been evaluated in accordance with BS 476-22, Method 5,
and Determination of fire resistance of partitions; the requirements of the standards were
satisfied for:

BS 476-22, Method 5,
Masonry walls constructed
using the following blocks Insulation(minutes) Integrity (minutes)

8” Thermal 240 240

10” Thermal 240 240

Test Date - 3-Aug-14

Issue Date: 26-Aug-14
Reference No: OF041

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A Member Of Al Shafar – ASGC Holdings LLC

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Civil Defence/Comprehensive Safety Program

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A Member Of Al Shafar – ASGC Holdings LLC

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A Member Of Al Shafar – ASGC Holdings LLC

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Chapter 4

Dubai Municipality
Certificates Of Prouducts Conformity

 Implementation of factory assessment certification.

 DM Guidelines For Transition.

 Paving Blocks (certificate)

 Masonry blocks (certificate)
 Sandwich blocks (U-Value certificates)

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Chapter 5
Quality Systems

 Quality Policy

 Method Statement

 Quality Control System

 Interlocks Method Statement

 Roof Tiles Method Statement

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Quality Policy

HARD BLOCK FACTORY is committed to Customer Satisfaction

through quality products and services and by complying with and

continuously improving its Quality Management System.

HARD BLOCK FACTORY aims at achieving and periodically updating its

quality objectives that are considered the building blocks of its road to continual

improvement.

Bashar Abou- Mayaleh

Managing Director

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METHOD STATMENT

The production process of masonry block or pavement blocks is divided into 5 major parts.

1. The receipt and inspection of incoming raw material.

2. The manufacturing process.
3. The inspection of the final product internally and in laboratories.
4. Storage and delivery.
5. Quality Control through all production phases.

 Receiving of raw material used in production is subjected to different types of testing.

1. Visual inspection held by our trained plant operators, to determine roughly the grade of the material
crushing and the dust content.
2. Applying sieve test to make sure of our material order local specifications (ISO: Sieve Test Report).
3. Periodically send material to laboratories for chemical and physical analysis, to measure its
compatibility to our needs of high standard production (Arab Centre).
4. Collecting the supplier testing on the material and compare it with the previous tests, so as to track
the rate of change of the material compatibility.

 The Manufacturing process

Plant Make: MASA – West Germany.

Model: R 9001BV
Capacity: 40,000 blocks (8” hollow)
H.B.F. operates a fully computerized plant, which is the latest technology in the field of Semi-dry
concrete block industry.

1. Beginning from the auto-measure of the quantity of the raw material that follows the mix design
which is pre-settled, and hence it can not be changed except on the approval of the consultant. In
such cases records of the mix design changes shall be updated.
2. Through automated weighing scales, aggregates are measured for accurate complying with
recipe Mix-design.
3. Along with the bucket transfer mechanism (skip) to the mixer where automatic quantity of water
is added depending on the cement quantity and the moisture content of the mix.

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4. From the mixer down to the silo and the filling box, where it distributes the material equally
along the mould with the help of pre-vibration and agitator movement to provide high and equal
filling of each block vertically and horizontally.
5. Compaction and Vibration are then applied to maintain homogenous distribution of the
aggregates, removing of the inter-voids, acquiring high strength and correct dimensions.
6. Then, moving pallets transmits wet products to the Elevator that can stack up to 20 pallets. Along
the conveyor, the blocks (products) are checked for height and visual correctness (ISO: Dimension
Internal QC).
7. After that, a fully automated-computerized finger car (boogie car) transmits the fresh product to
the curing chambers, where the product stays there for at least 24 hours.
8. The curing chambers are climate controlled, by sophisticated automatic control system to control
temperature, humidity and air circulation.
9. After the curing period, dry products are transmitted to the bundling system (follows HBF
standard cubing system) and with the help of a cuber machine; blocks are stacked in bundles and
tagged for tractability.
10. With forklifts the bundles are transmitted to the stock yard (ISO: Stock Yard Report).
11. Through all these procedures, HBF documentation system follows ISO 9001:2000 procedures and
backing up our system, also, permits the tracing back of the final product to recognize the
production date, machine operator, curing chamber number, strength and height. Almost, each
and every property of the final product can be traced.

 Inspection of the final product internally and in laboratories.

1. Final product is stocked in our stock yard. Every production is its pre-planned area and in the form of
lanes. Usually, each lane forms a LOT (10,080 blocks).
2. “ISO: Yard Stoke Report” specifies and describes each and every Lot.
3. Random samples are collected for internal testing to assure final product high quality complies with
HBF standards, international standards and Dubai Municipality standards (ISO: Internal Test).
4. If the product is going to be sold within DM laws restriction, then each lot undergoes a certification
from DM, fully controlled by the Municipality itself and certification document is acquired.

 Loading & Delivery

1. Our trailers and 6-wheel fleet are capable of handling big volumes of delivery, as our 7 trucks are
delivering day and night.
2. Loading & Delivery orders are controlled by the store keeper and the Yard In Charge. A “Delivery
Note” and a daily planned delivery schedule are the main documents for controlling and tracing of
delivery.

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A Brief on the Quality Control system through all production

phases

Hard Block Factory is acquiring high production standard through our quality control system which does
NOT allow any product beyond our quality limits.
1. Visual inspection of the fresh (wet) product to eliminate defected pieces.
2. Manual measuring of wet product height and note the height in our “Dimension Internal QC”
documentation for referencing.
3. Visual inspection of the finished (dry) product to eliminate defected pieces.
4. Random selection of specimens from our storage yard for strength internal test. All tests are
documented and kept in block history achieves.
5. Every 10,000 blocks “1 Lot” is applied to Dubai Municipality for Lot- Certification, where the
municipality checks all dimensions and the block strength; against the British Standards.

Our documentation system which is controlled by ISO, allows us for each and every Lot tracing back,
even each and every individual block, to identify production date, machine operator, curing chamber
number, production date/time, Lot test situation visually and physically, also curing period, storage period and
delivery date.

Laying of Paving Interlocks Method Statement

The preparation of a suitable sub-base is of a primary importance with concrete paving blocks. It is
important to note that the life of the paving blocks installation will only be good as the sub-base, so
it is important to concentrate on doing the job correctly.

Procedures of Laying Paving Blocks:

1. Prepare level and compact the soil to be ready to receive the base material.
2. Lay sub-base material, level and compact.
3. Lay 50mm sand bedding over base.
4. Lay paving blocks to pattern selected over the sand bedding.
5. Compact paving blocks using plate compactor.
6. Spread clean sand over paving blocks, then compact with plate compactor.
7. Brush the extra sand.

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Laying of Roof Tiles Method Statement

The preparation of a suitable sub-base is of a primary importance with roof tiles. It

is important to note that the life of tiles can only be extended / durable as per the sub-base
proper preparations.

Procedures of Laying Roof Tiles on the ground:

1. Prepare level and compact the soil to be ready to receive the base material.
2. Lay sub-base material, level and compact.
3. Lay 50mm sand bedding over base.
4. Lay paving blocks to pattern selected over the sand bedding.
5. Spread clean sand over the tiles & compact it.
6. Brush the extra sand.

Procedures of Laying Roof Tiles on roof buildings:

1- Shifting and cleaning for all roof waterproofing materials.

2- Clearance from the consultant to proceed with roof cement tile works.
3- Setting out and alignment for PVC Chairs.
4- Lay first straight and perpendicular rows of roof cement tile.
5- Review and approval from the consultant.
6- Lay PVC Chairs and roof cement tile for the balance areas.

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C h a p ter 6
R u n i n g Pr o j e c t s

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Project City Walk - Jumeirah

CONTRACTOR OWNER CONSULTANT
Al Shafar General Contracting Co. LLC Meraas Holding Holford Architects,

Description
The project is in a prime location in Jumeirah with close proximity to Sheikh Zayed Road.
involves construction of 21 new low to medium rise apartment buildings .
Value: USD 450 million.

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Project Al Habtoor City

CONTRACTOR OWNER CONSULTANT
Atkins & Partners
Habtoor Leighton Group Al Habtoor Group
Overseas
Description
The project involves construction of hospitality 3 international luxury 5 & 6 Star hotel,
Cinema/Theatre/Auditorium,Residential- Housing Complex, Multi-Storey , Sports Complex.
Value: USD 2.99 billion

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Project The Distinction Tower

CONTRACTOR OWNER CONSULTANT
Commodore Contracting Co. LLC Damac Properties Zaspse

Description
The Distinction is a 195-metre, 53-storey, with enviable views of the world's highest
fountain, largest mall and tallest tower.
Value: USD 40 million

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Project The Exchange Tower

CONTRACTOR OWNER CONSULTANT

Delta Emirates Contracting Co. LLC Tanmiyat Group MBM Consultancy

Description
The project involves construction of a commercial tower comprising 3 basement levels, a
ground floor, 3 podium levels and 28 additional floors.
Value: USD 32.654 million

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Project Vision Tower

CONTRACTOR OWNER CONSULTANT
Al Shafar General Contracting Co. LLC Dubai Properties Dewan Al Emara

Description
The project involves construction of a 67 storey commercial tower that will stand at a height
of 264 meters, The tower will be connected to the Bay Avenue, health club, restaurants.
Value: USD 36 million

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Project Nestlé Manufacturing Facility

CONTRACTOR OWNER CONSULTANT
Al Shafar General Contracting Co. LLC Nestle Middle East Dar Al Handasah

Description
The project involves construction of a factory that will cover an area of 175,000
square feet. The factory will include 10 blocks for producing nutrition.
Value: USD 136 million

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Project 500 Villa Complex, Legends

CONTRACTOR OWNER CONSULTANT
Al Burj
Delta Emirates Contracting Co. LLC Tanmiyat Group
Engineering
Description
The project involves construction of 500 villas each comprising a ground floor and an
additional floor
Value: USD 200 million

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Project Al Hikma automated car park

CONTRACTOR OWNER CONSULTANT
Techno Steel Construction LLC HH Issa bin Zayed Arab Expert

Description
The project involves construction of an automated car park building comprising 6 basement
levels, a ground floor and 14 additional floors.
Value: USD 13.6125 million

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Project The Onyx

CONTRACTOR OWNER CONSULTANT
Al Shafar General Contracting Co. LLC Ishraqah KEO Consultants

Description
The project involves construction of a three-tower mixed use development that consists of
two office and residential buildings, a four-star boutique hotel.
Value: USD 500 million

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Project Damac Akoya

CONTRACTOR OWNER CONSULTANT
Damac Crescent Naga Architects,
Trojan General Contracting. LLC
Properties Llc Designers
Description
The project involves construction of a residential community consisting of 682 villas each
comprising a ground floor and an additional floor.
Value: USD 316 million

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Project The Regent Emirates Pearl

CONTRACTOR OWNER CONSULTANT
Arkan (Architects
Arabian Construction Co. LLC Grand Hyatt
Consultants)
Description
The project involves construction of a 5 star hotel comprising 4 basement levels, a lower
ground floor, an upper ground floor, 3 podium levels, 368 spacious rooms and suites.
Value: USD 237 million

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Chapter 7
Landmark Projects

 JBR (Jumeirah beach residence tower)

 DUBAI Marina Residence Tower
 Other Projects

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Project JUMEIRAH BEACH RESIDENCE TOWER

CONTRACTORS OWNER CONSULTANT
Dubai Technology, E-commerce &
AL Shafar General Contracting DAR Consultants
media free zone authority

AL Habtoor Engineering Enterprises Dubai Islamic Bank DAR Consultants

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Project Al Mas Tower

CONTRACTOR OWNER CONSULTANT
Arabian Construction Co. (ACC) Nakheel Properties Dar Al Handasah

Project The-Exuctive-towers
CONTRACTOR OWNER CONSULTANT
Al Habtoor Engineering Dubai Properties DAR Consult GC

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Project Etihad Towers

CONTRACTORS OWNER CONSULTANT
Arabian Construction Co Jumeirah group Golden Planner

Project Omniyat
CONTRACTOR OWNER CONSULTANT
Al Shafar General Contracting Omniyat Properties Kling Consult GmbH

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Project The BAY Gate Tower

CONTRACTOR OWNER CONSULTANT
Al Nekhreh Contracting Co. LLC (ANC) Dubai Properties Whitby & Bird

Project Emirates crown tower

CONTRACTOR OWNER CONSULTANT
Al Shafar General Contracting Mr.Mohamed Saif Design & Architecture

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Project Bay Square

CONTRACTOR OWNER CONSULTANT
Al Shafar General Contracting Dubai Properties Khatib & Alami

Project Al Furjan
CONTRACTOR OWNER CONSULTANT
AL Shafar Transport co L.L.C Nakheel Dar Al Handasah

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Project Ibn Batuta Mall

CONTRACTORS OWNER CONSULTANT
Arabian contracting co L.L.C Nakheel Dar Al Handasah

Project Discovery gardens

CONTRACTORS OWNER CONSULTANT
AL Shafar Transport co L.L.C Nakheel ACE INTERNATIONAL

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Project Knowledge Village

CONTRACTORS OWNER CONSULTANT
AL Basti Muktha L.L.C TECOM DAR Consultants

Project Al Fattan Towers

CONTRACTORS OWNER CONSULTANT
Al Nekhreh Contracting Co. LLC (ANC) Al Fattan Properties Tabanlioglu

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Project Al Wasl Square

CONTRACTORS OWNER CONSULTANT
AL Shafar General Contracting l.l.c Meraas Development Naga Consultants

Project Oceanscape (Reem Island, Abu Dhabi)

CONTRACTOR OWNER CONSULTANT
AL Shafar General Contracting DAMAC LUXURY Khatib & Alami

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Project AL Murooj Rotana Complex

CONTRACTORS OWNER CONSULTANT
H.H Sheikh Hamdan Bin
AL AHMADIAH Contracting L.L.C Rashed
ARTEC Consultants

Project Formula - 1 Cafe

CONTRACTORS OWNER CONSULTANT
Al Shafar General Contracting ALDAR Properties MZ Architects

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Project Baniyas Hotel(Mafraq Hotel)

CONTRACTORS OWNER CONSULTANT
Pivot General Contracting Company National Hotel Company Shankland Cox

Project Al Yaquob Tower

CONTRACTORS OWNER CONSULTANT
Arabian contracting co Nakheel Dar Al Handasah

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OTHER PROJECTS

CONTRACTORS AL SHAFAR General Contracting L.L.C

PROJECT LOCATION CONSULTANT

Golden Mile Palm Jumeirah DSA

Kazim Tower Internet city National Engineering Bureau

Al Barsha Tower Barsha Al Maktab Al Asri

Citadel Tower Business Bay DAR

Al Tayer Tower Business Bay Khatib & Alami

(2B+G+M+4P+59) Stored Complx
Al Marsa Design Architecture
Res Building
(G+12 Residential Bldg Port Saeed ARENCO Management

( 3B+G+39 Floor Bldg ) Dubai Media City National Engineering Bureau

G+1 ×30 Villas Al Barsh 1 ARENCO

National Engineering Bureau
(3B+G+6P+2F+44)Floors
Internet City Architectural Engineers
Commercial Office Building
Consultant
G+M+39 Bldges Trade Center First ARENCO
(3B+G+8P+32 )Floors Office
Dubai Media City
( Shate Tower)
21 Commercial & Residential Alsatwa
Hyder consulting
Building City walk
( G+M+39 Floor Bldg ) Sheikh Zayed Roed ARENCO
B+G+4 Nos . 3 Bldgs
Internet City ARENCO Consultants
B+G+5 Nos . 2 Bldgs
(B+G+M+5) Commercial &
AL Karam Bel – Yoahah Consultants
Residential Building
Ambulatory Healthcare3Tower Abu dahbi Cornish road

CONTRACTORS Trojan General Contracting L.L.C

PROJECT LOCATION CONSULTANT
Damac Akoya Gulf Villas Dubailand Naga Designer planner
CONTRACTORS DELTA CONTRACTING L.L.C
PROJECT LOCATION CONSULTANT
500villas in living legends Dubailand AL Burj Consultants
CONTRACTORS Al Oroba Contracting Co LLC
PROJECT LOCATION CONSULTANT
260 Villa+6building+mall Jumeirah Khateb & Almi

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CONTRACTORS AL Habtoor Engineering co L.L.C

PROJECT LOCATION CONSULTANT
AL Habtoor City sheikh zayed road Khateb & Almi
CONTRACTORS Commodore contracting co L.L.C
PROJECT LOCATION CONSULTANT
IPIC Headquarters building Abu dhabi ATKINS
CONTRACTORS ARAB Technical Constructing L.L.C
PROJECT LOCATION CONSULTANT
( 565 Residential Villas ) Meadows Villas AL Gurg Consultants
CONTRACTORS United Engineering Construction L.L.C
PROJECT LOCATION CONSULTANT
B+GFM+38 Towers AL Quoze DAR Consultants
CONTRACTORS AL SHAFAR National Contracting L.L.C
PROJECT LOCATION CONSULTANT
( B+g+5+Gym ) Oud Mehta Dubai Consultants
( B+g+12+Gym ) ALqusais 1 AL Dana Engineering
CONTRACTORS Al Shafar Transport contracting L.L.C
PROJECT LOCATION CONSULTANT
27 Buildings - International International City Ace International
Ottoman Palace Hotel The Palm Jumierah ZSML
CONTRACTORS AL Habbai Contracting company L.L.C
PROJECT LOCATION CONSULTANT
( B+G+4 Residential AL Karama DUBAI Consultant
AL Mujassam Architects
( G+4 Residential Building ) AL Qusais Ind
Engineers
CONTRACTORS ARABIAN CONSTRACTION CO - ACC-
PROJECT LOCATION CONSULTANT
Residential Bldg H.H Sheikh
Zaraya thouth ArchitecturePlanning APG
Diab Bin Zayed
LUXURY Beach Residence AL Marssa DAR Consultants
Princess Tower DUBAI ENG-Adnan Zaffarani
CONTRACTORS Enginiring Contracting co L.L.C
PROJECT LOCATION CONSULTANT
AMESCO Tower JLT Jumerrah Lake Tower National Engineerig
Retail Center &Resturant
ARABIAN RANCHES AL Gurg consulting
Residenta Club

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Chapter 8
C o n s u l t a n ts A p p r o v a l s

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Chapter 9
Raw Materials Technical Data Sheets

 Cement Certificates
 Aggregates & Sand Certificates

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