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Case Study: High-Bay Industrial Warehouse Construction (PEB System)

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Project Reference: JAFZA/WH-ALMANA/2026/094Location: Jebel Ali Free Zone (South), Dubai, UAETotal Area: 5,000 sq.ft 465 SQM Eave Height: 40 ft This project is a prime example of our capabilities in Industrial Steel Structures, serving as a foundation for our wider portfolio of Mezzanine Floors in UAE.For this logistics facility in JAFZA, the client prioritized “Volumetric Capacity” over floor area. By engineering a Pre-Engineered Building (PEB) with a soaring 40ft (12.2m) eave height, we maximized the vertical storage potential. This design specifically allows for the future installation of a Rack Supported Mezzanine system to triple the pallet capacity without modifying the roof structure.The scope involved complete design-and-build responsibility, from the Plate Load Tests on the soil to the final Trakhees (EHS) fitness certificate.

Precision steel fabrication process for construction-grade components

💡 Wasleen Expert Insight

The “FM2” Floor Standard: For a 40ft high warehouse, a standard concrete slab is useless. If the floor has even a 5mm bump, a forklift extending its mast to 12 meters will lean dangerously. We utilized Laser Screed Technology to achieve “FM2” flatness, ensuring safe operations for any future Steel Structural Mezzanine or VNA racking.

1. Structural Engineering: The PEB Advantage

We selected a rigid frame PEB system using ASTM A572M Grade 50 steel. This high-tensile steel allows for a “Clear Span” design (no internal columns), giving the client 100% forklift maneuverability. Thermal Efficiency: The roof and wall cladding utilize Double-Skin Sandwich Panels with a 50mm Polyisocyanurate (PIR) core. This reduces the cooling load significantly compared to single-skin sheets, crucial for maintaining ambient temperatures in Dubai summers. Structural Grid: Cold-formed galvanized Z-purlins (Grade 345 MPa) are spaced at 1.5m intervals to support the cladding and resist wind loads up to 160 km/h. Loading Docks: The facility includes two 4m x 4.5m heavy-duty electric roller shutters, engineered to interface with hydraulic dock levelers for rapid container offloading. 2. FM2 Heavy-Duty Flooring Specification The warehouse floor is the engine of the facility. We engineered a 200mm thick Reinforced Concrete (RCC) slab. Concrete Mix: Grade 40/50 (High Strength). Reinforcement: Double layer A252 steel mesh with 50mm cover to prevent surface cracking. Hardener: We applied a “Dry-Shake” non-metallic hardener at 6kg/m² immediately after casting, followed by a power float finish. This creates an abrasion-resistant surface that will not dust or chip under heavy forklift traffic or when supporting the point loads of a Warehouse Mezzanine Floor.
Requirement Structural Steel System Rack Supported System
Load Capacity High (up to 2,500 kg/m2) Medium (up to 500 kg/m2)
Column Spacing Wide (6m – 12m clear spans) Narrow (1m – 3m aisles)
Future Flexibility Can be repurposed for Office/Storage Storage Only (Fixed layout)
Installation Speed 4-6 Weeks 2-3 Weeks
COST EFFICIENCY Best for Heavy Loads Best for Bulk Volume

3. Verified Construction Costs (2026 Market Rates)

Below is the verified Bill of Quantities (BOQ) for this high-spec industrial facility.
Line Item Engineering Specification Value (AED)
01. PEB Structure Supply & Erection Supply and Install of ASTM A572 Grade 50 Steel Frame (40ft Height). Includes Z-Purlins, X-Bracing, and 50mm PIR Insulated Sandwich Panel Roofing. 725,000.00
02. Heavy-Duty FM2 Flooring Casting of 200mm Grade 40/50 RCC Slab. Laser Screed leveling to FM2 tolerance. Application of 300-micron High-Gloss Epoxy Coating. 175,000.00
03. Office Fit-Out & Wet Areas Construction of 2 x Office Units and Pantry using 100mm fire-rated Gypsum. Includes Porcelain tiling, Painting, and HVAC (Multi-Split 4.0 TR). 99,000.00
04. Firefighting System Supply & Install of Hose Reel System, Sprinkler Grid (High Bay Spec), and integration with Civil Defense 24/7 Panel. 110,000.00
05. MEP & Electrical High-Bay LED Lighting (200 Lux), DB Termination, and Power Sockets. Security System (CCTV & Access Control). 83,500.00
06. Loading Docks 2 Nos Heavy Duty Electric Roller Shutters (4m x 4.5m) with Dock Leveler pits. 56,000.00
TOTAL CONSTRUCTION COST Excluding Racking & Authority Fees AED 1,248,500.00

💡 Wasleen Expert Insight

Soil Risk Management: JAFZA soil can be loose and sandy. Before casting the AED 175k floor, we conducted a Plate Load Test. The results required us to perform 1.5m of backfilling with crushed aggregate (Gars) to ensure the ground wouldn’t sink under the weight of the client’s heavy machinery. Never skip the soil test.

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3. Verified Project Cost Breakdown (2026)

Transparency is the foundation of trust. Below is the actual engineering quotation for this specific scope.
Line Item Engineering Specification & Details Value (AED)
01. Structural Steel Fabrication Supply & Install Hot Rolled Steel (12 Tons). Includes IPE 270 Main Beams, SHS Columns, 20mm Base Plates, and Hilti Chemical Anchors. Finish: Zinc Phosphate Primer. 156,000.00
02. Fire Protection (DCD) Application of Intumescent Paint (Interchar/Jotun) to main structural members to achieve 120-minute Fire Resistance Rating (FRR) as per Trakhees code. 22,000.00
03. Glass Partitions & Doors 145 sqm of 12mm Tempered Glass Partitions with Black Anodized Aluminum profiles. Includes Frameless Glass Doors with Dorma Floor Springs and Patch Fittings. 79,750.00
04. Civil & Interior Works Aluminum Clip-in Ceiling system (60×60), Gypsum bulkheads, Commercial Carpet Tiles, and Painting. Includes all sub-floor preparation. 67,200.00
05. MEP & HVAC Services Extension of DX/VRF AC system with VAV controls. LED Lighting (4000K), Power distribution, Data Cabling (Cat6), and Floor boxes for MD Cabin. 85,000.00
06. Joinery & Pantry Custom High-Gloss Pantry Cabinetry with Corian Countertop, Sink, and Mixer. Storage units for Manager Cabins. 35,000.00
07. Firefighting System Modification of existing sprinkler network. Installation of new Pendent Sprinklers below ceiling and Smoke Detectors connected to FACP. 25,000.00
08. Engineering & Approvals Professional fees for Structural Calculations, Trakhees Submission, MEP Drawings, and Consultant supervision. (Excludes Authority Fees). 18,000.00
TOTAL PROJECT VALUE Turnkey Execution (Excluding VAT) AED 487,950.00

💡 Wasleen Expert Insight

The Trakhees “Trap”: Many contractors fail to budget for the Environment, Health & Safety (EHS) inspection. Trakhees EHS is strict. If your contractor does not use certified scaffolding or fails to provide a “Risk Assessment Method Statement” (RAMS), the project will be stopped. We include full safety compliance documentation in our AED 18,000 engineering fee.

4. Execution & Regulatory Roadmap

JAFZA projects fall under the jurisdiction of Trakhees. The approval process is distinct from Dubai Municipality.

  1. Soil Testing & Enabling: Verification of ground bearing capacity.

  2. Steel Erection (Weeks 1-12): Scissor lifts and spider cranes were used to safely install the 40ft high roof structure. Safety nets were mandatory.

  3. Approvals Strategy:

    • Trakhees CED: Building Permit (~AED 5,000).

    • Trakhees EHS: Operational Fitness NOC (~AED 3,500).

    • DCD: Fire Strategy Approval (~AED 2,500).

💡 Wasleen Expert Insight

The Racking Option: Because we built the warehouse to 12.2m height, the client had the option to install a 5-Level Selective Pallet Racking System. This creates 400 Pallet Positions (worth AED 128,000) on a floor footprint of just 465 sqm. This is how you maximize ROI on industrial real estate.

Frequently Asked Questions (Technical & Regulatory)

1. What is a PEB Structure and why use it in JAFZA?
PEB (Pre-Engineered Building) is a steel structural system that is designed and fabricated in a factory, then bolted together on-site. It is 30% lighter and 50% faster to build than conventional steel, making it the standard for industrial units in Free Zones like JAFZA.
2. Why is FM2 flooring important?
“FM2” refers to the floor flatness classification. In a warehouse with 12m high racking, even minor unevenness in the floor can cause a forklift mast to sway or hit the racks. Laser screed FM2 floors ensure safe, high-speed forklift operation.
3. What approvals are needed for JAFZA construction?
You need a Lease NOC from JAFZA, a Building Permit from Trakhees (CED), and Fire Safety Approval from Dubai Civil Defence (DCD). Post-construction, you need an Operational Fitness Certificate from Trakhees (EHS).
4. How long does it take to build a warehouse?
For a 5,000 sq.ft unit like this: Approvals take 4-6 weeks. Civil & Steel works take 12 weeks. MEP & Finishing takes 6 weeks. Total project duration is typically 5-6 months.
5. Can you install a mezzanine later?
Yes. Since we designed this warehouse with a 12.2m eave height, there is ample space to install a structural steel mezzanine or a multi-tier racking system in the future without modifying the roof.

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How We Works...

Our process is engineered to deliver maximum structural strength, high load capacity, and premium finishing for every Heavy Duty Steel Mezzanine project. We follow a clear, efficient, and professional workflow to ensure precision from start to finish.

1. Site Assessment & Load Analysis

We begin with a complete site inspection to understand the available space, required load capacity, and operational flow. This helps us determine the perfect structural layout and design approach for your mezzanine.

2. Engineering Design & Structural Planning

Our engineers prepare a customized mezzanine design that includes beam sizes, column spacing, joist layout, staircase placement, railing safety, and expansion possibilities. The structure is planned to deliver maximum durability and long-term load-bearing strength.

3. Transparent Quotation & BOQ

You receive a clear quotation with a complete Bill of Quantities, material list, and detailed scope of work. No hidden charges—just accurate costing designed for heavy-duty performance and long-term value.

4. Precision Fabrication in Our Workshop

We fabricate all components—columns, beams, joists, staircases, safety rails—using premium structural steel and advanced cutting and welding technologies. Every piece is treated with anti-rust protection and built to engineering standards.

5. Safe & Efficient On-Site Installation

Our professional team installs the mezzanine with high-strength anchor bolts, accurate leveling, and strict safety protocols. The structure is assembled to be stable, vibration-free, and capable of supporting heavy commercial loads.

6. Flooring, Finishing & Safety Integration

We complete the mezzanine with your selected flooring—steel deck, cement board, plywood with vinyl, or commercial finishes. Railing systems, access gates, lighting points, and staircase safety accessories are added for a fully functional upper level.

7. Final Inspection & Handover

Once installation is complete, we perform a full structural and finishing inspection. You receive a ready-to-use mezzanine that is safe, strong, and built to enhance your retail, warehouse, or commercial operations.

Our Service Areas:

We provide design, fabrication, and installation services across all major commercial and industrial zones in the UAE:

  • Dubai: Business Bay, Al Quoz, Dubai Investment Park (DIP), Jebel Ali Free Zone (JAFZA), Dubai Design District, and all major Malls. All other areas in UAE

  • Sharjah: Industrial Areas 1-18, SAIF Zone, Al Nahda, and commercial retail centers.

  • Ajman: Ajman Industrial Area, Al Jurf, and the Free Zone.

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