A construction company has many needs, especially in terms of raw materials and resources. Considering the vastness of the resources needed and the magnitude of projects that Ayoubco undertakes, we have expanded into many operations that relate to and strengthen our main corporate focus.
A prime example of this is the quarrying and transport division of our company. We operate four quarry sites, which extract limestone and gravel. To satisfy the needs of Ayoubco S.A.E and its clients, we handle more than one million cubic meters of raw materials per year, which is mined from our own quarries. In order to transport these resources at the best cost, we built a transport fleet in excess of one hundred trucks and trailers that work to distribute gravel and limestone to our numerous and varied construction sites.
A by-product of producing gravel is the production of ready-mixed concrete, the hauling of which required the use of more than 60 of our trucks.
The limestone is recycled in the production of blocks that are used by the construction division. At one time we had 10 such block-making facilities, which annually produced more than 10 million blocks of varying size and weight. To complement these activities, we also operated two tile-making plants to produce terrazzo tiles, steel crete and cement paving at an impressive rate of 400,000 m2 per year.
We operate four woodworking factories, a crittall window-making factory and an aluminium production facility. These facilities together produce the 50,000 doors and windows of various sizes utilized by the company on its many projects.
Another major division is our plant equipment fleet, which at one time comprised over 700 pieces of heavy equipment including tower cranes, batch plants, excavating machinery, generators, compressors, and the usual range of machinery and equipment used in a company of our size. The maintenance of this fleet has resulted in a large chain of workshops, which included the capacities for engine rebuilding, tyre repair and painting work.
In the construction work process, the foundation phase is considered the most difficult. It requires a special aptitude to overcome all the difficulties that stand between the company and a successful completion of a contract. This is especially true for undertakings of great size such as buildings in the Nile Valley or alongside the shores of the Mediterranean, where underground water can wreak havoc. In order to streamline operations and to avoid the time consuming and costly delays that result from sub-contracting for foundation work, Ayoubco has established a special division to deal with foundations.
Ayoubco has historically done all of its own foundation work on its contracts. The Hilton Hotel required more than 1,000 driven, precast piles – all were placed by Ayoubco. In the Moustafa Kamel housing project (on the Mediterranean), two types of pilings were employed with success, including Alexandrine caissons. Piles were also used in many residential buildings such as the Manial Towers, the Maadi Gem, the Maadi Star, and other gigantic projects.
In the Doha-Maspiro project, along the Corniche in Cairo, piles were used in the construction of a basement that was three floors underground, beneath the water level of the nearby Nile. Despite the fact that the river was less than 30 m away, the use of concrete diaphragm walls allowed the construction of this building. Work included projects that use driven, precast piles, steel sheet piling, one-meter diameter bentonite slurry piles and 1.2-meter diameter bored cast in situ piles of various depths down to 40 meters.