Portacabin construction: every layer, taken apart

Perimeter I-beams with cross beams to the approved structural design. Mechanically and brush cleaned, then one coat of red oxide primer and two coats of approved enamel.

Material

Mild steel I-beam

Thickness

IPE AA 120 & IPE AA 100

Dimensions

12.0 x 3.6 m perimeter with cross beams per design

Finish

Red oxide primer + 2 coats enamel

Standard

Approved structural design

Perimeter

IPE AA 120 & IPE AA 100

Preparation

Mechanical / brush cleaning

Protection

1 coat red oxide primer, 2 coats enamel

Square hollow section joists spaced at 610 mm centres and securely welded to the chassis, carrying the cement board deck.

Material

Mild steel SHS

Thickness

38 x 38 x 3.0 mm

Dimensions

610 mm centres

Finish

Red oxide primer + enamel

Section

SHS 38 x 38 x 3 mm

Spacing

610 mm c/c

Fixing

Welded to chassis

One layer of 18 mm cement board fixed to the floor joists with suitable self-tapping screws, forming the structural floor deck.

Material

Cement board

Thickness

18 mm

Finish

Screw fixed to joists

Fixing

Self-tapping screws to joists

GI studs fixed with suitable screws at approximately 1220 mm vertical and 815 mm horizontal spacing, or as required by the approved fire-rated wall system.

Material

Galvanised steel stud

Thickness

89 x 41 x 0.6 mm

Dimensions

≈1220 mm vertical / 815 mm horizontal fixing

Section

89 x 41 x 0.6 mm GI

Fixing

≈1220 mm vertical, 815 mm horizontal

6 mm fire-rated cement board fixed to the GI framing. All surfaces jointed, sealed, prepared and finished with approved exterior-grade enamel paint.

Material

Fire-rated cement board

Thickness

6 mm

Finish

Exterior-grade enamel paint

Approved fire-rated gypsum board fixed to the GI framing. Joints, screw heads, corners and penetrations treated with approved fire-rated compounds, tapes and joint strips.

Material

Fire-rated gypsum board

Finish

Jointed, sanded, interior-grade paint

Treatment

Fire-rated compound, tape and joint strips

Room partitions built from GI framing with approved fire-rated gypsum board and fire-resistant rock wool. Thickness and construction follow the approved tested system.

Material

GI framing, fire-rated gypsum, rock wool

Layout

2 offices, kitchen, bathroom

Sealing

All joints and penetrations

Fire-resistant rock wool with thickness and density corresponding to the approved tested fire-rated system.

Material

Rock wool

Specification

Per approved fire-rated system

50 mm fire-resistant rock wool at a minimum density of 60 kg/m³, installed continuously within the wall cavities without gaps or voids.

Material

Rock wool

Thickness

50 mm

Dimensions

Continuous within stud cavities

Standard

Minimum density 60 kg/m³

Density

≥ 60 kg/m³

Installation

Continuous, gap free

GI ceiling framing installed as part of the approved fire-rated construction.

Material

Galvanised steel

System

Approved fire-rated ceiling system

Fire-rated gypsum board fixed to the ceiling framing, with all joints, screw heads, perimeters, service penetrations and openings sealed using approved fire-rated materials.

Material

Fire-rated gypsum board

Finish

Painted

Sealing

Approved fire-rated materials at all openings

GI/MS roof framing to the approved structural design, set out as a twin slope so rainwater sheds to both eaves.

Material

GI / mild steel

Dimensions

Twin slope, both sides

Structure

GI/MS framing

Geometry

Double-pitch roof

Insulated sandwich panels / approved fire-rated roofing system, with thickness and fire performance as required by the approved design. All joints and penetrations sealed.

Material

Insulated sandwich panel

Finish

Sealed joints and penetrations

System

Per approved design

Sealing

All joints and penetrations

Aluminium framing and glazing per the approved architectural drawings. Windows in fire-rated walls are supplied as a certified fire-rated assembly including frame, glazing, seals and fixings. All perimeter gaps sealed.

Material

Aluminium frame, glazed

Finish

Powder coated

Standard

Fire-rated assembly where required

Framing

Aluminium

Fire compartments

Certified fire-rated window assembly

Powder-coated aluminium framed entrance set with door closer and approved ironmongery. Twin brown leaves carry tempered vision panels under a glazed transom: 6 mm reflective tempered outside, 12 mm air space, 6 mm clear float Guardian tempered inside.

Material

Powder-coated aluminium, tempered glass

Thickness

6 mm / 12 mm air / 6 mm

Dimensions

Clear opening 2200 x 2200 mm

Finish

Brown leaves in a graphite grey aluminium frame

Standard

Non-thermal-break glazed door

Leaf finish

Brown

External glass

6 mm reflective tempered

Air space

12 mm

Internal glass

6 mm clear float Guardian tempered

Frame colour

RAL 7024 graphite grey

Hardware

Door closer and approved ironmongery

2-hour fire-rated powder-coated steel door with approved fire-rated frame, closer, fire-rated hardware and vision panel where required.

Material

Powder-coated steel

Finish

Powder coated

Standard

2-hour fire rating

Rating

2 hours

Frame

Approved fire-rated

Hardware

Fire-rated set + closer

60-minute fire-rated solid wooden flush door with meranti frame, approved fire-rated core and shutter, fire-rated hardware and approved paint finish.

Material

Solid wooden flush leaf, meranti frame

Finish

Approved paint

Standard

60 minute fire rating

Rating

60 minutes

Frame

Meranti

Non-fire-rated semi-solid wooden flush door with meranti frame and shutter, finished with approved paint.

Material

Semi-solid wooden flush leaf

Finish

Approved paint

Type

Semi-solid flush, non fire-rated

Lighting fixtures, switches and sockets installed to the approved electrical layout, suitably rated for the room they serve.

Scope

Fixtures, switches and sockets

Wiring and conduits per the approved electrical layout, suitably rated and installed to UAE regulations. All penetrations through fire-rated assemblies are fire-stopped.

Material

Copper conductor, PVC conduit

Standard

Applicable UAE regulations

Installation

Per approved electrical layout

Distribution board complete with suitable protective devices, isolators and circuit breakers, installed to UAE regulations and the approved electrical layout.

Material

Powder-coated enclosure

Standard

Applicable UAE regulations

Contents

Protective devices, isolators, circuit breakers

Provision for split-type air-conditioning units as required by the approved layout, each with a suitable electrical isolator. Pipe penetrations through fire-rated walls are sealed with approved fire-rated systems.

Type

Split type

Isolator

One per unit

Approved standard quality sanitary fixtures: WC, wash basin, taps, mirror, floor drain and associated accessories, with hot and cold water and drainage connections per the approved plumbing layout.

Fixtures

WC, wash basin, taps, mirror, floor drain

Areas

Bathroom and kitchen

Pantry counter with sink, taps and drainage, GRP or PVC flooring with a waterproof upturn, and power outlets to the approved layout.

Flooring

3 mm GRP / PVC with 100 mm upturn

All fire-rated wall, ceiling, floor, door, glazing and penetration components are installed as a complete tested and approved system, supported by test certificates and technical data sheets. No cutting or alteration without prior approval.

Standard

UAE Civil Defence, approved tested system

Compliance

UAE Civil Defence requirements

Documentation

Test reports, data sheets, approvals

Electrical, mechanical, plumbing, HVAC and other service penetrations through fire-rated walls, floors and ceilings are sealed with approved fire-stopping systems suitable for the required rating.

Standard

UAE Civil Defence requirements

Scope

All service penetrations through rated construction

Engraved name plate mounted beside the main entrance carrying the company or project name.

Material

Brushed stainless / acrylic

Dimensions

400 x 150 mm typical

Mounting

Adhesive and mechanical fixings

External joints, wall-to-floor connections, roof joints, window and door frames and service penetrations sealed with approved weather-resistant sealants for UAE heat, dust and moisture.

Scope

All external joints and penetrations

1.5 mm PVC/vinyl roll flooring in the offices, complete with 50 mm high painted MDF/PVC skirting, bonded and jointed to a neat durable surface.

Material

PVC / vinyl roll

Thickness

1.5 mm

Finish

50 mm painted MDF/PVC skirting

Areas

Offices and circulation

Skirting

50 mm MDF/PVC, painted

3 mm GRP lamination / PVC flooring to the toilet and pantry, turned up approximately 100 mm onto the walls to form a waterproof skirting.

Material

GRP lamination / PVC

Thickness

3 mm

Finish

100 mm upturn waterproof skirting

Areas

Toilet and pantry

Upturn

≈100 mm onto walls

9 mm cement board or approved equivalent closing the bottom perimeter of the cabin, finished to match the external wall colour and protecting the underside.

Material

Cement board

Thickness

9 mm

Finish

Painted to match external walls