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Project Case Study: MBC Post Production :

1. Project Overview

  • Project Name: MBC Post Production
  • Location: Narjis, Riyadh
  • Client/Owner: MBC Group
  • Architect/Designer: MBC Group
  • Contractor: Riyadh Villas Contracting Company
  • Project Duration: 03 Months

2. Project Background

  • Objective: Renovation of wet area walls in the existing living quarters
  • Building Type: Commercial
  • Scope of Work: Wet area Partition

3. Product and Material Details

  • Fiber Cement Board Brand/Type: ACFA Premium & ACFA Plus Boards
  • Thickness/Dimensions: 12mm ACFA Premium Board (2400mm x 1200mm) & 12mm ACFA Plus (2400mm x 1200mm)
  • Quantity Used: 600 Sqm
  • Key Product Features:
    • Durability
    • Fire Resistance
    • Moisture Resistance
    • Sound Insulation
    • Fast Construction

4. Installation Process

  • Preparation Work: It was the renovation of the existing wet area partition where the existing wet area wall was to be dismantled, the existing entrance to be shifted to the new partition to be erected and the door cutout to be closed with the partition. The wall assembly should be designed to give 45 dB sound insulation.
  • Installation Technique:
    • Fixing Methods: The total thickness of the partition wall was 150mm to match the existing block wall.  There was a dual requirement of matching the existing block wall and an STC rating of 45 dB. To match both requirements, we suggested a twin-frame partition system with a 50mm x 0.6mm GI frame @ 400mm c/c with an air gap between the 2 frames as per site conditions. The cavity inside the frames is filled with 50mm thick & 48 Kg/cum density Mineral Wool insulation. Both the frames are bridged together with 12mm ACFA board fillets of size 120mm x 50mm @ 600mm c/c. 2 layers of 12mm ACFA Premium & ACFA Plus Boards are fixed to both sides of the framework with 32mm and 45mm Screws. Care was taken to stagger the joints of all the layers of boards to avoid the leakage of sound.
    • Surface & Joint Treatments: A special Jointing and surface preparation methodology was adopted for the project. Jointing was done using 2 layers of jointing tape to reinforce and strengthen the joints on the wet area side where tiling will be done on the board surface. The complete board surface on the wet side was hacked to make it rough to increase the bonding between tiles, adhesives, and the board surface. All the periphery of the walls were sealed with Fire cum Acoustic sealant to avoid any leakages.
    • Painting/Finishing Work: On the wet area side the complete surface was tiled with 6mm thick ceramic tiles and the corridor side was painted after joint treatment
  • Challenges Faced: The wall thickness of the existing block wall was not uniform, therefore, the framework had to be customized for every room as per the site conditions. Also, it was a fast-track project, timelines were to be maintained both in the supply of material and handing over the finished site.
  • Solutions Implemented: The design and solution were successfully implemented and executed, and the site was successfully handed over to the client.

5. Outcomes and Benefits

  • Final Appearance: The partition wall was erected as per the requirement of the project. The solution provided was able to fulfil both the requirement of the project i.e. 150mm wall thickness and 45 dB STC rating. Apart from functional requirements, the board surface was able to take the tile cladding on the wet side and paint finish on the corridor side.
  • Performance Highlights:
    • Moisture Resistance
    • Sound Insulation
    • Fast Construction
    • Cost-effective solution
  • Client/Stakeholder Feedback: Looking at the technical and commercial support we had given, including the timely delivery of the materials at the site, RVCC showed confidence in us and implemented the solution as per our guidelines and supervision. They were able to hand over the site to their client on time and as per the client's requirements.

7. Key Learnings and Takeaways

  • Lessons Learned: Vendor management, Project planning, Working under tight schedule
  • Innovations/Unique Features Introduced: Twin framework with insulation in both the cavity to achieve the thickness of 150mm and 45 dB sound insulation.

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