ArchitecturalEnvelope Experts

Aluminum

Table of Contents

Company Introduction 2

Introduction to Aluminum Division 3-5

Services Offered 6-9

Design Services 10

Sustainability in Production and Design 11

Structural Design 12

The Principles of Façades-Design 13-17

Hybrid Systems 18-19

Expected Technical Work Output Chart 20-21

Derivatives and Expected Deliverables: Schedule 22-23

Thermal Modeling 24

Cladtech International Green Building Agencies 25

Aluminum Interior 26

Aluminum Workflow 27

Aluminum Machinery 28

COMPANY INTRODUCTION

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Cladtech International is the region’s leading building envelope specialist. Backed by Al Rajhi Holding,

a distinguished building solutions firm, we strive to provide our clients with comprehensive answers

to their needs.

Our vertically integrated business structure, including design, development and processing

capabilities, allows us to meet all your construction requirements. The Aluminium, Metals, Cladding

and Glass divisions offer a full range of services including the very best in customer care. No project

is beyond our capacity and we can respond to any challenge.

The company’s skilled craftsmen are capable of producing more than 600 bespoke, unitised wall

panels per day to the highest standard of quality. Using the latest technologies and techniques, they

ensure that Cladtech products continue to enjoy a reputation for excellence.

Line managers and quality control officials carefully check every step of the production process,

making certain your products arrive in perfect condition. Installation professionals are available to

assemble them into a customised whole.

Expert teams of engineers and consultants can enhance your project with unique integrated solutions

through value assessments and site management. Competitive pricing and built-in cost savings will

ensure the success of your venture in both the short and long term.

Cladtech. We are the solution.

INTRODUCTION TO CTI ALUMINUM DIVISION

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Cladtech InternationaI are specialists in the design, manufacture,

and installation of aluminium curtain walling, windows and

doors for every type of commercial and residential building.

CTI are equipped with a comprehensive range of modern

technology in aluminium fabrication.

CTI’s new factory is designed to take full advantage of modern

mass-production techniques to ensure highest levels of

accuracy combined with high outputs at optimum cost. All

design-work is generated in-house and all installation-works

are handled by CTI’s Contracts Department including all labour

and project management on site. This detailed integration of

personnel and plant is a guarantee of CTI’s capacity to deliver

even the most complex orders in a timely and efficient manner,

and to the standards specified by the Client.

Curtain walling techniques have been used to cover the

structural skeletons of high-rise buildings for over a hundred

years. Up to around 1960, steel (probably galvanized) was

the most commonly used material prior to the arrival of mass-

produced aluminium extrusions in the USA. The most famous

pioneer of aluminium and glass curtain wall technology was the

American Architect, Mies Van Der Rohe, who recognized the

colossal advantages of creating a building envelope using these

materials. Van Der Rohe described curtain walls as “LESS IS

MORE”. And today, at CT international we are committed to this

philosophy that curtain walling is still the most cost-effective

way to clad the exterior of a building structure and to maximise

the rented floor space for the developer.

Curtain walling is a grid (sometimes quite massive) of thousands

of metal components whose joints are formed mechanically,

that-is-to-say they are not welded. This system of mechanical

connection is designed to allow for all kinds of differential

movement over the life of the curtain wall including thermal

expansion and contraction, wind loads, building movements

and seismic effects. Nevertheless, the curtain wall’s main

function is to protect the interior of the building from air and

water penetration and so we can begin to appreciate the

complexity of creating a cladding system which can move and

yet maintain a high level of indoor comfort. How is this done?

Curtain wall is designed on the principle of allowing air and

water to partially penetrate the system and then to get rid of

it by means of pressure-equalised drained joints. Each curtain

wall panel or frame-member is designed to interlock with it’s

adjacent components to create a grid of enormous strength

INTRODUCTION TO ALUMINUM DIVISION

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when attached to the underlying building structure, while

allowing independent movement.

These principles acknowledge the need to provide a building

envelope which is, as far as possible, wind-proof, rain-proof

but remains light and elegant, thereby enhancing the aesthetic

appearance of the building. Frequently, the curtain wall is what

we actually see (mainly) when we look at a typical modern

structure.

CTI recognize that, in spite of every reasonable effort to prepare

the joints in the facade, it is likely that water way penetrate

at some location. This may be due to loss of adhesion in the

sealants, or through gaskets which have become partially

dislodged, possibly during installation, or subsequently. Since

there will be (potentially) many linear meters of joints in the

surface of a major curtain wall, CTI curtain walls are designed

on the “Rain Screen” principle which allows for some random

water-penetration through the external seals.

Following from this, CTI curtain wall systems incorporate

“pressure equalisation” which is a technique to neutralize

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any localized build-up of air pressure which might force it’s

way (together with water) through the inner seals and, thus,

into the building, Small openings, formed as notches, in the

joint-cavities allow water to drain horizontally left and right to

be carried down through the mullions and ultimately to the

exterior. Thus, the interior seals are not compromised, and the

rain screen system is able to perform it’s function which is to

protect the indoor environment.

As expected, the success of the system depends on accuracy

of fabrication and installation which depends on the high level

of professional attention to detail at CTI.

The design requirement for cutting and machining of extrusions

are prepared using Cad/Cam software which is integrated with

the factory equipment and directly programmed to carry out

all cutting and machining operations. On loading any particular

extrusion to the production line, the operation is substantially

automated through to completion of the manufacturing

sequence.

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INTRODUCTION TO ALUMINUM DIVISION

Seagram Tower, New York, 1958. Mies Van Der Rohe and Philip Johnson "Less is More"

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SERVICES OFFERED

Design Office

Employs specialized computer-assisted drafting

and design software for:

• Curtain wall and window wall systems

• Glass walls

• Structural steel

• Natural stone cladding

• Precast concrete

• Roofing

• Water proofing

• Metal stud systems

• GFRC Systems

• Mock-up drawings

• Installation Diagrams

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SERVICES OFFERED

Structural Engineering

• Complete structural analysis and design including

windload engineering

• Evaluation and testing of materials

• Evaluation of structural integrity of

proposed design solutions

• Buckling and stability analysis for façade designs

• Finite element analysis

• Large deflection and membrane stress analysis

• Thermal stress analysis

• Thermal transmission analysis of glazed aluminium

façades.

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SERVICES OFFERED

New Systems Design and Development

• Purpose-made and standard curtain walls

• Unitized

• Panelized

• Stick system

• Bolted frameless glass facades with

glass fins, stainless steel spider-

connections, patch-fittings etc

• Structural silicone glazing

• Window designs

• Sliding glass doors

• Sloped glazing and sky lights

• Cladding in a wide variety of materials

• Roofing and water proofing

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SERVICES OFFERED

Research and Development • Structural silicone testing

• Splice designs

• Expansion joints

• Adhesive anchors

• Mechanical anchors

• Gasket designs

• Blast resistance

• Hurricane resistance

• On-going development of Co. QA/QC

procedures.

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Cladtech International design engineers become involved

with the project architect and work closely with him from the

earliest concept stage of the project and through the many

steps required to start the delivery process. We are able to

develop practical and cost-effective design solutions which

take full account of aesthetic and performance requirements.

All of this detailed interaction between us and our Partners/

Clients is based on solid design and engineering principles

from our in-house resources.

In addition, CTI can produce value engineering experience to

ensure that all engineering proposals and solutions are not

over-designed and are kept within the project budget, but

without compromise to safety and long-term performance.

CTI are able to provide this strong advisory role across their

entire product range.

DESIGN SERVICES

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SUSTAINABILITY IN PRODUCTION AND DESIGN

Cladtech International has a strong belief in, and an equally

strong commitment to the principles of sustainability in all

our corporate activities. We thoroughly implement these

principles both internally as well as in our total interaction

with suppliers and clients at all levels. It is our clear objective

to exercise caution at every stage of our processing,

administration, manufacture and installation, in order to

minimize human impact on the environment.

As specialists in the provision of materials and systems to

form the building envelope we are concerned to achieve a

deep understanding of the total performance of our work in

the terms if energy efficiency, indoor comfort, daylight and

views and avoidance of condensation.

These are the fundamentals of good sustainable design for

the 21st century and we believe that our highly qualified

teams have the experience and knowledge to support

sustainable design and product-quality at least equal to the

best.

Façade Engineering ServicesThe building envelope is a key element in the creation of the

built environment. The selected cladding system at the heart

of the building fabric (Stick, Unitized, or Double Skin) must

perform a number of critical tasks without fail, namely:

To – Filter light

To – Moderate heat

To – Block infiltration of air and water

To – Enhance life cycle cost-benefit to the client

CTI provide the following services to the achieve these goals:

– Research, development and design

– Engineering

– Performance testing

– Thermal analysis

– Code and authority compliance.

Our main focus is on practical and buildable solutions

which can be efficiently realized by the State-of-the-Art

equipment and technology and by our experienced design

and production teams.

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Structural design is an engineering process to determine all

the “fail safe” aspects of a structure exposed to the most

severe and dynamic forces of nature.

All buildings are subject to movement, and the façade

engineer must predict and confirm the effect of complex

building motion in relation to the equality complex motion

of his materials which all have different coefficients of linear

expansion and contraction.

Façade engineering is a specialized link between Civil

Engineering and Architecture, and at Cladtech International,

we bring this expertise to our industry as specialists at this

critical interface, in all our project-work.

The structural design of the façade works at:

– Wind load deflection calculations.

– Glass strength and deflection calculations.

– Fixing methods.

– Sealant application and gasket design.

– Ease and efficiency of installation.

– Method statements.

In addition to the above, the structural design team must

assess the overall thermal performance of the façade with

regard to system U-values and glass performance.

Cladtech International undertake thermal modeling studies

to ensure that their metal works conduct the minimum

amount of heat to the structure and the room-interior even

under the most severe solar exposure.

Cladtech International also bring their expertise in glass to

produce high performance glazing products, in-house, to

meet the requirements of the project specification and to

minimize direct solar heat gain. In particular, our design team

has to ensure the CTI glass has an SHGC (Solar Heat Gain

Coefficient) to conform with the calculation by the Project

Mechanical Engineer for the capacity of the air-conditioning

equipment.

Finally, the structural design team must be aware of all the

current Green Building rating systems and municipal building

codes which are now in use throughout the Gulf region. This

is of particular importance for projects which require LEED

or Estidama Certification which apply to our industry.

STRUCTURAL DESIGN

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THE PRINCIPLES OF FAÇADE-DESIGN

"LESS IS MORE"The principle of attaching a glazed aluminum framework

to a concrete or structural steel skeleton was perfectly

demonstrated in 1958 by Mies Van Der Rohe and Phillip

Johnson in the famous 38-storey Seagram Tower, New York,

which is still in perfect condition today.

By means of highly durable bronze anodized extruded

aluminum profiles attached to galvanized steel brackets,

it was possible to create an elegant fully glazed building

envelope which also allowed the owners to maximize the

use of the floor space.

"STICK" SYSTEM CURTAINWALLEssentially, the “ Stick Curtainwall System” is constructed

on site using aluminum profiles to create a grid of transoms

and mullions all mechanically connected. The majority

of the work is ex-factory and the installation starts at the

bottom of the façade and proceeds upwards. Aluminum

components are attached to galvanized steel brackets

which have been accurately pre-fixed to the structure.

Stainless steel screws and bolts are used in order to prevent

anodic reaction between steel and aluminum. Stick System

Technology is relatively simple and competitive, although

its competitiveness today is somewhat offset by relatively

high labour cost and slow pace of installation. All glass has

to be installed on site and extreme care must be exercised

to ensure that all joints are perfectly sealed with appropriate

materials. In general, it is more difficult to incorporate

“rainscreen” principles and pressure equalization into

a typical stick system design. Furthermore, this type of

curtainwall construction may require external scaffolding

and this will, for practical purposes, limit the effective height

of the façade. It is not an appropriate technology for “fast

track” construction schedules and progress can also be

negatively affected by adverse weather.

In terms of aesthetics, the stick system depends on

pressure-plates to contain the vision glass and the spandrel

panels. The pressure-plates, in mill-finish aluminum, have

to be concealed by “snap-on” covers which project beyond

the plane of the glazing and are a strong visual characteristic

of the system.

A provision of weep-holes and drainage-slots is included to

allow water to drain to the exterior.

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PRINCIPLES OF FAÇADE-DESIGN

STRUCTURAL SILICONE CURTAINWALLIn today’s architecture, the main preference is for “flush

glazing” in order to avoid the solid appearance of the

standard stick-system grid. Thus, the stick system can

be adapted to a modification where the same millions

and transoms are bolted to the structure, but the glass

and spandrels are factory-assembled into aluminum

“carrier frames” which are clipped into place on site. The

advantages are:

– All panels can be flushed-glazed off site using structural silicone sealant.

– Site work is reduced.

– Installation programme accelerated.

– Openable windows and insulated spandrel panels can be accommodated.

– Frameless appearance achieved.

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PRINCIPLES OF FAÇADE-DESIGN

TW0 (2) SIDE STRUCTURAL CURTAINWALLThis is a popular curtainwall solution which employs

pressure plates and snap-on covers for the transome joints

and structural silicone for the mullions, thus providing

flush glazing whilst using the horizontal covers as a mainly

decorative feature.

Overall, the stick system curtain walling, still has a useful

position in contemporary architectural design, particularly

for low-rise buildings, and is a mature engineering concept

which has evolved over 50 years as a reliable and cost-

effective building envelope.

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UNITIZED (ON-LINE) CURTAINWALLThe astonishing progress in the design and construction of

very high-rise buildings over the past 25 years has called

for considerable innovation in the means of making and

installing the building envelope. Today, and no doubt in the

future, glass and aluminum will feature as the dominant

materials of choice to satisfy this “love affair” with glazed

façades.

The combination of taller buildings, faster construction

schedules and rising labour costs have lead to the

development of cladding systems which are substantially

built off-site and which are designed to the accelerate

installation productivity on site.

The unitized system curtain walling is logical response to

these demands and brings the benefits of mass-production

into play.

Unitization also makes use of advanced labour practices

in fabrication and supervision resulting in output of high

quality, close tolerances and fast efficient delivery.

For buildings higher than 20 floors, unitized curtainwall

panels can be attached by operatives working at the edge

of the slab in conjunction with a skilled crane operator.

All seals and gaskets are pre-installed and the connection of

one panel to its neighbour provides pressure-equalised self-

draining properties according to the “rainscreen” principle

to ensure no infiltration of air or water to the interior of a

building, and that smoke / fire-stop materials are correctly

and accurately positioned.

The system can accommodate openable windows and

spandrel panels with insulated back-pans.

PRINCIPLES OF FAÇADE-DESIGN▲

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CTI GLASS AVAILABILITY IN GB SECTION

DOORS AND WINDOWSFor virtually every type of building, CTI are able to offer a

very broad range of hinged and sliding aluminum doors and

windows. The use of robust hardware and well-designed

extruded aluminum profiles gives the CTI range of doors

and windows a combination of quality, serviceability and

durability to perform at maximum efficiency in the most

challenging environments. Door and Window glazing

is mainly sourced from CTI glass division and includes

tempered and laminated safety glass as well as insulated

glass units.

BOLTED FRAMELESS GLASS FAÇADESCTI are able to undertake full design, fabrication and

installation of bolted glazing systems incorporating stainless

steel patch-fittings, glass fins, spider connectors and a very

large combination of tension-rod designs.

CTI bolted glazing can be single or double glazed with

sourcing of structural tempered, tempered-laminated,

and tempered-laminated insulated units from CTI's glass-

processing division.

CTI are also able to undertake are all types of frameless

tempered glass for shop-lifting and partitions including

a wide range of frameless glass doors with standard or

customed-designed metal hardware

PRINCIPLES OF FAÇADE-DESIGN

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HYBRID SYSTEMS

Double Skin Façades

The principle of this technology is to provide a glazed

façade in which two separate glazed aluminum walls are

constructed with a large space between them. The inter-

space contains an openable blind system which can be

remotely controlled by a photo electric switch reacting

to ambient daylight / sunlight levels. Cooling of the inter-

space is done mechanically using low-voltage extractor-

fans located above the false ceiling, and, in some designs,

return the air back to the bottom edge of the curtainwall via

hollow-core concrete floor slabs.

Glazing in this type of system generally comprises a clear,

or light reflective, single glazed outer skin and a clear IG unit

with a low – E coating on surface # 2 as the inner skin. It is

effectively a triple-glazed system in which solar control is

achieved by the internal blinds.

There are no openable windows in the system and all room

and inter-space ventilation is done mechanically.

Although coming at a relatively higher cost, double skin

façades claim to be cost-effective by providing high levels

of daylight and insulation due to their sophisticated control

mechanism.

1919

2020

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EXPECTED TECHNICAL WORK OUTPUT CHART

I . 1. – ARCHITECTURAL

– Plan

– Elevation

– Sections

2. – STRUCTURAL

– Embeded layout

– Bracket Detail

II. CONCEPT / SYSTEM DRAWINGS

III. DIE DRAWINGS

IV. PERFORMANCE MOCK-UP

V. SHOP DRAWINGS

VI. FABRICATION DRAWINGS

VII. INSTALLATION DRAWINGS

– Cast in

– Panel layout and I.D.

VIII. MATERIAL TAKE-OFF

IX. AS BUILT

PRE AWARDED

X. TENDER DRAWINGS

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TENDER STAGE

DERIVATIVES DELIVERABLES END USE END USER

EXTERNAL INTERNAL

• Architectural drawings/input

– Plans – Section – Elevation – Details – Perspective

• Specification

• BOQ

DERIVATIVES AND EXPECTED DELIVERABLES: SCHEDULE

• Tender / System Design

• System Drawings – Typical Plan/ section/elevation – Details – Isometric/ Perspective – Initial Project Milestone – Engineering Cost

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AWARDED STAGE

DERIVATIVES DELIVERABLES DERIVATIVES END USE END USER

EXTERNAL INTERNAL

A1 • Construction Schedule

• Architectural Drawings(100%) – Plans – Section – Elevation – Details

A2 • Structural drawings – Floor slabs – Beam/column schemes – Walls/blockwork

A3 • Specifications drawings

A4 • BOQ (Cost/price not required

DERIVATIVES AND EXPECTED DELIVERABLES: SCHEDULE

Planning Dept.B1 • Schedule

Commercial Dept.B2 • Tender Drawing • Eng'g cost • Tendered Milestone

PurchasingB3 • Material availability • Material cost • Material lamination • Material cost value

FabricationB4 • Production limitation • Production cost value

Project ManagementB5 • Method statement • Installation sequence • Installation/ site limitation

Technicalwork schedule

manpower allocation

• Project milestone

• System design development

• Die Drawing

• Structural calculation

• Project specs.

• Visual mock-up drawing

• Shop drawings – Developement – Layout/module plan – Embeded layout – Panel tag layout – Joinery detail – Isometrics• Fabrication• MTO – Bulk – Release

A1B1

REQ'D

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THERMAL MODELING

Depending on various parameters, the solar radiation

that strikes any glass surface is partly transmitted, partly

absorbed and partly reflected. Basically, the major part that

is used to define the thermal behavior of curtain wall is the

thermal transmittance of surface or U-value. Arithmetically,

the U-value (the overall heat transfer coefficient) of material

defines the rate of heat transfer through an element over a

given area and under standardized conditions.

The significant part of the cooling load in a building is due to

solar heat gains subject to the area of the façade cover. So

the thermal constraint in designing the façade in hot regions

is on how to minimize the solar heat gain. On the other

extreme end of building envelope design, the heating load of

a given space, in cold climate region, is highly influenced by

the proposed envelope.

For the above major reason, thermal analysis of curtain wall

is carried out analytically. The output of the analysis finally

reflects the heat exchange phenomena between the two

separated environments and measures the thermal efficiency

of the system. As part and parcel of the structural verification

CTI carries out the representative thermal analysis for all

systems adopted in a project.

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CLADTECH INTERNATIONAL AND GREEN BUILDING AGENCIES

Sustainable Façade Design

It is an alarming fact that the UAE has one of the world’s

largest per capita carbon footprints, and is among the top three

countries for GHG emissions.

Our cooling dominated environment, ultra-low rainfall and

minimal cloud-cover result in an extremely high demand for air-

conditioning and water. Over 70% of the power generated in

the UAE is for cooling.

Considering that the main source of heat gain is through

the window, it can be seen that thermal efficiency and solar

resistance are of paramount importance in the design and

construction of modern façades.

In recognition of the urgent need to raise the standard of

building design in our region there is now a growing adherence

by developers, government agencies and designers to the

principles of the LEED Green Building Rating System. LEED

(Leadership in Energy and Environment Design) is a guide

to sustainable design and is, at the option of the client, a

certification process at various levels of compliance which are:

1. Certified only

2. Silver grade

3. Gold grade

4. Platinum grade

Recently, the government of Abu Dhabi has established the

Estidama Pearl Green Building Rating System which has been

created with special attention to Gulf Environmental Conditions.

Estidama is a guide to sustainable design and, like LEED, is

certifiable according to Pearl Awards at the following levels:

1. Pearl (least stringent)

2. Pearls

3. Pearls

4. Pearls

5. Pearls (most stringent)

The government of Abu Dhabi has ordered that all new

Government buildings must be designed at least up to 2 Pearl

standard.

Both LEED and Estidama are strongly supported by the current

American ASHRAE 90.1 Standard.

LEED and Esitidama place a high degree of importance on

three critical aspects relating to the design of the building

envelope, namely:

1. Energy and atmosphere.

2. Daylight and views including indoor air quality.

3. Regional sourcing and recycling of materials.

Together, these three categories can potentially account for

over 45% of the points required to achieve a LEED Platinum

or a 5-Pearl Estidama sustainable design rating.

Cladtech International is well placed to enable it’s clients

to earn valuable points at every level of Green Building

Certification as a result of:

– Thermally efficient designs.

– Locally-produced extrusions and gaskets.

– Locally-produced float glass.

– Locally-produced solar reflective and low – E glass.

– In-house glass processing.

– In-house anodizing and powder coating.

– Recycling of metal waste.

– Partial re-cycling of glass waste.

Furthermore, CTI engineers are well-qualified to work with

architects and LEED AP’s (Accredited Professionals) and

Estidama AP's to assist in the achievement of competent

sustainable façades which, potentially, can make a significant

contribution of the UAE’s progress in lowering GHG emissions

and shrinking it’s swollen national carbon footprint.

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ALUMINUM INTERIOR

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ALUMINUM WORKFLOW

ALUMINUM MACHINERY

INSTALLATION

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www.cladtech-int.com

UAE : Tel.: +971 7 244 61 14 Fax: +971 7 244 61 12 P.O. Box 6674 Ras Al Khaimah, UAE

KSA : Tel.: +966 (1) 219 05 66Fax: +966 (1) 293 57 52P.O. Box 18927 Riyadh, KSA