Brands and Partners

Celebrating a Year of Unprecedented Success

GENAVCO, a leading name in the Heavy Equipment sector in the UAE, recently had the privilege of hosting a prestigious delegation led by Mr. Jason Ambroson, the Managing Director of Wirtgen International. The visit marked a pivotal moment in the ongoing collaboration between the two industry giants and unfolded as a comprehensive review of the remarkable achievements of 2023. The high-level delegation represented six prominent companies under the Wirtgen Group banner, including Vogele, Hamm, Wirtgen, Benninghoven, Kleemann, and Streumaster. The purpose of the visit extended beyond a routine performance review; it aimed to delve into strategic discussions regarding the business plan and collaborative strategies for the upcoming year, 2024. A focal point of the visit was GENAVCO's all-new facilities in Umm Ramoul, meticulously designed to meet the demands of the rapidly evolving Heavy Equipment sector. The delegation was given an immersive tour, providing insights into the latest technological advancements and operational excellence embedded in the facility. The state-of-the-art infrastructure left an indelible impression on the Wirtgen Group delegates, reinforcing the strength of the partnership. As the review of 2023 performance unfolded, it became evident that this year had been truly exceptional, setting records for Wirtgen Group products. GENAVCO's effective distribution network and commitment to excellence played a pivotal role in achieving these milestones, highlighting the synergy between the two entities. Strategic discussions centered on aligning business plans and formulating forward-looking strategies for 2024. The collaborative efforts aim to leverage market trends, embrace technological innovations, and address evolving industry demands. Mr. Jason Ambroson, Managing Director of Wirtgen International, expressed his overwhelming appreciation for GENAVCO's role in the success of Wirtgen Group products in the region. He commended GENAVCO's dedication, expertise, and its pivotal position as a strategic partner. "We are delighted to witness the remarkable growth and success achieved by GENAVCO in 2023. The dedication, expertise, and state-of-the-art facilities exemplify the qualities we value in a strategic partner. The collaborative spirit between Wirtgen Group and GENAVCO is a driving force behind our shared success," remarked Mr. Ambroson. As the collaboration between GENAVCO and Wirtgen Group continues to strengthen, the two entities look forward to shaping the future of the Heavy Equipment sector, setting new benchmarks and redefining industry standards.

Big 5 Dubai: Genavco shows off its family of equipment, debuts new partner brands

Juma Al Majid Group company Genavco brings its big-name principals such as Denair, JLG, Avant Tecno, Husqvarna, Bull, Hamm and others to region's largest construction sector event The Big 5 Heavy saw UAE-based equipment and vehicles heavyweight Genavco bring several of its important brands to the event. The Juma Al Majid Group company, which represents some of the biggest names in the road-construction equipment, AWP, earthmoving and various other segments, exhibited together with its partners at Big 5. The Genvaco stand saw representatives and machinery from Denair compressors, Bull compact earthmoving equipment, access sector heavyweight JLG, Avant Tecno and Husqvarna, apart from other brands the company represents such as Hamm. Speaking about Genavco’s brands exhibited at Big 5, Asif Sayeed Khan, General Manager, Heavy Equipment, Genavco, said: “We have a leading position in the road construction segment, where we represent the Wirtgen Group of brands, comprising the Wirtgen milling machines, Vogele asphalt pavers and Hamm rollers and compactors. We are by far the market leaders in this segment in the UAE for many years now. All the road contractors are our key customers. The airports and major highways in the country have been built using machines that we have supplied. “We have had great success in 2023 with Hamm compaction equipment and we are planning to go aggressively into the soil compaction segment in 2024. Bull is a new partner for us and a promising one, too, on the compact earthmoving side. Genavco Power Solutions “Last but not least, we have our own brand, GPS or Genavco Power Solutions, with products powered by John Deere engines, which we also represent. We offer generators starting from 30KVa to 3,000KVa and we can also offer them with Perkins or Cummins engines. We use another quality product – Leroy Somer – on the alternators side.”

Group holds 2022 performance awards ceremony

During a ceremony held on 25 January 2023 at the Le Méridien Dubai Hotel & Conference Centre, Mr. Tarig Shalabi, Group Chief Operating Officer for Juma Al Majid Holding Group, hosted and awarded the best performing business units and over 100 employees from across the Group’s businesses and divisions for their respective 2022 performance. Congratulating the best performing business units on receiving their awards, Mr. Tarig Shalabi said: “2022 was an exceptional year and multiple business units performed well, however this time it was Genavco and Juma Al Majid Est/Hyundai UAE who performed outstandingly well and each deserving the title of Number 1 Best Performing Business for their efforts, delivery of their KPIs and performance throughout 2022.” The ceremony was also attended by members of the C-suite team, Mr. Abdullah Al Majid - Executive Director, as well as directors, general managers, and executives from across the group’s businesses and divisions. The ceremony also included individual awards for performance delivered beyond expectations: - Special Award: Mr. Vijayan Asirvadam for securing savings in the millions of UAE Dirhams to Gulfco’s opera- tions; it is worth noting that Mr. Asirvadam was awarded a KIA Sonnet as a thank you for his outstanding performance. - Best Salesman of the Year: Mr. Hamid Muhd Iqbal for exceeding his vehicle sales target for Isuzu at Genavco. Addressing the attendees, Mr. Shalabi said: “All employees, irrespective of grade level, role or position contribute towards delivering the KPI’s of any organisation. With this in mind, I am pleased to announce that this year we are recognizing those employees – grade 7 and below – for their exceptional individual efforts and contributions to the businesses they are part of. We are also recognizing the Group’s best drivers, best security guards and supervisor, and best labor camp and the team behind it.” Mr. Shalabi continued: “These employees went above and beyond their job responsibilities to deliver excep- tional performance, and for that it gives me great pleasure to award each of them with a certificate and a financial reward. On behalf of the Group, I would like to convey my sincere gratitude for their contributions, outstanding performance, dedication, and professionalism.” The Ceremony ended with Mr. Shalabi stating: “We have by far exceeded all the KPI’s we had set – so thanks to all for the great performance and hard work… congratulations once again to all the winners, and I look forward to your contributions and equally impressive results in 2023.”

Truck & Fleet Awards ISUZU

In a gala dinner held at the Raffles Hotel in Dubai, Truck and Fleet Magazine voted ISUZU N-Series as the Light Duty Truck of the Year for 2021. 3,000 people along with a specially recruited judging panel voted in the awards aimed at celebrating manufacturers and dealers whose trucks play a key role in the operations, logistics and projects at the heart of the region’s economy. The awards honor the achievements of the key players responsible for the industry’s dramatic post-Covid re-set. With its singular combination of cutting-edge safety features, unbeatable performance, effortless drive-ability, unparalleled driver comfort, low operating costs, and high productivity, the ISUZU N-Series ticks all those must-haves for business and fleet owners alike – it’s little wonder it was voted the Truck & Fleet Light Duty Truck of the Year award. The N-Series lineup covers a comprehensive array of models between 4,550 to 8,500 GVW (Kg) - designed to handle the full range of trucking needs of any business. This smart and innovative series has garnered a strong following around the world and certainly in the UAE too. “I am proud of my team for their dedication and hard work over the past 3 years – this award is dedicated to them” said Anton Du Plessis, General Manager – Commercial Vehicles Division at GENAVCO, the exclusive distributor for ISUZU in the UAE.  

Once a jaw crusher has reduced quarried rock to a manageable size, something has to take it down to saleable gradings. In hard, abrasive stone — which describes most of what is quarried in this region — that machine is almost always a cone crusher. The reason is economic rather than technical. An impact crusher would produce better-shaped aggregate from the same feed, but in abrasive rock it consumes blow bars at a rate that makes the cost per tonne uncompetitive. The cone crusher trades some product shape for wear part economics, and in hard stone that trade is decisively worth making. This guide covers how a cone crusher reduces material, why choke feeding matters more than any other operating variable, how closed side setting controls product, and the Kleemann MOBICONE machines GENAVCO supplies. How a Cone Crusher Works A cone crusher reduces material between two conical surfaces. The outer one — the concave — is fixed. The inner one — the mantle — sits on a shaft that gyrates, so it sweeps toward and away from the concave continuously around the full circumference. Material entering the top falls into the gap between them. As the mantle sweeps toward the concave at any given point the material is compressed and fractures; as it sweeps away the material drops further into the narrowing chamber. This repeats until the material passes the closed side setting at the discharge. The important difference from a jaw crusher is that crushing happens continuously around the circumference rather than in a single reciprocating action. That means more crushing events per unit of time and a higher reduction ratio, which is why the cone sits second in the circuit rather than first. It also means the machine depends on being kept full. A cone crusher does much of its work through particle-on-particle crushing, and that only happens when the chamber is packed. Choke Feeding: The Single Most Important Operating Variable More cone crusher performance is lost to feeding technique than to any other cause, and the mechanism is worth understanding properly. A full chamber crushes material against itself: When the chamber is packed, particles are compressed against each other as well as against the mantle and concave. This inter-particle crushing produces better reduction, better product shape and — critically — spreads wear across the whole liner surface. A partly full chamber does not: With insufficient material, particles are crushed only between mantle and concave. Reduction falls, shape worsens, and the wear concentrates in a narrow band where the material happens to sit. Uneven distribution wears one side: Material entering off-centre wears the liners asymmetrically. The machine then produces inconsistent products and the liners reach end of life with usable material remaining on the opposite side. Continuous feed control maintains it automatically: Systems that match the feed rate to actual crusher loading keep the chamber choke-fed without the operator having to manage it manually through the shift. The practical test is straightforward: if the feed is visibly surging, or the chamber can be seen to empty between loads, the machine is producing below what it is rated to deliver and wearing unevenly while doing so. Closed Side Setting and Product Control The closed side setting — the smallest gap between mantle and concave during the gyration cycle — is the primary control over what the machine produces. Adjustment Effect on product Effect on operation Tighter setting Smaller top size, more fines Lower throughput, higher wear rate Wider setting Larger top size, fewer fines Higher throughput, lower wear rate Setting drifts wider (wear) Product top size creeps up Recirculation rises, gradings fail testing Setting drift is the routine issue. As the mantle and concave wear, the effective gap widens and product top size creeps upward. Because it happens gradually, it is usually noticed when the product fails a grading test rather than when it starts. Checking and resetting on a schedule is considerably cheaper than reprocessing an out-of-specification stockpile. Advantages of a Cone Crusher as Secondary These are the characteristics that make it the standard second stage in hard rock circuits. Excellent economics in abrasive stone: Compression crushing consumes wear parts far more slowly than impact crushing in hard siliceous material, which dominates cost per tonne over a season. High reduction ratio: Continuous crushing around the full circumference achieves more reduction per pass than a reciprocating machine. Consistent product gradings: With a stable closed side setting and choke feeding, output gradings are repeatable shift to shift. High throughput for the footprint: Substantial tonnage from a machine that occupies comparatively little space in the circuit. Long liner life when fed correctly: Choke feeding spreads wear across the full liner surface rather than concentrating it in a band. Adjustable to changing specifications: Closed side setting can be changed to shift the product balance when demand moves between gradings. Overload protection as standard: Systems that release on uncrushable material protect the machine rather than requiring perfect feed screening. Designed to pair with a matched primary: Manufacturer-specified jaw and cone combinations remove the guesswork from balancing the two stages. Kleemann MOBICONE Cone Crushers Available in the UAE GENAVCO supplies Kleemann crushing and screening equipment in the UAE. Two MOBICONE machines cover secondary crushing duty. 1. MOBICONE MCO 90i EVO2 — hard stone secondary Built as a secondary in hard stone, combining the product quality expected from a cone crusher with high production output and straightforward operation. Feed size: 200 mm Output: 270 t/h Drive: D-DRIVE (diesel-direct) Feed control: Continuous Feed System (CFS) for optimum crusher loading Protection: Innovative overload systems for protecting the crusher Control: Simple and intuitive SPECTIVE control concept Circuit: Linkage option with other KLEEMANN plants The Continuous Feed System is worth more on a cone crusher than on any other machine type, because choke feeding is what delivers inter-particle crushing. Automating it removes the largest source of variability between operators and between shifts. View the MOBICONE MCO 90i EVO2 2. MOBICONE MCO 110i PRO — high-output secondary The PRO Line secondary, characterised by extremely robust design and very high performance, with the option of running from an external power source. Feed size: 240 mm Output: 470 t/h Drive: E-DRIVE (diesel-electric), with option to connect an external power supply Construction: Extremely robust design Operation: Very high production output with low-maintenance operation Circuit pairing: Optimal combination with upstream jaw crusher MOBICAT MC 120i PRO Kleemann specifies this machine as the matched partner to the MOBICAT MC 120i PRO jaw crusher, which removes the balancing calculation between primary and secondary. On sites with a mains connection, the external power option changes the cost per tonne materially, since the secondary typically runs the most hours of any machine in the circuit. View the MOBICONE MCO 110i PRO Not sure which secondary suits your rock? Send us your material type and abrasiveness, the feed size from your primary and your target gradings - our team will size the secondary and check the circuit balance. Request a Secondary Crushing Specification Mantle and Concave Wear Liners are the main consumable in cone crushing, and their consumption is the largest single variable cost after fuel. Abrasiveness sets the baseline: Hard siliceous rock wears liners considerably faster than softer material. Liner life quoted without reference to material is not a useful figure. Choke feeding extends life substantially: Spreading wear across the full liner profile rather than concentrating it in a band is the single largest controllable factor in liner life. Uneven wear indicates a feed distribution problem: Liners worn asymmetrically mean material is entering off-centre. Correcting the feed arrangement recovers the wasted liner life at no equipment cost. Running too tight accelerates everything: Attempting excessive reduction in one pass raises wear rate, power draw and the risk of packing. The secondary should hand the remaining reduction to a tertiary stage or a screen rather than absorbing it all. Liner profile should match the duty: Coarse, medium and fine chamber configurations exist for a reason. A liner profile mismatched to the feed produces poor reduction regardless of how well the machine is operated. Secondary Crushing in UAE Conditions Regional rock favours compression crushing: Hard abrasive formations are exactly where cone crushers earn their position over impact machines, and it is the main reason jaw-and-cone circuits dominate quarrying here. Dust accelerates wear beyond the liners: Fine abrasive dust reaches bearings and seals as well as the crushing chamber. Filtration and lubrication schedules should follow the environment rather than a manual written for temperate conditions. Heat raises hydraulic and lubrication temperatures: Cone crushers run a lubrication circuit that must stay within temperature. Sustained ambient heat reduces the cooling margin, so positioning and cooler cleanliness become production issues rather than maintenance details. Continuous operation compresses maintenance windows: Where a plant runs extended shifts to meet aggregate demand, liner changes have to be planned into the production schedule rather than fitted in when output drops. Why Choose GENAVCO for Crushing Equipment in the UAE Buying the machine is the easy part. What determines whether the investment performs is everything that happens afterwards. Part of Juma Al Majid Holding Group: Decades of established presence in the UAE market and the financial stability that comes with a major regional group — this matters when you are signing multi-year service agreements. Authorised Kleemann representation: Genuine equipment, factory-backed specification and full warranty integrity — not grey-market imports with uncertain parts availability. Liners and wear parts held locally: Liner changes are planned events and the secondary usually runs the most hours in the circuit. Our genuine spare parts operation holds stock in-country so a change does not become a shutdown. Certified service and maintenance: Scheduled servicing, preventive maintenance and on-site breakdown response through our repairs and maintenance division across Dubai, Abu Dhabi, Sharjah and the wider UAE. Operator training: Choke feeding and setting discipline decide output, product and liner life. Our operator training centre covers correct operation and daily checks. Matched circuit specification: We specify the secondary against the primary feeding it and the screens following it. The framework is set out in our guide to designing a crushing circuit. Depth across quarry and mining: Crushing and screening within our wider quarry and mining equipment range. Common Cone Crusher Problems Product top size creeping upward: Closed side setting has drifted wider as liners wear. Routine checking and resetting prevents the out-of-specification stockpile that otherwise reveals it. Throughput below rating: Almost always insufficient feed rather than machine capability. A chamber that is not choke fed produces well below its rating and wears unevenly at the same time. Liners worn on one side only: Material entering the chamber off-centre. Correcting feed distribution recovers the linear life being wasted on the opposite side. Poor product shape: Under-fed chamber removing the inter-particle crushing that produces better shape. Choke feeding usually resolves it without changing machines. Frequent overload releases: Uncrushable material reaching the chamber, or feed top size exceeding what the machine should accept from the primary. Rising power draw at constant output: Often liner profile worn out of shape, or an attempt to take too much reduction in a single pass. Frequently Asked Questions How does a cone crusher work? Material is compressed between a fixed outer concave and a gyrating inner mantle. As the mantle sweeps toward the concave the material fractures, and as it sweeps away the material drops further down the narrowing chamber. Crushing happens continuously around the full circumference, giving a higher reduction ratio than a jaw crusher. What is choke feeding and why does it matter? Choke feeding means keeping the crushing chamber consistently full. A full chamber crushes particles against each other as well as against the liners, which improves reduction and product shape and spreads wear across the whole liner surface. An under-fed chamber produces less, shapes worse and wears unevenly. Should I choose a cone crusher or an impact crusher for secondary duty? It depends mainly on the rock. Hard abrasive stone favours a cone crusher, because impact crushing consumes blow bars rapidly in that material and the cost per tonne becomes uncompetitive. Softer stone and recycled concrete favour impact crushing, which also produces better-shaped aggregate. What is the closed side setting on a cone crusher? It is the smallest gap between the mantle and the concave during the gyration cycle, and it is the main control over product top size. As liners wear the effective setting widens gradually, so it should be checked and reset on a schedule rather than when the product fails testing. How long do cone crusher liners last? It depends primarily on the abrasiveness of the material and on how consistently the machine is choke fed. Hard siliceous rock wears liners considerably faster, and an under-fed chamber concentrates wear in a narrow band that shortens usable life well before the full profile is consumed. Does GENAVCO supply spare parts and servicing for the Kleemann plant in the UAE? Yes. GENAVCO holds genuine parts in-country and operates a certified service network covering Dubai, Abu Dhabi, Sharjah and the wider UAE, with preventive maintenance programmes, operator training and on-site breakdown support. Ready to Specify Your Secondary Crusher? Cone crusher performance comes down to two things: keeping the chamber full and keeping the setting where it belongs. Both are operating disciplines rather than purchasing decisions, and both make more difference to cost per tonne than the choice between two comparable machines. GENAVCO supplies the full Kleemann MOBICONE range across the UAE, backed by genuine parts, certified service and operator training. For the stage that feeds it, see our guide to jaw crushers for primary crushing. Tell us your rock and your target gradings. We will size the secondary and price it properly. ENQUIRE NOW — GET YOUR SECONDARY CRUSHING SPECIFICATION Serving Dubai, Abu Dhabi, Sharjah and the wider UAE.

Earthmoving is the first trade on site and frequently the last. Before anything is built, ground has to be cleared, cut, filled, levelled and compacted — and the fleet chosen to do that work determines the programme for everything that follows. The mistake most operations make is buying machines individually. A site fleet is a system: the excavator loads what the trucks carry, the dozer pushes what the excavator cannot reach, the grader finishes what the dozer roughs out. Specify them in isolation and you end up with capacity sitting idle in one place and a bottleneck in another. This guide covers what each class of earth moving equipment is built to do, how to match machines to the work, what drives cost across a fleet, and the Shantui range GENAVCO supplies in the UAE. What Each Machine Class Is Actually For Every earthmoving machine is a compromise between digging, carrying, pushing and finishing. Understanding which of those a machine is optimised for prevents most specification errors. Excavators dig: A boom, arm and bucket on a rotating superstructure, digging below the machine and loading to the side without repositioning. The most versatile machine on site and the natural centre of most fleets. Wheel loaders carry: A bucket on a front linkage with rubber tyres underneath. Built to scoop loose material and move it over distance at speed, which is a different job from digging into undisturbed ground. Bulldozers push: A blade on a tracked chassis with the traction to move large volumes of material short distances, and the ground pressure to work on soft or uneven terrain where wheels would sink. Motor graders finish: A long wheelbase and an adjustable blade between the axles, producing the accurate, flat surface that a dozer cannot. This is a precision machine, not a bulk earthmoving one. Matching Machines to Site Tasks Task Primary machine Why Bulk excavation Excavator Digs below grade and loads trucks without repositioning Truck loading from stockpile Wheel loader Faster cycle on loose material than an excavator Site clearance and stripping Bulldozer Blade width and traction move volume over short distance Cut and fill over distance Bulldozer Pushes material where haulage would not be economical Subgrade levelling Motor grader Blade between axles produces accurate finished level Haul road maintenance Motor grader Restores surface and profile quickly across long runs Material rehandling in yards Wheel loader Travel speed and manoeuvrability over repeated cycles Two of these decisions have enough depth to warrant their own guides. Loader selection and the load-and-carry question are covered in our guide to wheel loaders for load and carry, and the undercarriage question — whether an excavator should run on tracks or tyres — in our guide to choosing an excavator undercarriage. Sizing the Fleet, Not the Machine Fleet productivity is governed by how machines feed each other, and a fleet is limited by its slowest link in exactly the way a crushing circuit is. Match the loading tool to the haulage: An excavator should fill a truck in a sensible number of passes — too few and the bucket is oversized for the truck, too many and the truck waits. This ratio determines both machine sizes. Count the trucks the loading tool can serve: Cycle time and haul distance determine how many trucks one machine keeps busy. Too few and the loader stands idle; too many and trucks queue, which is the more expensive error. Decide push distance before choosing dozer over haulage: Bulldozers move material economically over short distances. Beyond that, load-and-haul becomes cheaper. Knowing where that crossover falls for your site prevents buying the wrong solution entirely. Plan for the finishing trade: Bulk earthmoving that leaves an inaccurate surface creates grader work, and grader time is more expensive per cubic metre than dozer time. Getting the bulk work closer to level reduces the finishing bill. Advantages of Specifying a Fleet Correctly These benefits come from fleet composition rather than from any individual machine. Machines stay loaded: A balanced fleet keeps every unit working rather than paying for capacity that stands waiting on another machine. Lower cost per cubic metre: Fuel, hours and operator time spread across more moved material when the fleet is matched. Shorter programme: Earthmoving is on the critical path for most projects, and a fleet that does not bottleneck delivers the platform sooner. Less rework on levels: Bulk work brought closer to finished level reduces expensive grader and hand-finishing time. Predictable fuel budgeting: Machines working within their design envelope consume fuel at forecastable rates rather than being pushed beyond efficient output. Longer machine life: Equipment used for the work it was built for wears at expected rates, rather than a loader being used to dig or a dozer to finish. Simpler parts holding: A fleet from one manufacturer shares filters, fluids and service intervals, which reduces stock and technician training. Better resale position: Machines with documented, appropriate use hold value considerably better than those worked outside their intended application. The Shantui Range Available in the UAE GENAVCO supplies Shantui construction machinery in the UAE. Shantui was founded in 1980, is one of the top 50 construction equipment manufacturers worldwide, and holds more than 140 individual model numbers in its catalogue. The table below sets out the range GENAVCO carries. Machine Class Published range Bulldozers Tracked dozer 80 hp to 900 hp across mechanical, hydraulic, hydrostatic and electric types Wheel Loaders Wheeled loader 1 m³ / 60 kW up to 3.5 m³ / 175 kW, with larger models available Excavators Excavator 5.8 t / 0.2 m³ / 35.5 kW upward, built through the Komatsu joint venture Motor Grader Series Motor grader 15.4 t / 118 kW / 3,660 mm blade to 16.2 t / 160 kW / 4,270 mm blade Forklift Series Material handling Added to the Shantui line in 2007 Two machines are worth examining in detail here — the primary bulk earthmoving machine and the finishing machine, which between them define much of what an earthmoving fleet can do. 1. Shantui Bulldozers — 80 hp to 900 hp Shantui is the world’s largest bulldozer producer by production and sales, and the dozer line remains the strongest part of the range. Power range: 80 hp to 900 hp Types available: Mechanical, hydraulic, hydrostatic and electric Applications: Mines, forests, deserts, wetlands and coal fields SD16: 160 horsepower SD22: 220 horsepower SD90-C5 D11: 900 horsepower crawler bulldozer, the largest in the Shantui range Construction: Advanced structure providing reliable performance with convenient and flexible operation Desert working is named explicitly in the application list, which matters regionally. Soft sand demands low ground pressure and sustained traction, and it defeats wheeled machines that would perform adequately on firmer ground. View Shantui bulldozers 2. Shantui Motor Grader Series — precision finishing The finishing machine in the earthmoving sequence, producing the accurate, consistent surface that bulk earthmoving cannot deliver on its own. Operating weight: 15.4 tonnes to 16.2 tonnes Engine power: 118 kW to 160 kW Blade width: 3,660 mm to 4,270 mm Model series: SG16-3, SG18-3 and SG21-3 — similar characteristics with graduated engine size and power ratings, the "3" denoting the third generation SG19-B6: 151 kW, 16 tonnes, 3,965 mm blade SG21-3 features: External gears for high torque transference, linked swing frame for easy operation, capable of handling high workloads under harsh conditions Motor graders sit across the boundary between earthmoving and road construction, and are equally at home maintaining haul roads on an earthworks site or preparing subgrade ahead of the paving train. The road side of that work is covered in our road construction equipment range. View the Shantui motor grader series Planning a site fleet rather than a single machine? Send us your volumes, haul distances, ground conditions and programme — our team will size the fleet so the machines feed each other rather than bottleneck. Request a Fleet Specification What Drives Earthmoving Fleet Cost Purchase price is the visible number. Across a working life, fuel, operators, tyres or undercarriage, and downtime dominate. Machine size and power - the largest single factor, and the one most often specified above what the work requires Undercarriage or tyres - tracked machines consume undercarriage; wheeled machines consume tyres, and both are substantial recurring costs Attachment specification - bucket types, blade configurations and quick couplers Cab specification - air conditioning is not optional for sustained UAE summer operation Fuel consumption at working load - the figure that matters is consumption while producing, not idle or rated Operator availability - machines requiring specialist operators carry a hidden cost in a tight labour market Transport and mobilisation - weight and dimensions determine trailer class and permits between sites Service package - full maintenance contract versus parts-only support The figure that matters is cost per cubic metre moved, not the invoice. A correctly matched fleet moves more material per litre of fuel and per operator hour than an assortment of individually good machines. Ask any supplier to model it at fleet level rather than machine by machine. Earthmoving in UAE Conditions Sand behaves differently from soil: Loose desert sand offers poor traction and low bearing capacity. Tracked machines with low ground pressure work where wheeled equipment struggles, and this shapes fleet composition more here than in most markets. Heat is an operator issue before it is a machine issue: Sustained summer temperatures degrade concentration and productivity long before they affect the equipment. Cab air conditioning is a productivity specification, not a comfort one. Dust load shortens service intervals: Air filters and cooling packs load far faster than temperate-climate schedules assume. Intervals should follow the environment, particularly on machines working in their own dust cloud all shift. Night working is common on infrastructure: Lighting, visibility and machine sightlines matter more under artificial light, and fatigue management becomes part of the productivity calculation. Abrasive ground consumes ground engaging tools: Teeth, cutting edges and blade wear parts are consumed faster in abrasive material and should be budgeted realistically rather than from manufacturer baselines. Why Choose GENAVCO for Earth Moving Equipment in the UAE Buying the machine is the easy part. What determines whether the investment performs is everything that happens afterwards. Part of Juma Al Majid Holding Group: Decades of established presence in the UAE market and the financial stability that comes with a major regional group — this matters when you are signing multi-year service agreements. Authorised Shantui representation: Genuine equipment, factory-backed specification and full warranty integrity — not grey-market imports with uncertain parts availability. In-country spare parts inventory: A stopped machine holds up every trade behind it on an earthworks programme. Our genuine spare parts operation holds stock locally so filters and wear parts do not become programme delays. Certified service and maintenance: Scheduled servicing, preventive maintenance and on-site breakdown response through our repairs and maintenance division across Dubai, Abu Dhabi, Sharjah and the wider UAE. Operator training: Technique determines fuel consumption and cycle times as much as machine specification does. Our operator training centre covers correct operation and daily checks. Fleet-level specification: We size the fleet against volumes, haul distances and programme rather than quoting machines individually, because productivity is set by how the machines work together. Depth across site equipment: Earthmoving within our wider earthmoving and light construction equipment range, so the whole site fleet is supported from one relationship. Common Fleet Specification Mistakes Buying machines individually: A fleet is limited by its slowest link. Capacity added anywhere else produces no additional output and costs money every hour it stands. Mismatching loading tool to haulage: A bucket that fills a truck in an awkward number of passes wastes either loader capacity or truck time on every single cycle. Using a loader to dig: Wheel loaders scoop loose material efficiently and dig undisturbed ground badly. Using one to excavate wears the machine and produces poor output. Pushing material too far with a dozer: Beyond a certain distance, load-and-haul is cheaper. Dozing past that point burns fuel and hours for no economic gain. Skipping the finishing machine: Bulk earthmoving that leaves an inaccurate surface generates expensive grader and hand-finishing work later. Specifying oversized machines: A machine working well below its capacity is inefficient in fuel and capital alike. Bigger is not a safe default. Frequently Asked Questions What counts as earth moving equipment? The main classes are excavators for digging, wheel loaders for scooping and carrying, bulldozers for pushing material and clearing ground, and motor graders for producing accurate finished levels. What is the difference between a wheel loader and an excavator? A wheel loader has a bucket on a front linkage and rubber tyres, and is built to scoop loose material and carry it over distance at speed. An excavator has a boom, arm and bucket on a rotating superstructure, digging below its own level and loading to the side without repositioning. Loaders carry; excavators dig. When should I use a bulldozer instead of an excavator and trucks? Bulldozers move material economically over short distances, where the cost of loading and hauling would not be justified. Beyond a certain push distance, load-and-haul becomes cheaper. Establishing where that crossover falls for your site determines which approach is correct. How do I size an earthmoving fleet? Work from volumes, haul distances and the programme rather than machine by machine. Match the loading tool to the truck size so filling takes a sensible number of passes, then calculate how many trucks that machine can keep working. A fleet produces at the rate of its slowest link. Do tracked or wheeled machines suit UAE ground conditions better? It depends on the surface. Loose sand offers poor traction and low bearing capacity, which favours tracked machines with low ground pressure. On firm, prepared or sealed surfaces, wheeled machines offer better travel speed and lower running costs. Does GENAVCO supply spare parts and servicing for Shantui equipment in the UAE? Yes. GENAVCO holds genuine parts in-country and operates a certified service network covering Dubai, Abu Dhabi, Sharjah and the wider UAE, with preventive maintenance programmes, operator training and on-site breakdown support. Ready to Specify Your Site Fleet? Earthmoving productivity is decided by how the machines work together, not by the rating of any one of them. Match the loading tool to the haulage, put the right machine on each task, and the fleet delivers the platform on programme rather than becoming the reason it slips. GENAVCO supplies the Shantui range across the UAE — bulldozers, wheel loaders, excavators and motor graders — backed by genuine parts, certified service and operator training. Tell us your volumes, distances and programme. We will size the fleet and price it properly. ENQUIRE NOW — GET YOUR FLEET SPECIFICATION Serving Dubai, Abu Dhabi, Sharjah and the wider UAE.

Aggregate is the highest-volume material in construction, and almost all of it starts as rock that is too large to use. Crushing is the process that turns quarried stone, excavated rock and demolition arisings into the graded sizes that concrete, asphalt and road base specifications call for. Doing that efficiently is a circuit design problem rather than a machine purchase. A crusher chosen without reference to what feeds it and what follows it will either sit starved or choke, and in both cases the tonnage on the weighbridge falls short of what the machine is rated to produce. This guide covers what a stone crusher actually does at each stage, how primary, secondary and tertiary machines fit together, what governs throughput and product shape, and the Kleemann range GENAVCO supplies in the UAE. The Three Stages of Crushing Rock is not reduced in one step. Each stage takes a defined feed size and produces a defined output, and the machine types are built accordingly. Primary - the jaw crusher: Takes run-of-quarry rock or demolition material and reduces it to a size the rest of the circuit can handle. Two plates, one fixed and one moving, compress material between them. Built for large feed and high reduction rather than product shape. Secondary - the cone crusher: Takes pre-crushed material and reduces it further by compressing it between a gyrating mantle and a fixed concave. Efficient in hard, abrasive stone, and the standard second stage in a quarry circuit. Secondary or tertiary - the impact crusher: Reduces material by striking it with rotating blow bars rather than squeezing it. Produces better-shaped, more cubical aggregate and handles softer stone and recycled concrete well. Screening sits between and after these stages, separating material that is already at size from material that needs another pass. A crushing circuit is really a crushing-and-screening circuit, and the screens determine as much about output as the crushers do. Each stage is covered in depth in our guides to jaw crushers for primary crushing, cone crushers for hard stone and impact crushers for shaping and recycling. Compression or Impact: The Fundamental Choice Factor Compression (jaw, cone) Impact (impact crusher) Reduction method Squeezes material between two surfaces Strikes material with rotating blow bars Suits Hard, abrasive stone Softer stone, concrete and recycled material Product shape More elongated and flaky More cubical and well shaped Reduction ratio Lower per stage Higher per stage Wear part cost Lower in abrasive material Higher in abrasive material Fines generation Lower Higher Typical position Primary and secondary Secondary and tertiary This choice is driven by the rock, not by preference. Hard abrasive stone destroys blow bars quickly, which is why quarries in hard formations run jaw-and-cone circuits. Softer limestone and recycled concrete suit impact crushing, which is why demolition and recycling operations favour it and get better product shape as a result. Designing the Circuit Four decisions determine whether a crushing plant achieves its rated output on site. Feed size sets the primary: The largest rock that will enter the plant determines the feed opening required. A machine that has to be fed selectively because material will not enter is a machine running below capacity all shift. Product specification sets the last stage: The gradings and shape the end product must meet determine whether the circuit finishes on a cone, an impact crusher or a screen. Work backwards from the specification rather than forwards from the quarry face. Balance determines real throughput: Every stage must handle what the previous stage delivers. A circuit is limited by its narrowest point, and an oversized secondary behind an undersized primary produces the same tonnage as the primary alone. Screening decides how much is recirculated: Material already at size should leave the circuit rather than passing through another crusher. Scalping ahead of the primary and post-screening after the crusher both raise net output without adding crushing capacity. Advantages of a Correctly Designed Crushing Circuit These benefits follow from circuit design rather than from any single machine. Rated throughput actually achieved: A balanced circuit produces close to its design tonnage instead of being throttled at one stage. Lower cost per tonne produced: Fuel, wear parts and labour are spread across more tonnes when every machine runs loaded. Product meeting specification first time: Correct final stage and screening means gradings and shape pass testing without reprocessing. Reduced wear part consumption: Machines fed correctly and matched to the rock wear at the expected rate rather than being punished. Less recirculation: Effective scalping and post-screening remove at-size material instead of crushing it twice. Predictable stockpile build: Balanced output means stockpiles grow at a rate that can be planned around rather than managed reactively. Fewer blockages and stoppages: Correct feed size and continuous feed control prevent the bridging that causes most unplanned downtime. Simpler expansion later: A circuit designed with linkage in mind accepts an additional stage without redesigning everything upstream. The Kleemann Range Available in the UAE GENAVCO supplies Kleemann crushing and screening equipment in the UAE, covering every stage of the circuit. The table below sets out the full lineup and where each machine sits. Machine Stage Feed opening / size and output MOBICAT MC 100i EVO Primary jaw 855 x 530 x 320 mm — 220 t/h MOBICAT MC 110i EVO2 Primary jaw 990 x 620 x 370 mm — 400 t/h MOBICAT MC 120i PRO Primary jaw 1,080 x 680 x 410 mm — 650 t/h MOBICONE MCO 90i EVO2 Secondary cone 200 mm feed — 270 t/h MOBICONE MCO 110i PRO Secondary cone 240 mm feed — 470 t/h MOBIREX MR 110i EVO2 Impact 880 x 550 x 330 mm — 1,100 mm inlet MOBIREX MR 130i EVO2 Impact 1,040 x 650 x 390 mm — 450 t/h MOBIREX MR 130i PRO Impact 1,040 x 650 x 390 mm — 600 t/h MOBISCREEN MSS 802i EVO Scalping screen 800 x 500 x 300 mm — 500 t/h MOBIBELT MBT 20i Stacking Track-mounted conveyor Two machines are worth examining in detail here, because neither is a crusher and both are routinely under-specified — yet between them they determine how much of a circuit’s crushing capacity is actually usable. MOBISCREEN MSS 802i EVO — scalping screen A mobile coarse screen designed to work ahead of or alongside a crushing plant, separating material that does not need crushing before it reaches a crusher. Feed opening: 800 mm x 500 mm x 300 mm Output: 500 t/h Maximum feed size: 500 mm Screening unit: Mobile double-deck screening unit for coarse elements Drive: H-DRIVE (diesel-hydraulic) Flexibility: Large range of screen surfaces with simple setting of screening parameters, for adapting to new application conditions Scalping is the cheapest tonnage in any circuit. Material removed here never consumes crusher capacity, wear parts or fuel, so a screen ahead of the primary often raises net plant output more than a larger crusher would. View the MOBISCREEN MSS 802i EVO scalping screen MOBIBELT MBT 20i — track-mounted stacker A tracked conveyor that extends the discharge reach of crushing and screening plant, so stockpiles build higher and further from the machine. Series: MOBIBELT MBT 20(i) / MBT 24(i) Function: Extends the operating range of mobile crushing and screening plants Feed: Generously dimensioned feed hopper Adjustment: Hydraulically adjustable feeding and discharge height Drive: H-DRIVE diesel-hydraulic, with external power supply optional Operation: SPECTIVE operating position with local control elements Stockpile capacity is a real production limit that rarely appears in circuit calculations. A plant that has to stop because the discharge pile has reached the conveyor is losing output for reasons that have nothing to do with crushing. View the MOBIBELT MBT 20i track-mounted stacker Not sure how to configure your circuit? Send us your feed material and maximum lump size, your target gradings and your tonnage requirement — our team will configure the circuit and return a cost proposal. Request a Crushing Circuit Specification What Drives Crushing Plant Cost The purchase price is one input. Across a plant’s working life, wear parts, fuel and downtime dominate the cost per tonne. Feed opening and throughput - the largest single factor, and the one that should follow the material rather than ambition Crusher type - jaw, cone and impact are different machines at different price points and different wear economics Drive concept - diesel-direct, diesel-electric or diesel-hydraulic, with external power supply changing running cost substantially Prescreening and post-screening - integrated screens add cost and raise net output Wear part specification - jaw plates, mantles and blow bars matched to the abrasiveness of the rock Control and linkage systems - continuous feed control and plant-to-plant linkage Transport configuration - machine weight and dimensions determine trailer, permits and mobilisation cost Service package - full maintenance contract versus parts-only support The figure that matters is cost per tonne of saleable product, not the invoice. A machine that produces in-specification material at lower wear consumption will outperform a cheaper unit within a single season. Ask any supplier to model it that way rather than quoting a purchase price alone. Crushing in UAE Conditions Rock in the region is frequently hard and abrasive: That pushes circuits toward jaw and cone compression crushing and away from impact crushing in primary and secondary duty, because blow bar consumption in abrasive stone becomes the dominant operating cost. Dust load is severe and continuous: The crushing plant generates its own dust cloud and works inside it all shift. Air filtration and cooling packs load far faster than temperate-climate schedules assume, and service intervals should follow the environment rather than the manual. Heat affects hydraulics and cooling: Sustained high ambient temperature raises hydraulic oil temperature and reduces cooling margin. Positioning a plant where it can draw cool air, rather than recirculating its own exhaust heat, is a real operational decision. Water for dust suppression is a logistics constraint: Suppression systems consume water continuously and evaporation is high, so supply planning belongs in the production plan rather than being treated as a site detail. Why Choose GENAVCO for Crushing Equipment in the UAE Buying the machine is the easy part. What determines whether the investment performs is everything that happens afterwards. Part of Juma Al Majid Holding Group: Decades of established presence in the UAE market and the financial stability that comes with a major regional group — this matters when you are signing multi-year service agreements. Authorised Kleemann representation: Genuine equipment, factory-backed specification and full warranty integrity — not grey-market imports with uncertain parts availability. In-country spare parts inventory: Wear parts are consumed continuously in abrasive rock, and a plant waiting on jaw plates is a plant producing nothing. Our genuine spare parts operation holds stock locally. Certified service and maintenance: Scheduled servicing, preventive maintenance and on-site breakdown response through our repairs and maintenance division across Dubai, Abu Dhabi, Sharjah and the wider UAE. Operator training: Feed control and gap setting decide output and wear as much as the machine does. Our operator training centre covers correct operation and daily checks. Circuit-level specification: We configure the plant against your material, target gradings and tonnage rather than quoting a single crusher, because throughput is determined by the circuit and not by any one machine in it. Depth across quarry and mining: Crushing and screening within our wider quarry and mining equipment range, so the whole operation is supported from one supplier relationship. Common Crushing Circuit Mistakes Sizing the crusher and ignoring the screens: Screening capacity limits net output as often as crushing capacity does. A crusher fed material that was already at size is producing nothing saleable. Feeding intermittently: A crusher runs most efficiently when fed continuously and evenly. Surge feeding produces lower output and uneven wear than a steady, controlled feed. Choosing impact crushing for hard abrasive rock: Product shape improves but blow bar consumption can make the cost per tonne uncompetitive. The rock should decide, not the product spec alone. Oversizing one stage: A circuit produces at the rate of its narrowest point. Capacity added anywhere else is capital that generates no additional tonnes. Running gaps outside specification: Closed side setting drift changes product gradings and increases recirculation. It should be checked on a schedule, not when the product fails testing. Underestimating stockpile and haulage capacity: A plant that stops because the stockpile is full or trucks are not clearing it is losing output for reasons unrelated to crushing. Frequently Asked Questions What is a stone crusher and how does it work? A stone crusher reduces quarried rock, excavated stone or demolition material into graded aggregate sizes. Compression crushers such as jaw and cone machines squeeze material between two surfaces, while impact crushers strike it with rotating blow bars. Most operations use more than one type in sequence. What is the difference between primary, secondary and tertiary crushing? Primary crushing takes run-of-quarry rock and reduces it to a size the rest of the circuit can handle, usually with a jaw crusher. Secondary crushing reduces that material further, typically with a cone or impact crusher. Tertiary crushing produces the final product size and shape. Which crusher gives the best aggregate shape? Impact crushers generally produce more cubical, better-shaped aggregate because they fracture material by striking it. Compression crushers tend to produce more elongated particles. In hard abrasive rock, however, blow bar consumption often makes cone crushing the more economical route to the same specification. How do I work out what throughput I need? Work backwards from the product specification and required tonnage, then check that every stage in the circuit can handle what the previous stage delivers. A circuit produces at the rate of its narrowest point, so balance matters more than the rating of any individual machine. What limits crushing output in practice? Most commonly feeding, screening or stockpile capacity rather than crusher capacity. Intermittent feeding, insufficient scalping and full stockpiles all reduce achieved tonnage well below what the crusher is rated to produce. Does GENAVCO supply spare parts and servicing for the Kleemann plant in the UAE? Yes. GENAVCO holds genuine parts in-country and operates a certified service network covering Dubai, Abu Dhabi, Sharjah and the wider UAE, with preventive maintenance programmes, operator training and on-site breakdown support. Ready to Configure Your Crushing Circuit? Crushing output is decided by how the stages fit together, not by the rating on any single machine. Get the feed size, the balance between stages and the screening right, and the plant produces close to its design tonnage instead of somewhere well below it. GENAVCO supplies the full Kleemann range across the UAE — jaw, cone and impact crushers, scalping screens and track-mounted stackers — backed by genuine parts, certified service and operator training. Tell us your material, your gradings and your tonnage. We will configure the circuit and price it properly. ENQUIRE NOW — GET YOUR CRUSHING CIRCUIT SPECIFICATION Serving Dubai, Abu Dhabi, Sharjah and the wider UAE.

There are five ways to store a pallet, and the difference between them is not really about steel. It is about how many of your pallets you can reach without moving another one first. That figure — selectivity — runs from one hundred percent down to a single face per lane, and every step down buys storage density in exchange. Get it right and the warehouse holds what it needs and works quickly. Get it wrong and either the building is half empty or the forklifts spend their day shuffling pallets to reach the one they want. This guide compares all five pallet racking system types on the terms that actually decide the choice — SKU count, rotation and handling equipment — and sets out the Godrej range GENAVCO supplies in the UAE. The Five Systems at a Glance System Selectivity Best suited to Selective 100% — every pallet accessible Large SKU variety, any quantity Double Deep 50% — two pallets deep Medium or lower SKU variety, paired pallets Drive-in One face per lane Few SKUs produced or dispatched in batches Shuttle One face per lane, automated retrieval Limited SKU variety, high throughput Very Narrow Aisle 100% — same as selective Constrained floor area, high clear height Very narrow aisle is the one that surprises people. It is selective racking — full accessibility — but with the aisles narrowed to under two metres, so it recovers floor area without giving up any selectivity at all. The trade is equipment and floor tolerance rather than access. SKU Profile Decides the System One measure narrows the choice faster than anything else: how many different products you hold, relative to how much of each. Many SKUs, low quantity each: Any order might call for any product, so every pallet needs to be reachable. Selective racking, or very narrow aisle where the floor area is tight. Density systems would produce constant shuffling. Medium SKU variety, pallets in pairs: Where two pallets of the same product can reasonably sit one behind the other, double deep halves the number of aisles required while retaining workable access. Few SKUs, large quantities: Batch production or seasonal buffer stock. Drive-in or shuttle systems, where an entire lane holds one product and selectivity within the lane is irrelevant. Few SKUs but high throughput: Where density is needed but forklifts entering lanes would be too slow, shuttle systems provide the density with automated retrieval instead. Count the product lines before measuring the building. A warehouse holding four hundred SKUs and one holding twelve need entirely different systems even at identical tonnage and identical footprint. Rotation: The Constraint That Rules Systems Out Stock rotation requirements can eliminate otherwise suitable systems, and this is best established early rather than discovered at commissioning. FIFO — first in, first out: Required for dated goods, batch-controlled material and anything with shelf life. Loading and retrieval must happen from opposite ends, or from a fully selective face. LIFO — last in, first out: Acceptable where product does not age or where batch integrity is not tracked. Loading and retrieval from the same face, which allows simpler and denser configurations. Selective and VNA suit either: Full accessibility means rotation is managed by the warehouse management system rather than by the physical layout. Drive-in and shuttle are configurable: Both can be set up for LIFO or FIFO dispatch, but the configuration is a design decision made before installation rather than a setting changed afterwards. Advantages of Getting the Pallet System Right These returns follow from matching the system to the stock profile rather than from the racking itself. Fewer handling movements per pallet retrieved: A system matched to SKU profile means loads are not moved aside to reach other loads, which is pure lost time on every occurrence. More pallet positions in the same building: Correct density and aisle choice can substantially increase capacity without extending the facility. Faster put-away and retrieval cycles: Accessible positions for fast-moving lines shorten travel across thousands of movements a week. Rotation enforced by layout: A system configured for the required rotation makes FIFO a property of the racking rather than of operator discipline. Lower equipment count: Efficient layouts require fewer machines to achieve the same throughput, which reduces both capital and operator cost. Reduced product damage: Fewer movements per pallet means fewer opportunities for impact damage to stock and structure. Scalable as volumes grow: Modular systems expand vertically and horizontally rather than requiring replacement. Predictable throughput: A layout matched to demand produces consistent cycle times that can be planned and resourced around. Godrej Pallet Racking Systems Available in the UAE GENAVCO supplies Godrej storage solutions in the UAE. All five pallet racking systems are available and specified against the stock profile rather than sold as standard configurations. 1. Selective Pallet Racking — 100% accessibility The simplest and most economical racking system, and the default where product variety is high. Every pallet is directly accessible from the aisle. Selectivity: 100% accessibility to each pallet Suits: Large variety of SKUs irrespective of quantity Adaptability: Adaptable to varying pallet and load heights Configuration: Wide range of beams and uprights offering the optimal solution for any pallet size or load Applications: Raw material stores, finished goods stores, distribution centres Equipment: Compatible with most material handling equipment — forklift, stacker, reach truck Safety: Variety of racking accessories available to enhance safety during pallet handling Compatibility with standard handling equipment is the practical advantage. Selective racking works with whatever forklifts an operation already runs, which makes it the lowest-risk starting point for a facility whose stock profile may change. View Godrej selective pallet racking 2. Double Deep Pallet Racking — 50% selectivity, half the aisles Two pallets stored one behind the other, which halves the number of aisles needed and converts that floor area into storage. Selectivity: 50% — two pallets deep Suits: Medium or lower SKU variety, irrespective of quantity Ideal configuration: Two pallets of the same SKU kept one behind the other Equipment requirement: Needs special material handling equipment with extended reach — telescopic or pantograph Scalability: Scalable vertically and horizontally Adaptability: Adaptable to varying pallet and load heights, with a wide range of beams and uprights The equipment requirement is the item to settle first. Reaching the rear pallet needs a telescopic or pantograph reach truck, and that machine has to be specified alongside the racking. Ordering double deep racking without confirming the handling equipment leaves half the positions unreachable. View Godrej double deep pallet racking 3. Drive-in Pallet Racking — maximum density for few SKUs A dense storage system where handling equipment drives inside the racking structure to place and retrieve pallets, with each storage bay one pallet wide. Concept: Dense storage for few varieties of SKUs produced or dispatched in batches Operation: Material handling equipment such as reach trucks drive inside the racks to access pallets Bay configuration: Each storage bay is one pallet wide Rotation: Can be configured for LIFO or FIFO dispatch Suits: Industries involved in batch production Safety: Safety and stability elements to support operation, with a wide range of accessories Adaptability: Adaptable to varying pallet and load heights Because the truck enters the structure, operator care matters more here than in any other system. Impact damage to internal rails is harder to spot than damage to an external upright, which makes scheduled inspection particularly important on drive-in installations. View Godrej drive-in pallet racking 4. Shuttle Pallet Racking — density with automated retrieval A shuttle travels within the racking to carry pallets to the forklift, so the truck never enters the structure. Density comparable to drive-in, with considerably faster throughput. Operation: Shuttle on racks carries pallets to the forklifts, moved within the racks by remote control Rotation: Configurable in LIFO or FIFO Performance: Fast throughput while improving storage density Suits: Industries with limited variety of SKUs; ideal for buffer storage managing seasonal demand Safety: Highly safe, as forklifts stay away from the racks Temperature: Operates in subzero temperatures down to –30°C Upgrade path: Upgradeable from current static racks Two details make this system distinctive. Operating to –30°C makes it viable for cold storage, where dense storage matters most because refrigerated volume is expensive. And being upgradeable from existing static racks means an operation can move to shuttle without replacing the whole installation. View Godrej shuttle pallet racking 5. Very Narrow Aisle Racking — full selectivity, recovered floor space Selective pallet racking configured for VNA equipment, with aisles under two metres. Full accessibility is retained while a substantial share of the floor previously given to aisles becomes storage. Aisle width: Under 2 metres Height capability: VNA equipment can reach up to 18 metres Capacity effect: More pallet positions possible compared with other material handling equipment System basis: Selective pallet racking made compatible with VNA equipment Guidance required: Special guides — mechanical rails or electrical wires; mechanical rails widely used for ease and economy Floor requirement: VNA equipment demands a high level of floor accuracy Throughput: Offers fast throughput; scalable vertically and horizontally The floor accuracy requirement is the item that catches operations out. VNA equipment working at 18 metres needs a slab built to tight flatness tolerance, and that has to be established before the racking is designed rather than discovered during commissioning. The equipment side is covered by Crown reach trucks and VNA equipment, which GENAVCO specifies alongside the racking. View Godrej very narrow aisle racking Not sure which pallet system suits your stock? Send us your SKU count, quantity held per line, pallet dimensions and weights, rotation requirement and clear height — our team will design the system and return a cost proposal. Request a Pallet Racking Design How to Choose Between the Five Step 1 - Count your SKUs and quantity per line. This single measure eliminates most of the options immediately. High variety points to selective or VNA; low variety with high volume points to drive-in or shuttle. Step 2 - Establish the rotation requirement. Strict FIFO constrains the configuration of dense systems and must be designed in rather than added later. Step 3 - Confirm the handling equipment. Double deep needs extended reach; VNA needs guided equipment and an accurate floor; drive-in needs trucks that enter the structure. Racking and equipment are one decision. Step 4 - Measure the true clear height. Height to the lowest obstruction, not the roof. Sprinklers, services and lighting all reduce usable height and determine how many levels are achievable. Step 5 - Check the floor before committing to VNA. Flatness tolerance for high-level narrow-aisle operation is a construction specification. Establish it before design. Step 6 - Design for throughput as well as capacity. The configuration holding the most pallets is not always the one that moves them fastest. Fast lines need accessible positions. Pallet Racking in UAE Warehouses Land cost pushes operations toward density and height: Where floor area is expensive, VNA and dense systems deliver better returns than extending the building. This is why narrow-aisle configurations are more common here than in markets with cheaper land. Cold storage makes density particularly valuable: Refrigerated volume is expensive to build and to run, so getting more pallets into the same cold envelope has a direct operating benefit. Systems rated to subzero temperatures matter for this reason. Re-export operations tend toward high SKU variety: The region’s distribution role means many facilities hold wide product ranges for onward shipment, which favours selectivity over density. High utilisation accelerates impact damage: Racking worked hard across long shifts accumulates damage from handling equipment. Scheduled structural inspection is what keeps a busy installation safe. Racking is an engineered structure: Load ratings, bracing and design sign-off are not optional on a system carrying tonnes of material above people working beneath it. Why Choose GENAVCO for Pallet Racking in the UAE Buying the steel is the easy part. What determines whether the installation performs is the design work before it and the support after it. Part of Juma Al Majid Holding Group: Decades of established presence in the UAE market and the financial stability that comes with a major regional group — this matters when you are signing multi-year service agreements. Authorised Godrej representation: Genuine engineered components with factory-backed load ratings — not generic steel of uncertain provenance and unverified capacity. Design against your stock profile: We specify from SKU count, load profiles, rotation requirements and future expansion rather than quoting a bay count. The system choice is worth more than the price per bay. Racking and handling equipment together: Double deep, drive-in and VNA each demand particular equipment. Our material handling and racking solutions cover both sides, so the aisle and the truck are specified as one decision. Installation and team training: We manage installation and train warehouse teams so the system is used as designed from the first shift. Scheduled inspection and structural audits: Racking accumulates impact damage in service. Our repairs and maintenance division provides inspections, structural audits and rapid component replacement. Common Pallet Racking Mistakes Specifying density for a high-variety operation: Dense racking holding many product lines produces constant load shuffling. The handling cost exceeds the space saved, often within the first year. Ordering double deep without extended-reach equipment: The rear pallet cannot be reached with standard forklifts, leaving half the positions unusable. Committing to VNA before checking the floor: Flatness tolerance for high-level narrow-aisle work is a construction specification. Remediating a slab after installation is expensive and disruptive. Setting rotation configuration too late: Drive-in and shuttle systems are configured for LIFO or FIFO at design stage. Changing afterwards means reconfiguring the installation. Measuring to the roof rather than the obstruction: Sprinklers, lighting and services reduce usable height. Designing to the wrong figure loses a level or fails inspection. Skipping inspection on drive-in systems: Trucks entering the structure cause internal damage that is harder to see than damage to an external upright. Frequently Asked Questions Which pallet racking system should I choose? Start with SKU count and quantity held per line. Many product lines in small quantities point to selective racking, or very narrow aisle where floor area is constrained. Few product lines in large quantities point to drive-in or shuttle systems. Rotation requirements and available handling equipment then narrow it further. What does selectivity mean in pallet racking? Selectivity is the proportion of pallets you can reach without moving another one first. Selective racking offers 100% accessibility. Double deep offers 50%, since one pallet sits behind another. Drive-in and shuttle systems present one face per lane, so selectivity within the lane is limited. What is the difference between drive-in and shuttle racking? Both provide high-density storage for limited SKU varieties. With drive-in, handling equipment drives inside the racking to place and retrieve pallets. With shuttle racking a remote-controlled shuttle carries pallets within the racks and the forklift stays outside, which gives faster throughput and reduces impact risk to the structure. Can pallet racking be used in cold storage? Yes. Shuttle pallet racking operates in subzero temperatures down to minus 30 degrees Celsius, which suits cold storage where dense storage is particularly valuable because refrigerated volume is expensive to build and run. What handling equipment does each system need? Selective racking works with most standard equipment including forklifts, stackers and reach trucks. Double deep requires extended reach equipment with telescopic or pantograph forks. Drive-in requires trucks that enter the structure. A very narrow aisle requires guided VNA equipment and an accurate floor. Does GENAVCO install and maintain pallet racking in the UAE? Yes. GENAVCO manages installation, trains warehouse teams, and provides scheduled inspections, structural audits and component replacement across Dubai, Abu Dhabi, Sharjah and the wider UAE. Ready to Design Your Pallet Storage? The five systems are not better or worse than one another — they answer different questions. Count the SKUs, establish the rotation requirement, confirm the equipment, and the right system becomes obvious rather than a matter of preference. GENAVCO supplies all five Godrej pallet racking systems across the UAE, with layout design, installation, team training and scheduled structural inspection. For the wider selection framework, see our guide to choosing a warehouse racking system. Tell us your SKU profile and rotation requirement. We will design the system and price it properly. ENQUIRE NOW — GET YOUR PALLET RACKING DESIGN Serving Dubai, Abu Dhabi, Sharjah and the wider UAE.