Atlantis Contracting successfully delivered Hilti Firestop Systems and Expansion Joint Systems for the WE Telecom Project in Cairo, Egypt, covering 9,275 linear meters and providing comprehensive fire protection, structural movement accommodation, and long-term performance in accordance with international standards.
Atlantis Contracting successfully completed the supply and installation of Hilti Firestop Systems and high-performance Expansion Joint Systems for the WE Telecom Project in Cairo, Egypt — in collaboration with CCC Construction — covering a total installed length of 9,275 linear meters, completed in 2021. The dual-scope package delivered comprehensive passive fire protection across all MEP penetrations, cable trays, conduits, and construction joints utilizing Hilti's UL-listed firestop product range; and a complete expansion joint solution accommodating thermal, seismic, and structural movements across floor, wall, and waterproofed locations — all executed using approved materials, Hilti-trained installation teams, and strict quality control procedures in compliance with international standards and project specifications.
Project Overview
WE Telecom Project
Main Contractor: CCC Construction
Location:Cairo, Egypt
Contractor:Atlantis Contracting
Scope: Supply & Installation of Hilti Firestop Systems & Expansion Joint Systems — Dual Package
Total Quantity: 9,275 Linear Meters (LM)
Firestop Systems: Hilti FS-ONE Intumescent Sealant | Hilti CP 606 Firestop Collars | Hilti CFS-S ACR Sealant | Hilti Firestop Mortar & Wraps
Expansion Joint Systems: Floor & Wall Expansion Joints | Waterproof Expansion Joint Systems | High-Performance Sealants
Standards:UL Listed | FM Approved | International Fire Protection & Movement Joint Standards
Site Conditions Upon Arrival
Upon mobilization to the WE Telecom project site in Cairo, the Atlantis team conducted a full dual-scope survey. The following conditions were documented:
•MEP penetrations through fire-rated assemblies were in various stages of completion — many left open or partially sealed by preceding trades, requiring systematic audit, classification, and remediation across all zones.
•Telecommunications and data infrastructure created a particularly high density of cable trays, conduit bundles, and mixed-service penetrations — each requiring individual Hilti system selection and tested detail application.
•Expansion joint openings varied in width, geometry, and substrate condition across floor, wall, and external locations — requiring zone-specific Hilti system selection and preparation.
•Active construction environment across multiple concurrent trade packages operating in overlapping zones, requiring Atlantis to maintain continuous coordination to protect completed works.
•CCC Construction's project documentation standards required comprehensive Hilti penetration registers and joint records with photographic evidence and product traceability for every installed element.
Site Challenges & Atlantis Solutions
Challenge 1: Dual-Package Coordination Across 9,275 LM
Managing both Hilti firestop and expansion joint works simultaneously across a large, active project — each with its own material logistics, installation sequencing, inspection requirements, and documentation trail — required a highly disciplined internal programme management approach to prevent conflicts between the two work streams and maintain consistent Hilti system compliance across the full 9,275 LM scope.
Solution: Atlantis established separate dedicated supervisors for the firestop and expansion joint packages, operating under a unified site manager. A master programme mapped both work streams against zone readiness and CCC Construction's overall site schedule. Weekly internal coordination meetings reviewed cross-package conflicts and adjusted resource deployment, ensuring both packages progressed in parallel without interference.
Challenge 2: Hilti System Selection for High-Density Telecom Penetrations
WE Telecom's telecommunications infrastructure involved an exceptionally high density of cable trays, conduit bundles, data cables, and mixed-service penetrations — each requiring a specific Hilti UL-listed system detail matched to the service type, substrate, annular space, and required fire rating. The volume and variety of penetration types demanded a systematic pre-installation classification process to ensure every penetration received the correct, tested Hilti system.
Solution: A full penetration classification audit was conducted before installation commenced in each zone — categorizing penetrations by service type, substrate, void size, and required rating. Hilti FS-ONE sealant was applied to cable and conduit penetrations; Hilti CFS-S ACR to mixed and larger service openings; Hilti CP 606 collars to plastic pipe penetrations; and Hilti Firestop Mortar to large cable containment openings. All selections were cross-referenced to Hilti's tested system documentation, with a master system selection register maintained daily.
Challenge 3: Waterproof Expansion Joint Interface at Exposed Locations
Achieving full watertightness at expansion joint locations — particularly at floor-to-wall transitions, external perimeter joints, and locations exposed to water loading in a Cairo environment — required careful integration of the waterproof membrane system with the expansion joint assembly. The membrane-to-joint interface is the most vulnerable point in the system and the most frequent source of long-term water ingress if not correctly installed.
Solution: Atlantis followed manufacturer-approved waterproofing integration details at every joint location — applying membrane flashing and reinforcement strips at all transitions before installing the joint assembly. All membrane-to-joint interfaces were water-tested before cover plate or finishing works concealed the installation. A zero-defect tolerance was applied to waterproofed joint zones, with any deficiency immediately remediated and re-tested.
Challenge 4: Hilti Documentation & CCC Construction Handover Compliance
CCC Construction projects operate under rigorous quality and documentation frameworks. Both the Hilti firestop and expansion joint works required comprehensive installation records — individual penetration registers, joint location records, Hilti system references with tested detail numbers, photographic evidence, Hilti material certificates, and signed inspection reports — for the full 9,275 LM scope before handover acceptance.
Solution: Atlantis implemented a unified documentation system covering both packages from day one — unique reference numbers for every penetration and joint location, daily photographic records, Hilti system type notation with tested detail references, material batch certificates, and zone-by-zone inspection sign-off. A complete dual-scope handover package was compiled and submitted to CCC Construction at project completion.
Systems Applied
Hilti Firestop Systems
Product
Application
Standard
Hilti FS-ONE
Cable, conduit & metallic pipe penetrations through fire-rated walls & floors
UL Listed
Hilti CFS-S ACR
Mixed-service, large openings & construction joint penetrations
UL Listed
Hilti CP 606
Plastic & combustible pipe penetrations — flexible firestop collar
UL Listed
Hilti Firestop Mortar
Large cable tray openings, service risers & oversized penetrations
UL Listed
Hilti Firestop Wrap Strips
Combustible pipe & insulated service penetrations — intumescent wrap
UL Listed
Expansion Joint Systems
System
Application
Floor & Wall Expansion Joints
Structural movement accommodation at floor and wall joint locations — thermal, seismic & settlement
Waterproof Expansion Joint Systems
Floor, wall & perimeter joints requiring full watertight performance with membrane integration
High-Performance Sealants & Joint Fillers
Joint interface sealing and filler application at all expansion joint locations
Aluminum Cover Plates & SS Fixings
Durable architectural finish over joint assemblies with corrosion-resistant anchorage
Operations Summary
The following sequence was carried out by the Atlantis team across both work packages:
Hilti Firestop Works:
•Full MEP penetration audit — classifying every penetration by service type, substrate, annular space, and required UL fire rating, matched to correct Hilti system.
•Substrate preparation at all penetration locations — cleaning, surface prep, and priming.
•Application of Hilti FS-ONE intumescent sealant to cable, conduit, and metallic pipe penetrations.
•Application of Hilti CFS-S ACR to mixed-service, large, and construction joint penetrations.
•Installation of Hilti CP 606 firestop collars to all plastic and combustible pipe penetrations.
•Application of Hilti Firestop Mortar to large cable tray openings and oversized penetrations.
•Installation of Hilti Firestop Wrap Strips to all insulated pipe and combustible service penetrations.
•Labelling and photographic documentation of every completed penetration with Hilti system reference and tested detail number.
Expansion Joint Works:
•Full expansion joint location survey — mapping joint widths, movement requirements, and substrate conditions.
•Substrate preparation and edge repair at all joint locations.
•Waterproof membrane installation and flashing at all waterproofed joint interfaces.
•Water-testing of all membrane-to-joint interfaces before joint assembly installation.
•Supply and installation of floor, wall, and waterproof expansion joint assemblies.
•Installation of high-performance sealants, joint fillers, aluminum cover plates, and stainless steel fixings.
•Movement functionality testing and inspection across all installed joints.
Quality & Handover (Both Packages):
•Final re-inspection across all zones for both Hilti firestop and expansion joint works.
•Complete dual-scope handover documentation package submitted to CCC Construction.
Outcome & Performance
Upon completion, Atlantis Contracting successfully delivered a fully integrated Hilti firestop and expansion joint solution across the WE Telecom Project in Cairo — covering 9,275 linear meters in collaboration with CCC Construction. The installed Hilti systems provide comprehensive UL-listed fire compartmentation across all MEP penetrations, construction joints, and service routes; and reliable waterproof, high-movement expansion joint performance across all floor, wall, and perimeter locations. The project demonstrates Atlantis's capability in delivering complex dual-scope passive fire protection and movement joint packages using Hilti product systems for large-scale telecommunications infrastructure projects in Egypt, meeting international standards and the quality requirements of a major international contractor.
Gallery
