project report dxb – dubai international airport

[ Project Report ]

DXB – Dubai International Airport

2004 2005 2006

november

Initial contact: Proposal phase with consulting, planning, and technical clarification.

may

Project order for snapin ceiling, SIC.

october

Order issued for interior roof lining, IRL.

December

Founding and reg istration of the local company in Dubai, Armstrong Metal Ceilings L.L.C.

January

Order for metal wall cladding, MWC.

February

Formation of the project team in St.Gallen and Dubai.

Establishing of the construction site office.

Implementation phase with materials’ summaries, layout, detail and positioning plans as well as full engineering.

Beginning of manufacturing, delivery and installation of all ceilings and walls.

march

Initial deliveries of the interior ceiling.

Project Chronology

2007 2008

June

Initial deliveries of the snapin ceiling.

november

Additional order for the metal wall cladding.

December

Initial deliveries of the metal wall cladding.

July

Initial delivery of customfit panels for the interior ceiling.

october

Final delivery of the metal wall cladding.

may

Final subsequent delivery of customfit panels for the snapin ceiling.

June

Final subsequent delivery of customfit panels for the metal wall cladding.

July

Completion of the implementation phase.

october

Opening of Terminal 3, Concourse 2 on October 14, 2008.

march

Initial deliveries of the interior ceiling.

3 aRmstRong METAl CEIlIngS

Bigger, higher, more spectacular – there is hardly a place in the world that can match the construction boom in Dubai. Not only the highest tower in the world, the “Burj Dubai” with more than 200 storeys and a height of over 800 m, but also the artificial islands “The World Dubai” and “The Palm Dubai” are causing a stir. It is not surprising, then, that the expansion of Dubai Airport with the 900 m long departure hall (Concourse 2) and the underground Terminal 3 shatter the usual dimensions. The project, to whose success Armstrong has had the opportunity to contribute with an important role, was finished in October 2008. In particular the roof of the cocoonlike Concourse 2, which is curved in all three dimensions, required remarkable engineering, production, logistics and installation work. I look forward to presenting to you the success story of Armstrong’s contribution to the expansion of the airport in Dubai. I wish you much enjoyment while reading.

Marco StegManaging Director & CEO Armstrong Metal Ceiling Group Europe

Dear Readers

A Monumental BuildingAt the heart of the airport are the new

underground Terminal 3 and the connected

departure hall (Concourse 2). Five of the

26 new departure gates are designed to

accommodate the twostorey Airbus

A380. The building includes luxurious

lounges and separate checkin areas for

first class and business class passengers,

as well as elegant restaurants and cafés.

With 29 shops in an area of 11 000 m2,

the duty free area leaves no shopping wish

unsatisfied. At the ends of the terminal,

tired passengers can find some calm:

beautiful Zen gardens with lush green,

tropical flair and soothing water elements

beckon one to linger. Naturally the new

terminal is equipped with stateoftheart

airport technology (FIDS, BIDS, security

system, CCTV, public address system,

building management system and bag

gage handling system).

Cocoon with a Deep DraughtJust as with Concourse 1 for which Arm

strong supplied materials in 1998, the

impressive Concourse 2 resembles a

giant cocoon. The approximately 900 m

long, 90 m wide and up to 30 m high

building is remarkable because of its

unusual geometric shape. The roof, which

is curved in all three dimensions, made

unusually high demands on the engineer

ing and the construction of the ceiling.

Terminal 3, too, is a very sophisticated

construction with its underground arrival

and customs clearance hall on several

levels. Since it is situated to some extent

under the airfield, the construction materi

als have been engineered in such a way

that they can easily absorb the impact

and vibration load caused by aircraft

above. Strict regulations regarding cli

mate, seismics and fire protection ensure

that the safety of passengers is guaran

teed at all times.

Contract for a Joint VentureIn December 2004 the contract for the air

port expansion, with a value of a billion US

dollars, was awarded to a joint venture

(HMRT) of three companies: the engineer

ing company “Al Habtoor”, the leading

construction and planning group in South

Africa “Murray & Roberts” and the Japa

nese company Takenaka, active in con

struction site surveying and planning. Dur

ing peak periods there were around 25 000

people working on the airport project. The

experience of Al Habtoor and Murray &

Roberts, responsible years ago for the

award winning “Concourse” in the Sheikh

Rashid Terminal at Dubai Airport, was

a worthwhile factor. In order to ensure

a smooth collaboration with the other

involved companies, Armstrong founded

the locally registered Armstrong Metal

Ceilings L.L.C. in Dubai in December 2005

and opened an additional office directly

at the construction site in February 2006.

DXB – Dubai International Airport: A Construction Project in New Dimensions

The airport in Dubai is being made ever larger and has long become the most important hub in the Middle East. No other airport in the world recorded such high growth in 2008 in international passenger aircraft traffic. In order to manage the large numbers of passengers the airport is being continuously expanded. The most recent expansion is Terminal 3, Concourse 2, which was opened on October 14, 2008, and is exclusively available for Dubai’s airline “Emirates”.

PRoject RePoRt DXB – DUBAI InTERnATIOnAl AIRPORT 4

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01 Consulting and PlanningEach project at Armstrong begins with a clarification of the

needs, and indepth consulting with the architect or gener

al contractor: Which functionality is the ceiling to provide,

and which requirements must the ceiling construction

satisfy? Technical clarifications include the room size and

the ceiling suspension height, the composition of the

rough ceiling and wall, and questions about materials'

composition, production, installation and static loads.

04 Maintenance and SupportArmstrong also offers worldwide customer service when

adaptations or expansions of existing conditions take

place. We maintain partnerships with topnotch installation

companies around the world, which we also recommend

for repair or even cleaning work in addition to installation.

02 Engineering and ProductionThe construction and details to be created are defined

based on the basic analysis. The CAD service “plan

ning” supplies layouts, views, floor plans, perspectives

and variations. The CAD service “implementation” cre

ates the production and installation plans, instructions

for the suspension, quantity takeoffs, overview, docu

mentation and presentations as well as scheduling. Our

production stands for efficient processes and reliable,

expedient processing.

03 Logistics and InstallationEach project is unique. That is why Armstrong develops

a projectspecific logistics concept for each project as

basis for ontime execution. In order to ensure proper

installation, we supply detailed instructions or manuals

to the companies assigned to carry out the installation

and also offer construction site support.

Armstrong’s Service System


The model illustrates in detail the complexity of the project.

The cross section shows the unique curve of Concourse 2.

The 57 year old Australian, Bruce Neave,

has more than 35 years of experience in

large construction and infrastructure pro

jects such as airports, bridges, tunnels,

dams and power plants. His work has led

him, among other places to Hong Kong,

Malaysia, China, the Philippines and most

recently, to the United Arab Emirates,

where he was responsible for the billion

dollar project at the airport in Dubai.

Mr Neave, what was the biggest challenge for you, as project director, in this construction project?The biggest difficulty in this project was

in the timely procurement of construction

materials that complied with the specifi

cations and appropriately skilled installers

that could achieve the required quality

and timely installation.

What were the reasons for choosing Armstrong in the area of ceilings and walls?The company enjoys an outstanding

r eputation and has an excellent track

record. As one of the leading European

manufacturers of metal ceilings and walls,

Armstrong is capable of supplying large

quantities at required quality meeting pro

gramme deadlines. Seen this way, the

choice is a matter of trust.

Aside from the quantities, what were some of the challenges Armstrong had to cope with?Wall cladding and ceilings are typically

carried out in the final stages of the pro

ject and therefore customfit panels can

only be measured at a very late stage,

leaving very little time for production of

218 400 m2 of Metal Ceilings and Walls: Interview with Bruce Neave from Murray & Roberts

During the construction of Terminal 3, Con course 2, 218 400 m2 of metal ceilings and walls were produced by Armstrong, which corresponds to an area of around 30 football fields. Discover in a conversation with Bruce Neave, the project director from Murray & Roberts, South Africa, why Armstrong was awarded the contract for the ceilings and walls.

With the installation of the interior ceiling cladding (picture, left), the metal wall cladding (picture, middle) and the metal snapin ceiling, Armstrong made a significant contribution to the appearance of Terminal 3, Concourse 2.

Facts & Figures

[ ProJect]

Dubai International Airport Expansion,

Terminal 3, Concourse 2 & Car Park

[ builDing Promoter]

Dubai Airports (www.dubaiairport.com)

United Arab Emirates (UAE)

[ architect]

Aéroport de Paris (ADPi), France

[ client rePresentative]

Dar AlHandasah (DAR), Dubai Office

[ general contractor (Joint venture)]

Al Habtoor Engineering, Dubai, UAE

Murray & Roberts, Bedfordview, South Africa

Takenaka Corporation Dubai Office, UAE

[ ProDuct inFormation]

· Interior roof lining (IRL), 87 000 m2, 120 000

ceiling tiles, 60 000 different positions

· Metal wall cladding (MWC), 45 000 m2,

45 000 panels

· Snapin ceiling (SIC), 81000 m2,

130 000 ceiling tiles

[ Further inFormation]

29 designers in 2 project teams

(St.Gallen /Dubai)

[ execution]

November 2004 – July 2008

When you look back today on the construction after successful comple-tion of the project, which experience do you find particularly valuable?For construction projects of this size and

complexity, careful planning and profes

sional engineering prior to production and

installation must be carried out.

In your opinion, what should be particularly impressive to passengers who pass through Terminal 3 in Dubai airport?The curved ceiling, supplied by Armstrong,

is the highlight of the entire complex.

Does that mean that Armstrong was not only responsible for production of ceiling and wall elements but also for other services?Armstrong were heavily involved in the

design process and also engaged in tech

nical clarifications. In addition Armstrong

was also responsible for submitting layout

plans, related production and installation

plans as well as materials and static test

results.

How did Swiss quality and reliability harmonize with your project?All materials achieved the quality of the

project and the finish is world class. The

vaulted ceiling even won an international

award, the highest CISCA Award.

Would you again work with Armstrong on future projects of the same or a smaller size?Yes, Armstrong has already been invited

to again tender for the next expansion,

Concourse 3, which is already under con

struction.

these fitting panels. In order to keep pace

with the schedule, at times material was

flown in by air freight and installed only

days later.

Which expectations did you have towards Armstrong and how were they satisfied?We assumed that Armstrong would

accept these challenges and achieve

them. Armstrong managed to continu

ously reduce the delivery times through

ongoing optimization in procedures

and production processes.

At what time was Armstrong actually called in?Pretender stage.

[ Interior roof lining ]

87 000 m²

120 000 Ceiling Tiles with an Extremely Complex Geometry: The Interior Roof Lining

Complexity in New DimensionsConcourse 2 is curved in all three dimen

sions and resembles a giant cocoon. The

complex architecture with the curved roof,

with an area of 87 000 m2 in one space,

demanded a comprehensive design to

construct the ceiling parts. Because of the

unusual structure of the building, 120 000

ceiling tiles in 60 000 different positions

had to be designed and manufactured in

Switzerland. Each individual tile was pro

duced on a fully automated production

line and subsequently applied with a high

performance powder coating. The tiles

are not only excellent in terms of strength

and Swiss precision but also because of

their 100% perfectly smooth surface.

Logistics from Start to FinishThe project, Concourse 2, was not only a

construction project but also a logistic

challenge. Because the 900 m long com

plex was built from one end to the other,

the ceiling tiles had to be manufactured

and delivered to Dubai in exactly the right

order. Since the difference from one tile to

another is in the realm of tenths of millime

tres and was thus virtually imperceptible,

each tile was marked with a unique identi

fication number and the precise location

of installation. This way, each “element”

could be inserted at a predefined location

in the “largest puzzle in the world”. The

installation of the interior ceiling (IRL) was

carried out by the Australian subcontract

or, Chadwick Technology. The company,

which specializes in exterior cladding, was

distinguished with the CISCA award for

its work.


[ metal Wall cladding ]

45 000 m²


Customized Product Developments and Madetomeasure: Metal Wall Cladding

Innovations on Both SidesIn order to satisfy specific customer wish

es and conditions, Armstrong altered the

standardised wall cladding system and

had the new development tested and cer

tified in terms of statics. The wall cladding

was extremely engineeringintensive and

technically very demanding because of

the numerous interfaces and details inter

related with other trades. The impact

resistant composite panels used, in the

sizes of up to 1.2 x 2.7 m consist of a

painted, visible steel lining, a noninflam

mable medium density fibreboard (MDF)

and a steel plate. The high demands on

quality induced Armstrong, together with

the paint producer, to engineer a super

durable high performance powder coating

with increased scratch resistance.

Installation The Australian company, Chadwick

Technology, a specialist in exterior clad

ding, was again given the job for the

installation of the metal wall cladding.

Practically all walls in the new complex

were fitted with the newly developed

wall cladding system.

[ metal snap-in ceiling ]

81 000 m²


Comprehensive Precision and Perfection: The Snapin Metal Ceiling

An Order with ConsequencesArmstrong was working on the airport

project in Dubai more than two years

before the first order for the snapin metal

ceiling was recorded in spring of 2005.

The order was executed by Batimat Build

ing Materials, a local specialist for ceilings,

partitions and kitchens. Thanks to their

expertise, market knowhow and local

contacts, together we were able to get our

foot into this important project and build

strong amicable relations with the main

contractor. Slowly other significant orders

were posted such as e.g. the cladding

of the interior roof lining and metal wall

cladding made of metal.

A Reflection of QualityThe snapin metal ceiling was used in

both the terminal and the concourse.

The Armstrong metal ceiling products

underscore the hightech character of

the airport in both the public zones as

well as the restricted areas. Snapin

ceiling systems are not only economical,

but because of the unique, certified

suspension system Gema Grid by

Armstrong, they are also quick and easy

to install and maintain. The QClip and

RClip systems both create a uniform

perfectly flat appearance in large areas.

© Copyright by Armstrong Metal Ceilings Ltd. 2009

Switzerland Austria | Eastern EuropeArmstrong Metal Ceilings Ltd. Armstrong Metalldecken GmbHKunklerstrasse 9 Bundesstrasse 70CH9015 St.Gallen A6830 RankweilTel. +41 (0) 71 313 63 63 Tel. +43 (0) 55 22 34 440Fax +41 (0) 71 313 64 00 Fax +43 (0) 55 22 34 448

Western | North | South | Central Europe France United Kingdom | Republic of IrelandArmstrong Metal Ceilings Ltd. Armstrong Plafonds Métalliques SA Armstrong World Industries Ltd.Kunklerstrasse 9 3, rue GustaveMoynier Building Products DivisionCH9015 St.Gallen CH1202 Genève Armstrong House, 38 Market SquareTel. +41 (0) 71 313 63 63 Tel. +41 (0) 22 731 60 70 Uxbridge, Middlesex UB8 1NGFax +41 (0) 71 313 64 00 Fax +41 (0) 22 731 60 74 United Kingdom Tel. +44 (0) 1895 202 122 Fax +44 (0) 1895 202 195

Middle East | Asia | Africa USA ChinaArmstrong Building Products Armstrong World Industries Inc. Armstrong World Industries (China) Ltd.(Middle East) L.L.C. Attn. BPO Custumer Service Center 22/F, Cross TowerP.O. Box 73831 P.O. Box 3210 318 Fu Zhou RoadDubai Lancaster, Pennsylvania 17604 Shanghai 200001 United Arab Emirates USA ChinaTel. +971 42 045 686 Tel. +1 877 276 7876 Tel. +86 21 6391 3366 Fax +86 21 6391 3399

IndiaArmstrong World Industries (India) Pvt. Ltd. B2, G01, Marathon Innova Opp. Peninsula Corporate Park Off Ganpatrao Kadam Marg Lower Parel, Mumbai 400 013 India Tel. +91223046 0418/3048 0800 (Board Line)Fax +91222491 3604/3046 0439

[email protected]

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