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[ 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
PRoject RePoRt DXB – DUBAI InTERnATIOnAl AIRPORT 6
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.
9 aRmstRong METAl CEIlIngS
PRoject RePoRt DXB – DUBAI InTERnATIOnAl AIRPORT 10
11 aRmstRong METAl CEIlIngS
[ metal Wall cladding ]
45 000 m²
13 aRmstRong METAl CEIlIngS
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.
PRoject RePoRt DXB – DUBAI InTERnATIOnAl AIRPORT 14
[ metal snap-in ceiling ]
81 000 m²
17 aRmstRong METAl CEIlIngS
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.
PRoject RePoRt DXB – DUBAI InTERnATIOnAl AIRPORT 18
© Copyright by Armstrong Metal Ceilings Ltd. 2009
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