Dubai International Airport Phase-II: Terminal-3, Concourse-2 and Car Park, Dubai, UAE

Project Owner/Client : Department of Civil Aviation, Government of Dubai
Architects : Dar Al Handasah – adpi
Cost : US$ 5 billion +

Under the Dubai International Airport Master plan, reassessment of the runway system and development of the taxiways was done as phase 1.

Phase 2 has a total investment of around $5 billion, and construction began in 2002. For phase 2 of the master plan, a new terminal building was constructed to accommodate the increasing number of passengers, bringing the capacity of 33 million passengers a year (with 30 million of Terminal-1 and 3 million and Terminal-2), to at least 60 million (?27 Million) passengers per year by the end of 2008. This was phase 2, the construction of Terminal-3, Concourse-2 and Car Park.

Also as part of phase 2, the airport will expand to handle at least 75 million (?15 million) passengers per annum with the opening of Concourse-3 which will be part of Terminal-3. However, recent communications predict a further increase to 80 million passengers with additional reassessments of existing capacities.

Project involves construction of a new terminal (Terminal-3) and 2 concourses (Concourse-2 and Concourse-3) at Dubai International Airport. The third terminal will be capable of handling 20 million passengers a year. The third terminal will be a replica of the second terminal. It will have between 62 to 64 parking bays and 36 or 37 gates. The Terminal 3 will be located beneath the apron and taxiway area and will directly link with Concourse 2.

Contract No. AX059 covers the architectural finishes and MEP works for terminal 3, an underground structure covering a total area of 532,000sq.m, the open air car park structure having built up area of 257,000sq.m and the 670,000sq.m concourse 2. Contract Value of AX059 is $981 mn (AED 3,600 mn) which covers the finishes and MEP works for Terminal-3, Concourse-2 and the Car Park structure. HMRT JV (Habtoor – Murray & Roberts – Takenaka Joint Venture) carried out packge AX059.

The largest element of AX059 project is the MEP works, known as AX324. Provisional sums make up around 50 % of the total value of the contract. Three groups of companies were the bidders for AX324. AX324 (AED 1,800 million; US$490 million), the largest MEP contract so far in the UAE construction industry has been awarded to THERMO. The contract covers the MEP works and special airport systems (SAS) for Terminal-3, Concourse-2 and Car Park elements. Thermo is being assisted on the project by Alcatel and Arinc. Specialist subcontractors are carrying out six sub-packages. Amec (Hong Kong office) will provide engineering project management services. The other bidding groups for the project were BK Gulf with ETA and Kharafi National with Voltas International.

Butler Engineering were engaged by HMRT JV (Habtoor – Murray & Roberts – Takenaka Joint Venture) – the Finishing & MEP Contractor for Contract No. AX059 to carry out inspection and testing of Fire-resistive Joint Systems and Through Penetration Fire-stop Systems installed by THERMO LLC (the nominated sub-contractor for MEP and SAS work) for Contract No. AX324.

Summary of our Scope:

Inspection and testing of installed Fire-stop Systems covered:

  • Submittals Review
  • Design Listed Systems Review
  • Material Inspection
  • Mock-up Review
  • General Review
  • Observation Review
  • Destructive Review
  • Final Report & Certification

In addition, we were requested by the Engineer to coordinate Engineering Judgments in case of deviations from the Standard Design Listed Systems

The quantities of Fire-stop Systems inspected;

  • Fire-restive Joint Systems: 232 km in linear length
  • Through Penetrations: Over 200,000 units