Dubai International airport has expanded steadily since the first 1,800-metre compacted airstrip was opened in 1960. Construction of new terminals, gates, runways, taxiways and concourse buildings has punctuated the past four decades.

The most ambitious of these additions was the Emirates Terminal 3, which opened in 2008. The project trebled the capacity of the airport to 60 million passengers a year and despite this massive boost, Dubai prepared for more.

In January 2013, the landmark $3.3bn concourse 3 (now renamed concourse A) opened, bolstering capacity by a further 15 million passengers and with 20 new Airbus A380 gates to serve Emirates’ growing fleet. Currently, the existing Terminal 2, home to low-cost carrier FlyDubai, is undergoing expansion to double its capacity to 10 million passengers a year. This, combined with the new concourse 4, will enable the airport to serve 90 million passengers a year by 2018.

Airport legacy

Such a figure may sound ambitious for an airport that served just 5 million passengers in 1990, but the emirate has been consistent in successfully predicting the airport’s future potential. By 2000, the airport was handling 12.3 million passengers and subsequently a huge expansion programme began. This has enabled Dubai’s aviation sector to stay ahead of demand, outperforming expectations by growing at 15.5 per cent a year – even through the global economic downturn.

In 2012, 57.7 million passengers used the airport, 1.7 million more than forecast. Fortunately, the landmark Terminal 3 was ready. Bringing concourse 3 online in January 2013 allows Dubai to sustain its growth in the short term.

Dubai Airports, the owner and operator of Dubai International, predicts passenger numbers to rise at a more modest 7.2 per cent a year in future, with cargo growing at 6.7 per cent. This means the airport will reach capacity in 2018, despite $7.8bn being invested in expanding the facility between now and 2020.

For this reason, the 160-million-capacity super-size airport at Jebel Ali, Al-Maktoum International, is viewed as the long-term solution to Dubai’s future aviation needs. A timetable and a phasing schedule for the transition has yet to be defined.

For now, expansion at Dubai International is critical to meet the continuing passenger and cargo growth. By 2015, the airport will have increased its number of aircraft stands to 230 (from 144 in 2010), delivered the new concourse 4, and increased cargo capacity to 4.1 million tonnes from 2.5 million today.

Concourse 3

The most recent development at Dubai International was the delivery of the $3.2bn concourse 3, which extended the existing Emirates Terminal 3 by a further 528,000 square metres.

Opening in January 2013, the new concourse served 589,234 passengers in its first month, from 2,450 flights. Local contractor Al-Jaber LEGT Construction & Engineering (Alec) was awarded the contract in April 2009 after original contractor Al-Habtoor Leighton (local)/Murray Roberts (SouthAfrica)/Takenaka (Japan) withdrew. Despite having been awarded the deal in December 2008, the contractor group failed to agree contract terms with the aviation authorities, leading to the re-award four months later.

[Concourse 3] was a massive, technically complex project that was delivered on time

Barry Lewis, Alec

After the false start, construction of concourse 3 progressed well. “There are not many megaprojects delivered on time,” says Alec managing director Barry Lewis, who was also project manager at Dubai International. “This was a massive, technically complex project that was delivered on time and was able to be commissioned and integrated into airport operations without any major disruption.”

Dubai Aviation Engineering Projects (DAEP) department says that teamwork was critical in meeting project milestones. A dedicated design team – including members from DAEP, designer Dar al-Handasah, consultants ADPI and Alec – was based permanently on site so design changes could be dealt with immediately and daily meetings could be held to discuss progress.

This was particularly important given the complexity of the concourse 3 structure – an elliptical shell over a concrete superstructure – requiring bespoke design and construction solutions. In addition, late design changes based on meeting passenger needs better, could be swiftly managed.

Perhaps the biggest challenge in delivering the project was the management of the logistics and coordination of 19,000 workers from more than 50 sub-contractors, engaged on multiple work fronts over long periods of time. Ensuring designs were ready and approved and the materials and skilled employees were at the required work front at the right time was challenging.

“It required a massive effort from a committed management team with a very clear plan; a strong belief that the plan could be achieved; and an ability to adapt to change, yet still keep the tempo and volumes of works in the various areas going,” says Lewis.

Creating a fully A380-compatible concourse was another major challenge. “Unlike other commercial planes predominantly in operation, the A380s have an additional upper deck,” says DEAP chief executive officer, Suzanne al-Anani. “Hence, separate levels were created within the concourse allocating the lower level for the economy holding lounges, the second level for first class, and third level for the business class lounges.

“Secondly, the size of the holding lounges is governed by the capacity of the planes, hence these need to be enlarged for the A380s.”

Supporting infrastructure such as fuelling facilities, pre-cooled air supply, potable water, catering loaders and passenger boarding bridges had to be tailored specifically to A380 requirements.

Concourse 4

Fresh from success on concourse 3, in February 2012, Alec was awarded the $816m contract to build concourse 4. The new building will sit west of the existing Terminal 1, adjacent to the site of a cargo mega-terminal, currently undergoing expansion. DAEP tells MEED the concourse building will be architecturally simple and elegant, using prefabricated structural elements assembled on site. It will also be the airport’s first Leadership in Energy and Environmental Design (LEED) certified building. Canada’s Bombardier has been selected to supply rolling stock for the concourse people-mover, which will be built by the local Dutco Balfour Beatty.

Careful planning will be the key to successful delivery of concourse 4.“You need a very clear plan, it needs to be well communicated to all parties, and all people representing the various parties must be aligned and their actions must reflect the common objective at all times,” says Lewis.

Cargo Growth

Freight volumes at Dubai International have continued to grow steadily – even during the downturn – accelerating in the second half of 2012 and early 2013. In January 2013, the airport handled 188,520 tonnes, up from 173,531 tonnes recorded in January 2012. Overall growth for 2012 was 3.9 per cent with 2.28 million tonnes of cargo passing through the airport, which has a total cargo capacity of 2.5 million tonnes a year (t/y).

You need a clear plan [for airport expansion] … [the actions of all parties] must reflect the common objective

Barry Lewis, Alec

In line with Dubai Airport’s 2020 masterplan, the cargo capacity will increase to 4.1 million t/y once the cargo mega-terminal expansion is completed. The original $200m mega-terminal was opened in 2008 and increased capacity to the existing 2.5 million t/y from 150,000 t/y. Transfer time from port to air is about six hours.

Al-Maktoum International, with its 12 million tonnes of cargo capacity, will achieve this in four.

Terminal 2

Expansion of the original Terminal 2 is ongoing and remains a major component of the 2020 masterplan. The existing terminal opened in May 1998 to relieve the congested Terminal 1. It was expanded to cater for 5 million passengers from 3 million and more space is now needed.

Contractor Arabtec was awarded a $163m 25-month contract in January 2012 to double the size of the terminal to 60,000 sq m, as well as upgrading the existing facilities. This will bring capacity to 10 million passengers. A new terminal building, check-in hall, departure area and immigration hall will all be constructed as part of the scheme, scheduled for completion in early 2014.

Subcontracts have been awarded to Canada’s RMC Ready Mix for cement, the local Al-Abbar Aluminium for the cladding and glass, and local Smart World for information technology. Terminal 2 is currently the home of low-cost airline FlyDubai, which started operations in June 2009. It also hosts 50 other airlines, catering for charter flights and specialist carriers.