Dubai International Airport Expansion An Engineering Challenge

Cameron Bellman Admixture Systems Manager Degussa Middle East

Dubai International Airport

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An Evolving Skyline

1969 The Creek

1984 Sheikh Zayed Road

2004 Sheikh Zayed Road

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Dubai

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Dubai

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Dubai

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The Environment
Dubai and the Middle East is one of the most demanding and aggressive environments for concrete anywhere in the world. Summer Temperatures reach 50C (shade) Relative humidity at +90% Being on the coast the air is saturated with chlorides

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The Environment

Production of concrete is demanding Specifications for durability rival those anywhere in the world

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Existing Airfield
EXISTING TERMINAL & CONCOURSE 1 EXISTING TERMINAL 2

FUTURE TERMINAL 3 / CONCOURSES 2 & 3

EXISTING RUNWAYS

Aviation the engine of the economy

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Dubai International Airport

D Dubai has become a favoured tourist destination D Also a travel hub linking the East and the West D Passenger numbers have grown by over 100% since 1998 DIn 2005 over 25 million passengers passed through the airport D It was the 2nd fastest growing airport in the world in 2002

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Dubai Airport: projected passenger growth (m)

Total Pax 80.0

70.0 62.2 60.0 52.5 50.0 41.3 40.0 28.2 22.6 20.0 9.1 10.0 9.7 10.8 12.3 13.5 16.0 18.1 35.3 47.1 57.4

66.7

Heathrow Airport = 65 mil/yr

30.0

0.0 1997

1998

1999

2000

2001

2002

2003

2004

2005

2006

2007

2008

2009

2010

2011

2012

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The airport master plan

Free Zone Terminal 2

Emirates Engineering

Runways
Flower Centre Cargo Village
Concourse 3 Airshow
Fuel Farm

Concourses 1 & 2 Abela

Royal Airwing

Terminal 3

Emirates Operations Cargo Facilities by 2005 - 07 Complete Expansion by 2009

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Terminal Facilities by 2007 -09

Airfield Facilities by 2002 06

Dubai International Airport

D Projections are of over 60 million passengers travelling through, or to Dubai by 2010 D A $4.1 Billion expansion project announced for completion by 2006 D A dedicated Emirates terminal (Terminal 3) D Concourse 2 and 3

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Dubai International Airport

D Terminal 3s features Multi level underground structure 300m x 350m First class lounges and dedicated check in 180 check in desks Various restaurants 2600 underground car parking spaces Departure and arrivals hall is 10m below the apron and taxiways

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CONCOURSES 1 & 2

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Scope
D 2.4 Million cubic metres of concrete D Specification limit of 30 C maximum temperature. Target limit for massive concrete 27 C. D 24 month program D 500000 tonnes of steel D Manpower on site 7000 people D 40+ tower cranes D 3 creater cranes D 7 mobile pumps D 4 static pumps

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SCOPE
160000 140000 120000 100000 80000 61825.5 60000 40000 20000 0
Oct03 Nov03 Dec03 Jan04 Feb04 Mar04 Apr04 May04 Jun04 Jul04 Aug04 Sep04 Oct04 Nov04 Dec04 Jan05 Feb05 Mar05 Apr05 May05 Jun05 Jul05

145857 136483 138931.5 133546.5 130773 118324 108634.5 92485.5 94550.5 75084.5 99670 92592 89834.5 64356 62690.5 105417.5 100178 87019.5

Nov-03 Dec-03 Jan-04 Feb-04 Mar-04 Apr-04 May-04 Jun-04 Jul-04 Aug-04 Sep-04 Oct-04 Nov-04 Dec-04 Jan-05

19865

Feb-05 Mar-05 Apr-05 May-05 Jun-05

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The Concrete
1.6 Million cubic mt in mass Concrete 700000 cubic mt Structural Concrete 100000 cubic mt High Performance Concrete

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The Concrete (mass)

D 33 Mpa (cylinder) at 28days

D Temperature control: at placement less than 27C D Maximum core temperature 65C with 20C differential Durability D BS 1881 part 122 absorption max 2.5% D Din less than 20mm D RCP less than 1500 coulombs

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The Concrete (mass)

Total cementitious content 70 % GGBS & low heat Portland cement Limestone Aggregates used Slump retention of 150mm for two hours Max w/c ratio 0.38 365 kg / m

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The Concrete (Mass)

Raft concrete with 70% GGBS. Target temperature 27C. Ice percentage adjusted according to ambient temps. Maximum addition 80 kg per cubic metre.

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The Concrete (structural)

High early strength requirement, 75% at 3 days Mix contained 5% micro silica Total cementitious content 420 kg / m Required to be pumped in static line for 100 linear metres Slump extension of 200mm for over two hours Max 30C placement temperature

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The Concrete ( High Strength)

60 and 80 Mpa (cylinder) strengths required at 28 days Slump extension 200mm at over two hours Mixes Contained 5% micro silica Plus durability requirements

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Degussa Middle Easts Involvement

D Degussa had a long term involvement with the project D Worked with three potential suppliers D Cemex requirement Single admixture for majority of the concrete Give required water reduction and slump extension Will not delay set times even in 70% GGBS mixes Meet early age strengths in structural mixes

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The admixture
D In partnership with Cemex. D DCC developed a product to meet all of Cemexs stated requirements. D Enabled Cemex to bid project competitively D Rheobuild 858 A type G BNS based product Flexible Dosage range No retardation in GGBS mix Early age strength development

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The Result of the collaboration

August 2003 Cemex secured a project to supply 2.4 million cubic meters of concrete over a period of 24 months. Degussa secured supply of all admixtures.

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The Plant

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The Plant

Covered Aggregate Storage approx 7000 metric tonnes

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The Plant
Water spray on aggregate belt. Heat loss through evaporation. Dust control.

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The Plant
6 nos. KTI chillers with 600 M capacity Incoming water at 45C 1.2 million liters underground storage Chilled to 4-5C

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The Plant
2 nos. KTI Ammonia flaked ice plants with 550 tonnes capacity per day. 1 no. KTI Freon flaked ice plant with 50 mt capacity per day. 450 Tonnes of ice storage capacity

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The Plant
5000 metric tonnes of silo capacity. Incoming Cement at +60C. Incoming GGBS at +45C.

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The Plant
3 Erie Strayer plants 1 Cuoghi plant Combined production capacity 900 mt / hour rated 700 actual 65 truck mixers 600 tonnes flaked ice per day 450 tonnes storage flaked ice 1.2 million litres of chilled water 5000 tonnes powder storage 200000litre admixture storage

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Records and Achievements

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Records & Achievements

D 15 million litres of Rheobuild D 4.56 million tonnes aggregates D 900000 tonnes powder

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Records & Achievements

D 1.2 Million cubic metres in raft D Highly durable mix D Strict temperature control D 0.36 w/c ratio D 5.5 litres Rheobuild 858

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Records & Achievements

D Record pour 7386 cubic metres Supplied in just over 11 hrs 1810 tonnes GGBS 1150 tonnes OPC 12000 tonnes aggregate 2750 tonnes sand 445 tonnes ice 51700 litres Rheobuild 858

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Records & Achievements

D Record month logistics - 100 trucks of aggregate / day - 35 trucks of powder / day - 1.5 trucks of admixture / day

THIS EQUATES TO 1 DELIVERY EVERY TEN MINUTES EVERY DAY FOR A MONTH

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Records & Achievements

D Rheobuild 858 D Glenium 110M D Glenium Stream 2 D RMC P25 D Tetraguard AS 21 D Rheocrete 222+ 14.7 million litres 300000 litres 18000 litres 520000 litres 6500 litres 16000 litres

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Other Systems
D All columns supplied with Rheodynamic (SCC) concrete - C 45 & C80 mpa cylinder strength - All placed from bottom up max height 18 metre D Tetraguard AS 21 D Delvo technology for waste management D Rheocrete 222+ D C35 structural lightweight concrete

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Why Rheodynamic Concrete ?

D The main contractor was looking for means to enhance his work program and for early completion of the project. D Reduction in concrete repairs was also another aim. D In conjunction with Degussa CC, the readymix concrete producer proposed SCC as an answer to their needs. D Extensive tests were conducted in the site laboratory followed by plant trials to ensure the concrete meets the requirement of the Engineers.

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Where was it used?

In columns: Cylinder strength 45/20 60/10 80/20 No.of columns 180 62 78 approx volume 2,500 m3 2,000 m3 2,500 m3 7,000 m3

- Pumping from the bottom-up to 18m high columns in one go - In Car park, pumped from bottom-up to 30 m high column in one go

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Advantages
Speed of construction: The use of SCC reduced the columns casting cycle from 7 days (original design to cast in 3 layers), to one day. No remedial works required, therefore additional savings in manpower and materials. The client was sure of the high quality and durability of the columns.

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Limits are our Challenge.

Thank you for your attention

Adding Value to Concrete

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