[ Project Report] DXB Dubai International Airport

[ Project Report] DXB Dubai International Airport

Project Chronology 2004 2005 2006 november May October December January February March Initial contact: Proposal phase with consulting, planning, and technical clarification. Project order for snap-in ceiling, SIC. Order issued for interior roof lining, IRL. Founding and registration of the local company in Dubai, Armstrong Metal Ceilings L.L.C. Order for metal wall cladding, MWC. 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. Initial deliveries of the interior ceiling.

2007 2008 June November December July October May June July October Initial deliveries of the snap-in ceiling. Additional order for the metal wall cladding. Initial deliveries of the metal wall cladding. Initial delivery of custom-fit panels for the interior ceiling. Final delivery of the metal wall cladding. Final subsequent delivery of custom-fit panels for the snap-in ceiling. Final subsequent delivery of custom-fit panels for the metal wall cladding. Completion of the implementation phase. Opening of Terminal 3, Concourse 2 on October 14, 2008.

3 armstrong METal CeilingS Dear Readers 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 cocoon-like 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 Steg Managing Director & CEO Armstrong Metal Ceiling Group Europe

Project Report DXB DUBAI INTERNATIONAL AIRPORT 4 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. A Monumental Building At 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 two-storey Airbus A380. The building includes luxurious lounges and separate check-in areas for first class and business class passengers, as well as elegant restaurants and cafés. With 29 shops in an area of 11 000 m 2, 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 state-of-the-art airport technology (FIDS, BIDS, security system, CCTV, public address system, building management system and baggage handling system). Cocoon with a Deep Draught Just as with Concourse 1 for which Armstrong 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 engineering 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 materials have been engineered in such a way that they can easily absorb the impact and vibration load caused by aircraft above. Strict regulations regarding climate, seismics and fire protection ensure that the safety of passengers is guaranteed at all times. Contract for a Joint Venture In December 2004 the contract for the airport expansion, with a value of a billion US dollars, was awarded to a joint venture (HMRT) of three companies: the engineering company Al Habtoor, the leading construction and planning group in South Africa Murray & Roberts and the Japanese company Takenaka, active in construction site surveying and planning. During 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.

Armstrong s Service System 01 Consulting and Planning Each project at Armstrong begins with a clarification of the needs, and in-depth consulting with the architect or general 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. 02 Engineering and Production The construction and details to be created are defined based on the basic analysis. The CAD service planning supplies layouts, views, floor plans, perspectives and variations. The CAD service implementation creates the production and installation plans, instructions for the suspension, quantity take-offs, overview, documentation and presentations as well as scheduling. Our production stands for efficient processes and reliable, expedient processing. 04 Maintenance and Support Armstrong also offers worldwide customer service when adaptations or expansions of existing conditions take place. We maintain partnerships with top-notch installation companies around the world, which we also recommend for repair or even cleaning work in addition to installation. 03 Logistics and Installation Each project is unique. That is why Armstrong develops a project-specific logistics concept for each project as basis for on-time 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.

Project Report DXB DUBAI INTERNATIONAL AIRPORT 6 218 400 m 2 of Metal Ceilings and Walls: Interview with Bruce Neave from Murray & Roberts During the construction of Terminal 3, Concourse 2, 218 400 m 2 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. The 57 year old Australian, Bruce Neave, has more than 35 years of experience in large construction and infrastructure projects 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 specifications and appropriately skilled installers that could achieve the required quality and timely installation. 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 project and therefore custom-fit panels can only be measured at a very late stage, leaving very little time for production of 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 programme deadlines. Seen this way, the choice is a matter of trust. The model illustrates in detail the complexity of the project. The cross section shows the unique curve of Concourse 2.

With the installation of the interior ceiling cladding (picture, left), the metal wall cladding (picture, middle) and the metal snap-in ceiling, Armstrong made a significant contribution to the appearance of Terminal 3, Concourse 2. 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 continuously reduce the delivery times through ongoing optimization in procedures and production processes. At what time was Armstrong actually called in? Pre-tender stage. 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 technical 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 construction. When you look back today on the construction after successful completion of the project, which experience do you find particularly valuable? For construction projects of this size and complexity, careful planning and professional 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. 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 Al-Handasah (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 m 2, 120 000 ceiling tiles, 60 000 different positions Metal wall cladding (MWC), 45 000 m 2, 45 000 panels Snap-in ceiling (SIC), 81000 m 2, 130 000 ceiling tiles [ Further Information] 29 designers in 2 project teams (St.Gallen/Dubai) [ Execution] November 2004 July 2008

[ Interior roof lining] 87 000 m²

9 armstrong METal CeilingS 120 000 Ceiling Tiles with an Extremely Complex Geometry: The Interior Roof Lining Complexity in New Dimensions Concourse 2 is curved in all three dimensions and resembles a giant cocoon. The complex architecture with the curved roof, with an area of 87 000 m 2 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 produced 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. 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 subcontractor, Chadwick Technology. The company, which specializes in exterior cladding, was distinguished with the CISCA award for its work. Logistics from Start to Finish The project, Concourse 2, was not only a construction project but also a logistic challenge. Because the 900 m long complex 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 millimetres and was thus virtually imperceptible, each tile was marked with a unique identification number and the precise location of installation. This way, each element

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11 armstrong METal CeilingS

[ Metal Wall Cladding] 45 000 m²

13 armstrong METal CeilingS Customized Product Developments and Made-to-measure: Metal Wall Cladding Innovations on Both Sides In order to satisfy specific customer wishes and conditions, Armstrong altered the standardised wall cladding system and had the new development tested and certified in terms of statics. The wall cladding was extremely engineering-intensive and technically very demanding because of the numerous interfaces and details interrelated 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 non-inflammable medium density fibreboard (MDF) and a steel plate. The high demands on quality induced Armstrong, together with the paint producer, to engineer a superdurable high performance powder coating with increased scratch resistance. Installation The Australian company, Chadwick Technology, a specialist in exterior cladding, 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.

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[ Metal Snap-in Ceiling] 81 000 m²

17 armstrong METal CeilingS Comprehensive Precision and Perfection: The Snap-in Metal Ceiling An Order with Consequences Armstrong was working on the airport project in Dubai more than two years before the first order for the snap-in metal ceiling was recorded in spring of 2005. The order was executed by Batimat Building Materials, a local specialist for ceilings, partitions and kitchens. Thanks to their expertise, market know-how 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. suspension system Gema Grid by Armstrong, they are also quick and easy to install and maintain. The Q-Clip and R-Clip systems both create a uniform perfectly flat appearance in large areas. A Reflection of Quality The snap-in metal ceiling was used in both the terminal and the concourse. The Armstrong metal ceiling products underscore the high-tech character of the airport in both the public zones as well as the restricted areas. Snap-in ceiling systems are not only economical, but because of the unique, certified

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Switzerland Austria Eastern Europe Armstrong Metal Ceilings Ltd. Armstrong Metalldecken GmbH Kunklerstrasse 9 Bundesstrasse 70 CH-9015 St.Gallen A-6830 Rankweil Tel. +41 (0) 71 313 63 63 Tel. +43 (0) 55 22 34 44-0 Fax +41 (0) 71 313 64 00 Fax +43 (0) 55 22 34 44-8 Western North South Central Europe France United Kingdom Republic of Ireland Armstrong Metal Ceilings Ltd. Armstrong Plafonds Métalliques SA Armstrong World Industries Ltd. Kunklerstrasse 9 3, rue Gustave-Moynier Building Products Division CH-9015 St.Gallen CH-1202 Genève Armstrong House, 38 Market Square Tel. +41 (0) 71 313 63 63 Tel. +41 (0) 22 731 60 70 Uxbridge, Middlesex UB8 1NG Fax +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 China Armstrong Building Products Armstrong World Industries Inc. Armstrong World Industries (China) Ltd. (Middle East) L.L.C. Attn. BPO Custumer Service Center 22/F, Cross Tower P.O. Box 73831 P.O. Box 3210 318 Fu Zhou Road Dubai Lancaster, Pennsylvania 17604 Shanghai 200001 United Arab Emirates USA China Tel. +971 42 045 686 Tel. +1 877 276 7876 Tel. +86 21 6391 3366 Fax +86 21 6391 3399 India Armstrong World Industries (India) Pvt. Ltd. B2, G-01, Marathon Innova Opp. Peninsula Corporate Park Off Ganpatrao Kadam Marg Lower Parel, Mumbai 400 013 India Tel. +91-22-3046 0418/3048 0800 (Board Line) Fax +91-22-2491 3604/3046 0439 www.gema.biz www.armstrong.com gema@armstrong.com Copyright by Armstrong Metal Ceilings Ltd. 2009