Project Description:

Hamad International Airport, which was formerly known as New Doha International Airport, is the main airport for the State of Qatar. It is the operating base for the national carrier, Qatar Airways. The project’s Main structural steel works (total 131,150MT) were awarded into different packages among which we had secured most Structural steel works as follows.

• Phase 1 & 2 – About 65,600MT of structural steel works were secured from the Contractor M/s. Sky Oryx JV (SOJV) during the year 2006.
• CP10 Substation & Central Utility Plants – About 1,600MT of structural steel works were secured from the Contractors M/s. Sinohydro-Gamuda-WCT (SGW) JV and M/s. CAT International Qatar WL during the years 2009 and 2010 respectively.
• Phase 3 – 35,000MT of structural steel works were secured from the Contractor M/s. BeSix-Midmac JV as a nominated structural steel contractor during the year 2010.
• Package 013 – About 12,950MT of structural steel works were secured from the Contractor M/s. Midmac, Taisei & TAV JV (MTTJV) during the year 2020.
• Package 065 – About 16,000MT of structural steel works were secured from the Contractor M/s. Midmac and TAV JV (MTJV) during the year 2023.

Project Duration:

• Phase 1, 2 & 3 (About 102,200MT) were executed between the year 2006 & 2012.
• Package 013 (About 12,950MT) was executed between the year 2020 to 2022.
• Package 065 (About 16,000MT) works commenced during early 2023 and the works are under progress.

Scope of Work:

• Phase 1 – Connection Design, Engineering, Supply Material, Fabrication, Site Assembly and Erection of Structural Steel Works
• Phase 2 – Site Assembly and Erection Structural Steel Works.
• CP10 Substation & Central Utility Plants – Connection Design, Engineering, Supply Material, Fabrication, Surface Preparation & Painting, Transportation and Erection of Structural Steel.
• Phase 3 – Connection Design, Engineering, Material Supply, Fabrication, Surface Preparation & Painting, Metal Decking, Erection of Steel Structures
• Package 013 & 065 – Connection Design, Engineering, Material Supply, Fabrication and Erection of Structural Steel Work, Metal Decking and Fireproofing works.

Key Milestones:

Achievements in Phase 1 & 2:

• Certification of Achievement in achieving 2,000,000, 3,000,000, 4,000,000, 5,000,000 and 6,000,000 manhours without LTI.
• Certification of Achievement in Erecting 34,000MT of steel without LTI.
• Certificate of Recognition is awarded for the Best Behavior Observation Team.
• Certificate of Recognition is awarded for the Best Big Subcontractor of the Month (May & November 2010, February 2011).
• Certificate of Recognition is awarded for the Environmental Contractor.
• Letter of Appreciation in recognition of Construction, Quality, Health, Safety and Environmental Performance for the Completion of 65,000MT of specialized Structural steel.

Achievements in Phase 3:

• HSE Excellence Award in recognition for the excellent performance in achieving 35,000MT.
• HSE Excellence Award in recognition of outstanding HSE performance and compliance with the Project HSE programme for achieving 1,000,000 manhours without LTI.

Achievements in Package 013:

• Certificate of Safe work practice in the contribution of 1 million manhours without LTI.

Achievements in Package 065:

• Significant contribution award in recognition of support, dedication and commitment for achieving 1 million Man-hours.

Challenges Faced:

Technical Challenges:

• Arches in the Main Terminal Building

The Main Terminal Building features complex structures, such as arches, which require a specialized methodology to ensure their geometry and stability during construction. The Erection Engineering team developed a stage-by-stage methodology after coordinating with other trade subcontractors involved in the project. The arches were fabricated into parts and trial assemblies were carried out at the fabrication factory to ensure their geometry. They were then transported to the site and installed using a heavy crawler crane with temporary supports to achieve the geometry of the structure.

• Y Column with AESS Finish

Another complex structure in the project is the ‘Y-shaped’ box built-up column, which is sloped in two directions and consists of 50mm thick plates. Providing control dimensions for these columns in the fabrication drawings was challenging but was successfully addressed. These columns are Architecturally Exposed Steel Structures (AESS) with surface finishing done within 1mm tolerance.

• Cage Columns with AESS Finish

Additionally, there are special elements like box–built–up columns & Cage columns, which are formed with 4 individual legs tied together with horizontal & diagonal ties at every 2m height. These elements are also categorized as architecturally exposed items with very tight fabrication & erection tolerance limits.

• Security Canopies with AESS Finish

The “Security canopies” in concourse D & E are another complex element, featuring plate built-up columns that are curved in 3D-dimension and tilted in cross-section like a trapezoid. The structure is architecturally exposed and installed within very tight tolerance limits, following exhaustive 3D modelling and confirmation by the Architects.

• APM Track

An essential part of the Airport building is the APM (Automatic People Mover) track, consisting of 2-built-up cruciform-shaped beams 2m apart by 4.38m center to center. The track runs for a distance of 180m length in Concourses D & E, respectively, and is supported by APM columns every 30m, with special bearings. The track beams are installed within specified tolerance limits. Notably, the level and gradient of the new track beams match those of the previously built APM track beams in phase 2, which is over 500m long and has settled down.