In July 2005, a highly prestigious project was awarded by Dubai Civil Aviation to Rigidal Industries LLC. With more than 400,000 metres square of roof and wall area to be clad, The new Emirates engineering facility at Dubai International Airport was, at that time, one of the largest cladding contracts to have been secured by Rigidal.
Designed by Airport de Paris, the new facility is one of the largest civil aviation maintenance facilities in the world, encompassing 55 hectares and comprising eight aircraft hangars and one of the largest workshop facilities in the Middle East.
Rigidal commenced manufacturing materials in November 2005, supplying the aluminium roofing and cladding for the hangars.
Each extensive hangar is capable of accommodating one of the new double-decker Airbus A380 aircraft - each with a wing-span of 79.8 metres, length of 72.75 metres and height of 24.8 metres - as soon as they enter into service in the United Arab Emirates.
The roof cladding comprises the patented Rigidal Ziplok standing seam system, which is supported off a range of structural decks. The advanced Ziplok Standing Seam system provides a single sheet spanning from eaves to eaves without the need for endlaps or external fixations which are the norm with more traditional types of metal cladding systems. The United Arab Emirates lies within a desert region which experiences erratic rainfall, high level temperatures, high humidity, sunshine and sand storms, thus an impenetrable roof of this caliber was high on Dubai Civil Aviation’s list of priorities.
With the constraints of carrying out work on a live airport site, the coordination between the main contractor, sub-contractors, who were tasked with installing the material, and Rigidal needed to be seamless. As a testament to the dedication of all involved and the subsequent synchronisation of all parties, ensured the works were completed on time.
The Ziplok standing seam roof sheets were manufactured on site using one of Rigidals mobile manufacturing units. Some of the sheets measured 120 metres in length which, at the time of construction, were the longest to have been manufactured in Dubai. The perforated decking sheets provide the facility with enhanced acoustic performance, absorbing sound created internally and preventing the penetration of noise from outside.
The Rigidal Ziplok standing seam system can also accommodate complex designs, which in this instance called for curved roof panels. While the walls, which have an architectural profile of HC35-800 are supported on a horizontally laid structural lining tray which are also perforated for superior thermal and acoustic insulation; a necessity on an airport facility project.
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For further information regarding the materials used on this project or for further information on Rigidal’s complete range of metal cladding systems please contact their sales office on +971 (0)4-8854232 or by email at: