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How the Burj was builtPublished: Saturday, January 16, 2010 with119 Comments

By Construction Week Staff Writer www.arabianbusiness.com

Vision is a word you hear a lot in the GCC. But just imagine if you will, sitting down in a meetingand deciding to construct the worlds tallest building in your city. Not one that is going to be the

tallest by a few dozen metres, and relinquish its title to another tower, in another city, within a fewyears, but the tallest by a massive margin.

Burj Khalifa

If you can imagine that, then you can get a feeling for the vision that went into coming up with the BurjKhalifa, now open and officially the worlds tallest tower, a whopping 300m-plus taller than the next nearestrival. More than six years in the making and not fully-finished just yet, the project was and is a massiveundertaking, one that has paired bold vision with a brave leap into the engineering unknown.

Making it happen not only needed vision, but cash and a fair whack of design and engineering genius. Pushingat the envelope of engineering means trying new things, developing new techniques and doing a ton of testing.

And while its hard to find a construction contractor or supplier who doesnt claim to have been involved in themaking of the Burj Khalifa, CW takes a look at what those who were really there had to do to build an icon.FinanceOnce youve had the vision, the real work doesnt start until you find a way to pay. The final finished cost ofthe Burj Khalifa will be tough to calculate, once a complete interior fit-out is taken into account. MohammedAlabbar himself recently suggested a final budget of US $1.5 billion. Mashreqbank, Emirates Bank Internationaland Abu Dhabi Commercial Bank formed a syndicate to provide finance way back in 2005.

The triumvirate of banks signed a financing agreement with Korean contractor Samsung Corporation and itsproject partners Belhasa Six Construct and Arabtec. The good news is that around 90% of saleable space wassold off-plan, helping ensure that money never ran tight.DesignSkidmore, Owings & Merrill was the architecture firm behind the design and engineering of the tower.

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The design team developed what has become known as a spiraling Y shaped plan, which was used to shapethe structural core of the building.

Key considerations included the impact of wind forces and constructability, architecture cant for practicalconstruction considerations. The design employs a buttressed core, which has each wing of the buildingbuttressing the others via a six-sided central core.

It is this central core that provides the structures torsional resistance. The design of wall and corridorintersections means that all of the vertical concrete is used to support both gravity and lateral loads.

As the building spirals in height, the wings set back to provide many different floor plates. These setbacks alsohave the advantage of providing a different width to the tower for each differing floor plate. This stepping andshaping of the tower has the effect of disrupting the flow of the wind over the height of the building.

Foundations

If you want to build high, you must first dig deep, driving foundations down well below the surface. The towerssuperstructure is supported by a large reinforced concrete mat, which is in turn supported by 192 boredreinforced concrete piles.

The mat is 3.7m thick, and was constructed in four separate pours totaling 12,500 cubic metres (m) ofconcrete. Bauer Spezialtiefbau, with Middle East Foundations, took on much of the piling work, which requiredbores to be sunk for cast in-situ piles, to a depth of 43 metres.

Known by some as the Rolls-Royce of the drill rig world, the Bauer BG40 can deliver, as the name suggests,40nm of torque. Of course, there isnt a situation that we could imagine where you would need such heavypower for drilling piling holes half of this would be sufficient for most situations. However, a reserve of torquemeans there is less stress put on the machine, so it can get on with what it is required to do.

Around 45,000m of concrete, weighing more than 110,000 tonnes, were poured for the foundations thatsequivalent to 18 Olympic sized swimming pools with 192 piles running to a depth of over 50m.

A high density, low permeability concrete was used in the foundations, as well as a cathodic protection systemunder the mat. This is an effort to counter the effects of the highly-corrosive ground water.

Bores for the 192 deep piles were sunk in 2004. Each of them was designed to be cast in situ, and as suchneeded to be very deep. Ground conditions at the Burj site were favourable the soft, but not unstable, soilproved easy to dig into. Other sites in the region are not so fortunate naturally occurring limestone requiresbreaking with a breaker attachment first.Concrete and steelYou know already that over 45,000m of concrete was used to in construction of the towers foundations. Theoverall construction process will have used 330,000 m of concrete and 39,000 tonnes (43,000 ST; 38,000 LT)of steel rebar. Laid end to end, the rebar used in the tower would extend over a quarter of the way around theworld. For the construction of the tower, BASF developed a special concrete mix that was pumped to a heightof more than 600 metres without segregating.

Thanks to BASFs admixture Glenium Sky 504, the concrete could be worked on for more than three hoursbefore hardening took place. This allowed for a shorter construction time and gives the building a longer usefullife, making it more sustainable.PumpingIn November, 2007, the highest reinforced concrete corewalls were made using concrete pumped from groundlevel to a vertical height of 601 metres. This broke the previous pumping record for a building of 470m on theTaipei 101 and the previous overall world record for vertical pumping of 532 metres for an extension to theRiva del Garda Hydroelectric Power Plant in 1994. The concrete pressure during pumping to this level wasnearly 200 bars.

When the record was set, a photocall was arranged and a distance of 601 metres was reported as the newrecord. However, it was discovered shortly afterwards that the concrete needed to go a little further and so an

extension was added to move the concrete to 606 metres.

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The mix was able to reach such astounding heights by running through a high-pressure trailer mounted pump(a Putzmeister 14000 SHP D). The concrete required approximately 40 minutes from the filling of the hopper toits discharge from the delivery line. The concrete volume in the line amounted to approximately 11m with thisinstallation height meaning there was roughly 26 tonnes on the pump after every piston stroke or five bigelephants.

Over a period of about 32 months, the high pressure pump and two others delivered more than 165,000m of

high-strength concrete, which, using our preferred unit of measurement, is about 66 Olympic sized swimmingpools.CladdingExterior cladding of Burj Khalifa began in May 2007 and was completed in September 2009. At the initial stageof installation, the team progressed at the rate of about 20 to 30 panels per day and eventually achieved asmany as 175 panels per day. Burj Khalifa has set a new world record for the highest installation of analuminium and glass facade, at 512 metres.

The total weight of aluminium used on Burj Khalifa is equivalent to that of five A380 aircraft and the totallength of stainless steel bull nose fins is 293 times the height of Eiffel Tower in Paris.

The exterior cladding is comprised of reflective glazing with aluminum and textured stainless steel spandrelpanels and stainless steel vertical tubular fins. Close to 26,000 glass panels, each individually hand-cut, wereused in the exterior cladding of the tower.

Over 300 cladding specialists from China were brought in to do the work. The cladding system is designed towithstand Dubais extreme summer heat, and to further ensure its integrity, a World War II airplane enginewas used for dynamic wind and water testing. The curtain wall of Burj Khalifa is equivalent to 17 football(soccer) fields or 25 American football fields.Need a lift?Increasing high-rise construction worldwide has led lift manufacturers to develop a double-deck or twinelevator design.

With this, instead of the conventional one lift car per shaft design, two passenger cars are contained within thesame shaft, using the same guide rails.

Separate traction drives enable the two cars to travel to different floors simultaneously using the same set ofguide rails.

The passenger destination and direction of travel for the elevators is recorded at the start of all passenger callsand an electronic destination control system assigns the cars to the levels according to efficiency of operation.

The electronic control also ensures that the cars never collide within the lift shaft.

One of the major benefits of such a system is the reduction in service core space that is needed in a buildingby effectively combining two lift systems into one. Time saving for passengers is also a major advantage.

Cranes

Theyre graceful, mysterious and it seemed for a time everybodys favourite topic. The high level cranes at theBurj were always enigmatic, enshrouding the operator of the very highest unit in mystery. There were storiescirculating about the Indian on top of the world which speculated that he was paid a kings ransom, and thathe had been made an honorary UAE citizen.

All of this was really nothing more than idle gossip the figure had become more of a mystery man throughEmaars refusal to let the media have any access to him, though this was most likely due to the developerkeeping the exact height of the structure a closely guarded secret a figure which the high-level operatorsundoubtedly knew. Despite this conundrum, there is quite a lot that we do know about the high-level cranes.For a start, there was not one, but three Favelle Favco cranes that served right up to level 156.

Given that the machines worked 24 hours for much of the projects duration it would be safe to assume thatthere was a team of at least nine drivers and many other technicians to ensure safe operation. (In fact, Emaar

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recently confirmed that a 35-strong workforce were on hand to run the cranes, though this is a drop in theocean compared to the total of 12,000 employees on the project.)

Usually, the cranes loads consisted of steel reinforcement beams, but welding equipment, scaffolding, gensetsand even tanks of fuel for the diesel powered cranes all needed to be lifted to the correct floor. DismantlingInstalling the three high-level cranes was relatively straightforward as sections of the cranes could be movedup the tower with the completion of new levels.

Getting the towers down however, required a little more lateral thinking. The first high-level crane was movedin November 2007 down to level 99 in order to serve as a future recovery crane. The next high-level cranecame down in October 2008, leaving one prominent machine apparently stuck at the top, while people on theground speculated how it might come down.

The answer was that another small crane had to be lifted to floor 159. With a crane on this floor as well as theone on level 99, the dismantling process was ready to begin. The process started with the crane climbing downfrom its working height of over 700 metres. The crane removed its own mast sections and lowered them to theground until the boom and power pack were at the position of the Level 159 recovery crane.

From there, the Level 159 recovery crane dismantled the remainder of the main crane, lowering the pieces ofboom, mast and power pack to the recovery crane at Level 99, which further lowered them to the ground.

The dismantling of the cranes at Burj Khalifa was indeed a finely orchestrated set piece except that theartists here were huge machines.

The three cranes on the tower were all diesel Favelle Favco units, of various specifications. This type of diesel-hydraulic crane is popular on supertall skyscrapers, due to a useful turn of speed and power. However, one ofthe main challenges was actually getting the fuel to the required height there are no petrol stations on the159th floor.PeopleBurj Khalifa was an international collaboration between more than 60 contracting and consulting companiesfrom all over the world. At the peak of construction, over 12,000 workers and contractors were on site everyday, representing more than 100 nationalities. According to Emaar, construction will have taken 22 million manhours.Fire SafetyFire safety and speed of evacuation were prime factors in the design of Burj Khalifa. Concrete surrounds allstairwells and the building service and firemans elevator will have a capacity of 5500kg and will be the worldstallest service elevator. Since people cant reasonably be expected to walk down 160 floors, there arepressurised, air-conditioned refuge areas located approximately every 25 floors.Keep cool

To boost the energy efficiency of the Burj Khalifa cooling system, an ice thermal storage system is beingemployed within the district cooling plant serving the tower. This helps to reduce power consumption in thedaytime and high-load conditions.

The system involves the use of a store of ice slurry to reduce the temperature of the chilled water. The ice iscreated during off-peak periods and through the night-time and held within a thermal storage unit for usewhen required.

The system is now commonly used in the USA and Europe for commercial and district cooling applications; it isbelieved that the system at the Burj Khalifa development will be the first to be employed in the Middle East. Ingeneral, the use of an ice storage system can reduce the total installed chiller capacity by up to 35%.

The latent energy stored in ice is eight times greater than that possible with a similar volume of chilled water,

which makes such systems favourable for large district cooling plants.

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Further benefits include a reduction of 30-40% in the size and cost of all auxiliary equipment needed and theability to deliver chilled water at lower temperatures than would normally be possible from chillers, enablingthe use of smaller equipment such as pipes and pumps.

MEP

The mechanical, electrical and plumbing services for Burj Khalifa were developed in co-ordination during thedesign phase with the co-operation of the architect, structural engineer and other consultants. HyderConsulting was appointed as a supervision consultant with responsibility for overseeing execution of the MEP.An ETA-Hitachi-Voltas joint venture was awarded the buildings MEP contract.

Seven double-storey mechanical floors house the equipment that bring Burj Khalifa to life. Distributed aroundevery 30 storeys, the mechanical floors house the electrical sub-stations, water tanks, pumps and air handlingunits that are essential for the running of the building.

These mechanical areas typically serve the 15 floors above and below them. The primary distribution route forservices is through the main risers within the central core of the structure, which remains the same size tolevel 150 despite the overall building shape tapering with height. MEP operations are managed by a central

BMS, with local control panels in each plant room, all connected by fibre-optic cabling. During construction,deliveries of MEP equipment tended to be made during the night, with the podium and basement used asstorage space. Cranes, hoists and service lifts were used to transport the various materials.

The Burj Khalifas water system supplies an average of 946,000 litres (250,000 gallons) of water daily. At peakcooling, Burj Khalifa will require about 10,000 tonnes of cooling, equal to the cooling capacity provided byabout 10,000 tonnes of melting ice.

Dubais hot, humid climate combined with the buildings cooling requirements creates a significant amount ofcondensation. This water is collected and drained in a separate piping system to a holding tank in thebasement car park.

The condensate collection system provides about 15 million gallons of supplement water per year, equal toabout 20 Olympic-sized swimming pools. This water is to be redirected to the gardens surrounding the tower.

The towers peak electrical demand will be an estimated 36mW, equal to about 360,000 100 Watt bulbsoperating simultaneously. According to one report, the tower has more than one hundred thousand lightfittings, 375km of fire alarm cabling and 34km of chilled water pipes.Elevators & LiftsBurj Khalifa will be home to 57 elevators and eight escalators. The building service/firemans elevator will havea capacity of 5500kg and will be the worlds tallest service elevator.

The Burj Khalifa features distinct sections: residential apartments, serviced apartments and hotel rooms, andcorporate offices. Elevators have been arranged in zones to serve these different audiences, with what isknown as a sky lobby system.

The sky lobby is an intermediate floor where residents, guests and executives will change from an expresselevator to a local elevator, which stops at every floor within a certain segment of the building. Burj Khalifassky lobbies are located on level 43, 76 and 123 and will include a lounge area and kiosk, amongst otheramenities.

All elevators have been supplied and installed by Otis. No elevators are installed to travel all 160 floors of BurjKhalifa. Instead, they are grouped to align with the floor layout, offering passengers a direct express service totheir destination by bypassing other floors.

Is the Burj Khalifa a storm machine?

There is much speculation, on various architectural blogs, that the temperature of the Burj can be as much as

eight degrees different from top to bottom. This has led to some pretty wild suggestions about the physical

properties of the super-tall building. An article in the German newspaper Das Spegiel provided one of the bestexamples, with the most outlandish claim as follows: The tower is so enormous that the air temperature atthe top is up to eight degrees celsius lower than at the base.

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If anyone ever hit upon the idea of opening a door at the top and a door at the bottom, as well as the airlocksin between, a storm would rush through the air-conditioned building that would destroy most everything in itswake, except perhaps the heavy marble tiles in the luxury apartments.

There is certainly truth in that that there would be something of a chimney effect, this is why skyscrapers andother tall buildings with high atriums feature revolving doors which are never fully open to the air outside.

However, speculation on architectural blogs suggests this downdraft might be so great that it could modify, oreven cause, extreme weather over continents. The idea of a janitor being able to cause the next cyclone Gonuis an odd one. Trevor Patt, a Harvard graduate in theoretical maths disputes this though: Given that the cubic

volume of Burj Khalifa is more than 8 orders of magnitude (100 million times) smaller than the cubic volume ofeven a very small or midget cyclone, Im guessing the cyclone would be doing most of the negation; myunderstanding is that the Burj Khalifa was tested for winds up to 55m/s.

The main service elevator, positioned in the central core of Burj Khalifa, has the worlds highest elevator rise at

504 metres more than the height of Taipei 101 in Taiwan (448 metres). It travels at nine metres per secondand also has the worlds longest travelling distance for an elevator. Another service lift in the spire has theworlds highest landing point at 636.9 metres.

Double-deck elevators, with built-in light and entertainment features including LCD displays, will exclusivelyserve visitors to At The Top, Burj Khalifa, the worlds highest outdoor observation deck situated on level 124,as well as office users transferring at the sky lobby at level 123.

These double-deck units used for the first time in the Middle East by Otis are the highest rising double-deckelevators in the world and will travel at the speed of 10 metres per second. They have a capacity of 12 to 14people per cab.

Podium and access

The podium provides a base anchoring the tower to the ground, allowing access from three different sides tothree different levels of the building. Fully glazed entry pavilions constructed with a suspended cable-netstructure provide separate entries for the Corporate Suites at B1 and Concourse Levels, the Burj Khalifa

residences at Ground Level and the Armani Hotel at Level 1. The number of underground car parking spaces isreported to be 3000, which suggests that the owners are keen for people to use the nearby metro station anddowntown light railway for access.LandscapingAt the foot of the mighty Burj sits the The Park, an 11 hectare expanse of gardens, trees and water features.What is perhaps most noteworthy about The Park is that is irrigated using a water collection system thatrecovers the condensation from the towers cooling equipment. This provides the park with around 15 milliongallons of water a year or enough to fill 20 Olympic-sized swimming pools. The Park was designed by SOM,designer of the tower itself, and SWA Group of California. WET, the designers of The Dubai Fountain, developedthe parks six water features.FitoutThe interior design of Burj Khalifas public areas was done by the Chicago office of Skidmore, Owings & MerrillLLP and was led by award-winning designer Nada Andric. It features glass, stainless steel and polished darkstones, together with silver travertine flooring, Venetian stucco walls, handmade rugs and stone flooring. Over1000 pieces of art from prominent Middle Eastern and international artists will adorn Burj Khalifa and thesurrounding Emaar Boulevard. Many of the pieces were specially commissioned by Emaar.

The two main contractors for the interior fitout were DEPA and Fino International.

At one point, interior contracting specialist DEPA famously told Arabian Business magazine that the job offitting out the tower was a nightmare. The company won a US $600 million contact to oversee the fit -out ofnearly 1000 residential and serviced apartments as well as corridors and lift lobbies. Despite the challenges ofmoving men and materials up to as high as the 100th floor, the company got the job done in reasonable time. Spire

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The crowning glory of Burj Khalifa is its telescopic spire comprised of more than 4000 tons of structural steel.The spire was constructed from inside the building and jacked to its full height of over 200 metres (700 feet)using a hydraulic pump.

In addition to securing theBurj Khalifas place as the worlds tallest structure, the spire is integral to the overalldesign, creating a sense of completion for the landmark. The spire also houses communications equipment.

The top four floors of the Burj have been reserved for communications and broadcasting. These floors occupythe levels just below the spire.Window WashingAccess for the towers exterior for both window washing and faade maintenance is provided by 18permanently installed track and fixed telescopic, cradle equipped, building maintenance units. The trackmounted units are stored in garages, within the structure, and are not visible when not in use.

The manned cradles are capable of accessing the entire facade from tower top down to level seven. Thebuilding maintenance units jib arms, when fully extended, will have a maximum reach of 36 metres with anoverall length of approximately 45 metres.

When fully retracted to parked position, the jib arm length will measure approximately 15 metres. Undernormal conditions, with all building maintenance units in operation, it will take three to four months to cleanthe entire exterior facade.

Urban myths

Among the many facts and figures about the Burj Khalifa, here are some that just arent true:

The building will be the headquarters of the Dubai Base Jumping Association

Nothing within a 10km radius of the Burj Khalifa will ever be struck by lightning again

A construction worker, known only as Dev, set the unofficial record for the Burj Khalifa vertical marathon,

running to the top of the building in 23:45

The crane driver lived at the top of the Burj Khalifa for the duration of the construction and has been made aUAE citizen as a reward for his perilous task

The Burj can be seen from Iran

More levels can be added to the building at a later date, should any other structure surpass its height

The Burj Khalifa can be seen from space