IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308

BURJ KHALIFA – CONSTRUCTION AND QUALITY CONTROL

D.S. Rajendra Prasad1

1
Sr. QA/QC Projects Manager, Azmeel Contracting Company, Kingdom of Saudi Arabia

Abstract
This paper presents a snapshot of Construction and Quality Control system adopted during the construction of World’s Tallest
Tower, “The BurjKhalifa Tower”, Dubai, UAE. An effective, well-constructed and well-maintained building is essential for safety
and durability of any structure. In order to achieve this, the safety and quality aspects should be built-in during the design and
construction stage rather than at the inspection stage. The construction practices adopted at BurjKalifa Tower is simply “Do the
right thing, right, first time, every time” by following established approved Project Quality Plan (PQP) and Inspection Test Plans
(ITPs) with well narrated method statements and definite objective checklists/formats. Project Management Information System
(PMIS) was effectively and efficiently used in day-to-day construction activities for ensuring: an advanced information on
construction activity (what, when, where, who, how, with what), with well repository of documents, good track on resources,
providing precise information to subcontractors and keep a tab on commercials. DOKA Auto-climbing formwork was used for the
Tower cores and HunnebeckTable formwork for the Podium slabs and FRP shuttering for walls of circular Car parking ramps.
Aluminum shuttering (MevaDec panel formwork) was adopted for tower slabs. C80 grade concrete was used in tower columns
and shear walls and C50 grade concrete for beams and slabs. Podium rafts was casted with C50 grade concrete. Tower walls
constructed adopting 3-day cycle for each level and reinforcement bars were fabricated for the height of 2 levels with couplers for
the laps for beams and slabs and for nose columns. De-shuttering of tower walls after 10hours of pull-out tests complying with a
minimum strength of 10MPa. Composite link beams were used to connect core walls and nose columns. This multi-purpose, ultra-
high, skyscraper was successfully completed in a record time by the joint venture of Samsung, BeSix and ArabTec sponsored by
Emaar Properties.

Keywords: BurjKhalifa Tower, Quality, Construction, Formwork, Concrete.

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1. INTRODUCTION m2 that includes hotel, residential, commercial, shopping,

entertainment, observatory, communication and parking
The BurjKhalifa Tower is a multi-purpose, ultra-high, facilities[10]. The figure 1 is a snapshot of the project
skyscraper was successfully completed in a record time by summary.
the joint venture of Samsung, BeSix and ArabTec sponsored
by Emaar Properties. The tower has a total area of 479,830

Fig- 1a: Snapshot of Project Summary – Burj Development, Project Brief

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IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308

Fig- 1b: Snapshot of Project Summary – Building Usage, Mechanical

Fig- 1c: Snapshot of Project Summary – Electrical, Elevator & Escalator

1.1 Design Overview

The architectural design concept was derived from Blue
Dick, the flower of the desert[8].
 The plan is reducing in a spiral pattern, symbolizing the
Dubai economy.
 Seek the model of Future city for Middle East By the
beauty of shape & scale

An effective, well-constructed and well-maintained building

is essential for safety and durability of any structure. The
tower has adopted the most stabilized Y-Shape, which
provides stability by building weight shifts to end of the
wings and structure considering both stability,
constructability[9].

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Fig- 2: Design Overview – Architectural and Structural

Fig- 3: Design Overview – Structural

Emergency evacuation is given prime importance during Management Information System (PMIS) was effectively
design development stage. The construction practices and efficiently used in day-to-day construction activities[2].
adopted at BurjKalifa Tower is simply “Do the right thing, JV Operation Processed by Computer System and allows
right, first time, every time” by following established Information Real Time Update (Manager Group of JV
approved Project Quality Plan (PQP) and Inspection Test Informed Instantly) and Ubiquitous Access (Site – EMO –
Plans (ITPs) with well narrated method statements and Headquarter) to all stakeholders.
definite objective checklists/formats[3]. Project

Fig- 4: Life boat evacuation and Stack effect

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IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308

2. PROJECT QUALITY PLAN construction methods, construction programming, logistics

plan, site layout, identification of manpower requirements
Samsung JV considers the Project Quality Planning is a and training needs, material and plant acquisition, etc. The
crucial step and it should be done well before construction following diagram depicts the development of the Project
work is due to commence[3,4]. It is amalgamated with the Quality Plan.
traditional project planning in such activities as nomination
of subcontractors and suppliers, determination of

Fig-5: Project Quality Plan development and PMIS

2.1 Logistics Plan - Tower Section works, like stocking, lifting & concrete
pumping, occur at the same time with Podium Works.
The tower was located in the middle of Burj Dubai - Comparatively long distance from gate to Tower and
Development Site and there are favorable Access & disrupted by Podium construction.
Security (Air, Water, Road, Rail), mutual interface with
other Burj Dubai project (Dubai Mall & Lake, It is necessary to provide sufficient well planned Stock
Development Plan). The construction access is a crucial Yards for the storage of material for project and limited
factor for safe and timely transport of material, equipment Stock area for Tower Section. The tower site area is about
and manpower. 105,600m2 and which includes the tower and podium. The
- Tower Section is enclosed by Podium podium is dived into zone –A Office Annex, Zone-B the
Pool Annex and Zone-C the parking areas.

Fig- 6: Logistics Plan for Overall site

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IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308

Fig- 7: Logistics Plan for site for 37+ months and Plan for tower

2.2 Quality Control and Safety Plan procedures will be developed and submitted formally to the
consultant for approval and accordingly distributed to all
Quality Policy Statement is to ensure a totally Customer concerned.
driven approach that meets and exceeds customer
expectations through effective management and Repairs and Retrofitting if any should be carried with
performance, good co-ordination increased productivity approved method statements and with approved materials[1,
and greater focus on business objectives. 5]
Quality Control Procedures will be developed in line with BurjKhalifa safety program has been developed considering
the project specification, ITP, approved relevant documents, 4 phases as illustrated below.
submittals and approved method statements. All the

Fig- 8: Quality Control action Plan

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IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308

Fig- 9: Safety Control Program and procedure

Fig- 10: Safety Control Program and procedure

2.3 Construction Equipment and Plan

The three tower crane were installed in tower Cores 1,2 and 3:

Fig- 11: Construction Equipment and plan

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IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308

Fig- 12: Construction Equipment – Pumping Plan

3-day Cycle for walls and slabs have been adopted and sequencing of pouring concrete is shown below.

Fig-13: 3 day Cycle for Formwork and Rebar fabrication yard

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IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308

Fig-14: Tower Slab Formwork and FRP shuttering

Fig- 15: Concrete Mix design Summary and Testing

2.4 Concrete and Testing:

High performance concrete C60 and C80 grade concrete
was used for vertical members, and C50 grade concrete was
used for horizontal members.

Fig-17: High Strength concrete Quality Control Testing and Pouring

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IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308

Fig- 18: High Strength concrete Testing Register and Strength Profile of Tower C80 Concrete

2.5 Spire Erection Plan

Fig- 19: Spire Installation sequence

2.6 Building Movement Monitoring System

Fig- 20: Building Movement monitoring and Checking Verticality of Tower walls

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IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308

3. CONSTRUCTION PHOTOGRAPHS

Fig- 21: Auto Climbing Formwork

Fig- 22: Rebar: Mat Foundation and Tower Slab

Fig- 23: QC Inspection: Mat Foundation and Tower Beam

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IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308

Fig- 24: Safety is a must for every one- PPEs and Safety induction to Visitors

4. CONCLUSION [6] Rajendra Prasad D.S, Kiran Kumar H R, Dattatreya J

The successful completion of the BurjKhalifa tower is K, Development of design software for the analysis
mainly attributed to the adoption of latest construction of Tall Chimney, ICCIT, Mysore, June 2012.
technology, construction materials and Auto-climbing [7] Rajendra Prasad D.S, Swaroop N , Dattatreya J K,
formwork in addition to the excellent Project Quality Plan, Naveena.P.C , Selection of Pile Foundation Using
which encompasses Logistics plan, Equipment Plan, Spire Expert System and Design Using Visual Basic
Erection plan and consistently adhering to Inspection Test Programme For High Rise Building, International
plans for materials, equipment, and work inspections. The Engineering Post Graduate Research Conference
BurjKhalifa Tower becomes an objective evidence of ENGGPOS 2013 Technical program -2013, Feb 1-2,
„Quality Icon‟, which demonstrates the construction of an 2013, Coimbatore.
Ultra High skyscraper which meets all the technological and [8] Abdelrazaq, A, Kim, K. J., Kim, J.H. “Brief on the
constructional challenges and stands as a benchmark for Construction Planning of the Burj Dubai Project,
future construction of super ultra-high skyscrapers. Dubai, UAE”, 17tth IABSE Congress, Creating and
Renewing Urban Structures – Tall Buildings, Bridges
ACKNOWLEDGEMENT and Infrastructure, Chicago, September 17-19, 2008.
[9] Baker W, Pawlikowski J. Higher and higher: the
The author is highly indebted to the Managing Director, evolution of the buttressed core. Civil Eng. 2012;
Management consultant and VCEOs of Azmeel Contracting 82(10): 58–65.
Company, Saudi Arabia, for their continuous support while [10] Council on Tall Buildings and Urban Habitat. Tall
preparing this paper. The author also extends many thanks Building Database. ctbuh.org.
to BurjKhalifa Tower friends and especially to Samsung JV
Management. BIOGRAPHIES
REFERENCES Dr. Rajendra Prasad D S is a Quality
Head at Azemeel Contracting
[1] Rajendra Prasad D.S., Method statement for Company, one of the largest construction
Retrofitting of Tower slabs, Rev. 2, Samsung JV, companyin the Kingdom of Saudi Arabia,
Dubai, 2006 thatcaters to Buildings, Infrastructures,
[2] Rajendra Prasad D.S., Project Management -A Industrial and Refinery structures.
Simple Approach, Sapna Book House, Bangalore, Previously, Dr. Rajendra Prasad worked
2011 as a Chief Engineer-Qualityin BurjKhalifa
[3] Rajendra Prasad D.S., Quality Management System- TowerProject, Dubai with Samsung JV. He is a
A Simple Approach, Sapna Book House, Bangalore, postgraduatein Civil engineering from UVCE, Bangaloreand
2003, 2011 having a Post-Doctoral degree in Civil Engineering. He is an
[4] Rajendra Prasad D.S., ISO 9001:2015 Quality author of more than 48 research papers and 21 books in
Management Systems – Implementation, Sapna Book various disciplines.
House, Bangalore, 2015
[5] Rajendra Prasad D.S, Structural Evaluation of various
methods of retrofitting of Tower slabs, National
Conference on Recent Trends in Civil Engineering,
JSSIT, Bangalore, 2015

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