Customer

Bahrain Airport Company (BAC)

Context

Bahrain International Airport (BIA) has experienced continuous growth due to its convenient location as a midway stop between India, Asia, and Europe. BIA has become a major cargo hub for courier companies to reach the Middle East market.

In 2018, Bahrain Airport Company (BAC) decided to continue supporting growth through a modernisation programme that included developing new routes out of BIA and making air cargo one of the airport’s primary activities as part of the Kingdom´s vision for 2030. Alongside building the new passengers terminal commissioned in 2021, the new Cargo Express Area will focus on e-commerce and express packing. The area in its full development will accommodate additional yearly courier packaging capacity of 200,000 tons that will also include cargo apron expansion for courier airlines with direct access from their facilities.

They will offer more flexible and sustainable facilities to logistics companies and couriers who operate in the airport, as they will include a common processing facility (CPF) for quick and fast-track customs inspection and security screening of packages.

BAC will develop the Cargo Express Area north of the runway 12L-30R, where the former northern apron is located, that will be demolished in the final phase of development.

The first phase of the area will consist of four warehouses totalling 13,000m² that will support the growing express carrier operations at BIA providing new, effective infrastructure:

  • Warehouse space, tenant support facilities and offices
  • Landside truck access road and car parking
  • Landside staging area
  • Landside staff and customer parking
  • Cargo apron, taxiways, and airside service roads (aprons for 8 code C parking stands, taxiway, and service roads)
  • Airside staging area for GSE vehicles
  • Container and ground service equipment.

The area master plan and phasing will need to allow apron expansion for code E/F aircraft in the longer term. It will be compatible with the future MRO hangar for one code E or two code C aircraft and increase the area for cargo terminal (with airside boundary) if needed.

Role of Egis

BAC appointed Egis to review and validate the Cargo Express area master plan and to provide project management consultancy services; the latter in partnership with MSCEB for building design development and construction supervision and with Egis company Projacs on tender management and project controls.

Our services included:

  • Master plans, which must meet the operational and functional requirements related to airport cargo logistics areas, including compliance with BCAA and ICAO standards, such as ICAO Annex 14 and obstacle limitation surfaces (Chapter 4).
  • Concept, preliminary and detailed designs for airside and landside, including buildings. We have applied BIM technology in our work, based on close coordination between the different stakeholders and experts involved, with the objective to develop an optimised and evolutionary functional plan. Studies have integrated stringent technical requirements, in particular with regards to the future provision of photovoltaic solar panels on the warehouse roofs and car parking shades, as well as the management of runoff waters in a flat area located practically at sea level in the Persian Gulf.
  • Tender management of construction: documents preparation, clarification, evaluation, and selection for Cargo Express Area Phase 1.
  • Construction supervision of Phase 1 warehouse and relevant infrastructure construction, including:
    • Works inspection and monitoring
    • Review of submittals (shop drawings, materials, method of statement, etc.
    • BIM management
    • Time management and works planning
    • Cost control
    • Payments certification
    • Quality management
    • HSE management
    • Subcontractor prequalification and evaluation
    • Risk management
    • Resource management
    • Scope management (variation orders, etc.)
    • Value engineering of proposals from the contractor
    • Aerodrome certification (BCAA/ICAO Annex 14 compliance) of airside works
  • Defect liability period supervision, for a period of 24 months

Egis applied airport methodology included:

  1. Master planning of the area, land availability, demand and capacity analysis, commercial feasibility study, central utilities master planning, respecting the obstacle limitation (transitional surface) due to the proximity of the runway.
  2. Concept Design, including land surveying (topography and geotechnical), with optioning of building structure and configuration of different modules, performed by our building design consultant MSCEB, a local consultant with wide experience in Bahrain. In addition, the cost-saving concept of central utilities (for fire-fighting water and potable water) was developed so every facility within the Cargo Express Area will have this supply.
  3. Preliminary Design: utility master planning, provisions on phase 1 for future demands and expansions of the Cargo Express Area, as well as local regulations and standards. This also included a careful power supply and network design of different loops and power substations, with transformers and generators, and UPS, as per the expected demand, with room for expansion in each substation.
  4. Detailed Design: ensuring it is compatible with future expansions of the Cargo Express Area and coordinated between different design teams for the successful and quality delivery of the design services.
  5. Tender Documentation: Egis proposed a FIDIC Red Book template that was amended and updated to the client needs and aligned with the local Bahrain Tender Board requirements by our highly experienced team.
  6. Tender Evaluation: following BAC, the Bahrain Tender Board and MOTT (Ministry of Transportation and Telecommunication) directions.
  7. Construction supervision: Egis mobilized a professional and highly skilled team to carry out the construction supervision of the phase 1A (landside) works, that included warehouses and central utilities building (potable water and fire-water). The team comprised a resident engineer, architect, mechanical and electrical engineer, civil engineer, structural engineer, and ICT specialist, HSE officer, the project controls engineer, and inspection site team.

Results

Egis has master planned and designed 23 hectares of available land for the Cargo Express Area project, that is compatible with the existing constraints of the radar and the existing northern apron. It optimises land use for 25,000m² of express cargo terminal and 6,000m² of storage warehouses in second line, with car and truck parks, and 5,500m² of administration buildings with retail and food & beverage.

The master plan, enables future development of cargo terminals (airside boundary), storage warehouses within a customs-bounded zone, administration and retail buildings, and finally an MRO, all of them supported by the new north apron, designed for code C and E/F aircraft, respecting the obstacle limitation (transitional surface) set by the close presence of the runway.

The master plan also includes a central utilities building to support the need for fire-fighting water (storage and pumping station) and potable water.

FedEx has become the first courier and flagship operator of the CEV, with a warehouse of 5,500m² in place.

The Cargo Express Area development continues and is expected to be finalised and in operation by mid 2023.

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Oscar Aragon

Oscar Aragon

Project Manager

+973 36932079