In a region that is renowned for pushing the limits in architectural designs, The Museum of the Future in Dubai is one of the most complex composite projects to date, adding a unique new silhouette to the Dubai Downtown skyline.
“A building with this complexity has never been done before - not with this shape of the facade and the superstructure,” said Derek Bourke, BIM manager for construction firm BAM International.
Designed by architectural firm Killa Design, UAE, engineered by BuroHappold and with BAM International as the main contractor, this engineering marvel is a true example of the benefits of building with advanced composites.
Notus Composites, an innovative prepreg solutions provider in the UAE and Affan Innovative Structures, UAE, will work together to provide the materials and finished composite panels that will make up the exterior cladding, using more than 600,000m2 of multiaxial glass and carbon prepreg.
Due to open in 2019, the museum’s construction is moving fast and the first 200 of the 1,020 cladding panels have been installed. This unique project combines lightweight carbon and glass fibre prepregs, whose fire performance has been approved by the Dubai Civil Defence (DCD), with a stainless-steel outer cladding to produce the stunning outer skin of the torus shaped building.
Each panel is unique in shape as the Arabic calligraphy covering the façade is moulded into each individual panel, with the black letters also acting as glass windows in the façade.
The multiaxial prepregs are laminated in CNC-milled moulds at Affan’s factory in Dubai, before glazing and finishes are added, and the panels are delivered to site for installation.
Notus Composites, a relatively new entrant to the prepreg market in 2015 and winner of the Ras Al Khaimah Free Trade Zone Business Excellence Award for Best New Startup, is especially well known within the ME region for its products’ outstanding fire performance. Its epoxy and phenolic prepregs have been tested and certified to all of the key architectural industry standards and the company is the only prepreg manufacturer in the world whose epoxy FR materials have successfully passed the challenging NFPA 285 test in accordance to DCD standards. It has also received Class A results for ASTM E84.
Notus Composites FR epoxy system is also proven to provide equivalent superior performance to less sustainable polyester products, thereby offering a greener aspect in terms of its environmental impact and manufacturing process.
Dr Affan, CEO of Affan Innovative Structures said: “We are pleased to be working together with Notus Composites on this prestigious project. The company’s local presence, ability to quickly customise products and DCD approved fire resistance solutions make them a strong and reliable partner. We look forward to continuing our cooperation on more projects in the nearby future.”
With a background in wind energy and automotive, the company expanded into civil engineering and architectural composites in 2016. They now include material supply for the flagship Rolex Store in Dubai Mall and the 46m carbon fibre palm trees that form the entrance of a new shopping mall on the prestigious Palm Jumeirah, Dubai, in its portfolio of projects.
