Skip To Content Privacy Page
Back to Projects

Cargo Mega Terminal Upgrade & Expansion at Dubai International Airport (DXB)

The existing Cargo Mega Terminal at DXB was nearing capacity and had a low level of automation. BNP was retained to review, compile, and validate the previous analysis results.

image overlay Aerial view of a large commercial airport terminal with text Share a smile in 120 languages displayed on the building facade.

Overview

The existing Cargo Mega Terminal at DXB was nearing capacity and had a low level of automation. BNP was retained to review, compile, and validate the previous analysis results. This required validating the storage master plan, ULD storage staging, as well as the upgrade and expansion requirements for both current and new modules.

Project Scope

Scope of work included the upgrade and expansion of the existing Cargo Mega Terminal (CMT) at Dubai International Airport, increasing the cargo handling capacity of the existing 4 modules to handle the EK Passenger Aircrafts Belly Cargo for an additional 100,000 tons p.a., and upgrading the ASRS inline screening for transit shipments according to the new EU Security Regulation and TSA.

Another module was developed with an additional 300,00 tons p.a. for Emirates Sky Cargo by connecting the older modules and providing a West Cross Dock handling system and a new PCHS bridge connecting Freight Gate 1 with Module E. All these expansions were interconnected with one another physically and digitally, in order to allow system crossover.

Analysis and Design Solution

BNP analyzed and mapped the current operations at the CMT to recommend upgrades and expansions that align with the latest flight schedule. Several design options were explored, and the chosen solution involved upgrading a large part of the existing facility and adding a new Module I. This module connects to Freight Gate 1 and the West Cross Dock via the FG1-Module E bridge, allowing full integration with the mail, perishables, pharmaceuticals, pallet, and cargo systems.

System Components

The system upgrades and expansions contained the following key pieces of equipment:

  • General material handling conveyance (right angle decks, straight roller decks, storage, ball matting, truck docking system)
  • ULD and pallet hoists
  • Horizontal and elevating transfer vehicles (ULDS) and T-Cars (Pallets)
  • Automated Storage & Retrieval Systems
  • Fire shutters
  • Cold Storage Solutions

Implementation Support

BNP also assisted in preparing contract documents (including specifications) and evaluating suppliers during the bidding and procurement stages. During execution, BNP performed all site supervision activities including installation, testing, commissioning, handover, and closeout.

Project Start

2015

Client

Dubai Airports Company

Scope of Service

  • Feasibility Study
  • Conceptual Design
  • Design Development
  • Contract Documents
  • Bidding & Procurement
  • Construction Monitoring

Region

Middle East

Cargo Solutions Success Stories

image overlay Cargo Terminal 2 Mail and Courier Handling at Hamad International Airport (DOH)
Cargo Solutions

Middle East

Cargo Terminal 2 Mail and Courier Handling at Hamad International Airport (DOH)

MATAR has retained BNP and the leading Middle East A&E firm Dar Al-Handasah for the design, engineering, tendering, and construction administration services for a new air cargo terminal (Terminal 2).

image overlay Technical Feasibility Study of the MHS for the Redevelopment of the Hongkong Post Air Mail Center
Cargo Solutions

Asia

Technical Feasibility Study of the MHS for the Redevelopment of the Hongkong Post Air Mail Center

Hongkong Post will redevelop the existing Airmail Center at Hong Kong International Airport, and BNP was engaged to provide consultancy services for a redevelopment feasibility study.

image overlay Postal Automation Design Services at the Northern Taiwan Mail Processing Center
Cargo Solutions

Asia

Postal Automation Design Services at the Northern Taiwan Mail Processing Center

In 2017, BNP partnered with the local consultancy firm Sinotech to provide postal automation design services for the Northern Taiwan Mail Processing Center.

Partnering for Results: From Mega-Projects to Mid-Sized Success.

While building on our strong reputation, we aim to showcase our ability to deliver cost-effective solutions for mid-sized projects, educating clients on the latest technologies and ensuring their long-term success. We prioritize building relationships with clients, not just customers, often working closely with small teams in airport planning and development departments to deliver exceptional results.

Request Information See Projects

BNP Associates, Inc. is the worldwide leader in providing specialized consulting services to the air transportation and logistics industries. 

© 2025 BNP Associates, INC. all rights reserved