Emirates unveils first retrofitted two-class A380 with new premium economy cabins
New cabin upgrades debut on Dubai-Birmingham route
DUBAI – Emirates has reached a major milestone in its extensive fleet transformation strategy after completing the first-ever retrofit of a two-class Airbus A380 aircraft, introducing its sought-after Premium Economy product to a redesigned three-cabin configuration.
The newly refurbished aircraft, registered as A6-EUX, has already entered service and is now operating as EK39/40 between Dubai and Birmingham. The revamped aircraft showcases Emirates' newest cabin interiors and products, featuring 76 Business Class seats, 56 Premium Economy seats and 437 Economy Class seats.
The achievement marks another significant stage in Emirates’ multi-billion dollar retrofit initiative, one of the aviation industry's largest aircraft refurbishment projects. The upgraded A380 is also the first of 15 two-class A380 aircraft that the airline plans to transform in its fleet.
Fleet upgrade
The entire retrofit programme has been managed in-house by Emirates Engineering in Dubai. To date, work has been completed on 95 aircraft, including 42 Airbus A380s and 53 Boeing 777s. Those figures represent more than one-third of Emirates' active fleet.
According to Emirates, the refurbishment initiative is designed to create a consistent onboard experience across its global network, ensuring passengers encounter the airline's latest products regardless of route.
Sir Tim Clark, President of Emirates Airline, said the programme was built around the goal of delivering a more elevated customer experience. He noted that engineering teams had worked continuously alongside suppliers and partners to integrate upgraded products across the fleet while handling increasingly complex modifications.
He added that the conversion of a two-class A380 into a three-class layout demonstrated the scale and capabilities involved in the programme, particularly with the introduction of Premium Economy seating on the aircraft's upper deck.
Premium shift
One of the most notable changes introduced in the aircraft is the debut of Emirates Premium Economy on the upper deck of the A380, marking a fleet first for the airline.
The cabin adopts a 2-3-2 seating configuration and includes 56 leather seats with generous recline and added space. Passengers can access full leg and footrests, six-way adjustable headrests, built-in charging points and side cocktail tables. The onboard entertainment experience is delivered through a 13.3-inch personal screen, alongside upgraded dining options.
The redesign also introduces refreshed aesthetics throughout the aircraft. New carpets, updated ceiling panels and redesigned interiors have been installed from front to rear. Emirates said the cabins now incorporate modern colour schemes, premium wood finishes and signature Ghaf tree design elements across multiple sections.
Complex rebuild
The engineering effort behind the project required extensive structural changes and detailed reconstruction work.
During the refurbishment process, the entire cabin interior was dismantled and rebuilt. Engineers removed 120 Economy Class seats from the upper deck to make space for the new Premium Economy cabin and an additional 18 Business Class seats.
The redesign also required repositioning and upgrading numerous onboard structures and systems. Galley modules, storage units, overhead compartments and cabin partitions were modified, while electrical and plumbing systems also underwent extensive adjustments to support the new layout.
Around 50 engineers and technicians worked on the project, collectively investing approximately 35,000 man-hours and utilising more than 2,500 different parts.
Emirates Engineering said the first retrofit took roughly two months to complete, including planning, modifications and extensive testing. Future projects are expected to proceed much faster, with upcoming two-class A380 refurbishments projected to take around 30 days after lessons from the first aircraft are integrated into operations.
By the end of 2026, all 15 two-class A380 aircraft are expected to receive the same treatment.
Retrofit programme
The retrofit programme was first announced in 2021, initially targeting 120 aircraft. However, Emirates steadily expanded its ambitions following customer feedback and programme performance.
By May 2024, the scope grew to 191 aircraft before later expanding again to encompass 219 aircraft across the Airbus A380 and Boeing 777 fleets.
A dedicated workforce of around 270 employees currently supports the operation, with Emirates Engineering facilities in Dubai now delivering an average of two refurbished aircraft every month.
Alongside cabin upgrades, Emirates has also incorporated sustainability efforts into the programme. Materials removed during refurbishment are assessed for reuse under the airline’s upcycling initiative.
The effort has already produced the "Aircrafted" collection of limited-edition products, including luggage pieces and children's backpacks created from repurposed Economy Class seat fabrics. Around 4,000 Aircrafted for Kids backpacks have already been distributed to children across 10 countries as Emirates continues reshaping its fleet from both operational and environmental perspectives.