Dublin Airport control tower

The challenge: pushing the boundaries of innovation

The visual control tower was a unique project, built higher than any occupied structure in the country, to extremely tight construction tolerances. The project involved several critical design and engineering challenges. 

Poured concrete forms the main component of the structure: so it’s critically important structurally, but it’s also a significant internal and external architectural feature on this highly visible building. 

The cab – the 360° glazed structure that sits atop the tower – is built around a cantilevered steel frame. Working at 70-90 metres above the ground, coupled with the outwardly tapering cone shape as you move up the building, created major access issues. 

The unique nature of the building means that the façade and glazing to the cab didn’t exist as a certified system. The glass had to be fixed directly to the structural steel, without a separate framing system, but with very tight margins for error. 

For BAM and its trusted supply chain, all this required an exceptional level of ingenuity and collaboration to ensure that the design – particularly the connection details – was in sync with the construction sequence and access methodologies. 

The BAM solution: innovation for a unique result

The new control tower consists of the five-level cab and its associated plant and technical support facilities, which are housed in a single-storey building linked to the tower via a glazed corridor. 

Slipform concrete was used for the core construction of the tower itself. This involved continuously pouring concrete 24 hours a day, seven days a week for almost three weeks. Two different slipform configurations were needed to complete the full height of the shaft, but the concrete pour continued even while the necessary adjustments for this were being carried out.

Extremely detailed forward planning, collaboration and co-ordination with all the different teams involved – including the concrete and reinforcement suppliers, structural engineers, steel fixers and slipform contractors – meant that the pour was a huge success. Even prevailing winds and temperatures as low as -4°C didn’t halt progress. 

BAM and its partners also developed an innovative new façade system for the cab, which needed to be put through a full suite of CE certification tests extremely fast. BAM’s buying power in the market, combined with its expertise and relentless drive, made this happen on time to meet the project deadlines. 

The detailing of this unique system was tailored to match the steel and façade installation sequence, as well as the access needs of operatives and inspectors.
Working at unprecedented heights meant that BAM’s lifting centre of expertise – part of the plant division – played a vital role, specifying, supplying and managing the tallest crane ever used in the Irish construction sector.

The project also involved demolishing a car park on the site and building a new one, as well as implementing a new landscaping scheme designed to protect the plant areas at the base of the tower against flooding. 

BAM was also responsible for upgrading the security infrastructure, which involved major diversions of utility services.

Most of the work was completed landside, although some activities were carried out under airside permits. All staff working on the project were vetted by the Garda and international police.

The result: a graceful, modern landmark 

The control tower was officially opened in 2022 by Hildegarde Naughton TD, Minister of State at the Department of Transport: the culmination of a highly collaborative programme of work delivered on time and to budget. 

Flexibility within the BAM supply chain helped to ensure seamless workflows and high productivity. Close communications between BAM and the client were also key: especially when it came to agreeing essential adjustments to the works. 

The project was recognized as Engineering project of the year at the 2019 Irish Building and Design Awards.