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Irish building The Business Magazine for Building Professionals

Dublin Airport Inside T2

Aviva stadium State of the art

The CONvention centre dublin Dublin’s newest landmark MSD Ireland Multi site profile HG Construction (IRL) Ltd Delivering excellence

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Contents Carlow VISUAL 209 CCD Page


4 6

Experts section Legal File Sentencing Trends for Health and Safety Offences Key Changes to the Public Works Contracts – Major or Minor??

Cover Story 45


25 HG Construction (IRL)ISSLtdIreland Page 39

News News round up Recent events and news stories including company, in brief & industry comment

T2 at Dublin Airport Designed, Engineered and Built with excellence in mind. Irish Building Magazine visits Ireland’s most ambitious transport project.



Cian Molloy vsits Dublin’s world class CCD and discusses our newest landmark with the team that designed, built and managed this PPP success. stadium 17 Aviva Sport meets engineering in the Aviva

Stadium. We take a tour of Irelnad’s finest sporting venue.



MSD Ireland Irish Building Magazine visit 3 of MSD’s recently developed and expanded facilities at Carlow, Ballydine and Brinny..

Construction (IRL) Ltd 39 HG Corks fastest growing construction company in profile.


Showcase Company and Product section All the latest in new products and company announcements

The Convention centre dublin MSD CArlow Page 23

AVIVA Page 17

Irish Building Managing Director: Colin Walsh Features Editor: Cian Molloy Administration Manager: Noelette Walsh Production: DN Design Advertising Enquiries Tel: 01 442 9264 Subscription Rate: €65.00 Rep. of Ireland Irish Building Magazine is published by National & International Publications Ltd 1 Windsor Mews, Summerhill Parade, Sandycove, Co. Dublin. The contents of this publication are subject to copyright laws and may not be reproduced in any form without the prior written consent of the publishers. The views expressed in articles do not necessarily represent those of the publishers. Printed by W&G Baird


20/20 Windows Advanced Eng Alucraft Asgard BAM Contractors Cork Builders Pro Cashel Const Daly Industrial Errigal Contracts Fisher Eng Garde Eng GB Services HA O’Neil-Jones HG Construction Jacobs JBTC Kirby Group KP Scanlon M J Spillane. M.McNamara Mercury Eng Murphy Contract PJ Edwards PJ Hegarty Profile Emergency Lighting PM Group Radley Eng. RMI Rockwell Eng. Rogers Blinds Sean Doyle Const. Siac Roof & Cladd Sirus Stone Systems Suir Engineering T&A Builders Tom Phillips & Associates Williiam Cox. WYG

30 14 12 36 16 38 12 38 10 8 40 30 32 28 30 48 24 38 38 20 42 27 10 44 44 22 22 12 36 12 14 34 24 46 34 40 20 18 ISF


Irish Building Magazine

News 50 new high quality jobs to be created serving EMEA market

Global biopharmaceutical company to build new facility at Carrigtwohill

DA Ireland welcomed the announcement by BNY Mellon, a global leader in investment management and investment servicing, that it is to establish a new company in Dublin, BNY Mellon Clearing International, with the creation of 50 new high quality jobs. BNY Mellon Clearing International will be an important addition to BNY Mellon’s Irish operations which currently employ over 1,800 people. IDA Ireland worked closely with BNY Mellon to help secure this new investment for Ireland. BNY Mellon Clearing International will clear listed futures and option trades on behalf of institutional clients in Europe, Middle East and Africa (EMEA). Services provided by the company are expected to include service delivery and operations, finance,compliance, risk management and client services. Welcoming the announcement, Barry O’Leary, CEO of IDA Ireland said, ‘The decision by BNY Mellon to establish this new company in Dublin is excellent news for the international financial services sector here. The company already employs a large work force at its operations in Dublin, Cork, Wexford and Navan, offering a broad range of services including asset servicing, alternative investment services and corporate trust. The addition of BNY Mellon Clearing International and the creation of 50 new jobs is great news for the industry.

angart, Inc., a global biopharmaceutical company dedicated to developing life-saving medicines specifically designed to enhance the perfusion and oxygenation of ischemic (oxygen deprived) tissues through targeted oxygen and other gas delivery, recently announced plans to build a new manufacturing facility in Ireland. The facility will serve as Sangart’s European headquarters and sales and manufacturing base in Europe for its investigational therapies, MP4OX and MP4CO. “The need for oxygen therapeutic agents such as MP4OX and MP4CO is a global one, and our manufacturing investment in Ireland is an important element of preparing for the potential future marketing of our therapies,” said Brian O’Callaghan, President and Chief Executive Officer of Sangart. “Expanding our global presence is a critical part of our commitment to getting Sangart’s therapies in the hands of physicians to benefit patients as quickly as possible.” The project is expected to create up to 125 jobs during construction of the facility, and the facility will staff up to 120 personnel once commercial activities are underway. “The building of this facility is a key step closer to the commercial availability of our products.” said Donald Brown, Chief Operating Officer of Sangart. “Because of its business-friendly environment, strong infrastructure and excellent talent pool, Ireland is an ideal location for our new manufacturing facility and entry into the European market.” Barry O’Leary, CEO of IDA Ireland said, “We are delighted that Sangart has decided to locate its European headquarters and commercial manufacturing facility in Ireland.



f your company is moving, shaking or you just cant keep your latest development to yourself, let us know and Irish Building Magazine we will deliver your message to Ireland’s key decision makers in the building sector.


HKR awarded three major design contracts in London


ondon HKR Architects (HKR), a leading international architecture and design practice, announces that it has been awarded three high-profile design contracts in London. These projects include; a 23 storey, five star hotel; a 19 storey mixeduse student housing project; and, a large office development in the City of London. The project wins reflect HKR’s strategy of focusing on largescale international architecture and design projects. Last year, HKR also won a contract to design a new international airport in Jordan including arrival and


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departure facilities, diplomatic suites, hangar and security buildings. Details of the London project wins are: 151 City Road - A five star hotel consisting of 273 rooms including a gym, spa, signature restaurant, banqueting, conference and business centre, corporate lounges and panoramic bar and restaurant. The 23 storey building is due for completion in 2012 and includes a high fritted glass façade and louvered roof over two levels of basement measuring approximately 200,000 sq ft. 33-35 Commercial Road, Aldgate - A student housing mixed-use development that includes: design of a 19 storey zinc clad tower, refurbishment of the existing listed buildings and design of a new category A office development. The completed project will provide nearly 340 student rooms and is due for completion in spring 2013. Telex, Fore Street, City of London - A 300,000 sq ft office development featuring green-terraced roof garden tiers stepping back from the Barbican. HKR is successfully building a best-of-breed international architecture and design practice, providing its growing number of global clients with the depth and breadth of expertise they require and with unique design solutions that meet and exceed their expectations. Jerry Ryan, HKR Architects CEO, commented: “These contract wins demonstrate the practice’s continuing commitment to capitalising on the diverse opportunities that exist in London and other international markets. The high-profile projects also reinforce the strength of our brand internationally.”

€50bn on infrastructure projects in Europe over the next decade

The Society of Chartered Surveyors Ireland has welcomed proposals by the European Commission to invest €50bn on infrastructure projects in Europe over the next decade. The Society said that these measures could provide a welcome boost to the construction sector in Ireland in the areas of transport, energy and digital networks. John Curtin, President of the Society of Chartered Surveyors Ireland said; ‘The proposed Connecting Europe Facility will promote cleaner transport modes, high speed broadband connections and facilitate the use of renewable energy in line with the Europe 2020 Strategy through a project bonds funding mechanism’. ‘It could provide funding for infrastructural projects in Ireland in the areas of high speed broadband provision, transport networks and renewable energy which would improve our competitiveness, provide enhanced services for consumers and businesses and would be a welcome boost for the Irish construction sector which still employs over 100,000 people”, Curtin said.

Health and Safety Regulations 2010 - The New Changes- what to be aware of. The Safety, Health and Welfare at Work (Construction) (Amendment) Regulations 2010 (the “Regulations”) give further effect to Council Directive 92/57/EEC on the minimum safety and health requirements at temporary or mobile construction sites and amend the Safety, Health and Welfare at Work (Construction) Regulations 2006 as previously amended. The Regulations came into effect on 2 November 2010. The Regulations make a number of amendments in 5 Areas- principally by inserting revised provisions in relation to the duties of the Project Supervisor Construction Stage (“PSCS”) in relation to notification of construction works to the Health and Safety Authority (“HSA”), under Regulation 22. Other amendments relate to duties in relation to safety precautions under Regulation 51, health hazards under Regulation 79 and the requirements for shelters and accommodation for clothing and taking of meals, under Regulation 98. This further tightening of Regulations will make Construction sites particular temporary or mobile sites safer and help foster a culture within the industry that all commit to such safety standards. Full details can be found on the HSA website follow this link and_Welfare_at_Work

Tell us and we will tell everyone!


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his latest affiliation is part of Technal’s commitment to creating strategic partnerships that reflect its passion for architecture, design, creativity and innovation. Acclaimed as one of the most important buildings of its time, the Guggenheim Museum Bilbao was designed by Frank Gehry and is a magnificent example of ground-breaking architecture. It was described by Time Magazine as ‘The Building of the Century’. With more than 90 exhibitions showcasing contemporary art and over 10 million visitors to date, the Guggenheim in Bilbao is credited with changing the way the world thinks about museums, and it continues to challenge assumptions about the connections between art and architecture. By supporting the Guggenheim in Bilbao via the corporate programme, Technal is demonstrating its commitment to culture and is helping this important, iconic museum meet its ambitious long-term goals. Technal is one of Europe’s market leaders in the design, manufacture and distribution of high performance aluminium glazing solutions, and is currently celebrating 50 years of innovation in façade design. It offers an innovative range of façade products, including curtain walling, doors, windows and low rise glazing systems, and has a network of approved, trained fabricators and installers in Ireland. Technal is now active in more than 70 countries and has operations in China, India, the Middle East, Morocco, South America, and South East Asia as well as across Europe. Its Irish headquarters is based in Dublin. For more information visit: www.

The Cork County Library built by BAM and officially opened by Derry Canty, Mayor of County Cork.


he Cork County Library built by BAM was officially opened on by Derry Canty, Mayor of County Cork. This new six storey over basement library building which extends to 4,500 square metres, forms part of the Civic Campus linking to the adjacent Cork County Hall which was comprehensively refurbished and handed over in 2006 by BAM. Both the Library and the County Hall Refurbishment were designed by Shay Cleary Architects. “We are very happy to have been in involved in this prestigious development which provides such an important service to the community” said Theo Cullinane CEO of BAM at the opening. BAM formerly Ascon Rohcon, is the largest civil engineering contractor in Ireland and is ranked second in the “Top Ten” of Ireland’s main / general contracting companies, with an approximate turnover of €362 million. BAM, based in Kill, Co. Kildare is the wholly owned subsidiary of Royal BAM Group, a worldwide construction services company, turning over €8bn and listed on Euronext Amsterdam

Left Picture – L to R; Martin Riordan - Cork County Manager, Shay Cleary – Shay Cleary Architects, Derry Canty, - Mayor of Cork County & Theo Cullinane – CEO of BAM Contractors. In other BAM News, BAM Contractors’ operating companies BAM Civil and BAM Building have again received recognition for their high safety standards at the 19th Annual Occupational Safety Awards 2010. The National Irish Safety Organisation (NISO) and Northern Ireland Safety Group (NISG) presented the awards at a ceremony on Friday 1st October last, held in Athlone. BAM Building were awarded the “Overall Regional/ Northern Ireland Award 2010” for the highest scoring organisation amongst all industries in Ireland and Northern Ireland and BAM Civil a “Distinction” for their outstanding safety systems and practices. Commenting at the ceremony, Tadhg Lucey, BAM Safety Director, complimented all BAM employees “from the very outset of implementing our safety systems and procedures in the 1980’s, all BAM staff embraced the principle of ‘work safely or don’t work at all’ and being presented with high awards like these, is a testimony to our overall commitment to safety”.


Comment Any thoughts

It says something about human nature that when major unexpected events occur we are suddenly surrounded by “experts” who dissect with the delicacy of a surgeon the circumstances leading up to the event, only to offer detailed forecasts of what the future might hold. In this country we are “blessed” with a proliferation of news media including radio, television, and print which offers us bucket loads of experts. One wonders where these experts were some time ago? Retrospective analysis unfortunately will only bring this country so far, what is needed is decisive action based on sound ideas. We should therefore collectively pool our ideas in order to select the best plans for moving forward. President Obama has led the way in this regard by inviting the top economists, equity experts, and financial brains in the US to meet with him and exchange ideas within days of his election. This reaching out is refreshing: it says to the country that whilst we have good civil servants all the best ideas do not necessarily come from within the Civil Service. When it comes to construction in this country we need an ideas forum that will inform Government, and work with civil servants to “test” good ideas. Such a forum would sift and screen ideas from all sectors with the industry in order to produce good plans based on good ideas to put forward to central government. Let the government reach out by initiating such a forum and give it teeth to make it work, and not be like the late Sir Peter Medawar who famously said, “The human mind treats a new idea the way a body treats a strange potein – it rejects it”.


Irish Building Magazine

Legal file

S e n t e n c i n g Tr e n d s for Health and Safety Offences

“For a punishment to be just it should consist of only such gradations of intensity as suffice to deter men from committing crimes.” – Cesare Beccaria (On Crimes and Punishments, 1764)


ackground: In 2010, the Health and Safety Authority (“HSA”) successfully completed 27 criminal prosecutions: 10 summary and 17 on indictment. In addition, a further 23 files were sent to the Director of Public Prosecutions for directions. These sentences resulted in total fines of €571,900. In addition, two twelve month (suspended) custodial sentences

When compared with other Western countries, Ireland retains a largely unstructured sentencing system. Maximum sentences are prescribed by statute for most offences, for example in the Safety, Health & Welfare at Work Act, 2005. However, there is no guidance on the severity of punishment appropriate for any particular offence. In the 2003 Australian case of R v Nemer1, the court said: “There is no sentence that is exactly right in a given case. In any particular case, the most that can usually be said is that an appropriate sentence will be within a certain range. Any sentence within that range will be appropriate.” Accordingly, one of the challenges in our sentencing system is overcoming the apparent inconsistencies between the approaches of individual sentencing courts. Reliance on Appellate Guidance All common law jurisdictions rely to some extent on appellate guidance as a means of structuring sentencing discretion. A useful summary of the relevant principles relating to sentencing comes from the decision of the Supreme Court in People (DPP) v RMcC2 where Kearns J. stated: “…there is a ‘due process requirement in sentencing’…This requires that any sentencing court should conduct a systematic analysis of the facts of the case, assess the gravity of the offence, the point on the spectrum which the particular offence or offences may lie, the circumstances and character of the offender and the mitigating factors to be taken into account – all with a view to arriving at a sentence which is both fair and proportionate.” In essence, the courts will have regard to three core principles:: 1.

Gravity of the crime

A court must make a judgment on the relative gravity of the offence, bearing in mind that maximum sentences should be reserved for the worst cases. In practical terms, this means that a court should begin by locating the offence on the overall scale of available punishment and decide on a notional sentence based on offence gravity alone. This, however, is only the first stage of the process. were handed down. These figures are slightly down on 2009 where a total of 38 prosecutions were concluded with total fines of €708,850. However, overall, the level of fines is on the increase (as is the level of (suspended) custodial sentences imposed). Sentencing Many of the principles for the sentencing of corporate offenders have developed out of well established principles applicable to individuals. This differs greatly from days gone by when corporations were thought to be exempt from the criminal law. Devising a suitable penalty was problematic, especially in olden days, when virtually every crime of any gravity carried the death penalty. “Can you hang its common seal?” asked one advocate during the reign of James II.


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Proportionality is concerned with the premise that the sentence to be imposed is not the appropriate sentence for the crime, but the appropriate sentence for the crime committed by the particular accused. The case of People (DPP) v Oran Pre-Cast Limited3 established that: where a fine is unlimited (as it was in that case), care and restraint must be used in the power to fine; and, the fine imposed must be proportionate to the level of fault and the means of the offender. 3.

Aggravating and Mitigating Circumstances

These are factors which may be taken into account by a court having firstly established both the gravity of the offence and

Legal file

having determined a proportionate sentence relative to both that offence and the circumstances of the offender. The leading case, in the context of health and safety prosecutions, is the English case of R v F. Howe & Son (Engineers) Limited,4. which has been adopted by the Court of Criminal Appeal in Ireland in People (DPP) v Roseberry Construction Limited5. While each case should be dealt with on its own particular circumstances, the following mitigating factors are relevant: 1. the previous safety record of the company; 1. a prompt admission of responsibility and an early guilty plea; 2. the means of the company and the effect of the fine on it; 3. the extent of the danger created, for example was it an isolated incident or a persistent one and steps taken to remedy deficiencies after they are drawn to the defendant’s attention. On the other hand, the court identified the following aggravating factors: 1. the deliberate breach of a duty to maximise profits; 2. where death results from the breach; and 3. a failure to heed warnings The Court observed that the size of the company and its financial strength or weakness could not affect the degree of care that was required in matters of safety. The extent to which mitigating factors are considered will vary depending on the circumstances of the particular case. For example, in a recent anti-competition prosecution, the extensive cooperation of the defendant company with the investigation of the Competition Authority was entered by the defence as a plea in mitigation. This was rejected by the judge on the basis that the defendant company only cooperated when it knew that ‘the game was up.’ Conclusion Judicial discretion in sentencing remains a cornerstone of our sentencing policy in Ireland. This brings with it certain attendant challenges such as overcoming the apparent inconsistency

of approach as between individual sentencing courts. Judges and appeal courts will naturally differ as to where particular offences should be located on the scale of gravity and how much weight should be attributed to the particular circumstances and characteristics of the offender. However, for the moment, judges and practitioners are loath to abandon discretionary sentencing lest it should curtail the capacity of the courts to fashion sentences which reflect all of the circumstances of specific cases. r 1 [2003] S.A.S.C. 375 2 [2008] 2 IR 92, 104 3 Unreported, Court of Criminal Appeal, Hardiman J. (ex tempore) December 16, 2003. 4 [1999] 2 Cr. App. R. 37 5 [2003] 4 IR 338

BIO Tristan is an Associate in the Construction and Engineering and Health and Safety Groups in Arthur Cox. His practice area is focussed primarily on construction and engineering law, advising on all aspects including both contentious and non-contentious matters. Tristan is experienced in various forms of dispute resolution having advised and represented employers, architects and contractors involved in various stages of disputes including settlement discussions, mediations and conciliations. Tristan also advises on all aspects of health and safety law and has represented a number of parties in criminal prosecutions taken against them by the Health & Safety Authority.

Tristan Conway-Behan, Construction and Projects Group, Arthur Cox can be contacted on: Tel. +353 1 618 0342


Irish Building Magazine

Legal file

Key Changes to the Public Works Contracts – Major or Minor?? More than 4 years after the introduction of the Public Works Contracts, parties are now familiar with their provisions. But are parties aware of the various amendments that are made to these Public Works Contracts on a regular basis?


‘This update considers some of the recent changes published by the Department of Finance on the Construction Procurement Reform website’


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everal versions of the Public Works Contracts (“the Contracts”) have been issued since their first publication, incorporating a range of amendments to various of their provisions. Many of these changes, however, are not fully advertised and people may not be aware of the extent of some of the changes made. This update considers some of the recent changes published by the Department of Finance on the Construction Procurement Reform website on 28 July 2011. This most recent version of the Contracts was accompanied by a note summarising the changes, describing them as “minor”. No point of reference was provided as to where the listed changes actually appear in the Contracts and their description as “minor” should be viewed with a degree of caution. It may also be unwise to assume that no further changes have been made to the Contracts other than those highlighted in the summary note of the changes. Key Changes made Background Information An entirely new clause has been inserted at clause 1.10 of the Contracts entitled “Background Information”. The clause is very broad in scope and seeks to absolve the employer from any responsibility for the newly defined ‘Background Information’ which may be provided to the contractor. “Background Information”, as defined, will include information made available to the contractor before, on or after the Contract Date and includes any information “stated to be Background Information”. The definition makes clear that it is intended to deal only with information which is not included within the Contract. Thus, information included within the Works Requirements is dealt with elsewhere in the Contract. Site surveys provided at tender will now be described as Background Information and cannot be relied upon, even in circumstances where there is no opportunity for the contractor to carry out its own testing. While this is not a dramatic shift in the usual allocation of risk, it does make clear beyond any doubt that no claim will lie against the employer if such information transpires to be incorrect or misleading. What if an Employer’s Representative fails to make any determination under Clause 10? A significant change now introduced is that where an Employer’s Representative (“ER”) simply fails to take any action within the prescribed time-limits in determining a claim submitted by the contractor under Clause 10.3 or in respect of a contractor proposal pursuant to clause 10.4, then the ER will be deemed to have made a determination of no adjustment to the Contract Sum

Karen Killoran is a Senior Associate in the Construction & Engineering Group at Arthur Cox. or Programme. The newly inserted sub-clause 10.5.4 then goes one step further and provides that all ER determinations (either made expressly or by default) will be final and binding unless the contractor or the employer disputes the determination and refers it to conciliation within 28 days of the date the determination was made or was taken to have been made. Thus, a contractor will need to ensure that, following submission of a claim, he has assessed the date by which a determination is to be made by the ER, and that, where no such determination is made within the prescribed time, he refers the ‘deemed’ determination of no adjustment to the Contract Sum or Programme on to conciliation within 28 days. Failure to do so will result in the contractor’s entitlement to pursue his claim being lost. This could result in the very inefficient situation whereby several mini conciliations are commenced and underway simultaneously during the course of a project by reason of disputed ER determinations or possibly due solely to failure by the ER to take any action at all in determining a claim. The contractor, as is true in respect of any conciliation, would be responsible for 50% of the costs of any such conciliations, even if the sole reason for initiating the conciliation proceedings is due to the ER’s inaction in failing to issue a determination within the prescribed timelimits and even if such a “default determination” is ultimately overturned. Contractor’s Final Statement Clause 11, already quite an onerous provision of the Contracts which prescribes that all items must be included within the contractor’s final statement in order to be assessed, has been amended to impose a further obligation on the contractor. Newly inserted clause 11.5.1 now provides a cut-off point for the delivery

Legal file

by the contractor of its final account, including particulars of all claims for any adjustment to the Contract Sum, after which, the employer will be released from any further liability to the contractor. If the contractor has not submitted its final statement within 2 months of Substantial Completion, the Contracts now provide that the employer will have no further liability to the contractor whatsoever. In effect, non-compliance with this timeframe will deny the contractor access to its final payment under the Contracts, including in respect of any claims.

the Arbitration Act 2010 and still maintain references to the Arbitration Acts 1954 – 1998 throughout. Specifically in relation to costs, the Arbitration Rules provide that the arbitrator will be responsible for fixing the costs of the arbitration and that the costs should in principle “follow the event”, namely, the successful party recoups its costs. This is quite clearly out of synch with what is now prescribed in the Form of Tender.

Arbitration Costs – who is responsible?

Far from “minor”, it is considered that the changes discussed in this note will have a fundamental impact on tenderers, employer’s representatives and contractors alike, particularly as regards the tendering and administration of the Contracts and the pursuit of contractual entitlements thereunder.

S. 21 (1) of the Arbitration Act 2010 allows for parties to make such provision as to the costs of the arbitration as they see fit. In or around early September of this year, the Government Construction Contracts Committee inserted a new costs undertaking in the Standard Form of Tender for use with the Contracts . This new costs undertaking prescribes that each party must bear its own costs of any arbitration entered into (relevant to that contract), except in the case where a sealed offer is made and the contractor does not beat it, then the contractor will be liable for both parties’ costs. The provision does not, however, allow for the reverse situation whereby the contractor beats the sealed offer and would ordinarily be entitled to recoup its reasonable costs. On the contrary, it seems that, in such circumstances, the contractor is still responsible for its own costs of the arbitration. The insertion of such a provision will clearly impact contractors when tendering as it may be viewed as an impediment to a contractor ever taking a claim forward to arbitration. Anyone involved in arbitration knows that the costs can be very significant, and the imposition of a requirement that each party bear their own costs, no matter what the outcome, and no matter whether a sealed offer is made or not, will render arbitration inaccessible to many, notwithstanding the merits which a contractor’s claim may have. It is difficult to reconcile the revised Standard Form of Tender with the Arbitration Rules 2008 (the “Arbitration Rules”) applicable to the Contracts (and also published on the Construction Procurement Website). The Arbitration Rules have yet to be updated to reflect


1 In this article, we consider changes to the five principal contracts, namely: Building Works Designed by the Employer, Building Works Designed by the Contractor, Civil Engineering Works Designed by the Employer, Civil Engineering Works Designed by the Contractor, Minor Building & Civil Engineering Works Designed by the Employer Bio - Karen Killoran Karen is a Senior Associate in the Construction & Engineering Group at Arthur Cox and advises on all aspects of construction law, specialising in contentious matters. She is experienced in various forms of dispute resolution, having advised and represented employers and contractors in arbitrations (domestic and international), court proceedings including commercial court proceedings, settlement discussions, mediations and conciliations. Karen has significant arbitration experience both at international and domestic level and has recently advised clients on complex disputes arising out of the construction of pharmaceutical and power plants. Karen holds a diploma in arbitration from University College Dublin and is a fellow of the Chartered Institute of Arbitrators. r

‘Far from “minor”, it is considered that the changes discussed in this note will have a fundamental impact on tenderers, employer’s representatives and contractors alike’


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Convention Centre Dublin

Located on the River Liffey, the new shining light in the Dublin landscape is the Convention Centre Dublin. 7500t of Structural Steelwork was utilised to provide a 2000 seater auditorium and over 40’000m2 of floor space. Key elements of the project were the long spanning trusses, weighing up to 160t and spanning 48m.

Staythorpe Power Station, Newark.

Located on a brownfield site which previously housed 2 coal stations, this project will become a state-of-the-art 1650MW power station. It will be a combined cycle gas turbine station and comprise four generating units, producing enough electricity to power around 2 million homes (or the whole of Nottinghamshire). Staythorpe will be the second largest CCGT (combined cycle gas turbine) power station in the UK when opened. The project will utilise approximately 5,000 tonnes of structural steelwork when complete.

Bombardier, Belfast (Fisher)

Located next to Belfast City Airport, Bombardier, the Canadian aircraft manufacturer is extending its facilities with a new 26,800 square metre building. The project had an onerous 12 Week program to erect 4,700 tonnes of structural steelwork which included 64 metre span trusses.

Excellence in Engineering

Fisher Engineering Limited Ballinamallard, Co Fermanagh, Northern Ireland, BT94 2FY. Telephone: (028) 6638 8521 Fax: (028) 6638 8706 (From ROI Code: 048) Email : Website :

A Severfiled-Rowen Group Company

The Convention Centre Dublin

Award Winner The Convention Centre Dublin (CCD) gives the capital city a new landmark building, but the real beauty of this world class facility lies within. The CCD Executive Chairman Dermod Dwyer gives Irish Building a whistle-stop tour of the centre designed by Pritzker Award-winning architect Kevin Roche


n many ways, the Convention Centre Dublin can be looked at as a real gift to the Irish nation. With 44,000m² of floor space, it is the largest single-use building constructed in Ireland in decades, and the largest state-owned publicaccess building built since the foundation of the state. Beautifully wrapped within a 7,000m2 granite facade and a 37m tubular steel glass drum, the elevators extending from ground level to the top floor within the atrium have the appearance of silver ribbons giving access to the delights within. Like any good present, the convention centre is something that Ireland has long needed – for decades, the tourism industry has been painfully aware that we have been missing out on top-tier business, because Ireland has not had a venue large enough to host the thousand of delegates that attend major international conferences. These delegates are valuable visitors, worth an estimated €1,507 each to the Irish economy. With some 300 conferences already scheduled to take place at the venue, amounting to more than 336,000 delegate visits, that amounts to a boost of some €126m to the Irish economy. When it is fully


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The Convention Centre Dublin

Errigal Contracts Interior Fitout Specialist On The Convention Centre Dublin Errigal Contracts is a successful organisation which is involved in the construction sectors throughout the UK and Ireland. As a market leader for Metal Stud Partitions and Ceilings, Suspended Ceiling Systems, Interior Fitout and Acoustic Systems we were able to showcase our skills and expertise in the development of this project. For more information about Errigal Contracts please visit our website at Dublin – Head Office Unit 701 Northwest Business Park Ballycoolin Dublin 15 T: 01 8809111 / F: 01 8809222 London 9 Devonshire Square London EC2M 4YF T: +203 4275608 / F: +203 31783221


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Derry 111 Gortnaghey Road Dungiven BT47 4PZ T: 02877740090

The Convention Centre Dublin

into its stride, The CCD will bring in between €25m and €50m of foreign revenue annually. Dwyer was delighted to say: “We are already set to meet our international delegate targets for the next four years.” Convention centres are normally developed by municipal authorities and are usually loss-making entities, but The CCD is the first conference centre of its type to be procured by a Public Private Partnership (PPP), with Spencer Dock Convention Centre Dublin Ltd taking the risk as to whether the venue turns a profit or not. The private company engaged Construction Management Partnership (CMP), a joint venture between Treasury Holdings Limited, founded by Richard Barrett and John Ronan, and John Sisk & Son Limited, to design and build the centre, with The CCD entering into a, operate, maintain and finance the venue for a 25-year-period after which time it will be handed over to the Office of Public Works (OPW). In the meantime, the State will pay SDCCD by way of annual Unitary Payments over 25 years, a total of just under €380m in present day values. The OPW brief called for a 2,000-seat world-class auditorium, a 2,000-seat banquet/exhibition hall and a 3,000-seat exhibition hall, along with numerous meeting rooms and back-of-house facilities, with the building required to have a 100-year structuraldesign life with major replaceable features, such as cladding, to be designed for a 40-year life span. On arriving at The CCD, Dwyer takes us to the top floor of the atrium where the view is stunning – probably the best in Dublin. When events are taking place at The CCD, mobile electronic signage is used to direct delegates around the building – this allows all notice-boards throughout the building to be updated immediately and remotely, while cutting down on clutter. There are bars on each of the lobbies overlooking the entrance foyer, but most of the time these are hidden behind mirrored feature-walls, again giving the entrance areas a clean, uncluttered and businesslike appearance – but when refreshments are required, the feature walls can be opened electronically at the touch of the button. The main auditorium, which occupies the top three levels of the building, is fitted with wood-panelled walls of steamed beech, this wood from sustainable forests is used throughout the building. The auditorium’s acoustics are excellent with every word uttered on stage easily audible in the remotest seats in the hall without

amplification. The tiered design ensures everyone present has an unobstructed view of onstage proceedings and the seating spaces are probably the most generous in any public meeting room or theatre in the country. The Figueras chairs used are designed to remain comfortable throughout an eight-hour long seating period, with each seat having its own ventilation control to adjust the temperature, Convention centres are normally developed by municipal plus a foldauthorities and are usually loss-making entities, but down writing tablet for a The CCD is the first conference centre of its type to laptop, plus be procured by a Public Private Partnership (PPP), power socket with Spencer Dock Convention Centre Dublin Ltd taking and data port. the risk as to whether the venue turns a profit or not. The auditorium has its own AV production room, allowing for the building to host live TV events such as Britain’s Got Talent, the X Factor and the 8th Irish Film and Television Awards, while also being ideal for the production of corporate videos. There are seven interpretation booths allowing conference proceedings to be translated live to

The Convention Centre Dublin

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The Convention Centre Dublin

the audience and there is an orchestra pit for 80 musicians. The auditorium can be used for smaller-sized events, such as product launches, with an intimate ambience created through judicious lighting and the blacking-out of the top two levels of the venue. The fly tower is large, with Dwyer saying: “There have been cars hidden up there as part of product launches and I have to say its big enough to hide a bus! Getting equipment onstage is easy because of our two goods elevator – one large enough to accommodate a van, the other large enough to accommodate a 40ft trailer.” The largest room is The Forum, a 2,721m2 flat-floored hall at ground level; large enough to accommodate 10 tennis courts, it can hold more than 3,000 delegates in theatre mode or up to 2,000 guests for a banquet. The room has a great deal of flexibility that isn’t immediate to the casual eye: canvas sails, hanging from the ceiling, can be raised or lowered depending on the atmosphere that an event manager wishes to create, with lighting used to provide colour or to project logos and/or messages on to the canvas. The lighting rigs descend to 2m above floor level, allowing for lighting adjustments and maintenance without the need for scaffolding or ladders. For exhibitions the ceiling can be raised to its maximum 8m height. Beneath the carpet tiles, there is a system of underfloor ducting allowing for maximum flexibility when power points and data ports are needed. Furnishing the room with expedition stands and banqueting props is made easy thanks to its ground floor location and its large-vehicle entrance door. The next largest room is The Liffey, a 1,550m2 space on the second level it is large enough to accommodate 1,606 delegates in theatre mode, 1,220 for banqueting. This room is equipped with a Skyfold system that lowers a sound-proof wall from the ceiling, creating two spaces with conference capacities of 710 and 954 delegates respectively and banqueting capacities of 470 and 610. Elsewhere on the second level there are 11 meeting rooms of various sizes, with a further eight meeting rooms on the third level. Each boardroom is plug-and-play ready for laptops and AV equipment, with push-button blinds to provide shade or total privacy where necessary. “The building was designed by Kevin Roche from the inside out,” says Dwyer. “When he started working on the project one of the first things we did together was visit other conference centres so that Kevin would have a really good idea of how a convention centre should really work properly and he has realised those ideas efficiently and beautifully. Every detail in the building is Kevin’s: from the door handles and light fittings to the 475 panes of glass, with no two panes identical, in the atrium drum. Everything says quality, right down to the most menial: in the toilets for example, the cubicles are separated by solid plasterboard partitions not by metal partitions. “What the convention centre means is that Dublin is becoming a first choice venue for international conferences, rather than being perceived as an alternative venue, a place to be considered only after looking first at what were more mainstream choices. Our main market is the international association conferences and conventions, which are often held maybe once every three to 10

years but which attract thousands of delegates from across the globe. We would have about a dozen sales and marketing staff who would spend a lot of time on research as part of winning business from these associations. We’re delighted that we will be hosting an International Bar Association conference in October 2012 – with a membership of lawyers and judges, they are a great reference client! Another important client is the TM Forum, whose members are involved in the telecoms and IT industries – they held their flagship Management World conference here in May andare due to hold the event here again next year.” A major selling point for The CCD is that it is the world’s first carbon neutral convention centre, a feat achieved through the use of low carbon cement and timber from sustainable sources, the use of a thermal wheel heat-recovery system and an ice storage thermal unit for air conditioning and the sourcing of electricity from sustainable energy providers, with any unavoidable carbon emissions offset through the purchasing of carbon credits. “Our carbon neutral status is helping us win business,” said Dwyer. “Johan Goreki, CEO of Globe Forum, said the only reason he chose Dublin as their venue for their 2010 conference was that we were a carbon neutral venue.” Security consultants Risk Management International (RMI) worked closely with the design and construction teams from prebid through construction to completion, using the principles of ‘Crime Prevention Through Environmental Design’ to avoid the need for an expensive security retrofit later. RMI CEO Cathal O’Neill said that a key challenge was to design a security solution that was proportionate to identified risks, including those from crime and terrorism, and that provided the optimal balance between safety and security. He said: “A key objective was that the security solution would be discrete, relevant and effective, while maintaining the quality of the space. We also needed a scalable solution, with a capability to increase security in response to any heightened threat associated with visiting dignitaries or organisations.” The CCD has won several awards, including Best Large Event Venue in the Irish Event Industry Awards 2011 and silver in the Best Overseas Convention Centre award at the Meetings and Incentive Travel Industry Awards 2011, but from a construction point of view the sweetest accolade, so far, has been the construction manager of the year gold medal awarded to project manager Donal McCarthy of CMP/Sisk by the Chartered Institute of Building. The judge’s citation said: ‘The construction of The CCD was a technically complex operation, demanding very high international standards of completion, the coordination of a large and diverse design team, a tight and difficult site together with a demanding cost and time schedule. The technical complications were considerable including a five-star M&E specification and stateof-the-art acoustic control throughout. That these high demand outcomes were achieved together with achieving a snag free completion date was outstanding.”

The largest room is The Forum, a 2,721m2 flat-floored hall at ground level; large enough to accommodate 10 tennis courts, it can hold more than 3,000 delegates in theatre mode or up to 2,000 guests for a banquet.


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The Convention Centre Dublin


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The Convention Centre Dublin “Logistics was a big issue during the initial construction stage,” said McCarthy. “The site is constricted by the north quays on one side, the Royal Canal on another side and to the rear of us the new LUAS line was being laid by the Railway Procurement Agency and Laing O’Rourke were building the new Spencer Dock Bridge. Keeping the four tower cranes fed with steel during the steel erection phase was a continuous challenge requiring day-to-day planning.” Ireland’s leading geotechnical firm, PJ Edwards was contracted to provide the secant piling on which The CCD is built. The company carried out work throughout the whole of the Spencer Dock development area, where in places piling outputs were the biggest ever achieved by this company with 350-500 cubic metres of pile concrete placed daily. The steel fabricators on The CCD site was Fisher Engineering, which was involved in the project on a lump sum, fixed price basis, calculated using a structural steel finite element analysis model, designed by O’Connor Sutton Cronin. Once Fisher had won the contract, it worked with O’Connor Sutton Cronin to develop the model further. “Logistically, it was a complex job,” said Fisher Engineering’s project manager Adrian McCoy. “The structure uses 7,500 tonnes of primary steelwork. Some of the larger elements involved exceptional loads requiring an escort to bring them to the site and a 350-tonne crane to put them in place. To allow the first-floor stage area to be free of columns, four 22m long x 3.5m deep x 48t Vierendeel trusses were used to support the stage area in the auditorium above. These trusses were brought to site in two sections then bolted together and lifted into place as one piece. Once we got to the second floor level, using a mobile crane wasn’t practical for the general steelwork because space on the ground was a premium. The largest single steel element is a 160t 48m-long x 6.5m roof truss, which was lifted into position in 24 individual pieces and it required temporary towers to support it until it was bolted into position. ” The basement slab involved Ireland’s largest concrete pour, where in a 17-hour operation 360 trucks were used to deliver

2,534m3 of low-carbon GGBS concrete. The ground granulated blast furnace slag concrete was chosen chiefly because of its hard-wearing quality, but its low-carbon credentials was one of the drivers that led The CCD to work towards full carbonneutral status. McCarthy said: “The tiered terracing used in the auditorium was initially planned to be poured insitu, but after serious consideration we changed this to precast which expedited the auditorium programme works.” Once the primary roof steelwork was in position, the auditorium’s precast seating was installed, a task undertaken by Creagh Concrete, with Cashel Construction installing the precast concrete sub-structure supporting Creagh’s work. Cashel Construction had previously worked with CMP/Sisk installing pre-cast concrete blocks used in the construction of apartments adjacent to the CCD site. The CCD uses a structural framing system, installed by Errigal Contracts, to support its external stone cladding. The external envelope uses a structural steel metal stud and external render system, comprising a 30m-high span section in excess of 1,200m2, which was completed off mast climbers. Inside the building, Errigal installed acoustic walls and ceilings in the main auditorium, specialist ceiling systems in breakout areas, bars and the conference and meeting rooms, and installed fire-rated cladding on the main structural steel supports. In back-of-house areas, Errigal Contracts were also responsible for fitting metal stud fire and acoustic partitions and suspended ceilings. “We did very well, delivering the project on time and on budget with a very good safety record – 1.3 million accidentfree working hours,” said McCarthy. “The formal handover was on August 5th, 2010, but we achieved a virtual handover three months earlier on May 5th. That allowed the operator to run the building in anger for three months, with the X Factor and Britain’s Got Talent events taking place ahead of the official opening and helping us to iron out any operational issues prior to contract completion. I am very pleased that we achieved a fivestar quality finish, everybody is happy with the building, it really is a great asset.” r

The CCD has won several awards, including Best Large Event Venue in the Irish Event Industry Awards 2011 and silver in the Best Overseas Convention Centre award at the Meetings and Incentive Travel Industry Awards 2011, but from a construction point of view the sweetest accolade, so far, has been the construction manager of the year gold medal awarded to project manager Donal McCarthy of CMP/ Sisk by the Chartered Institute of Building.


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Award Winning Solutions The Daylight Specialists

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Aviva Stadium “Winner of Best Project and Innovation Award”

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Aviva Stadium

Viva the Aviva

The Aviva Stadium provides the world’s oldest international rugby venue with a state-of-the-art facility. CIAN MOLLOY reports on the construction of a new home for Irish rugby and soccer at Lansdowne Road.


he €410m Aviva Stadium, with its eye-catching curvilinear design and its glazed 50m tall facade, not only provides Irish rugby and soccer with one of the world’s most modern sporting venues, capable of holding 50,000 spectators in four tiers of seating, it’s modern glazed curvilinear design also provides Dublin with an iconic new landmark. The lead architects were Populous, formerly known as HOK Sport, who previously designed Arsenal’s Emirates Stadium, Wembley Stadium and Stadium Australia in the Sydney Olympic Park. Interior design is by the Irish firm of Scott Tallon Walker. Built in the space of three years, the 48m tall stadium which is also a shining example of both teamwork and technical know-how in the Irish construction industry, with three of Ireland’s largest construction firms involved in the project. Before appointing Sisk as main contractor, the Lansdowne Road Stadium Development Company (LRSDC) engaged McNamara to demolish the old stadium and to isolate the Iarnród Éireann rail line that passes alongside the Western perimeter of the site. Ascon (now BAM ) were appointed as subcontractors to undertake foundations preparation and substructure. “We appointed McNamara before we had obtained planning permission, which was a risk,” said LRSDC project director Michael Greene. “But that meant we were ready to start working on site as soon as we had the planning permission obtained, it meant we had a real run at the work. We also appointed the major subcontractors under Sisk control for Foundations (BAM), Structural Steel (a SIAC/Cimolae joint venture), Mechanical (Mercury), Electrical (Kentz), Roofing and Cladding (Williaam Cox) and Pitch (Clive Richardson). After selection they were then appointed as domestic subcontractors to Sisk. If they had been appointed as sub-contractors by Sisk that would have added another year to the schedule.” As main contractor, Sisk employed more than 90 sub-contractors on the project. Following completion of the demolition in October 2007 Sisk commenced on site and completed all the work up to and including handover to the Stadium Operator on time at 30 April 2010.

Another factor that assisted the smooth, speedy and safe construction of the facility was the early appointment of project managers to oversee the entire process. PM Group’s Pat Molloy said: “One of the things that worked really well was that we were appointed at the same time as the design team, which meant that we were able to be involved in design development right from the start. This allowed us to do constructability reviews as the design developed. The poly-carbonate cladding is a good example of this where, working with the designers, a scheme was developed that maximised the use of off-site technology and resulted in minimal construction effort on site. Other examples of our input include the extensive use of precast concrete to replace in-situ concrete and the use of bolted connections on the roof steelwork rather than site welding. “It was clear at a very early stage in the design that the use of offsite manufacture would be a key element in the successful delivery of the project. Virtually the entire footprint of the site is built upon, so space for materials was always going to be a premium. Offsite manufacture, combined with a just-in-time delivery strategy greatly reduced the materials storage requirements on site. The extensive use of precast concrete elements had the additional benefit of providing a cleaner, whiter finish. To ensure that the planning process ran as smoothly as possible LRSDC were also assisted by Tom Phillips and Associates, the largest consultancy in Ireland specialising solely in planning matters. Phillips told Irish Building: “The public consultation exercise carried out in advance of seeking planning permission was the most extensive and best that I have ever been involved in, and it paid dividends. Dublin City Council did not give us an easy run, but they were very positive and hugely helpful because they saw the benefits to Dublin of this project. Many of the conditions involved in the planning permission were suggested by us and were chiefly aimed at reducing the project’s impact on the receiving environment.” On a practical level, one of the biggest improvements to the sports ground is that the busy DART line can now be crossed via overpasses and underpasses incorporated in the new stadium’s design. These crossings mean that the gates at the Lansdowne

“It was clear at a very early stage in the design that the use of offsite manufacture would be a key element in the successful delivery of the project, Virtually the entire footprint of the site is built upon, so space for materials was always going to be a premium” Photography by: Peter Barrow


Irish Building Magazine

stadium builders

business partners for building a better Ireland Main image: Soccer City Stadium, Johannesburg, South Africa Inset Images: Nelson Mandela Bay Stadium, Port Elizabeth, South Africa; AVIVA Stadium Substructure Works, Dublin :

Aviva Stadium Road DART station can remain permanently closed on match days – allowing for more efficient use of public transport and ensuring that no crush develops at the level crossing gates when fans are leaving the stadium at the end of a fixture. “Planning work on the rail corridor and the safe demolition of the West Stand was a big issue and involved numerous meetings between ourselves, PM Group, McNamara and Iarnród Eireann,” says Greene. “The rail line was shut down on the August bank holiday of 2007 and we took down the West Stand. The railway was shut down again on the following October bank holiday and work completed that weekend had us effectively separated from the rail line.” Separation from the rail line was largely achieved by McNamara installing a 3,500 tonne precast concrete structure over 150m of the line. McNamara constructed the new pedestrian underpass, a monolithic concrete tunnel box structure, using an incremental tunnel box jacking system and they also installed sheet piling to allow deep excavations to be carried out only 2m away from the live rail line. “Stringent monitoring of the water table was required so that the draw down did not exceed Iarnród Éireann’s requirements,” said McNamara’s chief operations officer Luke Gibbons. In all, McNamara removed some 2,000 tonnes of stand and another 2,000 of terracing in the process of demolishing the West Stand, a process made potentially hazardous because of the presence of asbestos in the old building. Gibbons said: “Special safety measures had to be adhered to, including completely sealing up all openings to the work area to ensure that no asbestos could pass to other areas, all employees working in the area had to wear specialist clothing and use specialist breathing equipment and once they left the working area there was a strict de-contamination process. The asbestos removed had to be double-bagged and disposed of offsite by an approved asbestos disposal contractor.” The demolition of the old west stand reinforced concrete structure that spanned the Dart line was achieved in a 72 hour window over the Bank Holiday weekend with work including the re-instatement of the overhead line to allow Dart services resume on the Tuesday morning. This was was a significant engineering achievement and

was a key milestone to ensure the overall stadium project progressed on schedule. All concrete from the demolished buildings was crushed onsite and used as hardcore, one of the key sustainability features of the construction, which used low carbon concrete for environmental reasons and for the better finish provided by GGBS cement. The new stadium includes a rain water collection system with water stored in underground tanks built beneath the East Stand by BAM. In addition to constructing piles and carrying out deep excavations adjacent to the DART line, one of the biggest challenges for BAM was the realigning of various culverts crossing the site, which include the River Swan and the Rathmines and Pembroke Sewer, with the sewer remaining ‘live’ thoughout the construction process. “We did all the site set up and enabling works, including site strip and excavation, disposal of unsuitable material and re-use of material where possible in capping and stoning works,” said BAM Construction’s Perry Haughton. “We were working 8m below ground level, so to cope with water table issues we used sheet piling. For the enabling works, we had about 1,600 bored piles designed and constructed – the whole building sits on these piles, which are like stilts bored 8-10m into the ground rock.” Beneath the East Stand, BAM have constructed a triple level basement, comprising some 3,000m2 of space, housing rainwater harvesting tanks, sprinkler tanks, fire main tanks and mains water tanks. BAM also constructed a new 8,000m2 single-level

“On a practical level, one of the biggest improvements to the sports ground is that the busy DART line can now be crossed via overpasses and underpasses incorporated in the new stadium’s design’.


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Aviva Stadium

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Town Planning and Economic Consultants Dublin | Mullingar | Cork |

Aviva Stadium

There are 36 corporate boxes and 11,000 seats at premium level.

A total of 5,000 tonnes of roof steel were employed in the construction of the stadium

constraints caused by the DART, low-level bridges underground basement car park and a double-level and residential areas.” basement plant room, immediately adjacent to the Previously, Sisk had worked on the redevelopment re-aligned Rathmines & Pembroke Sewer. Houghton of Croke Park, but as Barnwell points out: “That was said: “These works were constructed using a really four jobs over 12 years, the Aviva Stadium is perimeter sheet pile wall, anti-floatation piles and unique because we delivered the full 50,000 capacity waterproof concrete and they required the installation facility in one go and Sisk also delivered the full fit of a full-time dewatering system, with all temporary out of the stadium in one go. “There is 800,000ft2 works designed by BAM. “We also designed the new Swan culvert and its of fitting-out in the building. The stadium includes outfall into the River Dodder – this work required highly-finished catering areas that can seat up to the construction of a re-aligned river swale to 3,000 people the value of the catering installations maintain flows during construction and also required alone exceeds €20m. We have 75 different catering a cofferdam of sheet piles in the Dodder. We also areas, along with toilet and welfare facilities, players’ installed new flood defences along the Dodder from areas and changing rooms. There are 36 corporate London Bridge to Bath Avenue Bridge.” Before BAM had finished building the substructure, Sisk were working on the site on the second stage of the construction programme, the construction of the concrete frame. This was done ahead of schedule which opened up the building for the Mechanical/Electrical and finishing trades. This also allowed us to proceed with the installation of the roof structure, which is a polycarbonate clear roof on structural steel. “The steel roof structure is very complex and is what gives the “We achieved 1.5 million hours of work without an building its fantastic shape,” said Sisk’s project director Michael Barnwell. “Installing the steel was a logistical boxes and 11,000 seats at premium level. There is challenge. It came in six ship-loads from the Cimolai also an extensive provision for the media – two TV fabrication plant in Italy. Stored in Dublin Port it was studios, a press conference area and a photographers’ brought to the site overnight, as required, and once room.” on-site it was assembled on the pitch area into large One early decision made at the start of the design components of the roof structure and then lifted into process paid dividends at the fit-out stage two position like a Meccano set. The heavy roof structural years later, says Greene. “We were advised by the steel installation took place from December 2008 to architects to bring the catering company on board as October 2009. A total of 5,000 tonnes of roof steel early as possible and we did that. We had the kitchens were employed in the construction of the stadium and concessionary areas already designed, but the and, to install the roof structure, we used a 750-tonne caterers, Compass, changed nearly everything! They crane and several 500-tonne mobile tracked cranes.” had a different view of their world and how it was To facilitate speedy construction, the roof steelwork organised. Getting their input early, saved what is bolted together rather than welded, said Molloy of would have been a lot of wasted time and expense.” the PM Group. “It was clear at a very early stage Greene also points out that a lot of thought has that the use of off-site manufacture would be a key been put into the IT infrastructure in the building. element in the successful delivery of the project. Off “In addition to being a sporting venue, the stadium site manufacture of as many elements as possible, is also designed to be a major conference venue, combined with a just-in-time delivery strategy, which is why the interiors are of a five-star hotel greatly reduced the materials storage requirements on standard, with a substantial IT backbone to ensure site. The extensive use of precast concrete elements that conference delegates have easy broadband had the additional benefit of generating time savings connectivity, access to television and anything else because manufacture could commence earlier than that they might wish.” in-situ works. Off-site manufacture also reduced the While the fit out was being completed, the stadium’s number of truck movements required, which was spectacular glazed facade was erected by Williaam particularly beneficial given the site location and the Cox, a firm specialising in glazing and curtain

walling, who designed, supplied and installed the complete glazing facade, comprising the full building envelope, the glazing support structure and the internal glazed screens. Williaam Cox specialises in glazing projects worth in excess of €10m, but the scale of materials involved in creating the Aviva Stadium’s facade and roof was unprecedented; with some 19,000m2 of polycarbonate sheeting used on the roof and more than 17,000m2 of polycarbonate used on the facade, which consists of 4,500 louvres set of differing angles, the contract was worth €30m to the Dublin-based company. Thousands of individual bespoke components were designed and manufactured at Williaam Cox’s plant in Clondalkin plant. “We manufactured 4,500 individual lengths of mullion, each of them, with the exception of about a dozen with its own individual specification. Over the course of the manufacturing process we made five errors in the entire job, which is a fantastic engineering performance,” said the company’s operations director Bob Collins, who said that one of the most challenging aspects of the job was the actual construction methodology. “Our installation team used a walk-on net system, in accident”. conjunction with a team of abseilers, to install the roof panels. The geometry of the building meant that the installers were working on near vertical gradients.” Jointly owned by Sicon (the Sisk Group holding company) and CRH, Williaam Cox targets the overseas stadium construction market with its expertise in fabricating 53,000 – 87,000 seater stadiums to date. The construction of the new stadium at Lansdowne Road was fascinating, says Barnwell, because of the way ‘older skills, such as concrete construction and steel erection, were combined with the modern sophistication of high-tech building’. He added: “Projects such as the Aviva Stadium remind people that, as a country, we have the ability to deliver largescale projects in the public interest, safely, on budget and on time. We achieved 1.5 million hours of work without an accident. “The finished stadium is a great visual addition to the city skyline. It’s wonderful how it pops up dramatically in the most unexpected places, like when travelling over Ringsend Bridge or when driving over the canal at Grand Canal Street.” “Everyone is impressed by the building’s exterior,” said Michael Greene. “But it is not until they go inside and see the interior that they are really blown away. It has a real ‘wow’ factor!” r


Irish Building Magazine


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P.O. Box 22 Dungarvan Co. Waterford Tel. +353 58 41199 Fax. +353 58 42169 Email. Web.

MAIN MECHANICAL CONTRACTOR FOR MERCK SHARP & DOHME BIOLOGICS VBSF PROJECT Specialising in the design and manufacture of Stainless and Carbon Steel Fabrication including: Pressure Vessels, Limpet Coil Tanks, Storage/Heating/Cooling Tanks, Heat Exchangers, Condensers, Reactors, Specialised Stainless and Carbon Steel Fabrications, Pipe Work Systems and installations, Structures, Stainless Steel Pipe Work, Sanitary Pipe Work, Carbon Steel Pipe Work.

We are one of Irelands leading Mechanical Site Contractors with completed large-scale projects in the area of the Chemical, Bio-Chemical, Pharmaceutical, Brewing, Dairy and Food Industries. With facilites for: Submerged-arc, Computerised Orbital and Automatic Seam Welding, Machining, Polishing, Painting and Shot Blasting, Powder Coating, CAD Design, Non-Destructive Testing, FAT/SAT Protocols, Documentation, Certification Traceability, On and Off Site Passivation, Validation and Commissioning. Special designated building for Biotech/Semi Conductor Industries with the inclusion of certified Cleanroom Facilities Class 10, Class 1000, Class 10,000 for the welding of high purity pipework. 22

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MSD - Carlow Global Excellence Delivered Locally Ireland’s reputation as a hub for pharmaceutical expertise and endeavour has been enhanced by the opening of the €200m MSD Biologics facility in Carlow, where 140 highly skilled workers will be employed.


s well as being Ireland’s first stand-alone biologics facility, it is also the first green-field sterile processing facility to be built outside the United States by Merck & Co, one of the world’s three largest pharmaceutical companies. At a time when Ireland’s economy is in great difficulty, the Carlow vaccine and biologics sterile facility (VBSF) is a benchmark project in terms of attracting further inward investment. For more than 30 years, the IDA has worked to make Ireland a hub of pharmaceutical industry excellence and, at the moment, the industry is especially interested in the development of new largemolecule medicines of the kind that are produced using biologic processes. As well as vaccines, biologics can include allergenic materials, blood components and gene therapy tissue. The science of vaccination dates back to 1796 and Edward Jenner’s inspired use of cow pox to inoculate against small pox. In the last two centuries, vaccines have been developed against cholera, rabies, tetanus, typhoid fever and bubonic plague, diphtheria, whooping cough, TB, polio, measles, mumps, rubella, chicken pox and meningitis, hepatitis and Lyme disease. Today, the flu vaccine is an annual chore and there are now therapeutic vaccines used to treat certain cancers, as well as vaccines to prevent cancer.

This is a very exciting area of medical research and development, and the MSD VBSF has already given Ireland increased visibility in this field, as the Carlow plant was a winner of a Construction Users Roundtable (CURT) safety excellence award. High visibility The CURT safety award is presented by a body representing North America’s largest corporate consumers of construction services. CURT aims to promote cost effective construction methods and its members now know that Ireland is a place where complex construction projects can be delivered on time and on budget, to a tight schedule and with little or no safety problems. At MSD in Carlow there were more than 1.2 million construction hours worked without a lost-time incident (LTI). During peak building activity, there were more than 500 workers on site and rapid progress was made with the project going from conception to fruition in the space of 41 months; the project charter was agreed in September 2007, the Carlow site was acquired two months later in November, ground was broken in October 2008, mechanical completion of the final systems was achieved in May 2010 and operational qualification was achieved in February 2011.




Carlow there were more than 1.2 million construction


worked without a lost-time



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MSD Cork Office Unit 5, Centrepoint Marina Commercial Park Cork. T. 021 4315552 F. 021 4315556 E.

Dublin Office 13 The Westway Centre Ballymount Avenue Dublin 12. T. 01 460 2600 F. 01 450 7968 E.

Sirus Building Energy Solutions incorporates a number of complementary divisions within its structure. The Building Energy Management Systems division provides BEMS, Monitoring And Targeting, and Energy Management Systems for Life Science, Healthcare and Manufacturing plants throughout Ireland. These include most of the top multi-national pharmaceutical companies such as MSD, Pfizer, Schering Plough & Genzyme. Customers in manufacturing include Bausch and Lomb, Tyndall Institute and Stryker Osteonics. Healthcare customers include Cavan, Waterford, Mercy and other hospitals. Sirus has also installed and currently supports an extensive installation of BEMS across the campus of UCC. Our HVAC division provide full turnkey solutions for replacement HVAC plant. Some recent turnkey projects awarded to Sirus were the replacement of a complete ventilation system for an operating Theatre in a hospital, the complete HVAC system for the Glucksman Art Gallery in Cork and a new Chiller compound for the IAA in Shannon. Our Maintenance division provides maintenance of AHU’s, Boilers, Chillers, Pumps and a variety of other HVAC plant for customers in education, retail, manufacturing and Life Sciences. This division also includes a “Testing and Balancing” group for air and water balancing and a Cleanroom Validation group for testing of critical environmental parameters in Life Sciences, Healthcare, and manufacturing. Our new Energy division provides consultancy, project management and turnkey solutions for improvements in Energy Reduction, Energy Monitoring and Energy Management. Please visit our new website at to read more about Sirus.


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MSD “The achievement of a million manhours without an LTI was achieved only as the result of a constant commitment by everyone onsite towards embracing a positive attitude to safety,” said Sean Moloney, an Associate Director with PM Group, which provided architectural and engineering design, procurement and construction management services for the project. He added: “A ‘Hearts and Minds’ programme rolled out by PM Group proved to be the foundation on which the Positive Safety Culture blossomed with constant support from the client, the contractors management teams and craft workers. Safety Challenge Merck Global Engineering Services Director Paul Tubito is delighted to have won the CURT award and he says creating an exemplary safety culture during the construction period was his chief priority and greatest challenge. “I can’t stress enough how important that aspiration for a safety culture is to us. We see safety as a universal value that is based on taking personal responsibility, engaging with colleagues and being involved in two-way communications about safety issues. We did have a lost time incident early on, but in some ways that was fortuitous; it acted as a real rallying point and helped us put safety at the top of the agenda. Some of the people who were involved in that LTI became our best advocates for safety. “A good safety culture leads to having good systems and procedures in place, to having a well organised site, and helps establish high expectations on cleanliness and compliance. The safety culture leads to benefits in project execution and in productivity during the construction period, because when people feel safer at work, they are happier at work. The safety culture during the construction period lives on and continues in the safety culture when the facility becomes operational. This is a facility that has to be more than clean, it has to be sterile. It’s a facility that produces products that people will inject into their bodies: it has to be absolutely safe. We told our construction workers ‘In years to come, you or your children are likely to be injected by vaccines produced here in Carlow. As well as a duty to your colleagues and to your employer, you have a duty of care to yourself and your family’. “We were innovative in fostering the safety culture: in addition to ‘hearts and minds’ workshops for managers and supervisors, we had a system of ‘safety observation reports’ that allowed individual workers to raise matters of concern, anonymously if need be; we had weekly ‘town hall’ meetings to discuss safety issues (with robust feedback on some of the safety observation reports!); we had a scheme that linked good safety performance with support for local charities; there was a monthly newsletter and there were free health check-ups for all workers. “It was important that we worked under a no blame culture – people were not penalised when they made mistakes, providing they learned from their mistakes and then worked with others to ensure similar mistakes didn’t occur in the future. “Towards the end, we were getting some glowing safety observation reports – people who hadn’t worked with us before were saying ‘We’ve never been on a site like this before, it’s great. We’ve learned things here about safe working that we will carry with us into our future construction practice’.”

Project Management The heart of the Carlow VBSF is the 77,000 sq ft production building, which houses a vial-filling line and a syringe-filling line, plus associated formulation areas for vaccine products. Over time, millions of people across the world will receive vaccines sent to market from this location. Notably, the production building is built using modular construction and comprises 133 modules designed and fabricated by Pharmadule, the world leader in modular manufacturing for the pharmaceutical & biopharmaceutical industries. There are a number of advantages to choosing this method of building procurement: components are manufactured and assembled in an indoor workshop akin to a clean room; necessary elements can be preinstalled and integrated; sections of the building can be assembled for preliminary systems testing before being disassembled for shipping to the production site; generally, modular building allows shorter construction time than available using conventional building methods. The 133 modules used were first delivered in five consignments from Estonia to Waterford before being transported overland to Carlow. Next door to the production facility is a 95,000 sq ft production support and warehousing building. Built using conventional steel frame and concrete construction methods, it is roughly L-shaped. Behind the inverted corner of the warehouse, there is an 11,000 sq ft energy centre, which is partly modular in construction: the shell is ‘stick built’, but much of the plant inside was supplied on pre-fabricated utility skids. Moloney said: “Using the utility skids meant that as much plant equipment as possible – steamboilers, chillers, water purification systems, etc – could be fabricated and tested in contractors workshops and then brought to the site. This emphasis on modular construction helped lessen the time required on site getting the facility ready.” When work on the Carlow VBSF project started, Merck & Co – known outside the US and Canada as MSD – was the world’s eighth largest pharmaceutical company and employed about 500 people in the Republic: 350 employed at MSD (Manufacturing) in Ballydine, Co Tipperary and the remainder employed at MSD (Human Health) in Leopardstown, which is a centre for sales, marketing and other strategic activities. MSD became the world’s

The achievement of a million man-hours without an LTI was achieved only as the result of a constant commitment by everyone onsite towards embracing a positive attitude to safety,” said Sean Moloney, an Associate Director with PM Group


Irish Building Magazine


In the last five decades, MSD


invested €2.2 billion in


second largest pharmaceutical company at the end of 2009 when it merged with Schering-Plough and, as a result of the merger and further expansion, the company now employs a total of 2,300 people in the Republic. MSD manufacturing locations in Ireland now also include: Rathdrum, Co Wicklow, established in 1961, now employs 300 people in the manufacture and development of active pharmaceutical ingredients (APIs), which are currently exported to 20 countries for formulation to the final dosage form. Swords, Co. Dublin, employs more than 500 people, chiefly in the manufacture of a range of women’s health products, specifically in the area of fertility and contraception. This facility’s role is being expanded to include medicines in new therapeutic areas and MSD has selected Swords as a facility for the manufacture of a range of new medicines being launched in the next two years. Brinny, Co. Cork, established in 1980, is an API and sterile manufacturing centre of expertise employing more than 500 people. Generating sales in excess of €2 billion a year, Brinny

Welcoming Merck Sharp & Dohme to County Carlow in 2009, Cllr. Denis Foley, Cathaoirleach & Mr. Tom Barry, County Manager present welcome scroll to Mr. Willie Deese, Executive Vice President & President of Merck Manufacturing Division.

exports to 90 countries. Following a €28.6 million investment, two new facilities were opened here this year, the Brinny Biosassay Centre of Expertise and the Brinny Pneumoccocal Vaccine Conjucation Facility. Additionally, last year, MSD established a shared business services (SBS) centre in Leopardstown, Co Dublin, employing 150 people supporting the company’s activities in the EMEA region. MSD Animal Health, based in Tallaght, Dublin 24, supplies vaccines and pharmaceutical products for cattle, sheep, pigs, dogs, cats, horses, poultry and agriculture in the Republic and Northern Ireland. Repeat business In the last five decades, MSD has invested €2.2 billion in Ireland. As with all pharmaceutical companies, MSD likes to work with trusted long-term partners and many of the contractors working on the Carlow project had worked with the company previously. PM Group had previously worked with MSD on a number of projects at Ballydine. Moloney said: “Safety is always a key focus on all MSD projects and is also a core value in PM Group so from the outset there was very good synergy and common objectives in the management team. A lot of effort was put in to establishing an open, cooperative safety culture amongst the many project stakeholders. The emphasis was taken away from ‘policing’ conformance to safety rules and regulations and instead was placed on changing people’s attitudes to safety so that when a person is planning a job the first thing they think about is how to do it safely. This paid great dividends in terms of meeting the safety objectives for the project.” “We started on the Concept Design in February 2008 and submited for Planning Permission in June. Carlow County Council dealt with all issues expeditiously and there was very good proactive engagement with neighbours and land-owners adjacent to the site resulting in planning permission being granted in mid September

MSD 2008.” A key element of PM Group’s design role was the coordination and integration of the modular production building provided by Pharmadule with the all the supporting facilities which were designed by PM Group. As Construction Managers for the project, PM Group retained sub-contractors for each of the major elements of the work. PJ Hegarty & Sons carried out the Site Development and Building Works. Radley Engineering did the Mechanical work as well as installation of the Production Building Modules. JRE Group and Kirby Group did the electrical work while the HVAC and Fire Protection works were carried out by Dornans and Mercury Engineering respectively. There were over twenty construction subcontractors for the various other elements of the work. Three months after breaking ground some 200,000m3 of soil cutting and filling had been carried out, piling and concrete works were underway and structural steel erection started. The support building was ‘weathered’ by May 08 and the Production Modules were installed from June to December 09. Mechanical Completion was achieved in May 2010.” At present, the majority of PM Group’s work is overseas but Moloney said: “We are seeing a little increase in activity in the Irish pharma and biopharma sector. Clients in this sector are quite clear about their expectations from contractors: if you meet or exceed their expectations they will work with you again and recommend you to other companies.” PM Group is recognised as a world leading provider of project management and design services to the biopharma industry. Moloney said: “We have an in-depth understanding of the biopharmaceutical industry and a proven project execution model. We help clients around the world to plan and execute state-of-the-art facilities. The result is faster time-to-market for products, and innovative cost effective facilities designed for future needs”. Delivering High Standards of Quality Management Building energy management system (BEMS) contractors Sirus first worked with MSD in 2008 and since then the relationship has grown to the stage where MSD now has a master services agreement with Sirus, who have offices in Cork and Dublin. In Carlow, Sirus were responsible for the installation of the Validated Siemens BMS system. This system consisted of 14 qualified (GMP) air handling units managed by a Siemens Desigo Insight Front end hosted on a 2 node Cluster server arrangement and various non GMP utilities skids. These skids are connected to the HVAC plant over a number of networks using MODbus protocol which is in turn converted to BacNET. The topology consists of 35 BACnet/IP compatible controllers housed in 29 control panels , networked to 2 servers for management and archiving. “Each of the systems goes through a series of strict Quality testing protocols; installation qualification (IQ) site acceptance testing (SAT) & and operational qualification (OQ), incorporating all aspects of the BEMS control and how it handles temperature ,humidity, pressure control and Quality critical alarming “ says Sean Skelly, Project Manager. “One of the reasons that have won repeat business with MSD, and other pharmaceutical Clients, is our attention to quality .All our engineers are GMP trained and have many years experience in the HVAC & BMS sector. As part of our quality control we generate our own Quality documentation. This in turn is adopted by companies like MSD. MSD are looking for quality and safety in their day to day work and at Sirus both these are Paramount to us” r

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email: 27

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MSD Ireland’s largest Roofing and Cladding contractor. Building Excellence for a century Preferred contractor of Merck Sharp & Dohme “SIAC Roofing and Cladding strive to exceed our customers’ expectations”

SIAC Roofing and Cladding Limited SIAC House, Ballycurreen Cross Airport Road, Co.Cork. T. 021 431 1322 F. 021 496 6779

BS EN ISO 9001:2008

Please visit the SIAC Group at

Imtech Suir Engineering Ltd. Imtech Suir Engineering Ltd. is one of Ireland’s leading providers of Electrical, Mechanical and Instrumentation services. Suir Engineering was established in 1984 and remained in private ownership until October 2007 when it became part of the Imtech Group (Imtech NV). Imtech N.V. is a European technical services provider in the fields of electrical engineering, ICT and mechanical engineering. Imtech, with approximately 23,000 employees, achieves annual revenue of over 5 billion euro. Imtech Suir Engineering Ltd. is proud to be associated with Merck Sharp & Dohme over the past 28 years. We acknowledge the positive impact that MSD has on our economy and community and would like to wish them every success in the future. Imtech Suir Engineering Limited Unit 9A Cleaboy Business Park, Old Kilmeaden Road, Waterford.


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Imtech Suir Engineering’s core competence centres on Electrical, Instrumentation and Mechanical Installations across a wide variety of sectors. These sectors included : • • • •

Pharmaceutical , Biopharmaceuticals & Medical Devices Power Generation , Power Distribution , Renewables Industrial , Food and Beverage, Health Care, Data & IT , Oil & Gas

Web: Tel: +353 51 359500 Contact : David Phelan


MSD - Ballydine - 35 years of success


The MSD plant in Ballydine, Co Tipperary, has been placed at the heart of the pharmaceutical company’s future development plans with the opening of a new €100m R&D centre there. ounded in 1975 as a producer of active pharmaceutical ingredients (APIs), the Ballydine plant, near Clonmel, now has increased importance within the world’s second largest pharmaceutical company, now that MSD, which is known as Merck & Co in Canada and the US, has opened a new R&D centre at the site. Ballydine continues to produce APIs: it produces compounds that are exported to some 30 different MSD formulation sites across the world, with four of its main products being worldwide supply for the active ingredients for use in the formulations of the asthma dug Singulair, the osteoporosis drug Fosamax, the migraine drug Maxalt and the cholesterol-lowering drug ZOCOR. With the opening of the R&D centre it will also now support the manufacture of Phase IIb, Phase III and IV clinical supplies for drug product formumations and will be involved in the process development and scale up activities, the registration, validation and launch of new products followed by supply for the first two years of market requirements nominally. The new facility has boosted employment by 70, bringing the total number of workers there to 450 employed directly by MSD and additional 70 who are employed by contractors but who work permanently at Ballydine. The new R&D facility has the ability to produce finished drug products with roller compaction , direct tabletting, and coating technologies included in the new facility . Once a new product has been successfully launched from Ballydine, mass production will be switched to other sites and Ballydine will turn its focus to the development of the next innovation in MSD’s development portfolio. In-built flexibility allows the facility to develop and manufacture one product and then, with reasonable ease, switch to manufacturing another, says Aidan Hennessy, who was project manager on the design and construction for PM Group. This company with offices in Dublin and Cork in Ireland and Internationally in the US, UK, Western and Eastern Europe,the Middle East and Asia.regularly worked with MSD in Ireland and abroad and, indeed, more than 80% of the projects handled by PM Group’s Cork offices are for bio-pharma clients. Hennessy said: “The 10,000sqm facility includes a three storey manufacturing area with 3,000sqm of cleanrooms, a two storey labs and office building and low bay warehouse. The three-storey areas are known as vertical stacks, with different steps in the manufacturing process taking place on each floor. The facility design allows flexible manufacturing, so that the process can be changed easily depending on the product requirements. For example product charged on the top floor can pass through various equipment options on the middle floor before being collected on the ground floor. The equipment is designed to be interchangeable and importantly capable of being replicated for easy transfer of products to other MSD sites. “Additional future flexibility is also provided by the fact that each of the manufacturing areascan be extended in a modular fashion.” MSD Ireland (Ballydine) General Manager David O’Connell said: “We have about 20 products in late stage development in the company, five of which are being given top priority by the company, and three of these five top priority programme –

medicines for treating hepatitis, insomnia and hypertension – are being developed here by us. In the year that we celebrate 35 years of successful operations at Ballydine, the site has now evolved to be firmly rooted in R&D commercialisation, which will enable us to bring new and innovative medicines to the patients who need them faster. From a site perspective, this underpins Ballydine’s strategic importance within the MSD global network and significantly increases and diversifies the level of high-profile

research and development conducted at the site, which, in turn, is the lifeblood for the growth of the company and the life sciences industry as a whole.” The €100m development was supported by the IDA, who have been targeting the pharmaceutical industry for inward investment since the 1960s. When Ireland joined the EEC in 1973, there were less than 2,000 people employed in the sector in Ireland and exports amounted to less than €100m a year; now the life sciences sector directly employs 50,000 people in Ireland and last year our net medical and pharmaceutical exports exceeded €24bn, making Ireland the world’s largest next exporter of pharmaceuticals in the world. “We have established Ireland as one of the leading locations for the development and manufacturing of pharmaceuticals and biopharmaceuticals,” said IDA chief executive Barry O’Leary at the official opening of the centre in September. “This investment is yet another demonstration of MSD’s continuing commitment to Ireland. The Ballydine site plays an increasingly strategic role in delivering MSD’s pipeline of drugs and is an excellent addition to the southeast region.” Construction Work on the centre began in October 2007, with planning permission granted on first application, which O’Connell said was a credit to the design team and the efficiency of South Tipperary County Council. Hennessy said: “The project was mechanically

The new facility has boosted employment by 70, bringing the total number of workers there to 450 employed directly by MSD and additional 70 who are employed by contractors but who work permanently at Ballydine 29

Irish Building Magazine


Building your new facility is not just about teamwork. It’s about a team that works. PM Group works with the world’s leading firms, conceiving, planning, designing and delivering state-of-the-art facilities wherever in the world they are needed. We work as a team that integrates seamlessly into your team to create a multi-disciplined, highly experienced, expert group totally focused on the successful delivery of your facility.

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15/08/2011 09:09:55

Cleanroom Design, Construction and Maintenance

HVAC, Mechanical Services and Clean Room Specialist Contractors 30 years supplying engineering services to high tech industry in Ireland and abroad. Rockwell’s strength is it’s people. Twenty one of our team have an average service of seventeen years with the company. The team at Rockwell are ready to be your partner.

Providing high quality Cleanroom Finishes to MSD in Clonmel, Carlow, Dublin and Cork For further information, please contact: Asgard Cleanroom Solutions Ltd, Unit E, Sark Business Park, Purcellsinch Industrial Estate, Dublin Road, Kilkenny.


Tel: + 353 (0) 56 7771 771, Fax: +353 (0) 56 7771 701 Email:

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• • • •

• • • • •

Areas of Expertise Clean Rooms and GMP Facilities HVAC Distribution Ductwork Systems Energy Management & Heat Recovery Specialist Extract & Dust Control Systems Services Provided Project Management, Turnkey Projects Design Development and Innovation Project Build Certification & Commissioning Maintenance & Support Contact: Martin Conheady or Jim Devaney on + 35326 20040

Rockwell Engineering, Millstreet Rd, Macroom, Co. Cork.


complete after 17 months of construction and commissioning activities commenced about 10 months after construction start, so there was a significant overlap between design construction and commissioning.” The construction team faced a number of challenges. The new facility is located on low-lying land, near the River Suir. ‘There was extensive site preparation work that had to be completed before construction could commence properly” said Hennessy. “The weather that winter didn’t help with poor ground conditions and high winds delaying the erection of the structural steel and we had to put various work around solutions in place to keep the project schedule on track’. “Another challenge was the fact that we were building next to a live manufacturing facility this required careful co-ordination with the existing plant as we leveraged utilities, including steam, chilled water and purified water, from the existing site infrastructure. As part of this project, we also upgraded the purified water system and we put in a new fire-water retention system.” Work progressed rapidly and the new facility was commissioned and qualified in 2009 and since then it has been through a gamut of development runs, stability runs and clinical testing. It was licensed by the Irish Medicines Board (IMB) in November 2010 and it passed a pre-approval inspection by the US Food and Drug Administration (FDA) in May this year. “We were very pleased with the result of the FDA audit,” says O’Connell. “In that process, it is possible for them to issue notifications of conditions that need to be implemented before approval can take place. The FDA terms these notifications 483s (in reference to the form used by the agency). We received compliments from the FDA on the design, qualification and systems built to operate this new facility with zero 483 notifications issued and a recommendation for approval first time through.” The building is designed to be expanded in modular fashion, as and when required, with ‘break outs’ possible on either side. With the total Ballydine site covering 188 acres, there is plenty of room to extend the 10,000m2 building. O’Connell says that it was a straight-forward build with the biggest challenge being that the R&D centre is located on land that was at a different grade to other buildings on the site. A pro-active effort to create a strong safety culture during the construction period helped ensure that lost time incidents (LTIs) were minimised during the build. The centre has its own warehouse, receiving area, despatch area and cafeteria and much of the equipment that you would expect to find in a pharmaceutical formulation and finishing facility:

Mr. David O’Connell, Plant Manager, MSD Ireland (Ballydine), Mr. Willie Deese, Executive Vice President, President MMD, An Taoiseach, Enda Kenny, TD.

blending and compression machinery, roller compactors for certain products and film coating equipment. Notably, however, it also has a bi-layer compression capability that allows for the production of tablets containing two different layers of medicine, allowing for two drugs to be taken in a single dosage that vastly improves patient compliance. Also, the facility is fitted with process analytical technology (PAT) that allows for the real-time monitoring of the production process, especially the blending of APIs and excipients, which are pharmacologically-inactive substances that are used in a variety of ways to provide ‘bulk’ to tablets or to ensure that APIs are released into a patient’s body rapidly or gradually, as required. “This is the first time that we have filed a new product using the Quality by Design (QbD) filing approach” said O’Connell. “It is also the first time we have used PAT to validate and routinely track blend homogeneity before compression using online measurement of the blend with near-infrared spectroscopy.” Another notable feature of the building is the floor used in the production areas , which have a highspec epoxy terrazzo finish. The material used is similar to glass in appearance when installed, but is extremely hardwearing and has anti-static and self-smoothing properties, two qualities ideal for a clean room environment, while also being able to withstand rigorous cleaning regimes. Supplied by a UK company, Flowcrete, and installed by Cork-based Ancorite Floor Protection, installing the floor was a labour-intensive process that also required strict environmental controls. The project enjoyed a good safety record, during peak activity there was about 320 construction workers on site and during this period more than 250,000 man-hours were worked without a losttime incident (LTI). In many ways, the establishment of the R&D Centre represents a further milestone for MSD and for the Ballydine facility, says Willie Deese, Merck & Co Vice President and President of the Merck Manufacturing Division. He said: “The decision to locate a worldwide pharmaceutical R&D centre in Mr. David O’Connell, Plant Ballydine was due to a number of factors, chief among which was Manager, MSD Ireland the credibility, track record and expertise of the Ballydine team, (Ballydine) the technology and infrastructure at the site and the support we have received from the Irish government and IDA Ireland.” r


Irish Building Magazine


Two new facilities at MSD Brinny keep site at value end of market Two new developments at MSD’s Brinny Plant in County Cork have secured the location’s reputation as a biotechnological centre of expertise, as well as adding to MSD Ireland’s reputation for procuring capital projects efficiently and safely. CIAN MOLLOY reports.


wo new developments at MSD’s Brinny Plant in County Cork have secured the location’s reputation as a biotechnological centre of expertise, as well as adding to MSD Ireland’s reputation for procuring capital projects efficiently and safely. CIAN MOLLOY reports. The two new facilities in Cork, the Brinny Pneumococcal Vaccine Conjugation Facility and the Brinny Bioassay Centre of Expertise, represent a financial investment of €28.6 million and will result in the creation of 70 high-skilled jobs. They are “a tangible manifestation of the site business transformation plan” that was announced by the company last year, said MSD Brinny General Manager, John Howell. “As a site we are continually focussed on our costs and our operational excellence. The locating of these two facilities at Brinny underlines the strategic importance of this site within the MSD global network.” Notably, for the PCV facility, the time between breaking ground on the site and achieving installation qualification (IQ) and operational qualification (OQ) was only 19 months, while there were no lost time incidents (LTI’s) for a 12 month period during construction. This achievement has been noted by senior company personnel and bodes well for future MSD projects in Ireland, says Howell. “From a business point of view, the speed of delivery between committing to a capital spend, the delivery of that capital infrastructure and the start of commercial production is critical in the pharmaceutical industry. Sales of a successful new product

can be worth several billion dollars a year, so a one month delay can be worth millions of dollars. There is also a high attrition rate in the industry for Research & Development (R&D) projects. The ability to construct the necessary facilities rapidly, at late stage and at low cost, reduces the overall financial risk of bringing new products to market.” “The collaborative team structure that existed between Merck and Jacobs Engineering was extended to the contractors, where the requirement for an accelerated construction programme was achieved by an extended working week as part of the base contract conditions. In addition, when weekend or late night working was required, this was reviewed at the daily construction meetings amongst all stakeholders as a means of achieving scheduled work in a safe and controlled environment,” said Aidan O’Dwyer of Jacobs Engineering. The official opening took place, with the Minister for Research and Innovation, Seán Sherlock TD, performing the formalities in a ceremony that was attended by Dr. Mike Kamarck, President of Merck BioVentures and Senior Vice President of Merck & Co Vaccines and Biologics Manufacturing, along with other senior Merck & Co personnel and representatives of the IDA. The project engineers on the vaccine conjugation facility were Jacobs Engineers with civil engineering by Bowen Construction. Project engineering on the Bioassay Centre was completed using the site based team along with architectural input from McElroy Associates and some other discipline expertise provided by DPS

As a site we are continually focussed on our costs and our operational excellence. The locating of these two facilities at Brinny underlines the strategic importance of this site within the MSD global network 33

Irish Building Magazine

Jacobs Engineering Ireland Limited Jacobs Engineering Ireland Limited Mahon Industrial Estate, Blackrock, Cork Tel: +353 21 4515777 Fax: +353 21 435 8977 Merrion House, Merrion Road, Dublin 4 Tel: + 353 1 269 5666 Fax: +353 1 269 5497 Contact: Ken Gilmartin Director of Business Development Email: Jacobs, with over 700 employees in our Cork, Dublin and Belfast offices, has over 37 years experience of successful project delivery in Ireland. We offer our clients the full range of Architectural and Engineering Professional Services, from Concept through to Final Handover of the validated facility including safety, cost and schedule. • • • • •

• •

Full Service Project Delivery Site Master Planning Project Management Architecture Engineering o Process o Civil / Structural o Mechanical / Electrical o Automation o Piping Construction Management Commissioning & Qualification


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Engineering. Other companies involved in the projects included Asgard on clean rooms, HA O’Neil on mechanical and HVAC works, HG Construction on civil works and Provincial Sprinklers on fire control equipment. Founded by Schering Plough in 1985, Brinny is one of the longest established pharmaceutical facilities in the southwest, but it has been part of MSD (known in the United States as Merck & Co) since November 2009 when the two companies merged. When originally established, Brinny was set up as a centre of excellence for the manufacture and quality assurance of biotechnology-based pharmaceutical products and the facility includes large-scale fermentation, purification, sterile-manufacturing and qualitycontrol operations. For the 500 people working at Brinny, the developments are a vote of confidence in their abilities. Howell said: “When two companies come together there are significant competitive pressures as the new entity works to eliminate duplication and achieve synergies. To meet that challenge, we launched a competitiveness plan for the Brinny site in September 2009. As part of this plan, we reorganised our site along Lean Manufacturing principles, introduced new process efficiencies and improvements using Lean Six Sigma and diversified our activities. To compliment our traditional manufacturing mandate, we have identified value-added services we can offer our parent company. As part of this diversification, we have developed a Bioassay Centre of Excellence and clinical manufacturing capacity for Pneumococcal Conjugate Vaccine.” The Pneumococcal Vaccine Conjugation Facility makes Brinny central to MSD’s status as the leading supplier of adult pneumococcal vaccine globally, having distributed more than 140 million doses worldwide. Pneumococcal disease is an infection caused by the bacteria Streptococcus pneumoniae and there are more than 90 different types of pneumococcal bacteria, some which cause localised infections such as middle-ear infections, and some which cause very serious disease such as pneumonia (an infection of the lungs), meningitis (an inflammation of the lining around the brain), and septicaemia (blood poisoning).

These bacteria are a major cause of illness and death, particularly Dr. Mike Kamarck, President amongst the very young, the very old or those with weakened Merck BioVentures and Senior immunity. The Brinny facility will produce vaccine for clinical Vice President, Vaccines and trials in immunisation against pneumococcal disease for paediatric Biologics Manufacturing at Merck use and will initially employ 30 highly-qualified technicians. Once & Co. Inc., Mr John Howell, clinical trials are completed, the facility will have the capacity to General Manager, MSD Brinny produce 100 million doses of pneumococcal conjugate vaccine and Minister for Research and a year. The vaccine has the potential to immunise against the 13 Innovation, Séan Sherlock TD most common types of pneumococcal disease. Notably, the construction and fit-out of the Pneumococcal Vaccine Conjugation Facility eschewed the stainless-steel equipment and fittings normally used in pharmaceutical sterile environments and instead it uses single-use disposable plastic fittings, connections and bags. In addition to avoiding the capital cost associated with stainless steel, leveraging single-use technology meant that the Pneumococcal Vaccine Conjugation Facility had a shorter qualifying period than would normally be the case, something that allowed for the expedited delivery of the project. The bioassay facility builds on Brinny’s 20 years For the 500 experience of working in this area and the new people working Bioassay Centre of Expertise will focus on bioassays for therapeutic protein products. It will support other at Brinny, the MSD sites, including the newly commissioned €200m developments vaccine and biologics formulation and filling facility in Carlow. Bioassay, short for biological assay, is the are a vote of term used to describe experimental tests to measure confidence in the effects of a substance on a living organism and the discipline is essential in the development of new drugs. their abilities The Brinny Bioassay Centre of Expertise is involved in MSD R&D projects across the globe where it takes drugs in development and conducts tests to find the best versions using cell lines. “Another factor that aided the accelerated procurement was that the Bioassay Centre of Expertise is housed in a building that already stood on the site and had been acting as a fully functioning laboratory,” said Donal Kelleher, MSD Brinny’s Facilities Management & Engineering (FM&E) Site Lead. “However, this


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MSD meant that there was significant traffic management required during the construction period as the building site was right next door to our sterile facility and to our warehouse facility. We also spent quite a lot of time surveying the area to give us a high level of confidence that we wouldn’t run into cabling or utilities when work began – construction was taking place next to a live production facility and it was vital that production would not be interrupted at any stage. “There wasn’t much change needed to be done to the existing building, apart from some minor internal modifications to allow for the installation of the bioassay laboratory facility and associated equipment and utilities. That said there are always issues to be dealt with when you are dealing with an older building.” With respect to retrofitting the vaccine facility, O’Dwyer said that dealing with a legacy building created a number of challenges. He explains: “Because of the age of the building and the modifications made to it over the years, there was a requirement to verify the relevant engineering drawings and decide on what equipment and utility services would be maintained or replaced. In addition, because of the accelerated capital acquisition programme being used, gutting the building and preparing it for construction started two months before the design was finalised and when the construction programme commenced there was still detailed engineering design to be completed. The project team were constantly working to fit the design into the construction conditions present on the site. Again the integrated team structure of MSD, Jacobs and the nominated contractor staff ensured that there was minimum disruption or rework to the construction programme. Jacobs Engineering, with offices in Cork and Dublin, employs more than 1,000 engineers in Ireland and 60% of company revenue comes from the pharmaceutical and life sciences sector. The company has had a long-standing relationship with MSD and is currently the pharmaceutical company’s engineering services provider in Ballydine and Carlow. Looking at the design of the project and the completed building, Howell says they will continue to provide value to the company for many years to come: “The design for both the retrofit and the

new vaccine conjugation facility were based on Lean Six Sigma which ingrains both effective and efficient process operation.” Among these inbuilt efficiency measures are variable frequency drives on air handling systems and passive infrared sensors on lighting to ensure that lights aren’t used when no one is present in part of either building, along with the appointment of designated ‘energy champions’ within the workforce to promote energy efficiency. Both buildings also have a great deal of inbuilt flexibility and the design has allowed for easy re-configuration should this be required thanks to conduits that are preinstalled in their ceilings. The Technical Operations Laboratory is also equipped with an advanced IT system that allows online process support to the local team. In the vaccine conjugation facility, bottle filling has been automated where previously this was done manually. “Not only does this reduce costs, it mistake proofs the process,” said Howell. “The Lean Six Sigma process is about improving quality and staying focussed on operational excellence. This reduces waste and and creates a better, safer work environment. “We work in a pharmaceutical industry environment where there are significant competitive pressures from low cost countries and outsource providers. As a result, we need to stay lean, stay relevant and be at the value-added end of the business. We are constantly working to grab new opportunities and to leverage our historical skill set.” r


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building on a Quality reputation One of the contractors on the MSD Brinny extension project was HG Construction (IRL) Ltd, a civil engineering building company that is experiencing steady year-on-year growth. Cian Molloy speaks with Mr. Ronnie Hennessy MD


onnie Hennessy says his company is doing reasonably well in the current environment thanks to a strategic decision to concentrate on project work for core clients and because of the company’s ethos which focuses on quality, reliability and safety. Founded in 2003, the company was born out of RH Maintenance, a separate company founded specifically to provide maintenance services to the pharmaceutical industry sector in 1986 by Ronnie’s father, Ronald Hennessy Snr. Ronnie said: “That company is still trading very successfully, but we were regularly getting enquiries from core clients if we were interested in taking on larger building projects and, my philosophy is ‘If it isn’t broken, don’t fix it’, so we set up HG Construction (IRL) Ltd to take on construction projects. Although separate, the two companies complement each other and work very well together.” Synergies between both companies allow us to provide our clients with many benefits such as we can provide a greater depth of resources that can be utilised as required, and at short notice, while maintaining the same level of quality and safety. HG Construction (IRL) Ltd is a member of the Construction Industry Federation, Homebond, and the Master Builders and Contractors Association and all employees are registered with the Construction Workers Pension Scheme. These affiliations are important to us as we set the highest bench mark for quality in the delivery of our works and services and fully recognise that we trade on our reputation of quality workmanship. “We’ve done very well by sticking to project work – during the housing construction boom when there was a lot of money to be made in development, we made a decision to stick at what we were good at it so we didn’t become property developers or to start investing in property,” said Ronnie. “As a result, and very fortunately, that has meant we are still in a strong position and we have a good business model. More than 90% of our business is repeat or referral. The company, based in Watergrasshill, Co. Cork, has worked hard on building a reputation for quality and reliability. “We are a relationship based company and invest time in building strong and lasting relationships based on trust, integrity and reliability.

We believe that our focus on providing value for Money is our key differentiator in the current climate. We are not a firm that sends in a big variation bill at the end of a contract,” says Ronnie. “We pride ourselves on working within budget and have a dedicated fulltime management accountant to ensure that we do that. In the pharmaceutical industry, you could say that all projects these days are accelerated projects, but nevertheless we try to complete the work ahead of the agreed deadline – that way the client is happier and the rewards for us are greater. To ensure everything is on schedule, we have a hands-on approach to managing work-in-progress with a weekly meeting to review how we are doing on all projects and to identify any problems as early as possible so that they can be dealt with. “Maintaining direct links with clients is paramount. The site management team together with a dedicated directly employed workforce of foremen, tradesmen, skilled general operatives,

Mr. Ronnie Hennessy MD

“We are a relationship based company and invest time in building strong and lasting relationships based on trust, integrity and reliability. We believe that our focus on providing value for Money is our key differentiator in the current climate” long serving sub-contractors, plus an excellent office back up, reinforces the strong resolve of the company to produce quality and value for its clients.” “We also have our own in-house designated Quality Manager and our own Standard Operation Procedures to ensure quality, which are certified to the ISO9000 quality management standard. We believe that the quality of our management systems has been a key factor in our successful development and growth. Additionally, looking at our success at winning repeat business in the pharmaceutical area, we have built up specialist knowhow in working in clean environments. We also pay attention to building a relationship with clients and to fitting in with their

Pic Left: Richard Cashman (Financial Director) Martin O’Shea Health & Safety Officer, Mr Joe O’Brien (Centre) of the CIF presenting the Safe T Cert to Ronnie Hennessy MD and Ronan O’Regan Projects Director.


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HG Construction (IRL) Ltd way of working. For example, typically a pharmaceutical company like MSD will hold a safety briefing and a plant induction for all contractor personnel before any work begins. We also have our own dedicated safety officer and the company has earned the prestigious Safe T Cert for the construction industry.” The company employs 20 full-time members of staff, hiring extra workers on temporary contracts when needed. While working on the recent project at MSD Brinny it had some 20 workers on site, including part-timers. MSD Brinny’s Facilities Management and Engineering COE Lead Donal Kelleher said he would recommend HG Construction (IRL) Ltd. “They have done a good amount of work for us. They are a relatively small company, but are very flexible and very willing to work with the site management to ensure all work is to our requirements.” To illustrate the constraints that apply to working in a pharmaceutical plant as opposed to any other industrial or commercial development, Ronnie says: “Working in sterile environments and clean rooms requires strict adherence to mandatory procedures for all personnel including subcontractors under our control.

other micro-organisms, all that work was successfully completed under negative pressure regimes. “The majority of our clients are in the Pharmaceutical / LifeSciences sector – as well as MSD Brinny and Schering Plough before them, we have also worked for Leo Laboratories, GlaxoSmithKline Ipsen and Cara Partners. In addition to the Pharma sector HG Construction (IRL) Ltd are also involved in Industrial, Hotels, Healthcare, Offices, Schools, Colleges, Sports facilities, Civic centres, Food Manufacturing and Commercial sectors. “HG Construction (IRL) Ltd has a built up a strong reference list of successfully completed Projects in the Munster region. Many of these have been for Government, State and Local Authority bodies and agencies; included in this list would be Cork City Council, Cork County Council, Cork VEC, University College Cork, Cork Institute of Technology, the Department of Defence and FAS More recently we’ve worked on pedestrian bridges at Doneraile Park for the OPW, refurbishment of the FÁS offices in Cork and the building of a the new Community Centre just outside Midleton. In addition we have a strong list of private sector clients that rely on us for their civil engineering project requirements including: Irish Life The HG Construction (IRL) Ltd Team outside their offices in Watergrasshill, Cork. Investment Managers, Sisters of Charity and First This work is generally carried out under a very tight timeframe, Plus Pharmacy Group. We also carry out bond work for Quinn in difficult working conditions and in conjunction with various Insurance. specialist contractors who we have to work side by side with to HG Construction (IRL) Ltd have experience with working with the complete the work. HG Construction (IRL) Ltd also have proven major Architectural, Civil Engineering and Project Engineering experience in providing services to the Medical Sector and recently companies including RKD Architects, JODA Engineering completed a project with Mercury at Cork University Hospital. Consultants, David Kelly Partnership, Johnson Controls, KOBW This project included new bulk gas and oxygen storage tanks and Architects, Mott MacDonald, Malachy Walsh and Partners control systems and where the work involved cutting through Horgan Lynch Consultant Engineers, Ger Neff Designs and internal facility walls for distribution pipe networks – to ensure Jacobs Engineering Ireland Ltd. that there was no possibility of contamination from aspergillus or As a client focused company we provide fully adaptable services to meet the specific needs of our clients. We tailor our execution strategies to meet and exceed these needs. We work in difficult environments, at nights and week-ends and alongside on-going production / manufacturing facilities to achieve successfully deliver these projects. All of our work is supervised by Civil Engineering and Site Management personnel. We have a prestigious Safety Record which is our companies highrest priority. “Until now, we’ve mainly been active in Munster, but we are now trying to extend our reach up into Connaught and Leinster and we believe that our excellent reputation will stand us in good stead as we look for new business.” We recently completed a project in Ipsen Manufacturing Ireland in their Blanchardstown facility. r

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T2 A Complex Beauty Europe’s newest aviation gateway, Terminal 2 at Dublin Airport, resolves the chronic passenger congestion problems that had bedevilled the airport in recent years while also giving the country an iconic new building. CIAN MOLLOY reports on what is being hailed as the 2010 public building of the year.


erminal 2 at Dublin Airport was not only the largest construction project in the history of the state, arguably it was also one of the country’s most complex. Constructing a high-spec, high-tech 1million sq.ft. development in the middle of a fully-functional airport was the engineering equivalent of open heart surgery, says Colm Moran, Dublin Airport Authority’s chief asset management and development officer. “People don’t realise how sophisticated and complex a building it is,” says Paul Coughlan, a director with Arup, who were the lead consultant and design engineers. “The public see the exterior and the interior fit-out and finishes, but that isn’t really the airport terminal. The airport terminal is the systems that make it work and the building is wrapped around those systems, all of which have to be fully integrated and working together.” Moran adds: “There are some 200 different systems working within the building, ranging from the baggage handling to the BMS, the BES and the zoned fire alarms. The baggage system comprises 6km of conveyors – there is not a factory line in Ireland that would use that amount. Further complexity was created by the fact that the terminal has a US immigration and customs pre-clearance facility, the second after Shannon outside North America and the Caribbean, and all the details in the construction of that area had to be signed-off in advance by the US Department of Homeland Security. The main security area also had to be designed to be

as flexible as possible to allow for any future changes in airport regulations.” Systems sophistication aside, there is no doubt that the silver-clad terminal, with its sweeping curved exterior walls and roofs has been given an eye-catching design by architects Pascall+Watson. Inside, the interior is bright, airy and spacious, with natural lighting from overhead and sweeping exterior views via the glazed walls at either end of the building. The overall effect is calming and is a marked contrast to the low-ceilinged, artificially-lit environment found in Terminal 1. Moran adds: “In addition to increasing the natural lighting, the central glazed channel overhead is like a way marker that acts as a guide to take you from airside to landside.” The new terminal building, which had a construction cost of €600 million increases the airport’s passenger capacity to more than 30m passengers a year. Almost 50% of the airport’s passengers have transferred to T2 and Terminal 1 is now much less crowded thanks to the neighbouring facility. In addition to the 750,000sq. ft. terminal, with its 58 check-in desks, 18 x-ray machines and 18 immigration booths, the project also includes Pier E, a 250,000sq. ft structure providing the airport with 25 new departure gates. From the exterior, it is obvious that Terminal 2 is a building of two elements, with a wide connecting bridge between the two and an approach road bisecting the structure. However within the building one feels no sense of division between the two areas. Moran says: “The road passing beneath the building is one of the cleverest pieces of the design. The airport road layout now forms concentric circles that allow vehicles to approach Terminal 2 without going near Terminal 1 and vice versa, it’s an excellent

There are some 200 different systems working within the building, ranging from the baggage handling to the BMS, the BES and the zoned fire alarms


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TERMINAL 2 DUBLIN AIRPORT Pier E Shell & Core / Terminal 2 & Pier E Fit-Out

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T2 solution that substantially reduces traffic movements. Previously, in another role, I had worked on the airport master development plan and a good traffic circulation within the campus was always one of the greatest challenges. The project team of lead consultant engineers Arup, architects Pascall+Watson, construction managers Mace and independent cost consultants Davis Langdon PKS, was appointed in February 2006. Founded in 1946, Arup is one of Ireland’s leading consulting engineering practices, employing 300 people in this country and the practice has extensive experience in working on airport projects – currently it is involved in building airports in Azerbaijan and Kuwait and it is advising on the transfer of ownership of two Spanish airports. P+W is a specialist in transport project design and its portfolio includes work on more than 20 airports. Planning permission was granted in August of that year, but following appeals final planning permission wasn’t granted until August 2007, with construction work starting on 1st October that year. One of the first challenges facing the team was mapping the existing infrastructure and deciding what was redundant and what needed to be salvaged. Moran said: “There were hundreds and hundreds of cables and we couldn’t assume that any of them were dead and no longer in use, each had to be checked and, if necessary moved. The survey also found fuel reservoirs that had once been used by car-hire operators and which needed to be dealt with.” The first concrete pour was in February 2008, starting with T2’s energy centre, which required several 12-hour long pours – the centre is a big advance on the turf-fired boiler room that heated the original Desmond FitzGerald-designed terminal building (which is considered Ireland’s most important pre-war building in the International Style). Steel erection started a month later and by September 2008 the structure was ready for cladding and glazing, an operation carried out largely by a Portuguese-Irish consortium comprising Martifer, Mota-Engil and Coffey Construction. “It was a landmark contract for the Portuguese companies as it was their first big contract outside the Iberian Peninsula,” said Moran. “They brought more than 200 of their own people over to do the job and they delivered on time and on budget.” Once the building was made watertight, work on the interior could begin and PJ Hegarty & Sons, and engineering firm that has

earned a reputation for quality with such projects as the Dublin Criminal Court Complex, the Elysian Apartments in Cork and Fingal County Hall, was given responsibility for the fit out. “We were responsible for everything you see inside the Terminal and Pier E, the floor, the walls, the ceilings, all the glass, the furnishings, the desks and the chairs.” says PJ Hegarty & Son’s director Declan O’Grady. “The architect chose a colour scheme inspired by the Irish landscape and presented use with a concept design and then we presented the clients with a range of options that met their brief. For example, the floor was to be brown and speckled and easy to maintain and we provided a range of possibilities that fitted that brief. There was extensive consultation and complete mock-ups done of nearly everything before a final decision was made – we had a complete, fully-functional, toilet block built in a warehouse and had all the stake holders, the airport operator, the maintenance people, come to look at it and give their views on what worked best. “One innovation within the building is the fabric ceiling – it looks like plasterboard, but is lighter and has a seamless finish. Because of the speed of the procurement, extra care was needed to protect some of the sensitive finishes, as the materials were being stored in an unheated building.” In addition to fitting out the terminal building, PJ Hegarty & Sons were also the contractors on Pier E, a three-storey building that is 425m long, with 11 nodes serving 19 airbridges and 25 gates. “We took from concept design and built the entire building from ground up to the final finishes,” said O’Grady. “Working in a live airport environment close to aircraft taxiways required detailed co-ordination with the airport operations team throughout the entire construction programme. There was also the challenge of installing the 25m link-bridge between Pier E and the Terminal, which required the escalators to be installed first and then the structure and finishes to be built around the escalators. “We had about 70 staff working on the project and more than 1,000 sub-contractors, with the vast majority of them and our suppliers being Irish, for example the desks are provided by Fitzgeralds of Kells. There was a great interest in this project, because it was a landmark building and also because 1million square-foot projects don’t come around that often.” Moran said: “I don’t think there was a county in Ireland that didn’t have a company that was involved in either sub-contracting or supplying materials to the project. It was a great generator of

PJ Hegarty & Son’s were responsible for everything you see inside and

the Pier

Terminal E,


floor, the walls, the ceilings, all the glass, the furnishings, the desks and the chairs


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At the peak of our activity, we had 740 people on site, with a project office staff of about 90 people. We also had a team employment.” Nevertheless, O’Grady said: “It was a challenge to procure everything within quite a tight time frame – this was a period when the Irish construction industry was still busy and there is a substantial amount of resources needed for a fit-out of this size. Certainly, it was the biggest project that I’ve ever been involved in.” The baggage handling system was supplied and installed by Siemens and it is a credit to the project team that the terminal suffered none of the embarrassing problems that affected Heathrow Airport when failures in the baggage handling system led to flight cancellations and thousands of passengers travelling without their luggage. DAA public affairs director Paul O’Kane said: “We avoided baggage handling problems because we put a strong focus on staff training and because we did practices involving sending grab bags, suitcases and golfbags, hundreds, maybe thousands, of times through the system. We also had a dress rehearsal in October, a month before we opened and became operational, where nearly 4,000 members of the public volunteered to come up to the airport to help us test our systems – we checked them in, took their baggage, passed them through security and put them on a plane, before taking them off the plane, past immigration, into the baggage reclaim area and out to the arrivals hall and then did that all over again. That cooperation from the public helped ensure that everything worked on the first day we were open for business and then once we were open we didn’t do so at maximum capacity, we built up activity on a phased basis to ensure that everything worked smoothly.” Aer Lingus were the first carrier to use T2 and it now also serves American Airlines, Continental Airlines, Emirates, Etihad Airways, US Airways and Delta. Apart from the baggage handling system, all other mechanical and electrical systems were installed by Mercury Engineering, with director Frank Matthews describing it as ‘a very complex project’. He said: “The systems installed included: more than 27km of ductwork, 102 BMS control stations and more than 5,000 BMS interfaces; 30km of LV cabling, 10km ELV cabling and 5km MV cabling; 400 distribution boards and more than 7,000 circuits, 47km of pipework and 1,100 plus valves; 14,000 fire alarm devices plus 2,000 third-party fire alarm connections; 16,000 lighting fittings and 3,500 emergency lighting fittings; a sprinkler system with 18,500 sprinkler heads and 66km of pipework

and 1,500 data points with 70km of data cabling. “Integration of all the systems into the building system integration (BSI) module was a major challenge, but we were helped by using a 3D modelling tool for services co-ordination and offsite modularisation and pre-fabrication to minimise site works and complete works on schedule. The BSI involved providing a common platform to access, control and monitor a wide variety of sub-systems including: the vertical and horizontal transport management systems, the building management system, the CCTVs, the live safety systems, lighting control, baggage handling and power management. At the peak of our activity, we had 740 people on site, with a project office staff of about 90 people. We also had a team of 14 safety officers working with the DAA, Arup, MACE and the other key contractors to deliver a safe working environment for all site employees and Mercury was responsible for the project supervisor construction stage (PSCS) during the intensive building period.” While the requirement to keep the airport open and fully-functional during the three-year long construction period was critical, safety was seen by all parties as an even more important issue, not only for the construction workers but for all of the airport’s users: one lose piece of building site debris had the potential to cause catastrophic damage to aircraft or aviation equipment. Remarkably, thanks to an excellent safety culture, during one phase of construction there was more than two-million man hours worked without a lost time incident (LTI), said O’Kane. “We had a bottom up and top down approach to promoting a very strong safety culture, so there was safety leadership and a team approach, with everyone not only

of 14 safety officers


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At its peak, Terminal 2 was the largest construction project in the state, employing up to 2,600 workers on site.


Irish Building Magazine

responsible for their own safety but for the safety of those around them. There were 20 reportable incidents with the loss of three days work, but there were no serious accidents. “There was a dedicated five-minute period set aside three times a day where people stood down and cleaned and tidied the area around them. We had standardised personal protection equipment (PPE) for everyone – gloves, glasses, boots and high-visibility vests. If you were seen without your PPE, you were immediately stood down. We had regular town hall meetings on safety and we sponsored a painting competition for the children of site workers on the theme ‘Safety at T2 – Bring Daddy Home’. We also got all 17 of the main contractors to contribute funding, which the DAA then matched, towards providing raffle prizes when we hit key milestones, such as half-a-million accident free hours. When we reached the two-million hours without an accident milestone, we raffled a car!” At its peak, Terminal 2 was the largest construction project in the state, employing up to 2,600 workers on site. During three years eight times a year of construction, more than 10,400 men and women were involved “When you build infrastructure like this, you are not building for in the project. Coughlan said: “As a project director you are present day capacity,” said O’Kane. “In fact Terminal 2 is designed taking on a huge responsibility for the safety of people when you so it can be extended when required with another pier, Pier F, to embark on a major construction project. Your worst nightmare is the south of the terminal. The original terminal was completed that someone will get killed or seriously injured and construction in 1943, T1 was built in 1973 and T2 in 2010. The longterm is a dangerous business. We worked worldwide trend is for air travel to increase and Dublin Airport more than 10million man hours and is the tenth busiest airport in Europe at present for international had no serious injuries or fatalities – traffic. Importantly, unlike other major infrastructure projects in that in itself is a huge success for the the state, T2 was completely funded by the DAA, there was no cost to the taxpayer. When you are building infrastructure like project.” The other major success is the this, you are building for the capacity you will need in 10, 20 or 30 contrast between arriving and years time. T2 is a building that is designed to meet Ireland’s air departing at Dublin Airport through travel needs for the next 50 years and, from the feedback we’ve T2 and making the same journey received, it looks like it will do that very successfully.” r through T1 just over five years ago. In the mid-1990s, Dublin Airport was operating at almost Jetway Systems® full capacity during peak travel periods, Congratulations to Dublin Airport on the with long queues successful completion of T2. at check-ins and Jetway® is proud to be a part of the Dublin Airport’s security gates. T2 has relieved congestion design and construction team for the T2 project. in the old terminal building, while T2 Delivering Excellence Since 1959 itself has an interior decor that speaks of modernity, quality and quiet calm. The new terminal has the capacity to handle 15 million passengers annually, thereby allowing the airport to handle more than 30 million passengers a year. As the terminal approached completion, naysayers were declaring that T2 was an unnecessary piece of infrastructure as the economic downturn had caused passenger numbers to plummet. However such criticism misses the point of infrastructural investments, which are for the long term rather than merely the next year or two. Passenger numbers at Dublin increased by 2% to 16.2 million in the first ten months of this year. No doubt, when the economy finally does recover the increase in numbers will be even more rapid. In addition to Jetway® Passenger Boarding Bridges holidaymakers, because of Ireland’s open economy Jetpower® 400Hz Ground Power Units there are a large number of people who regularly fly in and out of the country on business and, at present, the average Irish person flies more than

Jetaire® Preconditioned Air Units

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1/9/2012 3:57:13 PM

New Products & Company Showcase


Sealant specialist Geocel is relaunching a new improved version of one of the most popular Dow Corning sealants on the market, 794. The new sealant, known as Dow Corning 799 boasts all of the qualities which have made 794 the market’s favourite glazing and curtain walling sealant, but with some improved characteristics to make it even better. Specifiers, applicators and professional tradesmen have trusted Dow Corning 794 since its launch in the 1980s for its excellent, consistent quality. Its newly formulated replacement, Dow Corning 799, will continue to meet the toughest specifications but with a number of significant improvements including improved and advanced adhesion to PVCu. The new Dow Corning 799 is a one part, neutral curing clear sealant that is ideal for use with polycarbonate sheeting and as a perimeter pointing sealant for door and window frames since it demonstrates excellent adhesion to the majority of porous and non-porous substrates. Because Dow Corning 799 has excellent weathering characteristics - including resistance to ozone, UV radiation and temperature extremes- and guaranteed no slumping it will give a long lasting and high quality finish to any glazing application and will not experience any of the discolouration, or “yellowing” issues common with many clear sealants. Its impressive movement capability means new Dow Corning 799 offers ± 50% joint movement capability, allowing for the expansion and contraction of glazing substrates and enabling it to cope with a wide variety of applications especially since it cures tack free in just two hours. It conforms to BS5889 Type A, the British Standard for low modulus silicone sealants. Geocel combines a wealth of innovative technical and manufacturing expertise with a strong commitment to quality in sealants and adhesives. This is matched with the experience and excellence of Dow Corning in its field of silicone technology. For more details contact: - Annette Lewis, Geocel Ltd, Tel: 0044 1752 202060, e-mail:

Rockwool Launches RockShell Wall System Rockwool, the world’s largest producer of stonewool, has launched a new exterior load bearing wall system which integrates high levels of insulation into its design to deliver an energy efficient solution to the Zero Carbon challenge – while keeping wall thickness to a minimum. Passivhaus certified, the system achieves a typical U-Value of 0.143W/m2K, making it an ideal specification for projects targeting superior thermal performance or higher levels of the Code for Sustainable Homes. RockShell is delivered to site in ‘kit form’ according to the specified building design. Constructed of I-shaped steel profiles encompassed in heavy Rockwool insulation and an OSB lining on the inside, RockShell is quick and easy to install and requires no specialist equipment. Matthew Bromley, UK Business Manager for the RockShell Wall System, explains: “In simple terms, RockShell takes the insulation that would traditionally be used for wall cavity insulation and turns it into part of the load bearing structure. In doing so, far superior levels of thermal performance can be achieved without increasing wall thickness. From a compliance perspective, system performance has already been proven with Passivhaus certification.” Suitable for buildings up to two and a half storeys and with most types of foundation, RockShell has also been designed to offer maximum flexibility in building design and simplicity of installation. For example, the system interfaces with many common building components while the exterior can accept most types of finish, such as render and cladding. Rockwool has underpinned the launch of RockShell with comprehensive technical support, which includes a detailed building manual, access to the local technical team for specification guidance and project meetings as well as a free design service. For further information on the RockShell wall system please visit www. or email

KMT becomes exclusive distributor for Lakes Bathrooms Shower enclosure specialist, Lakes Bathrooms, has announced the appointment of KMT Wholesale Limited as the exclusive distributor for its products in Eire. KMT now stocks a complete range of Lakes Bathrooms’ shower enclosures, low profile ABS and lightweight SMC shower trays, bath screens and accessories from the Classic Collection, new 8mm Coastline Collection and the Safety and Comfort range. KMT serves merchants and retailers supplying the bathroom and kitchen market in Eire, with Ian A Kernohan representing Lakes Bathrooms in Northern Ireland. From its south eastern head quarters in Thomastown, County Kilkenny, KMT delivers ex-stock to all 26 counties in the Republic of Ireland. Lakes Bathrooms products will now be the only shower range stocked by KMT, as the deal sees the distributor ceasing a long relationship with an Italian manufacturer. Explaining the decision to lead with Lakes Bathrooms, KMT’s managing director, John Kent, said, “Price and quality are the key factors for KMT. We have built our reputation on offering the best quality products and service, but in this market we must also be competitive in terms of price. Having researched the entire market our view is that Lakes Bathrooms is the manufacturer that offers the best combination on price and quality; offering really unbeatable value for money with stylish products that are supremely well built. We have been very impressed so far with the introduction of shower enclosures, doors, trays and screens from both the Classic and Coastline Collections. The reaction from our customers has been very positive and we have displays going up rapidly across the country. Certainly a great start - but this is just the beginning of what we expect will be significant demand.” For more information visit or contact KMT on 056-7724308 to request the KMT/Lakes Bathrooms exclusive brochure.

Extra low U-value Kalzip roof system Kalzip has developed a new dual-insulation roof system that achieves U-values as low as 0.09 W/m²K. This technically proven, low U-value roof system is extremely cost effective and utilises the combined benefits of two complementary types of insulation materials - mineral fibre quilt and Kalzip Insulation 23 high performance rigid polyisocyanurate (PIR) board. Combining these two insulation material enables a significantly greater overall thermal resistance to be achieved compared with using just a single layer of mineral fibre of the same thickness. The new low U-value system is based upon standard Kalzip standing seam roof build-up configurations that have been further developed to comply with anticipated changes to Part L of the Building Regulations due in 2010 and to satisfy the ever-tightening design limits on thermal performance levels demanded for modern construction. .. For more information and a copy of the new ‘Kalzip low U-value roof system’ product review, please visit www.kalzip. com or Email:

Customers to Benefit from Dedicated MyFreefoam Website Freefoam Plastics, the market leader in environmentally friendly, innovative roofline and rainwater products, has launched a new customer-focussed guarantee website www.myfreefoam. com that includes a number of exciting new features for its customers. This new website replaces the original guarantee website and includes features such as the ability for customers to view registered installation statistics, edit guarantee details, order marketing materials and generate guarantee certificates. In addition all the original features, such as the ability to register installations and update contact details, are still in place in a new streamlined website with improved navigation to make it quicker and easier for customers to use. Freefoam offers a range of market leading product guarantees that help Freefoam stockists and registered installers maintain their competitive advantage in a challenging market. Having had many years of trouble free performance in all weathers from Scotland to the South of France with its lead free formulations, its proprietary COLORMAX® technology and its extra TiO2 UV protection, Freefoam offers an extended, transferable 30 year guarantee on all white roofline, cladding and rainwater products that are registered online. Freefoam’s standard guarantee on white products is 20 years, while its guarantee on coloured and foiled products is a market leading 10 years. Aidan Harte, Managing Director, comments “We’re delighted to launch at this time as it provides our customers with a range of exciting new features that makes their jobs easier and tools that help them maintain their competitive advantage in a challenging market. The guarantees we offer result from our investment in research and development over many years and have led to the innovative UV resistance and colour technology in our products. We plan to continue innovating to meet the building product needs of our customers for many years to come.” For further information and images please contact: Brendan Hyland, 021 4911043,


Disability rights campaigner Gerry Maguire MBE is enhancing his knowledge of people’s toileting needs through personal experience.. Gerry has cerebral palsy, works parttime for his local Health Trust, and plays a major role in Northern Ireland championing the needs of disabled people who make up 20% of the province’s population- work which has been recognized through his award of an MBE*. Now, he has added toileting needs to his agenda, partly as a result of his own experience, having a Clos-o-Mat Palma Vita ‘wash and dry’ toilet being installed under a Disabled Facilities Grant at his Enniskillen home. The Clos-o-Mat, which looks just like a conventional WC, features integral douche and drying facilities, all operated by simple hand or body pressure on the flush lever. When the lever is pressed, the unit flushes and simultaneously automatically warm-water washes the user, then dries him or her through its built-in warm air drying facility. Full details are available on the company’s website

Lakes Bathrooms moves to new premises Continued growth for shower specialist Lakes Bathrooms has seen the company relocate to new, significantly larger premises. The move doubles the space for Lakes Bathrooms to a total 60,000 square feet and consolidates its four existing Gloucestershire sites into one much larger head quarters. Still based at Tewkesbury in Gloucestershire, Lakes Bathrooms is now adjacent to the M5 motorway, in a modern building that combines office and warehouse space for the full range of the manufacturer’s shower enclosures and associated products:  the Coastline Collection, the Classic Collection, shower trays and the Safety and Comfort range. “Sustained business growth and the overwhelming success of our new Coastline Collection means that we need much more space,” said Robin Craddock, managing director of Lakes Bathrooms.  “In the last year we have launched Coastline and two new ranges of shower trays.  We’ve also added to our hugely popular Classic Collection.  The breadth of our portfolio of products and the volume of demand means that we continue to invest in significant stockholding – essential to ensure we can keep our 24/48 hour delivery service across the UK.” Lakes Bathrooms reports that the move went to plan, with no interruption to business.  Its £1m value of stock has now all been transferred and will be expanded to provide a minimum of eight weeks worth of product to fulfil demand, with the fastest moving lines stocked to even higher levels.  From its new headquarters, Lakes Bathrooms will operate its fleet of 14 delivery vehicles nationwide. Robin Craddock says; “Our strategic approach has always been careful and considered in terms of stability, yet proactive and positive in terms of growth.  We are confident that our new premises will provide flexibility to accommodate not only our extensive existing product range, but also for all the new products we have in development.” For more information visit

The new pump with XVARI technology! End of time-honoured hydraulic foot pump with linear air motor is near. Hydraulic pump technology is undergoing its definitive change. The new Enerpac XA-series air driven hydraulic pump with XVARI(r) Technology. The breaktrough in hydraulic pump technology and ergonomics. A tremendously high delivery, accurately controllable and ergonomic, three characteristics of the new pump with XVARI(r) Technology developed by Enerpac. The XVARI(r) Technology replaces the popular and widelyused linear air motor technology and, besides strongly improved ergonomics and a more accurate metering of the hydraulic oil flow, also offers a higher delivery and higher efficiency. Enquiries: Enerpac Ltd., Bentley Road South Darlaston, West Midlands, WS10 8LQ, UK. Tel: +44 (0) 121 50 50 787, Fax: +44 (0) 121 50 50 799, Email:

The best way to reach decision makers in the Irish Building sector is to reach for the phone and call Colin Walsh, on 01 4429264 or email

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Irish Building Magazine  

Irelands leading business read for building professionals.