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25 May, 2017 4 min read

FAC’s Project Management Role in the Development of Dublin Port

Categories: Development

Dublin Port is a vital component of Ireland’s economy and is of national as well as regional importance for both trade and employment.


The Port occupies 260 ha of land at the city’s doorstep and is an integral part of the city’s infrastructure and critical to its economic functioning. The Dublin Port Company, who operate the Port, have prepared a Masterplan to guide its development to 2040.


The Masterplan presents a vision for future operations at the Port and critically examines how the existing land use can be optimised for greater gain and made more compatible with the future needs of the shipping and trade sector. A significant part of the Masterplan is the capital investment in reconfiguring the port to this end, and the Alexandra Basin Redevelopment project is one of the largest such capital projects; at over 300 million euro.


In conjunction with our consortium partners, O’Reilly Hyland Tierney & Associates (ORHT), FAC have been commissioned by the Dublin Port Company to deliver project management services for the implementation of these capital projects. Encompassing all stages of project delivery from design and formulation of project proposals, the administration of project documents and resources, monitoring of project activities and milestones, to the culmination of their successful delivery.


The following article offers an on-the-ground insight into some of the activities being undertaken by Mr. Declan Sullivan, a FAC project manager within the Dublin Port Capital Projects Management Office.


On Wednesday the 12th April 2017, the Dublin Port Company project management office, along with the main contractor on phase 1 of the ABR works at Dublin Port, RoadBridge/L&M Keating JV , visited ArcelorMittal to tour their factory in the Netherlands. ArcelorMittal are manufacturing the piles, one of the main components of the new quay combi-wall structure.


ArcelorMittal are the world’s leading steel and mining company, with 114 million tonnes of annual production capacity across 60 countries, and have worked on ports such as Rotterdam and Hull.


As part of their contract, RoadBridge/L&M Keating JV have ordered a large quantity of piles for the construction of the new quay walls for the Alexandra Basin Redevelopment (ABR) project, varying in diameter, thickness and length.


Manufacture Process

The steel arrives at the factory rolled up in a coil. The straps around the coil need to be removed safely by a machine (fig. 01) to ensure no accidents occur as the coil can spring open. Once open, the coil is placed into another machine to begin the manufacturing process of the pile. This machine rolls the coil out until it is flat (fig. 02). Once the end of the coil is reached, the next coil is rolled out and welded to the previous coil to the required length of the pile. Following this, the steel strip moves to the next phase on the machine which rotates the strip into the pile until the requested length is met, this is shown in fig 3. When this is completed the tubular pile is almost complete. The final step is to weld on the clutches to two sides of the pile (fig. 04), which will allow the sheet pile to connect to the tubular pile. Once the clutches are welded to the pile, the pile is complete and stored in ArcelorMittal’s yard until the delivery date.


What is a Combi-Wall?

A combi wall is made up of two main elements:


    1. Tubular piles which are the main retaining elements of the combi-wall, carrying horizontal loads from soil and water pressures and vertical foundation loads.

    2. Intermediary Z-type sheet piles transfer horizontal loads to the tubular piles.


The first delivery of piles from ArcelorMittal to Dublin Port Company was on the 01st November 2016. Piling works are ongoing at Dublin Port for the Alexandra Basin Redevelopment (ABR) project. Fig. 06 shows piling works on Alexandra Quay West (AQW).


Fig. 01 Straps of steel coil being safely removed


Fig. 02 Machine used to roll out the coil.


Fig. 03 Machine used to roll the flattened coil into the tubular pile.


Fig. 04 Clutches being welded to the tubular pile


Fig 05: Typical Combi Wall Plan


Fig. 06 Tubular Piles (Pile Length 33m) currently being installed on Berth 31 as part of the ABR phase 1 works by the main contractor RB/LMK.


To find out more about FACs project management role in the development of Dublin Port, please contact us on 01 6394836.


Categories: Development

FAC is a leading Chartered Town Planning, Development and Socio-economic Analytics Consultancy based in Dublin with an extensive project portfolio throughout Ireland. FAC has extensive experience in town and village renewal, town and village health checks, and settlement profiling.