Projects:

Dublin Airport

Design, Build & Installation

As part of broader upgrade plans at Dublin Airport’s South Apron, the Dublin Aviation Authority (DAA) began relocating key infrastructure to make space for future expansion. This included moving critical airside operational facilities and upgrading the supporting assets.

We were engaged directly by DAA during the early design phase to support the specification and integration of two essential systems: a Potassium Acetate (PA) storage and pumping system for airfield de-icing operations, and a new foul waste (Honey Pot) disposal facility to serve aircraft sanitation vehicles.

This project sits alongside other development work undertaken by third parties, including new animal welfare building and bin wash facilities, bus parking and waste compactors. We were appointed as the specialist contractor for our expertise in airport chemical delivery systems and for our track record in design-led delivery.

COMPLETION DATE

October 2025

PROJECT TIMEFRAME

April 2025

DELIVERY MODEL

Design, Build & Installation

Key Partners

  • Sulzer
  • Crest Pumps
  • Tuffa Tanks
  • DAB
  • Enduramaxx

Project Scope

We were responsible for the full mechanical and electrical design, off-site fabrication, and on-site installation of two systems:

Potassium Acetate System

A relocation and upgrade to the airport’s existing de-icing infrastructure, the new system includes four 15,000L chemical storage tanks situated within a bunded concrete plinth and connected to a prefabricated pumping kiosk. The kiosk includes two Crest EOV 65- 50-125 pumps, a Siemens Mag 5000 flowmeter, fill and discharge hose connection points and a bespoke control panel. The system enables faster refills and has been designed for easy future maintenance.

Foul Waste Disposal Facility

This system includes a below-ground chamber housing dual Sulzer channel grinders, actuated penstock valves, and a bespoke spray bar with angled wash jets.

Above ground, a 3,000L buffer tank, twin booster pumps, and control panels provide a fully automated wash-down and waste processing solution. Our team delivered a complete turnkey package for the facility, including panel integration and civil interface support. There is also an upstand for hose connection for manual washdown of the grinders.

Solving the Problem

Delivering the project required close coordination between ourselves, Flynn and CJK to ensure that installation works aligned with ongoing civil construction activity and met stringent safety protocols. Working within a high-security, multi-contractor site meant that precise planning and timing were essential.
 
Our confined-space qualified engineers safely carried out installation within the foul waste chamber using certified access equipment, gas monitors and a tripod rescue system to ensure compliance with the highest safety standards. To support the safe handling of heavy components, we deployed our own Porta Gantry system to assist with lifting and positioning of equipment.
 
Pre-fabrication of the potassium acetate pumping kiosk and the use of modular components helped streamline installation, reducing complexity and minimising the amount of work required on-site.
 
We used 3D modelling to visualise the site and highlight critical level changes within the chamber, allowing for more accurate design and improved collaboration among stakeholders.
 
Ongoing communication between us and the main contractors ensured that installation works remained on schedule, especially when the site became airside and required additional security measures and access limitations.

Outcomes & Benefits

  • Improved refilling speed for de-icing vehicles
  • Fully automated foul waste disposal and wash - down system
  • Local control panels adjacent to grinders for easier maintenance
  • Reliable, resilient systems delivered safely on a complex site

Through early engagement with DAA, we were able to leverage their airport systems experience, help to create a highly functional, easily maintained design, reflective of their currently used systems that will enable efficient ground operations at Dublin Airport for years to come.

Technical Specifications

  • 4 x 15,000L chemical tanks (Tuffa) – two of these were relocated from existing airside location
  • 2 x Crest EOV 65-50- 125 pumps (20m head, 25 m³/hr)
  • 2 x Sulzer Muffin Monster channel grinders (141 m³/hr)
  • 1 x Enduramax 3,000L water tank
  • 1 x bespoke wash- down spray bar with optimally angled jets
  • DAB Esybox twin booster pump (3.2 m³/ hr)
  • Local and main control panels with fault condition feedback
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