PROJECT OVERVIEW

The original design called for a plain precast concrete building, but the Airport Authority wanted something unique to show off the airport. The precast concrete producer suggested a total–precast concrete solution, satisfying their need for both speed and budget. He calculated the entire tower could be installed in five weeks, after which they could hoist the steel cab on top and finish the interior.

A total of 380 ft of LED ribbon lighting on the exterior further accents the sails. Designing the lighting to follow the dramatic sweeping lines of the architecture required a unique precast concrete wall-within-wall structure that was precisely engineered and constructed off-site.

Read more about this project in the Fall 2019 issue of Ascent.

PRECAST SOLUTION

Collaboration among the project team was extremely important to keep within tight tolerances and the detailed connections. Precast concrete provided a single source, which kept costs down. In Florida, designing with resiliency in mind means meeting hurricane standards. The precast panels are very solid with no room for infiltration.

Project Team

Designer

CTBX Aviation

Engineer

Airport Engineering Company

Contractor

Walbridge Aldinger Company

Owners

Melbourne Airport Authority

Precast Concrete Producer

STABIL Precast Products

Precast Concrete Erector

Concrete Erectors

Precast Concrete Specialty Engineer

Wes Frey Engineering

Key Project Attributes

  • The octagon-shaped steel cab atop Orlando Melbourne International Airport's new air traffic control tower offers commanding, 360-degree views of Florida’s Space Coast. During a typical week, the airport handles 1900 private aircraft flights and 167 commercial flights.
  • With a total of eight floors, the new tower includes electrical rooms on the bottom floor. The ascending levels feature training room, conference room, manager's office, telecom, Federal Aviation Administration room, and break room.
  • The eighth floor cab is for the controllers. The airport stayed fully functional during construction; all work was conducted around the nearby existing operational tower without creating any visual obstructions.

Project/Precast Scope

  • 93-ft precast concrete building
  • 38 exterior wall panels, 9 interior wall panels, 5 interior narrow wall panels, 36 floor slabs, 20 stairs and landings
  • 51,000-lb panels were stacked on top of one another to create the tower
  • Nine and a half foot ceilings throughout