Case Study: Emergency High Altitude Solution for a Virginia Airport

Posted on March 28, 2024 in Case Studies, Scaffolding

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Dulles International Airport is one of the world’s largest airports, servicing the DC-metro region and beyond.  The air traffic control tower – the watchful eyes 330’ in the air ensures the safety of thousands of passengers daily. Recently this tower suffered an unexpected and highly critical window issue that required immediate attention. 

But how do you replace a window 330’ up in the air?

This is where Scaffolding Solutions took flight. 

The Challenge

The original contractor was unable to complete the job, leaving Dulles International Airport in a bind. A safe solution was needed and it was needed quickly. Scaffolding Solutions developed a solution that utilized a suspended scaffold platform (swing stage) that was hung from atop the tower.

This project presented several unique challenges:

• Tight Schedule: Due to the urgency of the situation, Scaffolding Solutions had to develop a plan and execute the project within a timeframe significantly shorter than the usual planning period for such a complex job. To plan and prepare for a job of this magnitude would usually take up to a month – we got it done in 2 days. 
• High-Security Environment: Working on the control tower required navigating stringent airport safety and security protocols to ensure the unimpeded flow of personnel and air traffic.
• Wind Load Concerns: The scaffolding needed to be erected at a height of 330 feet, where wind presented a critical challenge. Material movement via crane had to be precisely coordinated to avoid interfering with air traffic.
• Minimal Disruption: Scaffolding Solutions needed to ensure the project caused minimal disruption to ongoing air traffic control operations. Sticking to the schedule that was already in place from the previous contractor was essential in preventing any flight delays or cancellations. 

The Solution

Scaffolding Solutions rose to the challenge with a multifaceted solution:

• Swift Response: Our team sprang into action, immediately planning the project, securing permits, and mobilizing resources to meet the tight deadline. The airport already had a timeline in place when we were brought in and we had to quickly execute with no time to waste. In total, the project took us 5 days to complete – 2 days to plan, 2 days to execute, and 1 day to clear the site.
• Safety at Every Altitude: Working 330’ in the air, safely managing wind load issues as we stocked and de-stocked the tower required a highly coordinated effort by the whole team. A crew of highly skilled and safety-focused installers were assigned to the project, ensuring the well-being of the airport staff and safety personnel, tower management, airport management, head of maintenance, construction personnel, electricians, security team, control tower workers, and, of course, our staff as well.
• Custom Scaffolding Solutions: A swing stage with roof rigging, along with a combination of system scaffolding, was chosen specifically to address the control tower’s unique architecture and towering scale.
• Clear Communication and Coordination: Scaffolding Solutions maintained open communication with the contractor, Dulles Airport personnel, and air traffic control. This ensured everyone was aware of the project timeline, safety protocols, and potential airspace limitations.

The Result

Despite the urgency and complexity of the project, Scaffolding Solutions was able to complete the job on time, on budget, and most importantly, safely. The airport staff, the general contractor, and our crew were able to work together efficiently while adhering to strict safety protocols. Dulles Airport operations continued uninterrupted – the project didn’t cause any delays or interfere with the takeoffs or landings of any planes – and the necessary window repairs were completed quickly.

“Dulles Airport celebrated that the project did not cause any delays to the airport nor the landing and takeoff of airplanes. Work was completed 100% to the plan that was presented.” 

~ Frank Giuliano, Scaffolding Solutions

Scaffolding Solutions successfully and safely installed several systems, including a swing stage with roof rigging and a mixture of system scaffolding to fit the unique needs of the jobsite. Carolina Classic and Dulles Airport were extremely pleased with the results of this complicated project. Thanks to meticulous planning and execution, the job was completed on time and on budget with minimal disruption to airport operations – not just meeting, but exceeding their expectations.

Let Scaffolding Solutions Help You Tackle Your Next Scaffolding Install Project

The Dulles Airport Emergency Project is a prime example of Scaffolding Solutions’ unwavering commitment to safety and exceptional service. Even in a high-pressure situation with critical deadlines, our focus on ensuring the safety of workers, air traffic controllers, and the public never wavered. This dedication to safety is at the core of everything we do.

At Scaffolding Solutions, “safety” isn’t just a slogan – it’s a promise. Whether you’re 20’ in the air or 330’, safety is paramount. Our Scaffolding Solutions team members are all highly trained and dedicated to following strict safety protocols on every project – keeping you and your team safe at any job site.

We go beyond industry standards with comprehensive training programs, weather-resistant materials, and dedicated risk managers assigned to every project. Our meticulously planned installations adhere to strict OSHA guidelines, and thorough safety briefings ensure everyone on-site understands the protocols. We also utilize state-of-the-art equipment, including the innovative Turner OCTO® system and Bee Access suspended scaffold systems, for maximum stability and worker protection.

Partnering with Scaffolding Solutions goes beyond safety. We offer exceptional service and adaptability. Our team takes the time to understand your specific needs – from navigating oddly-shaped or complex structures to preserving historical buildings, we’ll craft a custom solution just for you. Together, we’ll find creative solutions to get your project done right, on time, and within budget. Choose Scaffolding Solutions – your trusted partner for safe and successful work at all heights.