The replacement roof at Pearse station in Dublin presented one of the most challenging engineering projects undertaken by John Sisk & Son (Sisk) in recent years.
As the busiest commuter station in the Iarnród Éireann network, with more than 30,000 daily passengers, Pearse station needed to remain operational throughout construction. This required a highly innovative, safety-led, and precisely engineered approach to complete the work above live rail lines, without disrupting services or compromising passenger safety.
Historic roof
Originally constructed in 1834, with the roof added in the 1870s, the station’s main train hall spans nearly 157 metres in length with a single curved span of almost 30 metres. Replacing this historic roof while keeping the station fully functional demanded a unique engineering solution.
Early proposals considered 13 weekend rail possessions – which would have meant intensive overnight work and high-pressure deadlines. Recognising the logistical and safety implications, Sisk, in close collaboration with the client, developed a less disruptive approach.
A steel portal frame platform was designed and put in place over the platforms and the tracks, allowing the team to create a safe and segregated working area above the station. This innovative structure enabled weekday work, during daylight hours. The platform served as both a protective barrier for the railway infrastructure below and a staging area for roof removal and installation.
The heart of the installation method was, at its core, a modified knuckle boom crane – the type typically mounted on trucks – which was adapted and fitted to travel the length of the station on a steel frame. This crane enabled precise positioning of roof components without interfering with operations below. The old roof was dismantled in stages, then installed the new trusses in stick-built format, assembling each in three components before propping them into place.
Reduced fatigue
This method provided significant advantages: safer working conditions, reduced fatigue, and more predictable shift patterns for the teams involved. Importantly, it eliminated the high-risk, time-sensitive pressures associated with weekend-only rail possessions. It also improved quality control, allowing works to progress methodically rather than being rushed through condensed time windows.
The engineering complexity was considerable; however, Sisk have a proven track record of successfully undertaking these challenges. The project required the fabrication and installation of more than 4,500 steel components – with 3,500 individually unique – as well as 1,100 cladding panels and 2,300 glazing units.
In addition to the roof replacement, the scope of the Pearse Roof Project included drainage works, remedial repairs to the office roof, brickwork restoration, painting, demolition and safe disposal, and other associated site services.
The project was recognised with 'Project of the Year' at the 2022 Irish Construction and Engineering Awards, with more than 15,000 public votes, as well as the CECA Excellence Award category for projects costing more than €15m. This underlines the talent of the Sisk team and the engineering excellence that is evident across the business.