Further information and case study for this project can be found at the De Gruyter Birkhäuser Modern Construction Online database

The following architectural theory-based case study is not available at Modern Construction Online

Interior GRC Casings in the Midfield Terminal Building, Abu Dhabi – Sculptural Continuity and Technical Integration

Within the monumental interior of the Midfield Terminal Building (MTB) at Abu Dhabi International Airport, sweeping geometries and soaring structural volumes articulate a spatial identity that is both civic and symbolic. Central to this interior expression is the use of glass fibre reinforced concrete (GRC) casings that wrap the terminal’s massive Y-shaped columns. These sculptural enclosures not only conceal structure and services but contribute to a coherent architectural language, transforming infrastructural necessity into spatial performance.

Conceived by Kohn Pedersen Fox (KPF) and developed in collaboration with technical specialists Newtecnic, the GRC enclosure system operates at the confluence of design ambition, digital fabrication, and environmental performance. The project extends a lineage of material and constructional innovation explored in Watts’ Modern Construction Handbook (2023), Modern Construction Envelopes (2019), and Modern Construction Case Studies (2016), where contemporary design is increasingly driven by the integration of expressive form, digital production, and performance-led detailing. The façade system developed for this project served as a conceptual and technical precedent for the system implemented in Project 04, featured in the second edition of Modern Construction Case Studies.

Design Intent

The architectural vision for MTB sought to evoke monumentality and fluidity while embedding regional cultural motifs. The Y-shaped structural columns that define the terminal’s concourse required a design solution that would elevate them from exposed structural components to continuous architectural elements. GRC was selected not only for its capacity to realise smooth, flowing geometry, but for its ability to unify structure and space through surface continuity.

Rather than leaving the steel and concrete columns exposed, the design introduced GRC casings that expand into the interior like branching trunks—at once referencing the aerodynamic smoothness of air travel and the shifting forms of desert landscapes. These organic enclosures conceal complex MEP systems while contributing to the architectural narrative. The continuity of surface, articulated in gently curving forms, evokes the fluid lines of Arabic calligraphy and wind-shaped dunes, integrating structure and ornament into a single formal strategy.

Material Innovation and Performance

The decision to use GRC was guided by both aesthetic and technical imperatives. As Watts (2019) outlines, GRC’s formability, dimensional precision, and non-combustibility make it ideal for large-span interiors where fire safety and reduced structural loading are critical. Its lightweight nature enabled tall casings—reaching up to 20 metres in height—to be applied without compromising the primary steel frame.

Unlike precast concrete, GRC offers finer surface articulation and thinner wall sections, supporting both the geometric ambition of the project and its logistical execution. Fabricated in segments using CNC-milled moulds and assembled on site with concealed mechanical fixings, the casings achieve a monolithic appearance despite their modular fabrication. Thermal expansion, dynamic wind loads, and long-term durability were addressed through bespoke anchoring systems and substructures that allowed flexibility without visual compromise.

Watts (2023) emphasises the importance of off-site prefabrication for achieving precision in high-performance enclosures. In this context, the GRC system's reliance on controlled fabrication environments ensured consistency in colour, texture, and tolerance—critical for a building of this scale and visibility.

Historical Precedents and Material Lineage

Although the use of GRC in MTB is grounded in contemporary technology, its architectural lineage traces back to a longer history of expressive surface construction and prefabricated assembly. Antoni Gaudí and Rafael Guastavino developed thin-tile vaulting systems that unified structure and surface, establishing a paradigm of integrated, flowing geometries that inform the conceptual approach seen in Abu Dhabi. Their work laid a foundation for form-active construction in which material and spatial logic are co-dependent.

Pier Luigi Nervi’s experiments with ferrocement and thin-shell structures further advanced this logic in the mid-twentieth century. In the Palazzetto dello Sport (1957), Nervi demonstrated that prefabricated segments could be assembled to form seamless, spatially expressive interiors. This ethos is echoed in the GRC panels of MTB, where tolerance, modularity, and surface continuity are treated as both technical and architectural priorities (Nervi, 1965; Watts, 2019).

Kenzo Tange’s Yoyogi National Gymnasium (1964) similarly exemplified how engineering and architectural expression can be reconciled at monumental scale. Though based on tensile rather than compressive forms, Tange’s emphasis on civic clarity and material expressiveness finds resonance in the MTB’s curvilinear GRC casings.

More immediate historical parallels may be drawn from the innovative use of prefabricated concrete in infrastructure projects of the late 20th century, such as Minoru Yamasaki’s Lambert-St. Louis International Airport (1956), where expressive roof forms and repetitive structural systems created both visual rhythm and civic identity. Likewise, Eero Saarinen’s TWA Terminal (1962) at JFK Airport demonstrates the early convergence of structure, enclosure, and symbolic form—foreshadowing the contemporary use of digitally-fabricated enclosures in transportation architecture.

Structural and Constructional Integration

Integration between the GRC system and the primary steel frame was a key factor in the project’s success. Working from the contractor side, Newtecnic developed a detailed coordination model that reconciled architectural geometry with technical and constructional constraints. As outlined in Watts (2023), such integration requires not only close collaboration across disciplines but also an advanced understanding of material behaviour under variable loads.

A bespoke subframe was developed to interface between the GRC panels and the steel structure, allowing for the absorption of differential movement caused by thermal expansion and dynamic forces. The mechanical fixings were fully concealed, ensuring a visually uninterrupted surface while allowing for disassembly and maintenance access. Service hatches and access panels were embedded within the system, maintaining operability without compromising design integrity.

This approach exemplifies what Watts (2016) terms "performance-led detailing," where technical, logistical, and aesthetic demands are resolved through integrated system design.

Construction Strategy

The realisation of the GRC casings was predicated on digital precision and industrialised fabrication. Building Information Modelling (BIM) enabled exact alignment between architectural forms, structural elements, and MEP systems, reducing conflict and facilitating streamlined coordination. CNC-milled moulds were fabricated from the coordinated digital models, ensuring geometric fidelity in the production of GRC panels.

The panels were manufactured under factory-controlled conditions using spray-up techniques, resulting in consistent surface finish and mechanical performance. On site, scaffold towers allowed for installation in active construction zones without halting overall terminal progress. The segments were mounted to the subframe using pre-coordinated fixings, and joints were carefully finished to create a seamless monolithic effect.

As Watts (2023) notes, the success of such systems lies in their ability to balance off-site fabrication with on-site adaptability—an approach clearly demonstrated in MTB’s column casings.

Architectural and Spatial Impact

The GRC casings play a central role in establishing the spatial identity of the terminal. Their rhythmic repetition introduces a monumental cadence to the vast interior, guiding visual focus and establishing spatial hierarchy. The soft matte texture of the GRC responds to changing light conditions, diffusing daylight from clerestory glazing into an ambient glow that animates the interior throughout the day.

Strategically located, the sculptural columns support wayfinding and spatial legibility in a building of enormous scale. Rather than relying solely on signage or graphic cues, the casings function as intuitive orientation devices—merging visual impact with user experience. This reflects a shift in transport infrastructure design, where enclosure systems are no longer ancillary but contribute directly to architectural meaning and operational clarity.

Conclusion

The Midfield Terminal Building demonstrates how GRC can function as a high-performance architectural medium—simultaneously resolving aesthetic, structural, and environmental demands. Through its advanced technical coordination, material performance, and sculptural clarity, the interior cladding system extends a lineage of innovation that begins with Guastavino and Nervi and continues into the digital fabrication era.

As Watts (2019; 2023) articulates, contemporary enclosure systems must reconcile design complexity with buildability and performance. The MTB’s GRC casings exemplify this reconciliation, showing how industrialised processes can support spatial expressiveness at civic scale. The project confirms GRC’s relevance in 21st-century infrastructure, particularly in climates and programmes that demand resilience, elegance, and precision.

References

Banham, R. (1960) Theory and Design in the First Machine Age. London: Architectural Press.

Glassfibre Reinforced Concrete Association (GRCA) (2020) Design & Manufacture Guidelines for GRC Cladding. UK: GRCA Publications.

Nervi, P. L. (1965) Aesthetics and Technology in Building. Cambridge, MA: Harvard University Press.

Taylor, M. (2016) ‘Material Futures in Mega-Terminal Design’, Detail, Issue 6/2016.

Watts, A. (2016) Modern Construction Case Studies. 1st ed. Basel: Birkhäuser.

Watts, A. (2019) Modern Construction Envelopes. 3rd ed. Basel: Birkhäuser.

Watts, A. (2023) Modern Construction Handbook. 6th ed. Basel: Birkhäuser.