15 m long x 7 m wide x 9 m deep ìvertical Conveyor foundation constructed 4 m below water table in coal wash fill and original swampy ground. Required braced sheet piling & ground water management.
Heavily reinforced machinery and building foundations totalling more than 2000 cubic metres with 2 pours in excess of 500 cubic metres.
2. Slainter Pnt Building Extension (OPUP, Ore Preparation Upgrade Project)
Construction of new 130 cubic metre column foundation inside the operating Sinter Cooler. The environment was extremely dusty with temperatures in excess of 50 degrees. All equipment, spoil and new material required lifting into and out of the work area using crane over the cooler. 8 steel UBP pipes were driven 22 metres to bed rock using hydraulic hammer suspended on overhead crane. This required the construction of guide frames at ground and 7 m levels.
Construction of new 100 cubic metre column foundation adjacent existing foundation under the operating Sinter Plant. The foundation was 6 m deep in fill material and constructed with only 2 meters of head room. Cast-in- situ concrete retaining walls were constructed in 2 stages in order to achieve the overall depth in a safe manner.
3. Coke Ovens Quencher. a. Cooling Water Tower Foundation.
6 x 9 m foundation with 6 steel driven piles constructed in the side of Coke Ovens rail line embankment.
Quencher Reconstruction. The existing coke quencher was extensively refurbished / overhauled and included
The manufacture of pre-cast concrete launders and wall panels.
Demolition of existing walls, launders and foundations.
Installation of pre-cast units in conjunction with cast-in situ foundations and launders. All to tight level & alignment tolerances with final grouting and water-tight sealing.
All work undertaken on 24 x 7 critical shutdown conditions with interaction with mechanical / structural / pipe work crews working overhead and in close proximity.
4. Boiler Island Foundation. (SAUP, Steam Asset Upgrade Project)
20 m x 35 m boiler foundation constructed adjacent to operational Boiler / Blower Station. Work included removal of existing structures, foundations, exposure of existing services and cooling water channels. 70 steel “Screw” pipes were driven 22 meters though difficult fill material. New service conduits were installed into existing underground electrical cable and cooling water ducts. The foundation included in excess of 150 Hold Down Bolts positioned precisely for mechanical and structural equipment. A total of 480 cubic metres poured in 3 stages.
5. Lysaghts Electrical Switchroom
Construction of a new electrical control room between an operational / live High Voltage Switch Yard on one side and operational Cold Rolling Mill on the other.
Location, removal / relocation of existing services.
Demolition of existing structures.
Construction of new rooms including concrete foundations and structural frame.
Cladding, insulation, fire resistant lining and fit-out.
Work was undertaken in basement, ground and roof levels with strict control of access though operational areas.