SkellerupCommercial / Office / Industrial

Structural
Geotechnical
Civil
Environmental
Fire
Project Management
Design
Fabrication Design
Building Information Modelling
Quantity Surveying


THE PROJECT

Project Floor Area:  18,900
18,900 m2
Project Budget: 48,000,000
$48,000,000
Project Year: 2016
2016

For over 75 years Skellerup has operated from a site that had a number of isolated buildings. When earthquake damage forced a strategic relocation they used the opportunity to create a new distribution, manufacturing and administration complex that would bring everything under one roof, with better integration of services and capability to handle growth.

This project was very large, complex and comprised six key distinctive areas:

  • Office and laboratory
  • Moulding hall (including moulding plant and processing, trim and inspect, de-flash)
  • Industrial hall (rubber plant and mixing facility, rubber processing)
  • Raw materials (eg. carbon black, carbon white, etc.)
  • Engineering and amenities (internal engineering and design facilities plus amenities to support operations)
  • Distribution (warehouse and logistics)

THE CHALLENGE

The Skellerup building provided challenges from both a design and a detailing point of view. The sheer scale and weight of the mechanical equipment to be supported required out of the box methodology to allow for both installation of plant machinery and construction of the supporting structure.

We were also tasked to redesign the building and entire scope of works to meet the needs of our client and reduce the construction budget from the previous preliminary design carried out by other parties.

“Project Viking is a complex engineering and construction project which has required innovation from its concept through to completion“


THE RESULT

The Skellerup complex has a commanding presence in the Wigram Business Park, not only in its foot print scale but the towering height of the general facility and office building, plus the 18m tall industrial hall that houses the new rubber processing facility at the south end of the building.

Through the process of innovation in the construction and design methodologies of the building, we were able to reduce the foundation costs significantly, increasing the height and size of the building by using more efficient structural construction techniques. We completely integrated the three-storey plant structure into the superstructure, while still reducing overall costs. Savings of several million dollars were able to be made!

The building was designed using BIM modelling which allowed us to control and produce documentation from concept through to fabrication with controlled QA held by the design team throughout the project. This allowed early procurement of subcontractors and enabled changes to occur with accuracy and coordination as final factory information came through from our client due to the fast track nature of the project.

This project was successful due to a team effort, completed under a design-build contract with Calder Stewart Construction. Early contractor collaboration meant the design of the facility was tailored to allow for significant construction efficiencies to reduce overall project cost and construction time frames. We were responsible for the review of construction sequencing, temporary works and lifting to ensure the highest levels of health and safety were maintained.


THE SOLUTION

Project Viking is a complex engineering and construction project which has required innovation from its concept through to the final delivery of the project. The building was master planned and BIM modelled (incorporating all plant, structure, services, machinery etc.) to ensure all components of the facility were accounted for in the design and construction.

The demanding nature of the Skellerup building required that all disciplines of the build were modelled using state of the art building information management techniques or BIM modelling. Literally thousands of aspects had to be coordinated with the superstructure to millimetre accuracy to allow proper function of the industrial plant. Each part of the building required integral design along its two hundred-metre length to ensure efficient productivity. All these aspects were 3D modelled across all disciplines right down to cast in supports for each piece of key plant.

We designed this facility using the most efficient and effective materials in each of its areas. Considerations in every element included durability, insulation, speed, fire requirements, sequencing, detailing and constructability. Other key considerations for the design and construction team were material supply and labour. Due to the Canterbury rebuilding and scale of this project, consideration of supply channels for materials had to be discussed and sequenced to ensure delivery of the project without holdup and any drop in quality.

The warehouse areas of the building are typically comprised of steel large span portal structures with concrete panels on the lower sections of the walls for impact loading and lightweight cladding on the upper structure.

The office building is a two-storey structure comprised of steel frames with concrete infill rib first floor, light weight portal frame roof structure and large precast fins as part of the architectural features at the front of the building to give scale against the rest of the structure.

The Industrial Hall is the most complex building of all with a three-storey structure supporting rubber manufacturing and process equipment. The entire 65-tonne powder mixers are supported on an isolated mezzanine floor to ensure vibration isolation for the rest of the structure. These platforms were designed for rigorous construction tolerances, vibration limits and seismic design. They support in excess of 60 tonnes of machinery and are constructed from large steel moment frames with a 600mm thick in-situ reinforced concrete slab. The main mezzanine structures were designed and detailed to also allow imperative function of the powder mixers feeding into the mills on the ground floor below.

As part of our innovative approach for this area of the building we were able to remove 50% of the columns from the preliminary design (from other parties) and clear spanned the upper floors, utilising a large floor truss, across the working space in front of the processing plant. This allows for better servicing, work space and flexibility in the industrial hall. The final solution also enables a huge reduction in foundation costs.

“Literally thousands of aspects had to be coordinated within the superstructure to millimetre accuracy to allow proper function of the industrial plant “


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