Port of Melbourne Control Shipping Tower

This was a most complex and challenging project. It was also a Design and Construct Project, leaving all design and detailing with Loaram to resolve.

The site is the PoMC Shipping Control Tower adjacent the Yarra River / Westgate Bridge in the Yarra Turning Basin. The Tower is 16 levels high, exposed to extreme climactic activity and required a complete re-skin as a consequence of the failure of the original facade (built in 2000).

The site does not have any commercial access to the top and the roof is not structurally capable of bearing any additional weight. Four levels of freestanding access was designed to sit atop the existing 1000mm wide steel catwalk. To locate the 25 tonnes of metal stanchions and walkways, an external commercial lift was deployed attached to the Control Tower Column and landing at the catwalk. An additional localised swing stage was deployed to areas incapable of accommodating any scaffold. Many weeks were consumed in the design and detailing of safe access.

In between the 6 weeks of access installation and the same for removal, approximately 500 square metres of Alucobond Aluminium Composite Material was custom manufactured and fitted over the existing facade. A ‘fishplate’ method was deployed, with all works finished to coastal environment corrosion protection levels. This requires all stainless steel fixings, Sikaflex adhesives / caulking and extensive additional waterproofing measures.

Conformance and Compliance for this project was paramount, with external OH&S consultants assisting the client to absolutely minimise site risks. Public Liability policies to $50M were deployed by Loaram supported by the Loaram $10M Professional Indemnity Policy. Weekly OH&S management reviews we conducted were underpinned by extensive site reporting. To ensure the safety of site works, Loaram dedicated one of our senior site supervisors to “own” the project, working closely with both Loaram directors.

With high winds the enemy of constant site activity, Loaram ensured multiple areas of potentially safe works were prepared either side of the tower – so there was effectively a windward and leeward option available at all times. To further assist site controls, the entire Control Tower was encapsulated in shade cloth.

As the site remained fully operational 24/7 for the duration of the project, every step and strategy employed had to be mindful of not distracting Port Shipping Operations.

The strategies deployed by Loaram were extremely successful. The site was delivered two weeks early, incurred no LTI’s and received very positive PoMC feedback with regard to the Loaram OH&S management system.

Project Reference: Kongngi Tang – 9683 1410.