Custom Steel Frames, a member of Steeline Group was awarded the contract to construct the roof structures for the expansion project at the Mid North Coast Correctional Facility in Kempsey.
This project consisted of supply and fit of the roof structures for each of the four new accommodation buildings, comprising of approximately 1800m2 of roof area for each building, with a total of 9,700m2 including the eaves.
The main building contractor, Watpac has strict building policies for having a harness free construction policy, and limited scaffold job site.
Hence the structures were constructed on the ground on site, including constructing the steel frame, installing the sheeting, insulation, ducting, fire systems and safety rails. They each of the four roofs weighing a total of approximately 20T were lifted into place in sections.
The project required the use of a 220T crane using a 21m spreader beam due to the length of each section being lifted. Each or the four final building roofs required 6 main lifts and two smaller lifts, meaning a total of 32 lifts over the entire project. The largest lift was 370m2 with a weight of 9.2T.
John Matterson, Custom Steel Frames Site Supervisor, has been doing roof lifts for over 25 years noted that whilst this approach to building lifting was the first time for a number of the trades on site, his job was to oversee the lifting process, and he said “I’m very happy with how the whole project turned out”.
Jason Mowll – Watpac Site Foreman, commented that the rigidity of the steel product and the ability to build on the ground at the sizes needed, and to be able to lift as one piece you would “struggle to get that design in timber frames”.
One of the key benefits of this system is the speed of construction and installation. The team achieved the build the structure and frames, sheeted, mechanical ducting and fire systems fitted on the ground prior to lift, meant in an average of 15 days per building.
Jack Walton, Watpac Site Manager noted that “There is a level of confidence in what the guys have delivered, and I think the trades can see the gains in the efficiencies”
Custom Steel Frames were on site for 4 months in the construction and lifting phases with all the works completed on the project in less than 6 months.