Stockpile Building Rehabilitation Methodology – Moving Access Platform 

The Stockpile Building located at the Port Site Facility in Karumba, in far north Queensland, is a 250m long, metal clad building storing zinc and lead ores during their final drying stage prior to shipping to overseas refineries. The ores are sulphides that, due to the high humidity within the building, create ‘Acid Rain’ which causes significant corrosion. Due to this corrosive environment, the cladding system of the building and steel structural framing members required rehabilitation. This included the inspection, cleaning, painting and replacement as required of purlins girts and the main structural portal frames and longitudinal bracing members. Robert Bird Group developed a rehabilitation methodology that used moving internal platforms to provide access to the roof area where the rehabilitation works were to be carried out. The project was restricted as the maintenance works were to be performed 10 to 30m above the stockpile. The building was to remain fully operational – no access scaffold from the ground could be used. 

Year Completed: 
2006-2015 
Sectors: 
Industrial 
Energy & resources
 

Client:  
Minerals and Metals Group 
Robert Bird Group Services:  
Structural Engineering  
Construction Engineering 

Key technical challenges

  • The primary tower structure consists of a composite slab and beam structure. Due to the long beam spans and thin slab, extensive analysis for footfall vibration was required to ensure the structure achieved code requirements and client expectations.
  • Working with the existing structure and developing design solutions that strengthened rather than demolished.
  • Extensive co-ordination with the mechanical engineer to develop a strategy that minimised beam penetrations and beam notches.
  • Differential shortening analysis with consideration of mega truss, steel structure, concrete structure and existing structural elements

Environmental performance

  • 5 Star Greenstar
  • 5 Star NABERs Energy and 4 Star NABERs Water ratings.

Design of Heavy Vehicle Workshop and Slab 

Robert Bird Group provided structural design for the main heavy vehicle workshop at the Century Mine at Lawn Hill. The design featured a gantry crane and slab strengthening for tracked vehicles. 

Excavator Wash Down & Awning Structure 

The Robert Bird Group team provided the structural concept and final design for an awning structure located at the Port Site Facility in Karumba. The awning was designed to prevent zinc or lead product from being discharged offsite during the wash down of excavators used to manage product within the Stockpile Building. 

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