The Amcor G3 project located in Gawler, South Australia increased the total area of the plant to over 70,000m2.  Amcor’s manufacturing facility featured the world’s most contemporary container glass technology. The production lines were designed to produce 750 ml premium-quality glass bottles in a variety of shapes and colours. In addition to these bottles; the Stage 3 production lines had the added capacity to produce 375ml beer bottles. 

The Stage 3 project scope included: 

  • Expansion of the existing batch plant 
  • A third furnace building with an additional 450 tpd capacity melting furnace. 
  • A third production building with two additional production lines. 
  • A third annealing and packaging line 
  • Expansion of the existing amenities building 
  • An expansion of the water treatment facilities.

Upon the completion of Stage 3, Amcor’s production capacity increased to approximately 600 million wine bottles per year. 

The Robert Bird Group provided consulting structural engineering services for the new buildings, furnace, silos and production lines. 

Project Value: 
$200 million  
Year Completed: 
2003 

Sectors: 
Industrial 
Client:  
Amcor Limited 
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.

Key technical challenges

RBG redesigned the steel plunge columns enabling complex bracing arrangements and programme hold-points to be removed, hence simplifying excavation and improving health and safety. The ground floor slab was redesigned for significant construction loads and to prop the basement wall whilst maintaining a large void to allow the core to rise.

RBG also checked all permanent works elements for the temporary loads induced by the innovative construction sequence. The construction method further reduced the ground movements, thereby minimising the risk to sensitive network rail facilities adjacent to the site.

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