The expansion at the Coca-Cola Amatil bottling facility at Northmead involved the construction of an automated high bay storage facility, associated staging areas, new truck docks, drivers amenities, new gatehouses and extensions to the existing warehouse buildings.  

The high bay facility was founded on variable fill material ranging in depths from 0.5m to over 5m.  Piled foundations were required to achieve the very tight defection limits necessary for the 32m high automated cranes that transport and store up to 55,000 pallets within the high bay facility. Staging area floors were constructed as post tensioned slab on ground to minimise joints and increase the speed of construction.. 

Burns Bridge Services PTY LTD 

Robert Bird Group Services:  
Structural Engineering  
Civil 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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