CSD Group Australia Pty Ltd - Based in Gold Coast, Queensland, Australia, CSD Group services the construction industry from early design works all the way through to on-site solutions, offering cost-saving and precision enhancing solutions to every process. They have handled major infrastructure projects across the marine, commercial, materials handling and resource industries in Australia, Hong Kong, and Papua New Guinea.
Jewel Fine Foods - A retrofit challenge.
The project scope for CSD Group was to retrofit a 10,760m2 existing warehouse to host a food processing and packaging plant for Jewel Fine Foods. Maybe best known as the caterer of the Sydney Summer Olympic Games in 2000, Jewel Fine Foods has gone through significant growth since 1997. The company now delivers prepackaged meals to supermarkets throughout Australia, supplying major grocery chains such as Coles and Woolworths, as well as a number of airlines.
Completed in 2017, the new facility fit-out was highly complex and included new cool rooms, cooking areas, production lines, as well as upgrades to the infrastructure - including two new kiosk substations with lead in cabling and a new gas main. The high-level services, refrigeration and steam plant were hung from the roof or raised on gantries. The roof was reinforced to take the weight of the equipment, some weighing more than eight tons.
Retrofit accuracy checked by laser scanning
In order to ensure a successful installation, CSD Group leveraged Trimble technologies to improve their workflow. A Trimble Robotic Total Station was used to 3D scan the existing facility. Over 505 million points were taken to capture the objects within the warehouse, including all necessary items: structural beams and columns, purlins, existing service pipes, and firewater, electrical cable trays, concrete step-downs and joints, and precast wall slabs.
“The initial 3D scanning showed that the cambers had not been added during the original construction of the building, causing some rafters to sag over 110 mm in the middle and bow in the horizontal axis by up to 35 mm", said Michael Williams, the managing director of CSD Group. Additional steelwork was immediately supplied to rectify the structural rafters. After that, a correction check survey was done to ensure the building moved as intended.
Using the scan, the additional steelwork was modeled using macros and details with pre-positioned layout points to connect the existing steelwork and concrete. “All steel lengths between existing rafters were bespoke, as no allowance for slotted holes was allowed to the hanging equipment frames. In addition, the rafter corrections did not allow for the rectification of the horizontal bowing of steelwork,” said Mr. Williams.
Optimized, clash-free accuracy
CSD Group also used Tekla BIMSight along with Trimble Connect for managing, sharing and reviewing 2D drawings and BIM models of the facilities aircon ducts and refrigeration components. The ability to access information quickly and securely in a single collaboration environment allowed the team to optimize their workflows and ensure clash-free installation - reducing rework and costly schedule delays.
Upon positional sign-off, while the models and drawings were being finalized, a team of two spent two days on-site with an RTS unit. They laid out over 460 chemset locations for the column base plates and 1,056 bolt locations to the existing 13-meter-high steel rafters. Once the steelwork arrived on site, all 3,419 new assemblies fit to the 1,520 site marked holes with millimeter precision and required no site alterations.
- Existing structure scanned: 10,760m2 (approx. 140,000m3 of scanned data)
- Scan size: 505 million points captured in 4 hours.
- Layout points (steel drillings): 1056 (1 day on site)
- Layout points (concrete chemsets): 464 (1 day on site)
- Assemblies retrofitted: 3419 assemblies supplied to be erected
- Software used: Tekla Structures v2016, Trimble Realworks v10.1, Trimble Connect, Tekla BIMSight
- Hardware used: Faro X130 scanner, Trimble Robot Total Station
- Drawings: 1340 assemblies, 1877 parts, 98 general arrangements