CLIENT Bob Biernet (Freedom Pools)
Freedom Pools Factory Replacement
Project Scope
The Freedom Pools Factory Replacement Project was a comprehensive endeavor to rebuild and upgrade facilities following significant fire damage. The project involved several critical phases and detailed specifications aimed at enhancing operational efficiency, safety, and accessibility.
Key components of the project
Demolition and Site Preparation:
Demolition: Complete demolition and removal of the fire-damaged factory structures.
Soil Remediation: Removal and replacement of contaminated and unsuitable soil materials to a depth of 1.2m equalling approx. 120% of the building footprint, ensuring a stable foundation for the new constructions.
Construction of Upgraded Factories:
Factory Specifications: Construction of two identical, state-of-the-art swimming pool fabrication factories, each covering 650m².
Design Focus: Emphasis on Occupational Health, Safety, and Environment (OHSE) standards and enhanced staff accessibility.
Monorail Cranes: Installation of twin monorail cranes in each factory, extending to an outdoor hardstand staging area to facilitate transportation loadout.
Gantry Boom: Implementation of a three-stage gantry boom for fabrication use within each factory.
Additional Structures and Facilities:
Lean-to Structure: Construction of an additional 365m² lean-to structure attached to one factory, designated for swimming pool preparation and dressing.
Lunchroom and Amenities: Building a joining lunchroom and amenities area between the two factories to serve all staff.
Hardstand Staging Area:
Staging Area: Development of a 650m² hardstand staging area to support logistics and operational activities.
Fire-Resistant Storage: Incorporation of fire-resistant, bunded resin stores and industrial compressor storage within the hardstand area to ensure safety and compliance with fire regulations.
Fire Suppression System:
Water Storage Tanks: Installation of two 145KL fire water storage tanks to provide an adequate supply of water for fire suppression.
Pump System: Integration of a diesel/electric pump system to ensure reliable operation of the fire suppression system in case of emergencies.
Summary:
The Freedom Pools Factory Replacement Project was meticulously designed and executed to not only restore but significantly upgrade the facilities. By addressing soil contamination, enhancing structural integrity, and incorporating advanced safety and operational features, the project successfully created a safer, more efficient, and sustainable environment for swimming pool fabrication. The inclusion of state-of-the-art equipment and thoughtful design considerations ensured that the new factories met the highest standards of quality and functionality, supporting the ongoing success of Freedom Pools.
Project Challenges
Challenge
Live working environment
Mitigation
Developing a detailed phased work schedule to minimize disruption to ongoing operations. This was so work could be planned during off-peak hours or in sections, ensuring that only a small portion of the facility is impacted at any given time.
Established clear communication channels between all stakeholders, including clients, contractors, and facility staff. Regular updates and coordination meetings will ensured everyone was aware of the ongoing activities and could plan accordingly. Implemented stringent safety protocols to protect both workers and the facility's staff. Provided clearly marked work zones, safety barriers, and signage to prevent unauthorized access which ensured that everyone is aware of the active construction areas. Worked closely with facility management to ensure that construction activities are integrated seamlessly into the day-to-day operations. This collaboration helped identify potential conflicts early and allow for adjustments to be made to the construction plan.
Challenge
Contaminated soil with asbestos and building rubble
Mitigation
Mitigating the risks associated with contaminated soil, particularly with asbestos and building rubble, required a strategic and cautious approach. By conducting a thorough soil testing to delineate the extent and type of contamination, including asbestos and building rubble that was present throughout the site. Adhered strictly to all laws and regulations governing the safe handling, removal, and disposal of the asbestos-contaminated materials. A design a plan was established for the careful segregation of contaminated soil, asbestos, and building rubble from clean materials to prevent cross-contamination. Arranged for the disposal of asbestos-contaminated soil and building rubble at the local licensed hazardous waste disposal facility. Ensuring continuous communication with the project team and adjusted schedules and plans as necessary based on the progress of remediation efforts.
Challenge
Limited site access due to live working environment
Mitigation
The challenges associated with limited site access in a live working environment required careful planning and coordination to ensure both safety and efficiency. Conducting thorough assessments of the site to identify all possible access points, potential bottlenecks, and areas of high traffic within the live working environment. By using physical barriers, such as temporary fencing or hoarding, to segregate the construction from live operational area, ensuring that both can function independently without interference. Conducted regular briefings with the construction team to review access plans, safety protocols, and any changes in the live working environment that may affect site access.
By implementing these strategies, the construction activities could proceed efficiently while maintaining safety and minimizing disruptions within the live working environment.
Project Photos
