The extension of a Sydney Airport parking building required a lot of props and problem-solving, before the construction could begin.
Sydney Airport Corporation needed 1,243 additional car spaces at its P6 parking building, and Lendlease led the project to build four additional levels onto the building which could not be shut-down during the construction.
 
To build the extra four floors, a JASO J300 tower crane was secured on the roof of P6 by concrete ballast, meaning the building had to be strengthened with props beneath the crane.
 
With something as crucial as temporary works, you can’t just hire-out the equipment. This job involved our engineers working with the Lendlease engineers to get the right solution.
Kelvin Seeto, Coates Hire Product Specialist - Lift, Shift, and Propping
Lendlease engineers decided to hire props to support the eight floors beneath the crane and Coates Hire Services Engineering division was engaged to design a solution. The solution would carry the required loading through the eight levels, using 122 props. The basement level’s 4.5 metre floor-to-ceiling space experienced the heaviest load from the crane, just under 300 tonnes working load per prop. So in the basement, Coates Hire used four MP250 hydraulic struts.
 
Kelvin Seeto, Coates Hire Product Specialist - Lift, Shift, and Propping, says the objective of the propping solution was two-fold: to isolate the weight and loading from the crane to the temporary support structure, in order to maintain the structural integrity of the building; while also allowing vehicles to be used in the parking building during construction.

“The building’s structure was engineered to support its use as a car park,” says Seeto. “The building wasn’t designed for such a massive crane sitting on the roof.”
Each level was assessed individually for the most efficient prop layout. This minimised prop numbers while delivering an efficient load-path to the basement. And to mitigate the risk of public traffic causing damage during construction, Coates Hire’s ArmorZone crash-barriers were installed around the prop locations in order to separate vehicles from the structure.
 
Lendlease Project Engineer on the car park building – David Drew – says the construction was not straightforward because the crane had to be supported, and the building was required to keep operating.
 
“We had around 60 tonnes sitting on the roof of the car park building - 48 tonnes of which was concrete ballast for the crane. The crane had to be properly supported.”
 
He says the Coates Hire team was fast and competent, and contributed designs. “Coates Hire have their own engineers, so they know what they’re doing and they could quickly see what we were trying to do.”
 
Coates Hire’s Kelvin Seeto says complex construction jobs require both high-quality equipment and expertise. “With something as crucial as temporary works, you can’t just hire-out the equipment. This job involved our engineers working with the Lendlease engineers to get the right solution designed and in place. It’s a solutions business.”

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