Large, complex projects have an uncanny ability to either expose the ill equipped and unprepared, or to bring out the very best of people who are up to the challenge, by choosing the right processes, equipment and materials to get the job done.
The enormous reroofing project of Townsville’s Bulk Sugar Terminal displayed all the hallmarks of a difficult job. Along with the size of the project which involved replacing 36,000m² of roof cladding on two 300m long sheds, other factors to contend with included a considerable roof pitch of 35° and working at heights of up to 27 metres.
Of course, there were also weather considerations, with work needing to be scheduled outside of Townville’s cyclone season from October to April. Additionally, the reroofing project significantly reduced sugar storage capacity on site, meaning time pressures came into play.
The catalyst for the reroof was a deteriorating substructure in certain areas of the sheds, requiring new purlins to be fitted and removal of the roof cladding to provide access. With the structural work completed the material of choice to replace the existing Galbestos cladding (galvanised iron sheets with a coating of asbestos on each side) was PERMALITE LT7® aluminium cladding, which is ideal for the salty oceanside environment and is backed by a generous PERMALITE® warranty for added peace of mind.
With a 0.9mm thickness (also available in 0.70mm and 1.2mm) and able to easily be rollformed to the required sheet lengths of 14.40 and 13.76 metres required for the roof dimensions of the sheds, PERMALITE LT7® provided a strong yet lightweight solution that would also deliver the strong anti-corrosion benefits required of the site thanks to its marine grade aluminium substrate. And unlike the preceding material, PERMALITE LT7® achieves its corrosion resistance without needing any problematic asbestos coating.
The reroof which was completed last year, was the latest of several similar projects which saw other assets in Cairns, Mourilyan, Bundaberg and Mackay rejuvenated over an eight-year period, with all work undertaken by Queensland Industrial Cladding (QIC).
QIC Project Manager, James Page, said throughout the duration of the program, support from Lysaght had been excellent at every step.
“During the eight years that these projects were undertaken, key personnel at Lysaght provided outstanding assistance and service, whether giving advice, preordering materials right through to general support to project completion,” James said.
Given the time restrains affecting the project, accessing construction materials in a timely manner was critical, with the PERMALITE LT7® cladding being roll formed in Sydney before transporting to the jobsite 2,000 kilometres away by road.
“Efficiency and scheduling of materials were key deliverables because the sheds couldn’t be used without a roof and there was also the building restrictions around cyclonic periods,” James said.
I’m pleased to say that all major deliveries were achieved within our required timeframes. The level of communication from Lysaght customer service personnel was outstanding, providing me with all the critical information I needed for scheduling.
Projects of this large scale and duration mean that clients and construction trades may need some technical assistance and extra support from time to time if any hurdles arise. James said that Lysaght managed these situations well on the rare occasions a problem had to be overcome.
“I must commend Lysaght technical staff for always being available and providing me with essential information ranging from product data to resolving several issues that arose on site over the years. The team made my job a lot easier,” he said.
PERMALITE LT7® is one of five cladding options available across the PERMALITE® product line-up, with ALSULATE-125®, ALSPAN®, V-RIB® and WAVELINE® also delivering outstanding results for engineers, installers and building owners who have selected the materials across a range of residential, commercial and industrial applications.
The PERMALITE® aluminium product range is also available in a number of finishes including mill finish, stucco embossed as well as in a choice of pre-painted colours. The PERMALITE LT7® used on the Townsville Bulk Sugar Terminal job was completed in Gull Grey™, chosen for its subtle hues, providing functionality and longevity along with a pleasing aesthetic.