Grosvenor Place
Complete HVAC Infrastructure Upgrade

Completed 2022

Introduction

Corellian undertook a comprehensive HVAC infrastructure upgrade at Grosvenor Place, one of Sydney CBD's premier office towers. This complex project required coordination across multiple building levels, from the rooftop cooling tower replacement to basement plant room construction, all while maintaining building operations. The scope demanded Corellian's expertise in high-rise rigging, confined space construction, and precision equipment installation across the full height of the skyscraper.

Original roof cooling towers prior to replacement

Original plant room before refurbishment

Car park area before construction work commences

Stage 1: Rooftop Works - Cooling Tower Replacement

Demolition and Removal

The project commenced with the careful demolition and removal of the existing rooftop cooling towers. Working at height on a CBD skyscraper presented unique logistical challenges, requiring Corellian to coordinate tower crane operations for the safe removal of the old equipment. The team meticulously planned each lift to ensure safety while minimizing disruption to the building's occupants and surrounding properties.

Structural Support Construction

Following demolition, Corellian constructed new steel support structures, platforms, and catwalks to accommodate the replacement cooling towers. This structural work required precise engineering to integrate with the building's existing framework while providing robust foundations for the new equipment.

Cooling tower support piers under construction on the rooftop

Cooling Tower Assembly

One of the project's most challenging aspects involved installing the new cooling towers on the rooftop. Due to lift capacity constraints, the cooling towers could not be delivered as complete units. Instead, Corellian coordinated the transport of cooling tower components through the building's small passenger lift, then assembled them in place on the rooftop. This required exceptional planning, with each component carefully sized to fit through lift dimensions while maintaining the ability to be assembled into fully functional cooling towers. The team's expertise in modular assembly ensured seamless integration of all components despite the challenging access conditions.

Completed cooling tower with access platform - assembled from components delivered via passenger lift

Cooling tower installation showing modular assembly methodology

Final cooling tower installation with all structural support elements

Stage 2: Basement Plant Room Construction

New Main Chiller Plant Room

Concurrent with rooftop works, Corellian constructed a new basement plant room to house the building's HVAC equipment and backup generators. This work required extensive structural and architectural modifications to create a purpose-built space that would accommodate large-scale mechanical equipment while meeting stringent building codes and ventilation requirements.

A critical feature of the new plant room was the installation of a permanent monorail beam system. This overhead rigging infrastructure provides ongoing capability for equipment maintenance, replacement, and repositioning throughout the life of the facility, demonstrating Corellian's commitment to long-term operational efficiency.

Original chiller plant room

Chiller plant room structural completion

Completed structural and architectural elements of the chiller plant room

Mezzanine Pump Room Construction

To optimize space utilization and create segregated areas for different mechanical systems, Corellian designed and constructed a mezzanine-level pump room within the basement. This elevated platform houses the chilled water and condenser water pumps, providing efficient access for maintenance while maximizing the available floor area for other equipment.

Newly constructed mezzanine pump room housing chilled water and condenser water pumps

Stage 3: Chiller and Equipment Installation

Site Preparation and Equipment Positioning

Before the installation of new equipment, Corellian prepared the plant room floor with new reinforced concrete plinths engineered to support the substantial weight of the chillers and associated equipment. The team documented the existing conditions to ensure proper planning for equipment removal and replacement.

Precision Rigging Using Permanent Monorail

The new chillers were positioned beneath the permanent monorail system that Corellian had installed in the plant room ceiling. This overhead rigging infrastructure enabled precise control during the lifting and positioning operations, allowing the team to maneuver the heavy equipment with millimeter accuracy to align with mounting points and piping connections.

Chiller positioned under the permanent monorail system ready for final placement

Complete Chiller Installation

Corellian successfully installed multiple new chillers, each rigged onto custom-fabricated plinths and connected to the building's water and electrical systems. The installation included all associated infrastructure such as doors, partitions, support steelwork, and the distinctive blue monorail system that now provides ongoing maintenance capabilities.

Chiller No. 1 fully installed with doors, walls, blue monorail, and support steel in place

Chiller No. 3 installation showing equipment configuration

Chiller No. 3 with associated pipework and systems integration

Stage 4: Vertical Services and Smoke Exhaust Riser

Full-Height Rigging Infrastructure

One of the project's most technically demanding aspects involved refurbishing the ventilation systems within the smoke exhaust riser that extends the full height of the tower. To enable access throughout this vertical shaft, Corellian designed and installed a custom man hoist system supported by a purpose-built mast structure.

This infrastructure also served a dual purpose, with structural beams used to rig new condenser water pipework serving floors 1 through 26, and subsequently floors 26 through 45. The rigging beam system was engineered to handle the substantial weight of the piping while providing the precision control necessary for installation in the constrained riser space.

Structural beam used to rig new condenser water pipe serving levels 1-26 and 26-45, and to support mast construction

Mast riser structure supporting the man hoist for smoke exhaust riser refurbishment work

The man hoist enabled Corellian's team to safely access all levels of the exhaust riser, facilitating the ventilation system refurbishment while maintaining compliance with confined space entry regulations and height safety requirements. This vertical access solution exemplified Corellian's capability to develop innovative rigging solutions for complex high-rise challenges.

Conclusion

The Grosvenor Place HVAC infrastructure upgrade showcased Corellian's comprehensive capabilities across every aspect of mechanical services construction. From rooftop cooling tower replacement using modular assembly techniques, through basement plant room construction with permanent rigging infrastructure, to full-building-height vertical services installation, the project demonstrated exceptional planning, engineering, and execution.

Corellian's ability to coordinate complex multi-level operations while maintaining building functionality highlights their expertise in occupied high-rise construction environments. The installation of permanent monorail systems and the innovative solutions for equipment access through passenger lifts reflect Corellian's commitment to both immediate project success and long-term facility management efficiency.

This project stands as a testament to Corellian's position as a premier provider of complex HVAC infrastructure solutions in challenging CBD environments, delivering precision results through expert rigging, construction, and project coordination.