The Star Sydney
Site Wide Infrastructure Project

Completed 2020

Introduction

Corellian's whole-package rigging skill was brought in to assist with undertaking an impressive scope of work for Fredon's Site Wide Infrastructure (SWIS) project at The Star Sydney casino and entertainment complex in Pyrmont, NSW. The project required Corellian to showcase their expertise in rigging and various construction trades to support the complex infrastructure upgrade. Let's take a closer look at the chronological steps involved in completing each stage of the work performed by Corellian.

Initial inspections of the unused space to be developed
Initial inspections of the unused space to be developed
Former seawater pump plant room to be upgraded
Former seawater pump plant room to be upgraded

Stage 1: Planning and Preparation

Before the commencement of the project, Corellian worked closely with Fredon to develop a comprehensive plan for the execution of the work. This involved conducting site surveys, reviewing drawings and specifications, and identifying potential challenges. Corellian also prepared detailed method statements and risk assessments to ensure the safety and efficiency of the project.

Stakeholders review and approve Corellian's plan of action
Stakeholders review and approve Corellian's plan of action

Stage 2: Demolition and Structural Preparations

Corellian began their work by demolishing and removing rock, earth, gravel and blockwork within the B4 plant room, and coordinated the rigging and removal of the old diesel tanks. This stage was crucial in preparing the area for the subsequent structural works. The team's specialists then started skillfully disassembling and cutting apart the existing plant within the B4 and B2 plant rooms. This process required careful planning and execution to ensure the safe removal of the equipment without damaging the surrounding structures. The team utilized specialized equipment, such as a Brokk hammer, to carefully demolish and remove the existing sandstone substrate while preventing damage to any adjacent fixtures.

The brokk hammer being used to excavate sandstone and expand the size of the plantroom
The brokk hammer being used to excavate sandstone and expand the size of the plantroom
Demolished plant is disassembled, cut apart and removed from site
Demolished plant is disassembled, cut apart and removed from site. Some of the old equipment had become completely obstructed over time

Once the demolition was complete, Corellian proceeded to construct new structural and architectural elements, including concrete slabs, hobs, plinths, blockwork, rock anchors, and structural steel. The team showcased their skills in establishing a multilevel static concrete pump lines, and arranging the formwork and pouring alongside their steel fabrication to ensure the structural integrity of the new elements and the existing structure.

The plant room extension required extensive excavation of up to 600m³ of sandstone rock to create a floor area for the new plant room layout. This created excavation depths below the invert of the diaphragm wall thus requiring coordination and installation of a series of ground anchors to a depth of 12.4m at 45 degrees.

Structural steel fabricated off-site, delivered and rigged to position
Structural steel fabricated off-site, delivered and rigged to position
Heavy loads are rigged with precision to protect floor surfaces and parts
Heavy loads are rigged with precision to protect floor surfaces and parts
Structural steel installed in place and built to last
Structural steel installed in place and built to last
Reinforced concrete is prepared and poured throughout the site
Reinforced concrete is prepared and poured throughout the site
Rock anchors are drilled into the stone to shore up the wall
Rock anchors are drilled into the stone to shore up the wall
The rock anchors are installed deep into the sandstone at an angle
The rock anchors are installed deep into the sandstone at an angle to protect the structure over time

Stage 3: Materials Handling and Hoisting Infrastructure

To facilitate the efficient movement of materials and equipment, Corellian installed a temporary vertical materials hoist operating between the B2 and B4 levels by removing asphalt at street level, installing the loadbearing structure. This hoist was essential in transporting construction materials and waste throughout the project, and the openings were resealed to a professional finish at the end of the project. The team also created a new slab penetration in the B2 plant room with a second material hoist customised to accommodate the new chiller components, demonstrating their precision in core drilling and concrete cutting.

The hoist installed on the concrete penetration
The hoist installed on the concrete penetration with structural steel and wood panelling, and electric hoists rigged and ready
A Franna crane is used to lower loads down through the street level hatch
A Franna crane is used to lower loads down through the street level hatch that Corellian has installed
Material hoists are used to lower loads down vertical tracks
Material hoists are used to lower loads down vertical tracks
When the work is done, the hatches are sealed
When the work is done, the hatches are sealed

Additionally, Corellian coordinated the logistics of material delivery and waste removal, coordinating traffic management and marking temporary roads through the car park to minimize disruption to public vehicles. The road surfaces and asphalt were also restored to a trade finish at the end of the work.

Traffic is managed carefully to divert pedestrians and cars
Traffic is managed carefully to divert pedestrians and cars around the work on public roads and in the private carpark underground

Stage 4: Core Drilling and Penetrations

With the structural preparations and materials handling infrastructure in place, Corellian proceeded to carry out a significant number of core drill penetrations through concrete slabs, internal walls, and external walls across multiple levels of the building to accommodate the new chilled water and condenser water pipework system. These penetrations were meticulously planned and executed to accommodate new pipework and services while minimizing the impact on any nearby works.

Core holes are cut in the concrete and protected safely with wooden covers
Core holes are cut in the concrete and protected safely with wooden covers
Wet cutting techniques are used to prevent silica dust
Wet cutting techniques are used to prevent silica dust

Corellian's team utilized dustless work techniques and implemented proper protection measures to ensure a clean and efficient process. The precision and accuracy of the core drilling were critical in ensuring the smooth installation of the new services with a priority on preventing any compromise to the structural integrity of the building.

Stage 5: Rigging and Equipment Installation

In the final stage of their scope, Corellian demonstrated their expertise in rigging by taking delivery of approximately 15 new chillwater pumps, condenser water pumps, seawater pumps, large diesel tank components, delicate switchboards, and the broad and awkwardly shaped 1.2m diameter GRP seawater header sections.

The main challenge of the project involved the installation of a 25 tonne, 5 mega watt Trane water-cooled Chiller into the newly constructed B4 plantroom at the lowest level of the works. This first required taking delivery of the chiller in component form at the curbside of the road and hoisting the parts from a crane down through the ground level hatch. From here it was moved into the B2 plantroom and the material hoist was disassembled to make space for the next stage of the move. To descend from B2 down to lower levels, a custom hoist was constructed from a structural steel framework and 3 phase electric chain hoists were installed to perform synchronised lifts by remote control. This hoist was used to lower the chiller down from B2 to a mezzanine. Twin monorails were installed above the mezzanine to move the suspended load down toward the B4 level, to manoeuvre it in space, and to assemble parts in their final position on the newly fabricated plinths. Every aspect of the work was controlled and finessed, with further adjustments being made to align with changes to the architect's design. Finally, the surfaces were painted to deliver on the project's complete vision.

The chiller components are safely transported to site
The chiller components are safely transported to site
The chiller is rigged to be lowered by the fabricated steel custom hoist
The chiller is rigged to be lowered by the fabricated steel custom hoist
Monorails are installed throughout the site
Monorails are installed throughout the site for precise rigging exactly where it is needed
Twin monorails are used for additional safety with heavier loads
Twin monorails are used for additional safety with heavier loads
The chiller is slowly moved from the mezzanine to the B4 floor
The chiller is slowly moved from the mezzanine to the B4 floor
Seawater GRP header sections are rigged into final position
Seawater pumps are rigged for precise movement

The rigging process required meticulous planning and orchestration of Franna craneage, lift plans and permits. Coordinated use of chain blocks, precise engineering of the lifts using available lifting points, and careful protection of the equipment completed job with success. Corellian's team carefully stored the pumps and chiller components until they were ready to be transported to the site and skillfully rigged all loads down into position, assembling the suspended loads in location. The team's attention to detail and adherence to safety protocols were evident throughout the rigging process.

Corellian also coordinated traffic control and arranged permits and lift plans for Franna cranes on Jones Bay Road to facilitate the delivery and hoisting of the new plant equipment and components. The precise and safe installation of the new equipment marked the successful completion of Corellian's scope of work, contributing to the overall success of Fredon's SWIS project.

The corridor space before the project commenced
The corridor space before the project commenced
The corridor area toward the end of the refurbishment project
The corridor area toward the end of the refurbishment project

Milestone Achievements

Throughout the project, Corellian achieved several significant milestones that demonstrated their commitment to delivering high-quality work.

Construction and delivery of the diesel tank room with all finishes

The completed diesel tank room as viewed from above
The completed diesel tank room as viewed from above

Installation of two diesel tanks, ready for connection and diesel transfer

The finishes and walkways surrounding the diesel tanks
The finishes and walkways surrounding the diesel tanks

Construction and installation of the new seawater header, culvert and thrust box

This milestone was completed to coincide with the site annual maintenance shutdown of the seawater system.

Closure of the street hatch and alteration of the lower levels hatch

New precast concrete panels were installed for future access.

Installation of handrails, firedoors, stairs, access platforms, walkways, blockwork, passive fire installations, gravel, floor and wall finishes

All installations were completed to meet BCA compliance.

Toward the end of the refurbishment project
Toward the end of the refurbishment project, showing handrails, gravel, finishes and doors for the access to the plant rooms
Professional finishes on all surfaces and fixtures
Professional finishes on all surfaces and fixtures with signage as required

Reinstatement and making good on all car park, footpaths, B2 plant rooms, and back of house area alterations

All areas were restored to meet existing conditions.

The private carpark returned to its former condition
The private carpark returned to its former condition
Catwalks and access, doors and finishes installed
Catwalks and access, doors and finishes installed throughout the project
Plant room finishes and space ready for expansion
Plant room finishes and space complete & ready for future expansion
New service access platform
New service access platform to new seawater valves and filters

Alteration and refurbishment of the seawater plant room

This included rigging in of new seawater pumps with structural restraints.

Refurbishment of the seawater plant
Refurbishment of the seawater plant

Construction and installation of the chiller plant room

This milestone included rigging in of all major equipment.

The new chiller installed in the refurbished plant room
The new chiller installed in the refurbished plant room
The plant room with all equipment installed
The plant room with all equipment installed

Conclusion

Corellian's work on Fredon's SWIS project at The Star Sydney showcased their expertise in rigging and various construction trades. From the initial planning stages to the final installation of equipment, Corellian demonstrated their ability to execute complex projects with precision, safety, and efficiency on a site with the most demanding access and underground conditions.

The successful completion of this project is a testament to Corellian's commitment to delivering exceptional results and their ability to overcome challenges in a dynamic construction environment. With their skilled team and extensive experience, Corellian continues to be a trusted partner for clients seeking high-quality rigging and construction services.

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