The section of the Kooragang Island depot known as the Bagging Plant Tower was found to be in poor structural condition in the areas of the existing wall girts and window framing. This was due to the corrosive nature of the raw fertiliser(s) being handled within the plant confines.
As the external wall sheeting consisted of “Deep 6” Bonded Asbestos being reliant on the structural integrity of the retention system, Incitec Pivot proactively authorised the rectification works to be carried out.
McMahon Services were awarded the contract for the removal of the existing asbestos wall sheeting and replacement with a non-corrosive PVC product (supplied by the client). The area for removal measured approximately 800 square metres and located at heights of up to 50 metres. The removal and replacement methodology called for the use of elevated work platforms for ground accessible areas and a purpose built aerial work platform suspended from crane to access the remaining works at height.
Incitec Pivot required the Bagging Plant to remain fully operational whilst undertaking these works so McMahon Services implemented the following measures to ensure the removal and replacement works were undertaken safely:
- The entire internal face of the area(s) identified for rectification was subject to scaffold erection for the purpose of:
– Safe egress / access for workers and providing a framework for the installation of a 200um plastic sheet barrier to create a safe working environment for the Incitec Pivot staff whilst removals of hazardous materials were being carried out. - Ground level exclusion zones were installed and monitored
- McMahon Services workers were subject to the clients’ internal Permit to Work system. This allowed for complete transparency of work schedules and control of all required interactions.
There were a number of external factors that contributed to a challenging working environment on this project. Raging bushfires in close proximity to the site resulted in large volumes of airborne ash and smoke, and on the other extreme, high winds and storms delivered up to 100mm of rain.
Despite these challenges, the highly skilled, in-house project team completed the project one week ahead of schedule and ensured no interruptions to Incitec Pivot’s daily operations.
