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Hickory Building Systems

Integrated, Prefabricated Structural Delivery

Presented by Shan Kumar, Principal Engineer – Innovation, Research & Development, Hickory Group

LA TROBE TOWER, MELBOURNE

CASE STUDY: Application of an integrated,

prefabricated structural building system to construct a 44 storey

Melbourne building

Engineers - Give Life to Structures

Eureka Tower

Telstra Dome

Wembley Stadium

East Link MCG

MSAC

Engineers – Give themselves to the community

• We build Hospitals

• We build Roads & Bridges

• We provide shelter to the community

• We provide good drinking water

• We be creative and innovative to build a safe, cost effective structure in a timely manner.

Hickory Prefab – Our Journey • Prefabrication allowed

Hickory to use our combined resources to deliver projects faster, more sustainably and more safely

• Process began with panelized UB system for low to mid-rise buildings

• Over 16 buildings of 2000+ modules completed

3:East, Bosisto Street

Stella B17, Perth WA One9 Hall St, Moonee Ponds

Little Hero, Melbourne

Unitised Building (UB) Module

Factory production- Brooklyn, Melbourne, Victoria

Stella Apartments WA – Structural Design

Module Lifting & Shipping

Module Lifting & Shipping

Building 4 storey high inside the hull

Module lifting & placing on site

Stella Apartments – module with facade

Spider Web

Facade

Curved Roof

HBS – Designing a new prefabrication system for high-rise structures

Case Study: La Trobe Tower

• 44 level building

• 19 month contract

• 27 months if built conventionally

La Trobe Tower – Architectural / Structural coordination

L1 Floor Layout

HBS Modules

Key structural

system elements:

Rapid shear wall/core construction

system, hybrid system using prefabricated

wall & shotcreting

Prefabricated, sliding load-bearing walls

assembled between modules

Lightweight concrete floor system to

enable ease of transportation & erection

Preassembled curtain wall system as part

of the module

Fully finished & fitted modular bathroom

pods (SYNC Pod)

Shotcrete Testing

Shotcrete Specification

• ACI C 660 - Shotcrete Nozzelmen Certification

• Valid 5 years ACI / 3 years MTQ

• Core Grading:

Module Production

Shotcreteing On Site

Steel Column Installation – Level 1 Level 2 Transfer Structure

Installation of internal precast walls -Sliding of load bearing precast

Steel column installation – L1

Precast Wall – Column Connection

Evening Installation Process 17m x 4.5m x 3.0m high module (22 ton)

being lifted

https://www.youtube.com/watch?v=JUHBX4SgMck

Bathroom Pod Integration Sync Bath pod module being lifted

& placed in position

Sync Bathroom Pod System

• Subassembled bathrooms

developed for use in

conventional or modular builds

Highpoint Hurstville NSW

Sydney Uni Student Accom

Bathrooms for John Holland

Sync Bathroom Pod System

Sync pods used by Hickory and other major builders across Australia to gain

on time, cost and quality

La Trobe Tower – Successfully Completed Project

La Trobe Tower – Successfully Completed Project

Peppers King Hotel– Successfully Completed Project

https://www.youtube.com/watch?v=bd-MhwiDkQ0&feature=youtu.be&a

HBS – Key Benefits • Less time and labour than a conventional in-situ approach.

• Majority of work performed in a controlled factory environment:

- Improves quality

- Reduces downtime due to inclement weather

- Improves safety by reducing work at heights

• Site logistics improved, as majority of construction materials

delivered to the point of fabrication, resulting in

- better trade coordination on site

- Improved vertical movement / less reliance on alimak

- Less onsite storage required

Thank you

Any Questions?