COVER STORY NSW PROJECT FEATURE NORTHERN BEACHES HOSPITAL CPB Contractors /

42 NSW PROJECT FEATURE NORTHERN BEACHES HOSPITAL AUSTRALIAN NATIONAL CONSTRUCTION REVIEW WWW.ANCR.COM.AU NSW PROJECT FEATURE NORTHERN BEACHES HOSPITAL 43 THE EPITOME OF The $600M Northern Beaches Hospital is the first 4 Star Green Star hospital in . The modern, 9-storey world class HEALTH CONSTRUCTION development contains 488 beds, a 50-space emergency department, support infrastructure, a helipad and 1,400 carpark spaces.

In December 2014 the NSW State contributing to reduced capital and Government contracted Healthscope, one maintenance costs. of ’s leading private healthcare operators, to deliver the Northern In January 2015 CPB Contractors started Beaches Hospital. The development is the concept design of the $600 million a ground breaking project for New South development which included 70,000m² Wales as the state’s first healthcare operator of hospital space along with 40,000m² of led public-private partnership, and the parking and a rooftop helipad. The complex state’s the first 4 Star Green Star hospital. also boasts campus wide roads and bike paths, The building project is a joint venture retail tenancies, café and outdoor eating areas. between Healthscope and major construction company CPB Contractors. The main building, surrounded by landscaping, has a spectacular light filled Set on a 6.5 hectare site at Frenchs Forest in atrium at the entrance, natural wood panelling the northern suburbs of Sydney, Northern throughout the interior and individual rooms Beaches Hospital is a 9-storey building that offer sweeping views across Middle providing clinical and non-clinical support Harbour to the city. services for both public and private patients. It comprises 488 beds, a 50 space emergency During the three year build CPB Contractors department, 14 operating theatres and six set new benchmarks for large scale surgical suites as well as modern intensive construction projects across many fields. care and critical care units, and inpatient The project required negotiation with mental health and training facilities. a network of infrastructure authorities; considered planning of the environmental Northern Beaches Hospital also houses features of the greenfield site; and the state-of-the-art digital technology solutions integration of stakeholder and local including equipment for modern medical community needs. imaging; real time location systems for medical equipment and utensils; a microwave A major challenge of the construction line-of-site link for transfer of large medical involved identifying and segregating hospital imaging files as well as wandering technology works from RMS works and continuing for mental health patients. coordination with the RMS. Road building projects were in progress at three of the site’s The hospital is set to use 15% less power boundaries and site access and egress had to when compared to other facilities of the be coordinated with existing infrastructure. same size and function, due to the integrated CPB Contractors worked with the RMS Energy Management System put in place. to finalise the design of boundary levels, A cogeneration base load plant was installed, road geometry and stormwater paths as well with the capacity for modular expansion, as the concurrent upgrade and connection of sewage, telecommunications, water and natural gas supplies and high voltage electrical upgrades.

Existing public roads around the site carry 130,000 cars per day and a high school on the western boundary contributed to flow of vehicular and pedestrian movement. CPB Contractors dealt with this challenge by creating a signalised intersection at the entry to the site, including digging 4kms of trenching through an RMS site to match DEVELOPER : Northern Sydney Central Coast Health and Healthshare NSW established traffic switching methodology. MAIN CONSTRUCTION COMPANY : CPB Contractors ARCHITECT : BVN Donovan Hill Significant traffic movement within the STRUCTURAL ENGINEER : Aecom Cost Consulting construction zone was dealt with by CONSTRUCTION VALUE : $600 million

44 NSW PROJECT FEATURE NORTHERN BEACHES HOSPITAL AUSTRALIAN NATIONAL CONSTRUCTION REVIEW WWW.ANCR.COM.AU NSW PROJECT FEATURE NORTHERN BEACHES HOSPITAL 45 Below Northern Beaches hospital is set on 6.5 hectares in Frenchs Forest and contains 14 operating theatres and six surgical suites.

constructing loop roads for the movement and training achievements are also of note. Another significant factor of the development of materials around the site and establishing Over the three year construction period a was the comprehensive stakeholder and an offsite truck staging area. Planning the peak workforce of 780 personnel worked community relations strategy put in place. deliveries was a key factor too, especially over 2.5 million hours and CPB Contractors Over 130 meetings were held to determine for the movement of many concrete trucks achieved an outstanding level of onsite specific requirements of end users and To minimise traffic impacts CPB Contractors safety performance with no serious incidents implement their needs. employed the innovative solution of using or injuries. two concrete plants, one to the east and one The CPB Contractors team had to determine to the west of the site, so that concrete trucks Particular attention was paid to the operation clinical functional requirements within the travelled against the peak hour flow of traffic. of mobile EWPs. By introducing new design, especially in relation to fittings, operating procedures and implementing furniture, fixtures and equipment. Site CPB Contractors scope of works also an innovative riser construction sequence, tours were offered to over 2,000 people included obtaining environmental approvals CPB Contractors was able to minimise including community groups, local health which involved working closely with the the major safety risks associated with mobile professionals and nursing staff who were local council as well as the Department of EWPs and virtually eliminate fall risks considering transfers to the new hospital. Planning and Environment. A concern at for workers. CPB Contractors became involved with the the greenfield site involved the control of local high school, participating in fundraising stormwater and a comprehensive stormwater CPB Contractors also exceeded targets events as well as providing career advice and management plan was devised early in the for workplace participation in training by work experience placements for students. project. CPB Contractors constructed a achieving a 23% worker involvement and by stormwater system with permanent detention creating over 700 jobs. The Northern Beaches Hospital opened tanks to act as sediment basins to minimise to great acclaim in October 2018. flooding risks to the local area. The construction project employed six The outstanding building, one of six undergraduate builders, engineers and nominees for 2018’s Australian Construction The critical interface with the high school on architects and contributed to two post Achievement Award, is a highly considered the western boundary of the site was dealt graduate studies, 44 apprenticeships and addition to NSW healthcare services. with by CPB Contractors by monitoring traineeships as well as undertaking 62 and controlling noise and air quality. vocational courses. Mental health training For more information contact CPB Contractors, Acoustic hoarding was put in place, was provided to over 1,000 people to Level 18, 177 Pacific Highway, North Sydney construction work scheduled around school deliver mental health awareness objectives NSW 2060, phone 02 8668 6000, fax 02 8668 exam periods and a final configuration of and access to mental health professionals. 6666, website www.cpbcon.com.au roads allowed service vehicles to use the CPB Contractors also provided additional hospital road infrastructure. training for onsite workers to maximise safe For more information contact Healthscope, working procedures in regards to mobile Level 1, 312 St Kilda Road, Melbourne VIC CPB Contractors used cutting edge plant, working around services and working 3004, phone 03 9926 7500, fax 03 9926 7599, technology to improve design collaboration at heights. website www.healthscope.com.au between stakeholders using BIM and introducing the room data sheet system dRofus which has since become standard practice on all NSW Health building projects.

For such a large project a major logistical challenge was the limited number of workers available. Concurrent excavation of the hospital and carpark was scheduled and the sequential construction which followed ensured maximum efficiencies.

Yet the construction of the Northern Beaches Hospital exceeded all expectations with major programme targets and an Interim Occupancy Certificate achieved months ahead of schedule.

CPB Contractors’ contribution to the construction industry’s safety standards

46 NSW PROJECT FEATURE NORTHERN BEACHES HOSPITAL AUSTRALIAN NATIONAL CONSTRUCTION REVIEW WWW.ANCR.COM.AU NSW PROJECT FEATURE NORTHERN BEACHES HOSPITAL 47 Below Star Group provided the electrical and communications infrastructure including lighting, security systems and the Distributions Antenna System.

Star Group specialises in the delivering For substations Star Group offers supply, of electrical engineering and installation installation and commissioning including services. Star Group was contracted by CPB excavation, conduit and cable jointing for Contractors to design and construct detailed, double and triple chamber substations, state-of-the-art electrical, high voltage and construction of underground and overhead communication services throughout the cables and cable support systems as well as Northern Beaches Hospital complex. high voltage switchgear, street lighting and power upgrades. In early 2015, Star Group’s team of 10 started designing the electrical infrastructure Star Group’s work for water and treatment that included the lighting control, nurse call, plants covers the design and installation audio/visual and security systems as well as of earthing systems and low voltage the Distribution Antenna System (DAS), switchboards, comprehensive thermographic lightning protection, diesel generator and testing and instrument calibration as well co-generation systems and high voltage as maintenance of switchgear and pumps. services. Onsite work started in June with The company adheres to stringent national 130 tradesmen excavating trenches, laying health regulations to ensure their construction cables and installing electrical hardware inside and maintenance processes don’t impede the the new building. Star Group completed the plant’s ability to treat and deliver water and contract by the end of July 2018. sewerage services.

“The challenge of the job involved the Star Group works across a range of sectors installation of the high voltage cables,” said such as the communications and data Construction Manager, Anthony Greenaway. industries, educational, commercial and “There was 1.6km of cabling to be laid for residential developments as well as rail connection to a nearby substation and we had infrastructure. The company install electrical to dig trenches alongside roads with a high hardware for road networks, power and gas volume of traffic.” utilities, industrial and manufacturing plants and materials handling facilities. “We also developed a new method for constructing the Medical Service Panels Health care projects for Star Group (MSPs) that were fitted behind patient beds,” include a four year long contract for CPB Anthony explained. “Our inhouse engineers Contractors at the Royal North Shore worked with our suppliers to design a Hospital started in 2008. “We’ve been modular system so the panels could be working for CPB Contractors for over 15 prefabricated. With 2,500MSPs required we years,” said Anthony. “Star Group are one certainly reduced the amount of onsite work, of their preferred contractors.” especially as 45 different types of panels were needed to service the different wards.” Star Group recently completed the electrical and communications infrastructure including Founded in 1957, Star Group is a privately the lighting and switchboards at Wynyard owned company employing 350 personnel. Walk, a tunnel running between Barangaroo They offer consultation, design engineering and Wynyard station. services and construction of new systems and upgrades as well as ongoing service and Within the mining and resources industry maintenance. Star Group is a Sydney based Star Group work at quarries, coal, oil, gas company with six regional offices located and metalliferous mines. In 2015 they along the eastern seaboard of Australia and is completed a 15 month long job at Boggabri accredited with both Ausgrid and Endeavour Coal Mine installing electrical infrastructure, Energy to deliver both high and low voltage lighting for tunnels, controls for conveyors, electrical infrastructure services nationwide. crushers and feeders, ventilation fans and air flow monitors. Star Group provides design and installation for infrastructure cabling, with both fibre and copper, for active network systems, carrier lead ins services, wireless access points and For more information contact Star Group, Ethernet installations. They also carry out 46 Harley Crescent, Condell Park NSW 2200, infrastructure audits, testing and certification phone 02 9708 7555, email info@star-group. and offer IT support. com.au, website www.star-group.com.au

48 NSW PROJECT FEATURE NORTHERN BEACHES HOSPITAL AUSTRALIAN NATIONAL CONSTRUCTION REVIEW WWW.ANCR.COM.AU NSW PROJECT FEATURE NORTHERN BEACHES HOSPITAL 49 Below Cherrie Civil Engineering completed the initial excavation as well as concrete pours and road works, laying the kerbing, pavements and roads.

Cherrie Civil Engineering is a diverse civil engineering footpaths. Other concrete and structural works included the Cherrie Civil Engineering in mid 2015 with the Northern Beaches Other work for CPB Contractors includes Nepean Hospital where contractor specialising in large scale projects. At the Northern construction of signage and plinth slabs and excavation for Hospital as their first job. “Our relationship with CPB Contractors Cherrie Civil Engineering carried out earthworks, remediation, Beaches Hospital project, Cherrie Civil Engineering carried out over stormwater, power and irrigation. stretches back well over 20 years. CPB’s policies and safe work excavation and construction of in ground components for the 100,000m³ of bulk and detailed excavation for the main hospital practices translated to a well run workplace for the 40 men we had carpark. In March 2018 the company commenced work at Green building, carpark, roadworks and landscaping. “It was a very busy site with the challenge of working around other onsite,” said Stephen. Square Aquatic Centre for CPB, carrying out ground remediation and trades, especially providing access for them while we were doing the constructing in ground structural concrete elements for stormwater In late June 2015 Cherrie Civil Engineering commenced the contract roadworks, but CPB Contractors had organised everything really well, With a reputation for delivering on time and an excellent safety and base slabs for swimming pools. for the main structure with detailed excavation for the drainage there was a good integration of the different contractors and the whole record, Cherrie Civil Engineering have established themselves as layer, footings, basement and lift cores as well as excavation shoring job ran very smoothly,” said Managing Director, Stephen Cherrie. a reliable and efficient contractor. In October 2018 the company Cherrie Civil Engineering have completed a number of jobs for of over 5,500m² of bored piers, shotcrete, anchors and soil nails. was named 3rd in BRW’s top 100 fastest growing start up major subdivisions including a $10 million project at Sparks Road, The company also carried out concrete works, forming and pouring “The challenge we set ourselves is to work efficiently and deliver a businesses in Australia with an annual turnover of approximately Wyong excavating for services and roadworks for 140 house lots of 320 structural piles with integral column footings, capping beam result ahead of schedule,” said Stephen. “We achieved this at Northern $40 million. including the construction of a wetland sediment basin with sandstone and integral structural walls. Beaches Hospital, handing over for construction of the lift cores retaining wall in June 2015. Recently Cherrie Civil Engineering months before the expected completion date. Finishing the basement Cherrie Civil Engineering works across New South Wales with completed the early enabling works at for Cherrie Civil Engineering returned to the site in September 2017 excavation and structural work early meant other contractors were able the bulk of their work in the greater Sydney area. Their services Multiplex at a value of $28 million which included asbestos works, to start the road works contract and, over the following 30 weeks, to start without delay. We were able to contribute to CPB Contractors include demolition, site remediation and asbestos removal as well structural works, services, bulk and detail excavation. laid 10,000m² of kerbing and asphalting for roads and pavements. delivering the project ahead of schedule.” as concrete works for the construction of bridges, foundations and Other work included the formation of natural swales, shaping the structural works. Cherrie Civil Engineering also recently achieved For more information contact Cherrie Civil Engineering, 407/29-31 wetland area and the supply and installation of an onsite water With 20 years experience in civil engineering projects Stephen Cherrie, their RMS Prequalification of R2, F20 meaning Cherrie Civil can Lexington Drive, Bella Vista NSW 2153, phone 02 8824 8225, email retention system, retaining walls, fencing and exposed aggregate along with his father Glenn Cherrie and Bob McKinnon, established tender on RMS projects up to $20 million in value. [email protected], website www.cherriecivil.com.au

50 NSW PROJECT FEATURE NORTHERN BEACHES HOSPITAL AUSTRALIAN NATIONAL CONSTRUCTION REVIEW WWW.ANCR.COM.AU NSW PROJECT FEATURE NORTHERN BEACHES HOSPITAL 51 Below Fredon Air designed and constructed the HVAC services for the project, including steam sterilising systems and pressure controlled environments.

Fredon Air NSW is the heating, ventilation largest scale and most complex projects in and air conditioning (HVAC) division of Australia. They also work for state and federal Fredon, a leading provider of engineering, government including the Department of construction and maintenance solutions. Defence on highly sensitive and mission Fredon Air NSW specialises in the design, critical environments. supply and installation of mechanical services for large scale commercial, industrial Fredon Air NSW has extensive experience and healthcare developments. The company’s working for highly rated NABERS Green four other areas of expertise are electrical and Star projects and has Green Star qualified communications, security, technology and engineers on their staff. They have worked asset services. on large scale innovative environmental projects, including 161 Castlereagh Street Fredon Air NSW started the design for the and 50 Martin Place, the largest heritage Northern Beaches Hospital in May 2015 listed building in Australia to achieve a 6 Star with a team of mechanical engineers and NABERS Green Star certification. drafters engaged to design and construct the mechanical services for the project, The Barangaroo development in Sydney was including steam plant for surgical equipment designed to be the largest carbon neutral sterilisation. Early engagement in the commercial precinct in Australia. Fredon design process allowed Fredon Air NSW Air NSW designed and installed mechanical to implement several value engineering services at the $47 million Lendlease building, initiatives, provide experienced input into a three tower development with 80,000m² the Safety in Design process, and produce a of commercial tenancies, achieving a 6 Star detailed construction programme. NABERS Rating for its use of advanced heat reclaiming systems. Fredon Air NSW also “The aggressive programme and the large designed and built the central plant, a vast scale of the job presented a challenge,” 62MW central chiller plant with the largest said Project Manager, Ben Clarke. “We had to seawater cooling system in Sydney, servicing utilise some innovative procurement strategies, all buildings in the 22 hectare precinct. contracting a number of subcontractors and The use of seawater saves 100 million litres suppliers for the installation.” of potable water per year.

Fredon Air NSW was a key member of the Recent healthcare projects for Fredon Air design team leading the multi-services BIM NSW include Royal North Shore Hospital, coordination process. Westmead Hospital, and Mount Druitt Hospital Stage 1. They are “Our work on the hospital certainly also currently engaged on a major healthcare showcases our inhouse design and drafting development at the Prince of Wales Hospital capabilities,” said Ben. “Fredon Air NSW in Randwick. took the design from an outline briefing document to a fully coordinated workshop Fredon is an active member of the Green drawing. The production of an efficient, Building Council of Australia and aims to fully coordinated design, paired with a very reduce their carbon footprint by increasing experienced inhouse site management team recycling, reducing packaging travelling to site resulted in a high quality mechanical services and by using preassembled project fixtures installation. This was all done while keeping made at their premises. a keen eye on providing value for the client.” Fredon was established 1968 as a privately The three year design and installation job owned electrical construction company had 140 installers at work during peak and today has offices across Australia’s periods, and with such a large workforce on capital cities and New Zealand to provide site, Fredon was a key member of the site maintenance and building services across the safety walks. “Ensuring everyone gets home commercial and industrial sectors. safe after a day’s work is key to what we do here at Fredon,” said Ben. For more information contact Fredon Air NSW, 123 Wetherill Street, Silverwater NSW Fredon Air NSW has designed and 2128, phone 02 9475 9400, email contact@ constructed HVAC systems for some of the fredon.com.au, website www.fredon.com.au

52 NSW PROJECT FEATURE NORTHERN BEACHES HOSPITAL AUSTRALIAN NATIONAL CONSTRUCTION REVIEW WWW.ANCR.COM.AU NSW PROJECT FEATURE NORTHERN BEACHES HOSPITAL 53 Below Peter Kelly Flooring laid the vinyl for the wards and surgeries, as well as the carpeting for admin and fitted Bolon feature walls.

Peter Kelly Flooring (PKF) is one of the largest providers importance of delivering commercial floor and wall solutions to of flooring services to the health care industry in Australia. meet specific building requirements,” said Owner, Peter Kelly. In January 2017 PKF started onsite at Northern Beaches Hospital with 30 tradesmen installing vinyl and carpet. “We’ve completed many large projects over the years including a three year job at Royal Adelaide Hospital installing carpet and vinyl floor Carpet was laid in the administration areas and vinyl for the many coverings for the entire hospital,” said Peter. “We’ve completed similar wards, surgeries and operating theatres. PKF also fixed carpet and work at Blacktown Hospital.” vinyl to walls and fitted Bolon, a woven vinyl material, to the 3.3m high walls of the lift lobby and atrium as well as to a ground floor PKF also works across the aged care, education, sports and transport, feature wall. commercial, retail, and high rise residential sectors. The company have recently completed the installation of carpet and vinyl flooring across PKF are expert at delivering commercial floor and wall solutions all the units and common areas of Opal Tower in March 2018. to meet many specific requirements such as for safety and fire compliance, abrasion and stain resistance, infection control and ease of maintenance as well as for anti-static environments.

With offices in both New South Wales and Queensland PKF provides high quality products and installation services throughout Australia and New Zealand. For more information contact Peter Kelly Flooring, 9/6 Gladstone “We have over 30 years experience in the supply and installation Road, Castle Hill NSW 2154, phone 02 9899 6688, email Northern Beaches Hospital, New South Wales of vinyl, carpet, timber and rubber flooring and we understand the [email protected], website www.pkflooring.com.au

54 NSW PROJECT FEATURE NORTHERN BEACHES HOSPITAL AUSTRALIAN NATIONAL CONSTRUCTION REVIEW WWW.ANCR.COM.AU NSW PROJECT FEATURE NORTHERN BEACHES HOSPITAL 55 Northern Beaches Hospital, New South Wales

56 NSW PROJECT FEATURE NORTHERN BEACHES HOSPITAL NSW PROJECT FEATURE NORTHERN BEACHES HOSPITAL 57