SHAPE Perth delivers its first tilt-up project in WA

SHAPE Perth has completed an exciting new build project in Western Australia that utilised tilt-up panels.

Australian Laboratory Services Pty Ltd (ALS) a prominent testing, inspection, certification, and verification company, engaged SHAPE to undertake the construction of its new facility in Malaga, Western Australia, in response to growing business demands.

Located on the northern side of the boundary, this state-of-the-art laboratory was built adjacent to ALS’s existing premises, which operate 24/7. Minimising disturbances to the client was a major consideration for SHAPE.

Marking a significant milestone for the branch, the SHAPE Perth team harnessed the use of tilt-up panels to successfully construct the new facility. This modern method of construction involves casting concrete panels horizontally on-site before lifting them into position to achieve cost savings, time efficiency, and reduced waste.

Chris Rigden, Project Director at SHAPE, said: “This construction method underscores our commitment to a client-centric approach, ensuring seamless efficiency and progress alongside the uninterrupted 24/7 operation of our client’s facilities on-site.”

The complexity of the project, particularly with panels of varying heights, required meticulous planning and execution. The build involved the on-site casting of 72 panels, each ranging from 8m to 14m in height and averaging between 20 to 25 tonnes – with the heaviest panel weighing in at 30.3 tonnes. The SHAPE Perth team worked with 15 casting beds and navigated the complexities of coordinating with nine different parties involved in the construction.

“According to our draftsman, this project presented with the largest and heaviest panels he had ever encountered in his 40 years in the industry. Coordinating the weight and managing on-site cranes proved to be a complex task for our team, which was overcome with open communication and proactive collaboration between the client, consultants and SHAPE team,” Chris said.

The multilevel facility was designed to meet diverse operational needs. It features a Spectroscopy Instrument Laboratory, located on the first floor of the building, with a meticulously crafted coordinated joinery unit seamlessly integrated with services.

The facility also houses a BLEGS and warehouse area, plant equipment room, Western Power substation, and administrative spaces like offices, meeting rooms, reception, as well as a car park. The rooftop terrace features a 99 kW rooftop solar panel system.

As part of ALS and SHAPE’s joint commitment to reducing their environmental impact, excess reinforcements for tilt-up panels and concrete slabs were recycled.

The facility’s unique finishes set it apart. The front face of the building features a curtain wall with a thermally etched artwork depicting a mineralised vein, while the tilt finishes on the southern elevation and parts of the northern elevation were tinted to effectively hide imperfections in the concrete.

According to our draftsman, this project presented with the largest and heaviest panels he had ever encountered in his 40 years in the industry.

Damian La Rosa, General Manager – WA at SHAPE, states, “SHAPE’s three decades of experience as a leading fitout and refurbishment provider has given us a strong foundation to broaden our capabilities to better service our clients. As innovation has always been at the core of our business, we’re excited to acknowledge SHAPE Perth’s adoption of modern methods of construction, namely tilt-up panel, marked by the successful completion of this groundbreaking testing facility. Despite the challenges, SHAPE’s innovative approach and commitment to sustainability have resulted in a state-of-the-art facility completed efficiently within the projected timeline of 14 months.

“Importantly, our collaborative approach ensured minimal disruption to our client’s ongoing operations. As we continue to expand our capabilities, we remain dedicated to shaping the future of construction and exceeding the expectations of our clients.”

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