Fenner Conveyors

Scope of Works

Shelford Constructions delivered the expansion of Fenner Conveyors' K-Mix facility, comprising a four-level industrial building designed to support specialised rubber mixing and manufacturing operations.

The approximately 9,300m² development incorporates full-height precast concrete external walls, suspended concrete floors, structural steelwork and specialist operational areas including laboratories, maintenance rooms, plant rooms and main drive rooms.

The facility was designed to accommodate current operations while providing capacity for future rubber mixing equipment expansion.

Specialist Building Services

The facility required substantial electrical infrastructure to support laboratories, maintenance areas, plant rooms and main drive rooms with significant power requirements.

An integrated transformer room was designed to accommodate three electrical transformers, with careful coordination of electrical loads and the strategic positioning of switchboards and distribution infrastructure supporting an efficient mains and submains design.

Bunded oil storage facilities were also incorporated with fire safety requirements considered during the design phase.

Passive and mechanical ventilation systems, together with specialist chemical fume exhaust infrastructure, were incorporated to support a safe working environment and manage potentially harmful gaseous emissions associated with the facility's operations.

Key Features

• Approximately 9,300m² GFA
• Four-level industrial manufacturing facility
• Maximum building height of approximately 31 metres
• Suspended concrete slabs at approximately 8m, 16m and 23m
• Full-height precast concrete external walls
• Designed for future rubber mixing equipment expansion
• Specialist dust collection infrastructure
• Recovered dust designed to be reused within the rubber mixing process
• Internal laboratories
• Maintenance and plant rooms
• Main drive rooms
• High-capacity electrical infrastructure
• Integrated transformer room capable of accommodating three electrical transformers
• Bunded oil storage tanks and associated room
• Passive and mechanical ventilation
• Chemical fume exhaust systems
• Designed to support 24/7 operation
• The project achieved 365 days without a Lost Time Injury while construction was undertaken within a complex, live industrial environment.

Construction Challenges

Delivering Within a Live Operational Environment

Construction was undertaken while Fenner Conveyors' existing facility remained operational on the same site.

This required daily coordination with the client to manage construction deliveries, concrete trucks, pumps and crane locations while maintaining the operational requirements of the existing facility.

Traffic management was also critical, with road closures and partial closures required during major construction activities, including complex suspended concrete slab pours.

Complex High-Rise Industrial Construction

The building's approximately 31-metre height introduced significant construction and workplace safety considerations.

High wind conditions were addressed through detailed planning and the design breakdown of the precast concrete panels. Separating installation into approximately 16-metre and 23-metre panel lifts enabled the project team to develop safe and efficient erection methodologies while accounting for seasonal and forecast weather conditions.

Installation of the structural steel frame also required work at heights of up to approximately 23 metres, requiring detailed WHS planning and ongoing weather monitoring.