Mt Thorley Reservoir Access Upgrade

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Scope

• Fabricate & install a new 20m high reservoir access stair tower 
• Remove the old reservoir accessway, remove the handrail around the top of the reservoir and the access hatch on the reservoir roof
• Replacement of the reservoir handrail, and access hatch
• Use cranage and elevated work platforms for removing old access & installing new structure 

Challenges

• Due to small size of the site it was identified that Working at heights throughout the job was going to be an issue with interactions with the crane and moving the EWP around the site  
• Pre planning with the project teams & other contractors allowed for a methodology to do as much of the works from the ground, by building the stair tower on its side, laid over ensuring minimal high risk work activities at all times
• Implementation and continual management of high risk works with the replacement of the access hatch and handrail on the reservoir roof
• Completing the roof replacement works over a weekend to reduce and minimise the overall risks of interrupting the water supply to critical council customers
• Completing the fabrication & installation on a tight deadline to minimise downtime of other works to be completed 
• Weld testing & quality control procedures to meet Australian standards 

Outcome 

• During the shutdown works, compliance with water safety standards and Singleton Council’s critical requirements were maintained
• Client allocated the project team 24 hours to complete specific works under a plant shutdown. The shutdown was completed in 12 hours
• The projects original methodology was to build the stair tower from EWPs with a crane to lift to position the structural steel elements
  • A revised methodology allowed to build the structure on its side at ground level, and then lift the entirety of the structure into place with a 130t crane
  • The revised methodology provided a safer outcome by reducing working at heights risks, and reducing the overall works program for the client.
• Fabrication & installation works completed without an defects or rework, meeting all quality standards/ requirements 
• Successful management of the project meant that all the fabrication/install works were completed on time & on budget