be2014 EDITION

BUILDING EFFICIENCY

FEATURED STORIES

Innovation, Growth, Leadership Transforming Sydney’s Darling Harbour Sustainable Maintenance for Greater Performance Data Centre Fire Protection – REVIT up Fresh New Home for Fruit, Vegetable and Flower Market Barangaroo Rising Healthy Start for New Bendigo Hospital Cool Solution for Fed Square Managing Commissioning for Targeted Outcomes Upgrading Sydney Airport

171 Collins St Melbourne

The 2013-2014 year has been an exciting period for the A.G Coombs Group with the successful completion of a large number of significant projects, ongoing development of our capabilities, and the provision of quality technical services to leading organisations as well as new landmark projects. It has also been a very challenging time for us and the industry in general with a continuing tight economic environment and a number of well established competitors ceasing to operate.

The A.G. Coombs Group’s clear point of difference is a unique breadth and depth of specialist capabilities across building services. This year, we have further developed this position that is strongly underpinned by our talented people, strong core values and organisational culture, ensuring that we will continue to deliver both innovative and performance based outcomes of the highest standard.

This year’s edition of Building Efficiency is larger than previous editions to accommodate the increasing scope of our activities. It highlights the innovative building services solutions provided by the A.G. Coombs Group.

Industry leadership, innovation and quality outcomes are central to our delivery of collaborative PPP arrangements, complex design and construction projects, sophisticated multi services maintenance, high end technical management and practical advisory services.

RUSSELL TELFORD

Managing Director

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INNOVATION, GROWTH, LEADERSHIP

Welcome to this year’s edition of A.G. Coombs’ publication, Building Efficiency.

This year has been particularly significant for the A.G. Coombs Group with further implementation of long-term strategic initiatives, including the continual strengthening of our technical expertise, multi service capability and geographic presence.

What has also been pleasing is that the substantial growth experienced over recent times has been accompanied with an ongoing commitment to the A.G. Coombs values based culture.

Also supporting growth is strong governance, with a Group Board comprising Executives and Non Executives with a wealth of diverse experience and a strong focus on the long-term success and prosperity of the A.G. Coombs Group.

The A.G. Coombs Group Building Efficiency magazine is testament to just some of our many achievements this year, and I recommend this publication to you.

CLIVE WEEKS

Chairman

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Technology is driving substantial change and improvement in our industry. Building Information Modelling (BIM) continues to transform the building services industry in Australia, and A.G. Coombs continues to lead in supporting the industry to leverage the radical improvements in design, fabrication, installation and operation that the technology offers. Ongoing implementation of our BIM initiative is further integrating A.G. Coombs’ design and delivery capabilities providing supply chain efficiencies, productivity improvements and better building services outcomes.

The new generation of field service communications technology has transformed the level of information available to technicians, and also the amount and value of information that can be made available from the field – further enhancing our service and maintenance capabilities to deliver important outcomes for facility owners, managers and occupants.

The Group has created and maintains a very strong and diverse pipeline of work. It is active across a very wide range of facilities with specialist services and clearly focused capabilities in healthcare, particularly in large acute care hospitals, specialist science facilities including high containment laboratories, Data Centres and telecommunications establishments, major airports and large complex commercial buildings.

As we approach our seventieth year in operation, our people continue to be our greatest strength. Their safety and wellbeing, continuing personal development and a strong teamwork culture are central to our collective success. Being incident and injury free wherever we have a presence, across every part of our operation is a fundamental commitment. We have maintained our certification to SafetyMap Advanced level as well as national certification to Australian Standard AS4801:2001, and have invested in a range of technology initiatives that contribute to significant safety improvements.

Sustainable business operations and providing valued environmental services to our clients remain a focus and A.G. Coombs’ Environmental Management System maintains independent certification to the AS/NZS ISO14001 Environmental Management Systems Standard.

Looking to the future, the A.G. Coombs Group is extremely well positioned with a strong pipeline of work and strengthened in-house capabilities, including a well-developed and robust business infrastructure, to continue to deliver outcomes of the highest standard for our valued clients.

CONTENTS02 Transforming Sydney’s Darling Harbour

04 Sustainable Maintenance for Greater Performance

06 Data Centre Fire Protection – REVIT up

07 Fresh New Home for Fruit, Vegetable and Flower Market

08 Barangaroo Rising

10 Healthy Start for New Bendigo Hospital

12 Cool Solution for Fed Square

14 Managing Commissioning for Targeted Outcomes

16 Upgrading Sydney Airport

02

TRANSFORMING SYDNEY’S DARLING HARBOUR

Darling Harbour will soon

become home to Australia’s

largest convention and

exhibition facilities, Sydney’s

largest entertainment venue,

a luxury hotel, and one of

the city’s most innovative

residential and working

districts, making it one of the

world’s best places to live,

meet and be entertained.

Sydney’s existing convention, exhibition and entertainment facilities were developed in the 1980s. With industry shifts, however, came the need for greater flexibility and better technology in the conference, exhibition and entertainment space.

The multi-billion dollar redevelopment of the Sydney International Convention, Exhibition & Entertainment Precinct is transforming the site into an exciting entertainment hub that promises to reconnect and re-energise the city through first class business and tourist facilities and the creation of a new urban neighbourhood that will house over 4,000 people and 2,000 workers.

Darling Harbour Live, comprising Lend Lease, Hostplus, Capella Capital, AEG Ogden

and Spotless, is partnering with the NSW Government to deliver the International Convention Centre Sydney (ICC Sydney) – the epicentre of the precinct’s most exciting renewal in 25 years.

Infrastructure NSW is the NSW Government agency managing the transformation. Darling Harbour and the new convention, exhibition and entertainment venues will continue to be publicly owned and managed through Sydney Harbour Foreshore Authority, which is presenting a dynamic calendar of events and entertainment during the redevelopment to keep the precinct active and vibrant.

Appointed by Lend Lease, A.G. Coombs Projects is the sole mechanical and HVAC services provider for the redevelopment of three separate buildings:

• Development of the main International Convention Centre Sydney (ICC Sydney) facility. The ICC Sydney will be capable of holding three concurrent events for an approximate total of 12,000 delegates and will house more than 40 meeting rooms.

• Construction of a new Exhibition Building to feature 35,000 square metres of exhibition space.

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• Construction of a new Theatre to feature an 8,000 seat high class entertainment centre.

The three building projects will be managed and coordinated simultaneously, and the size and complexity of the construction presents a major challenge.

A.G. Coombs is using its sophisticated Building Information Modelling (BIM) software and capability to complete the design and support the construction of the mechanical and HVAC systems across the three buildings. The effective use of BIM facilitates the integration of detailed information relating to design, procurement, building construction, services installation and operational and performance requirements, to significantly improve the design-installation-commissioning process.

The three buildings are very different and have very specific design requirements. The Convention Centre will retain some of its existing structure notwithstanding that it is set to increase in size from 25,000 square metres to 40,000 square metres. The new building’s smoke exhaust system will be double the current size. BIM is significantly assisting with the space restriction issues. Drawing on their experience at Melbourne’s iconic Hamer Hall and the Melbourne Recital Centre, A.G. Coombs is working to ensure that the acoustics in the 8,000 seat theatre are significantly enhanced by the new HVAC system.

Site works commenced in late 2013, with facilities set to open late in 2016. A.G. Coombs’ site preparation works included the draining of all water systems, reclaiming of refrigerant in all systems across the site, retention of pipework, fans and ductwork in the Convention Centre for temporary site accommodation, and the retention of underfloor plenums and ductwork where possible in the existing Theatre. Air handling, air diffusion and central chiller plant strategies have also been devised, which consider redundancy allowances, architectural design requirements, and the targeted LEED Gold environmental rating for the new complex.

Richard Eaton, Construction Director at Lend Lease is positive about A.G. Coombs’ contribution to date, and confident that the team will deliver to its targets.

“Lend Lease is very pleased to be involved with Darling Harbour’s exciting renewal,” said Mr Eaton. “We are confident in A.G. Coombs’ ability to take on the challenges posed by this project and deliver leading and innovative mechanical and HVAC services. Their expertise in BIM and their ability to coordinate, cooperate and collaborate across multiple projects is assisting us with building this vibrant world-class convention, exhibition and entertainment centre. Together, we are helping to renew and revitalise of one of Sydney’s favourite places.”

“We are confident in A.G. Coombs’ ability to take on the challenges posed by this project and deliver leading and innovative

mechanical and HVAC services. Their expertise in BIM and their ability to coordinate, cooperate and collaborate across multiple

projects is assisting us with building this vibrant world-class convention, exhibition and entertainment centre. Together, we are

helping to renew and revitalise of one of Sydney’s favourite places.” Richard Eaton – Construction Director, Lend Lease

TRANSFORMING SYDNEY’S DARLING HARBOUR

BEST OF BIM

A.G. Coombs continues to be recognised as a leader in Building Information Modelling (BIM) with digital models now being used throughout all phases of its project delivery. This includes design analysis, procurement, services coordination as well as BIM-to-field site layout.

With the leverage available from constructible Revit® modelling, and increasing amounts of data being embedded in the services model, the virtual build process has become a critical phase of project delivery. Involving the conversion of the design model to a fully constructible Revit® model, the virtual construction process is now the key to a wide range of innovative construction practices that are now being applied by A.G. Coombs.

Working closely with clients, consultants and key suppliers, A.G. Coombs continues to refine the virtual build process with efficiencies and risk and reward opportunities shared.

The delivery of sophisticated As-Built Revit® models is now a reality and A.G. Coombs is working with its facility management and maintenance clients to utilise these models to deliver benefits in building operation.

Copyright Darling Harbour Live

04

SUSTAINABLE MAINTENANCE FOR GREATER PERFORMANCE

For a building to operate effectively,

it must find the right balance between

system performance and energy

efficiency. Add to that occupant

comfort, and the whole process of

achieving optimal building operation

becomes even more of a challenge.

Justin Rooke (left) and Ben O’Brien, A.G. Coombs Service

Cromwell Property Group, an S&P 200 company listed on the ASX, is one of Australia’s leading property investment and funds management groups.

In recent years, Cromwell undertook extensive works at two of its Melbourne properties, 321 Exhibition Street and 700 Collins Street, aimed at improving sustainability performance whilst maintaining comfort conditions for occupants.

321 Exhibition Street is a 22-level, Property Council of Australia A-Grade office tower and home to anchor tenant, Origin Energy. When Australia Post vacated the building in 2010, Cromwell undertook a major refurbishment exercise, which included the introduction of a state-of-the-art gas fired tri-generation plant. The tri-generation plant runs on a 1.2 megawatt natural gas powered generator, and produces electricity and chilled and heating water for the building’s air conditioning system.

The refurbishment also incorporated a range of other green initiatives and was a finalist in the 2014 Property Council of Australia Innovation and Excellence Awards, in the category for Best Sustainable Development – Existing Buildings, and is rated as one of the most sustainable development projects in Australia.

To ensure the operational and energy efficiencies of the building are maintained, Cromwell enlisted A.G. Coombs as a partner in the operation of the building’s HVAC and energy services.

The A.G. Coombs team embarked on an energy performance audit and recommended a series of improvement works. It was found that the primary/secondary chilled water system was not functioning well, and modifications were identified to enable the Building Management Control System (BMCS) to better control chilled water flows and improve the sequencing of the chillers.

Cromwell and A.G. Coombs’ mechanical and electrical specialists continue to work together to investigate ways to improve the operation of

the building’s HVAC and electrical systems to ensure that the tri-generation system interacts seamlessly with the other building systems.

Cromwell’s Facilities Manager, Terry Byrne, is confident that with the support of A.G. Coombs, the building will continue to operate at its peak performance.

“Achieving our 5.5 Star NABERS Energy rating is not something we take for granted. We are pleased to have A.G. Coombs working as part of our team, to deliver ongoing reliability as well as actively seek continuous performance and service improvements wherever we can,” he said.

When constructed in 2004, 700 Collins Street was one of the pioneering commercial buildings in the now booming Docklands office precinct. The Property Council of Australia A-Grade office tower is the home of the Australian Bureau of Meteorology (BoM) and a prominent landmark at the gateway to the Docklands.

In 2011/12, Cromwell undertook a Green Building Fund sponsored project that targeted various improvements to the HVAC system to help achieve a targeted 4.5 Star NABERS Energy rating. The project incorporated a redesign of controls logic for heating and cooling and the operation of the air handling system. Other modifications to convert the chilled water loop into an in-series arrangement also contributed to improved chiller performance.

Formal rating following the project confirmed a successful outcome in excess of the targeted rating.

Impressed by A.G. Coombs’ performance at 321 Exhibition Street, Cromwell engaged the team to manage the ongoing maintenance of the air conditioning systems at 700 Collins Street. A structured continuous improvement process applied to the building’s systems has improved occupant satisfaction with the building’s air conditioning system. Key tenant BoM is also impressed with the work undertaken by A.G. Coombs, and has engaged A.G. Coombs directly to undertake its own maintenance and workspace improvements.

In 2013, Cromwell tasked A.G. Coombs Advisory to investigate and resolve a nagging issue with the chilled water loop. A.G. Coombs undertook an engineering review of the chiller system design and implemented a solution involving alterations to pipework and controls. The solution resolved the issue and also improved system reliability and performance.

As part of A.G. Coombs’ ongoing commitment to continuous performance, a recent audit of the building’s energy performance identified various Energy Conservation Measures (ECMs). These have been complied into an implementation plan that has already commenced. One such project involved chilled water flow sensing and has reduced the energy consumption of the two large primary chilled water pumps by almost half, confirming that only one of the pumps needs to run on most days of the year.

Ruway Cheok, Senior Facilities Manager at Cromwell, has expressed his satisfaction with A.G. Coombs’ performance. “A.G. Coombs came in after the Green Building Fund project targeted the ‘low lying fruit’ in energy savings... I’m impressed with the solutions that A.G. Coombs still found following the comprehensive energy audits.”

“Achieving our 5.5 Star NABERS

Energy rating is not something we take

for granted. We are pleased to have

A.G. Coombs working as part of our

team, to deliver ongoing reliability

as well as actively seek continuous

performance and service improvements

wherever we can.”

Terry Byrne – Facilities Manager, Cromwell

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171 COLLINS A WINNER

the Urban Taskforce Development Excellence Awards 2014, announced in July 2014.

BHP Billiton took out the Best Office Interior Award for both Australia and Asia Pacific for the design of its global head office and now goes through to the International Property Awards.

Appointed by construction managers Brookfield Multiplex, A.G. Coombs was responsible for installing and commissioning specialist HVAC and mechanical services to both the base building and BHP Billiton’s tenancy, and is proud to be associated with this successful building.

SUSTAINABLE MAINTENANCE FOR GREATER PERFORMANCE

As the first Premium Grade, 6 Star Green Star office building to be constructed in Melbourne, 171 Collins Street, which is also BHP Billiton’s Global Office Headquarters in Melbourne, has been recognised with a number of prestigious awards since its completion in mid 2013. At the 2014 International Property Awards (Asia Pacific), it was judged the Best Commercial High Rise Development in Australia, and was highly commended in the Office Development Australia category. It has also been awarded the Hanson’s Green Building Award at the United Nations Association of Australia World Environment Day Awards in June 2014, and received the Sustainability Development Award at

Equinix, the world’s largest IBX Data Centre and colocation provider, is building its first Melbourne Data Centre and Revit® software is being used to design the new integrated fire protection system.

Autodesk Revit® is building information modelling (BIM) software. It allows architects and engineers to design a building and structure its components in 3D accessing building information from databases.

The new Data Centre, MEL 1, is located in Port Melbourne, and will help to meet strong regional demand for premium Data Centre services driven by growth in data consumption and cloud services in the Australian and global IT markets.

The 9,800 square metre Data Centre is being built in four stages. The facility will ultimately

accommodate in excess of 1,500 cabinets, offering approximately 1,700 square metres of premium colocation space as well as interconnection and support services to a range of networks, financial institutions, and enterprise, content, cloud and IT services companies. Stage 1 is scheduled for completion in November 2014 and will house approximately 375 cabinets.

Large amounts of heat are generated by high speed data processing and, whilst high redundancy air conditioning is used in these critical facilities, effective fire detection and

suppression systems are very important for the high confidence operations required by the Data Centre’s clients.

Walker Fire Protection was appointed by builders FDC to install, commission, test and maintain a new integrated fire protection system in Stage 1. The fire system design incorporates VESDA® (Very Early Smoke Detection Apparatus) systems for earliest possible detection, a multi-zoned, dry-pipe, double-interlock, pre-action fire suppression system, and occupant warning systems. 3D BIM Revit® was used to optimise the design and identify installation issues, including potential system component clashes prior to construction. It has also assisted with planning for future Stages 2, 3 and 4.

The thousands of computer racks will all operate

at high capacity, increasing electrical power and significantly heating the air. If heat removal systems fail, fires can occur. Comprehensive cooling and fire safety is paramount to the entire project and for ongoing operations.

Following installation of the new fire detection and suppression system, comprehensive testing will ensure that it is operating effectively and efficiently.

FDC is pleased with the team’s commitment to deliver a safe, operational, integrated fire system for Equinix.

“The support of Walker Fire Protection together with the team’s leading capability

in Revit® is helping us to build the Data Centre for high confidence operations

now, and into the future.” FDC

DATA CENTRE FIRE PROTECTION – REVIT UP

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Effective fire protection in Data Centres is a priority, with these mission critical facilities housing high density information and communications technology and generating large amounts of heat. Careful design is critical to fire system end performance; Building Information Modelling is set to become the key to efficient design and smooth project delivery.

Located in West Melbourne since 1969, the Melbourne Markets is one of six large centralised fresh produce markets in Australia and is the wholesale trading and distribution centre for Victoria’s fresh produce industry. Its operations include the Wholesale Fruit and Vegetable Market and the National Flower Centre.

As part of a large infrastructure project being managed by the State Government of Victoria, these market facilities are being relocated to a new 70 hectare site in Epping in Melbourne’s north, where they will form the core of a modern, innovative and efficient fresh produce trading and distribution precinct.

Housing over 600 grower/wholesaler stands and 140 wholesaler trading units, and with an annual turnover in excess of $1 billion, the Wholesale Fruit and Vegetable Market is an important part of the state’s economic infrastructure, The National Flower Centre houses 140 permanent grower stands plus an extensive group of casual grower stands. Over 700 floristry businesses source their supplies though this market.

These large and complex facilities require a very significant amount of refrigeration to keep produce cool, and a central refrigeration reticulated system was identified as the most effective and efficient way to best meet this need.

Appointed by the Principal Contractor Lend Lease Building, A.G. Coombs has been responsible for the installation of a new ammonia/propylene glycol refrigeration system within the major warehouse buildings at Epping. Working in conjunction with specialist refrigeration subcontractor, Oomiak Industrial Refrigeration, the team has installed and undertaken the first stage of commissioning of this large-scale plant.

The system includes primary, secondary and tertiary components. The large central primary refrigeration plant features an ammonia-based fluid chilling system

with cooling capacity of up to 15,000kW (or 15MW). From this plant, propylene glycol (food grade) fluid at -9 degrees Celsius is circulated via a secondary pipe-work system located at high level in the buildings to multiple heat exchangers serving the tertiary systems. Cooling of the tenancies will be achieved by individual tertiary systems also using the propylene glycol fluid.

The sheer size and scale of the project required very large underground chilled propylene glycol pipes to be laid prior to building construction. A.G. Coombs maximised the use of its off-site integrated prefabrication facility to design and assemble the 124 frame mounted secondary system heat exchanger assemblies and 900mm diameter pipework support structures. These complex assemblies incorporated electronic sensors and controls and were pre-commissioned and tested prior to leaving the factory site. The use of prefabrication methodologies markedly reduced the extent of working at height on site, significantly lowering the safety risk and helping to reduce installation time.

All works have been delivered in accordance with the required environmental standards for the targeted 4 Star Green Star rating under the Industrial Pilot Rating Tool.

Ed Farrell, Services Manager at Lend Lease, is impressed but not surprised by A.G. Coombs’ ability to successfully deliver to such a large scope.

“Constructing such a sizable facility as the new Melbourne Markets demands the skills and experience of trusted service providers,” he said. “A.G. Coombs has a proven track record in effectively managing the complexities brought about by large-scale projects. Adding to this is their integrated prefabrication capability, which is of significant benefit to Lend Lease in reducing risk and improving on-site safety.”

“Constructing such a sizable facility as the new Melbourne Markets demands the skills and

experience of trusted service providers. A.G. Coombs has a proven track record in effectively

managing the complexities brought about by large-scale projects. Adding to this is their

integrated prefabrication capability, which is of significant benefit to Lend Lease in reducing

risk and improving on-site safety.” Ed Farrell – Services Manager, Lend Lease

FRESH NEW HOME FOR FRUIT, VEGETABLE AND FLOWER MARKET

DATA CENTRE FIRE PROTECTION – REVIT UP

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The relocation of Melbourne’s Wholesale Fruit, Vegetable and Flower Market is one of the biggest infrastructure projects recently undertaken in Victoria and its central refrigeration plant is one of the largest of its kind in Australia.

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BARANGAROO RISING

Construction of the largest commercial development in Australia, Barangaroo South, has commenced, and tower T2 – one of the three towers at the site’s iconic “International Towers Sydney” development – is on the rise. The use of innovative, risk lowering BIM and prefabrication methodologies is helping with the efficient, safe and effective installation of the tower’s critical systems.

Barangaroo South’s T2 tower is the second tallest tower of the three, comprising 42 floors and around 95,000 square metres of office space. From mid 2015, this world-class commercial office facility will be home to Westpac Banking Corporation and corporate law firm, Gilbert + Tobin, among others.

From the outset of the Barangaroo project, Lend Lease had identified the benefits of prefabrication for construction and safety. Typically, services risers are installed piecemeal, one component at a time. Lengths of duct, pipework, and components such as valves and service platform elements are put into place, joined and fixed by trades working in the shaft. Post installation system testing also often requires further work in the risers. In addition to the risks from working-at-height (up to 42 floors at T2 and 49 floors at T1), there are also risks of materials/debris falling from above during installation.

Lend Lease selected A.G. Coombs to deliver mechanical services to T2 and subsequently T1, which at 49 floors is the largest tower at International Towers Sydney.

As lead services coordinator, A.G. Coombs has commenced with the coordinated detailed design, supply, delivery and installation of T2’s mechanical systems. Building Information Modelling (BIM) has assisted significantly with system coordination and in developing optimised virtual build plans during design. Innovative services prefabrication and installation techniques are now helping to improve the on-site installation processes.

A.G. Coombs is applying its prefabricated services riser methodology and, working with principal contractor Lend Lease, has developed an integrated prefabricated riser solution for T2 at Barangaroo. This is believed to be a first for a high rise building.

A.G. Coombs is pre-installing ductwork, pipework, fire rated walls and platforms and other building services features into engineered 3-storey frames. This work is carried out in an off-site dedicated prefabrication factory and the riser sections are delivered to site and lifted into place.

At Barangaroo, the riser sections are taking less than an hour to install from the time the truck arrives on site. Craned into place and installed as the building grows, they are secured into the four riser shafts with fastenings that can be installed from the floor deck, further reducing the need for working at height. Installation of air handling plant and floor HVAC systems including duct, pipe and chilled beam units is also moving progressively up the building connecting to the risers, which are believed to be the tallest prefabricated services risers in Australia.

In short, on this building, many thousands of hours of complicated and high risk site installation are being transferred into a controlled factory environment. This new approach to services installation has significantly reduced construction risk on this landmark project and is set to become an industry standard in Australia.

The Lend Lease initiative is also seeing A.G. Coombs’ BIM capability and prefabrication methodology being applied to the tallest tower, T1, which will stand at 217 metres. Currently under detailed design, the construction of this building commenced in July 2014, with the installation of the services risers due to commence in March 2015.

The Barangaroo commercial towers are targeting a 6 Star Green Star Design (As Built v3) rating along with a minimum 5 Star NABERS Energy rating. Mechanical services have a significant role in the building’s operational energy usage and environmental impact. Energy efficient HVAC systems,

including state-of-the-art building management and controls, are being installed at T2 to address the demanding Climate Positive Barangaroo precinct master plan to achieve the benchmarks of Carbon neutral for operating energy, net water positive and zero waste. To date, T2 has received a 6 Star Green Star Design (Office Design v3) rating. It is the largest building in Australia to receive the 6 Star Green Star certified rating which represents world leadership in environmentally sustainable building practices.

Tom Waters, Lend Lease’s Construction Manager for tower T2, is impressed with A.G, Coombs’ prefabrication capability and the team’s commitment to delivering safe and compliant services to Barangaroo South.

“A project of this size and scope calls for innovative low-risk design and delivery methodologies. Lend Lease recognised the safety benefits prefabrication could bring to the project. A.G. Coombs has brought its BIM capabilities and leading prefabrication methodologies to the project and together we are focused on delivering a smooth, safe and high quality mechanical services installation.“

International Towers Sydney are scheduled for completion by the end of 2016.

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HORIZONTAL SERVICES PREFABRICATION

Large scale prefabrication has become an important aspect of A.G. Coombs’ project delivery with benefits to programme, quality and safety risk.

A.G. Coombs has introduced large prefabricated services risers on major projects including Sydney’s Barangaroo South development, and Melbourne’s 171 Collins Street building, the Box Hill Hospital redevelopment and Collins Square.

Prefabrication of horizontal services runs has also become an important A.G. Coombs innovation. Beginning with the new Royal Children’s Hospital in Parkville, this technique was subsequently applied at a major new town centre development project in Victoria, and now at the Bendigo Hospital project.

For the new town centre, 204 horizontal modules were prefabricated for four precincts, incorporating around 4.8 kilometres of pipework. At Bendigo, around 400 horizontal multi-services modules will be installed along with 45 riser sections.

Prefabrication of horizontal services modules allows the incorporation of design and installation features not possible and/or practical with on-site installation. These include features to enhance the building design, to simplify and improve construction and improve the safety of future access for maintenance. A.G. Coombs’ installation methodology also means virtual elimination of the use of oxy acetylene welding on site, significant reductions in time spent working at heights by A.G. Coombs and its subcontractors, and a reduction in the congestion of on-site trades.

“A project of this size and scope calls for innovative low-risk design and delivery

methodologies. Lend Lease recognised the safety benefits prefabrication could

bring to the project. A.G. Coombs has brought its BIM capabilities and leading

prefabrication methodologies to the project and together we are focused on

delivering a smooth, safe and high quality mechanical services installation.“

Tom Waters – Construction Manager for T2, Lend Lease

Bendigo Hospital was one of the earliest district hospitals established in Victoria. It started out in 1853 as the Bendigo Gold District Hospital and later, following relocation, became known as the Bendigo Hospital.

The hospital has grown significantly, particularly since 1990, and one of the key outcomes from the current project is the unification of the existing two sites and three precincts into one world-class regional hospital for the people of the Loddon Mallee region.

The Project is being delivered as a public-private partnership (PPP) under the State Government’s Partnerships Victoria policy. The Exemplar Health consortium, comprising Lend Lease, Capella Capital, Spotless and Siemens, is designing and building the new hospital and will provide a range of facilities management services to the new facility for 25 years after construction is completed. A.G. Coombs in conjunction with local Bendigo area alliance partners, including McCaig Air Conditioning, is delivering mechanical

services as part of the Lend Lease design and construction team.

The new hospital is being built on land behind the existing Anne Caudle Centre Campus and, in addition to 372 new beds and 10 new operating theatres, the $630 million development will include a childcare centre, wellness centre, patient and visitor accommodation options, conference facilities, a retail precinct with cafes and a new multi-storey car park.

The new hospital has been designed to accommodate increasing demand into the future and will incorporate the best elements of modern hospital design from around the world. Its large-scale mechanical and HVAC systems are being designed using A.G. Coombs’ sophisticated Building Information Modelling (BIM) software. Combined with leading prefabrication methodologies, BIM will help to streamline the process of manufacture, systems coordination, installation and commissioning, producing project delivery

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HEALTHY START FOR NEW BENDIGO HOSPITALThe Bendigo Hospital Project is the largest regional hospital development in Victoria. It will deliver

a world-class healthcare facility that will incorporate the latest design and technology solutions.

GIVING HELP, GIVING HOPE

A.G. Coombs continues its long-standing support of foundation charity, Challenge, with ongoing fundraising activities and the provision of maintenance services to the Challenge Family Centre in West Melbourne.

The Centre helps deliver programs and services to children and families living with cancer, including massage therapy, counselling, playgroup and information seminars. A.G. Coombs played a vital role in the redevelopment of the Centre providing a complete upgrade of the air conditioning system. The project included the delivery of full design, construction and commissioning services, with contributions from A.G. Coombs employees, suppliers and specialist contractors. A.G. Coombs and Service personnel now provide ongoing maintenance services for the Family Centre’s air conditioning system.

Recent fundraising, including the A.G. Coombs Group Annual Dinner & Awards Night and the inaugural A.G. Coombs Group Challenge Community Day, with employees donating leave days and funds, has exceeded over $30,000 for Challenge, contributing to the great work undertaken by the charity in the last year.

improvements and ongoing operational and maintenance advantages. It will also significantly enhance on-site safety with the virtual build pre-planning of works identifying any safety issues early, and prefabrication of substantial parts of the work seeing the transference of many complicated on-site tasks to a controlled factory environment.

Up to four hundred vertical and horizontal multi-services modules are being constructed off-site in A.G. Coombs’ integrated prefabrication facility. A.G. Coombs’ particular approach to this modular services installation is also helping reduce the unnecessary locating of services and equipment in patient and treatment areas, and will result in less disruption caused by maintenance activities.

The A.G. Coombs installation also includes specialist equipment such as fume cupboards, further adding to the services integration and coordination challenges.

A seismic survey undertaken in 2006 confirmed that Bendigo is located in an earthquake zone.

“A.G. Coombs is leveraging its ability to deliver large critical healthcare facilities,

such as Melbourne’s Royal Children’s Hospital. This, together with their leading

expertise in BIM and prefabrication strategies, and the local skills and expertise

offered by the Bendigo-based alliance partners, puts them in a great position to

successfully deliver the services fit for this world-class regional hospital and its

21st century environment.” David O’Shaughnessy – Project Director, Lend Lease

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Accordingly, all plant and equipment to be installed will be braced to meet the specific structural and safety seismic requirements, to ensure that the systems remain operational and safe in the event of an earthquake.

The new hospital is adjacent to a residential area and close acoustic controls are required for in-patients and the surrounding neighbourhood. Careful selection of mechanical equipment and placement of sound attenuation devices will help ensure the sound volume levels produced by the operational HVAC systems is minimised.

In support of the hospital’s vision to be sustainable, energy-efficient and future-ready, a new gas-powered tri-generation system will supply low Carbon electrical power, heating and cooling to the entire building. Rooftop adiabatic coolers, in place of standard cooling towers,

will help with reducing water consumption, as well as mitigating the risk of Legionella through the use of a closed loop heat rejection system.

David O’Shaughnessy, Project Director at Lend Lease, trusts in A.G. Coombs’ capability and relationships with local alliance partners to deliver a hospital that will meet Bendigo’s needs now and into the future.

“We are excited about building the new Bendigo Hospital; a key project for both the local area and for regional Victoria,” said Mr O’Shaughnessy. “A.G. Coombs is leveraging its ability to deliver large critical healthcare facilities, such as Melbourne’s Royal Children’s Hospital. This, together with their leading expertise in BIM and prefabrication strategies, and the local skills and expertise offered by their Bendigo-based alliance partners, puts them in a great position to successfully deliver the services fit for this world-class regional hospital and its 21st century environment.”

The new Bendigo Hospital is due for completion in December 2016.

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Federation Square is home to major cultural attractions, world-class events, tourism experiences and a wide array of restaurants, bars and speciality stores, all housed in visually stunning structures.

Completed in 2002, the complex features a range of innovative building services systems from the unique ‘Labyrinth’ passive cooling system through to sophisticated air conditioning, water management and lighting systems.

A.G. Coombs Service has provided maintenance services to Federation Square’s three chillers since 2009. These supply chilled cooling water for all the major facilities at the site including the National Gallery of Victoria’s Ian Potter Centre, and the Australian Centre for the Moving Image and SBS buildings, as well as the large enclosed public spaces.

In the middle of the night, during the week between Christmas and New Year 2013, A.G. Coombs Service received a call to advise that both of Federation Square’s large chillers had unexpectedly failed.

The site was reduced to just 20 percent cooling capacity at one of the busiest times of the year, and temperatures in Melbourne were moving into the 30s adding to the challenge. The reduction in cooling capacity posed a major challenge for the site, placing pressure on

both the comfort conditions across Federation Square’s many tenancies, as well as the site’s galleries, where consistent temperature and humidity levels are critical. This demanded an immediate response, and one of the 2300kW chiller units was reinstated within 24 hours, increasing the cooling capacity and lowering risk across the site.

The second chiller unit had unfortunately experienced a catastrophic electrical failure to an extent that required either a very extensive

repair or replacement of the 12-year-old 2300kW machine. A new chiller would take up to 10 weeks to source; a large-scale and reliable temporary cooling solution was required.

A.G. Coombs Service in conjunction with A.G. Coombs Projects worked throughout the New Year holiday period to design and install the temporary system. The sourcing, fabrication and installation of new pipework,

accessing a temporary chiller machine, power supply changes, structural building works and arranging rigging and scaffolding services were all made more challenging with subcontractor and supplier offices closed for the holidays. Additionally, the requirement to carry out work on-site over the very busy New Year period meant extra care was needed to minimise disruption to Federation Square’s large back of house area, which sees a significantly increased amount of activity during this time.

In parallel with the temporary replacement works, A.G. Coombs Service worked with Federation Square management to develop a short-term cooling load reduction and load shedding strategy to help ensure that critical conditions weren’t compromised and front of house areas were maintained at acceptable levels across the site.

The temporary cooling system was fully functional and site cooling capacity returned to 100 percent by the following week. It was

during the commissioning of the temporary plant that the second chiller unit also experienced a similar major electrical failure. The capacity of the temporary cooling system now required doubling. This had to be done quickly, as Melbourne was approaching a week of predicted 40+ degree Celsius days that turned out to be a record-breaking heatwave. Coupled with this was a heavy event program

Melbourne’s Federation Square is one of Victoria’s top

destinations, annually hosting over 2,000 events and

welcoming 10 million visitors. A major plant failure in late

December, ahead of predicated heatwave conditions,

severely compromised the facility’s cooling systems and

required an extraordinary effort to keep things cool.

“The works undertaken by A.G. Coombs Service demonstrate the team’s ability

to quickly and effectively deliver a solution in very challenging circumstances.

Their depth of expertise and capability and commitment to client outcomes, in

conjunction with the business’s strong subcontractor and supplier relationships,

effectively saved the day.” Mark Bullen – Manager Operations, Federation Square

COOL SOLUTION FOR FED SQUARE

AWARD WINNING APPRENTICES

It’s been another great year for A.G. Coombs apprentices and the recognition of their effort and dedication to training.

Fourth year sprinkler fitting apprentice, Callum Hearn of Walker Fire Protection, received the 2013 Allan Coombs Training Award in recognition of his ongoing application, effort and dedication to both his role and the building services industry.

A.G. Coombs Service refrigeration apprentice, Ryan O’Connor (pictured), has been awarded the 2014 First Year Apprentice of the Year – Alan Broadhead Award by the Box Hill Institute of TAFE; his second award from this Institute.

A.G. Coombs Projects drafting apprentice, Patrick O’Reilly, has been presented with the Drafting Traineeship Award at the 2014 AMCA Training Achievement Awards. Drafting apprentice

Jackson Taylor was a finalist in the same Award, and Michael Sealey, a refrigeration apprentice with A.G. Coombs Service, was a finalist in the Training Achievement Award category.

This year, A.G. Coombs’ award winning training program saw 15 apprentices graduate as qualified tradespeople and at July 2014, apprentice numbers stood at 50 across the Group.

where thousands of people were expected to gather in Federation Square to enjoy the festivities in the lead-up to the 2014 Australian Open tennis championships.

A second temporary replacement chiller was sourced by the Service team and transported from Queensland. Long hours on site saw the second temporary cooling system in place and fully functional within three days.

During this entire ordeal, temperatures and climate conditions were managed to minimise impact with no interruption to activities across the site; and the intense work behind the scenes to restore cooling capacity was totally unseen by the Melbourne holiday crowds.

Two new energy efficient chillers have since been successfully installed by A.G. Coombs Projects.

Mark Bullen, Manager Operations at Federation Square said “Federation Square is a major attraction in Victoria, having welcomed more than 90 million visits since its opening in 2002. Maintaining optimal operational performance of the site’s systems is essential in ensuring the positive experience sought by our visitors. The works undertaken by A.G. Coombs Service demonstrate the team’s ability to quickly and effectively deliver a solution in very challenging circumstances. Their depth of expertise and capability and commitment to client outcomes, in conjunction with the business’s strong subcontractor and supplier relationships, effectively saved the day.”

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Commissioning of building systems has become a key component of project delivery, ensuring the correct installation and operation of the critical systems that underpin the safe, effective and efficient operation of the building and its orderly handover from construction to operation. On complex and demanding projects, special attention is required to effectively manage the commissioning process across multiple trades, integrated and interdependent systems and facility features to ensure the required outcomes are achieved and clearly demonstrated on time. Strong planning, communication and disciplined management skills are must haves and the earlier the process starts the more advantage is gained.

The University of South Australia (UniSA) has a strong and clearly stated commitment to sustainability. Its new $80 million Learning Centre, The Jeffrey Smart Building, at its City West campus is set to be awarded a 5 Star Green Star Education Design Rating and is aiming to follow this with a Green Star As-Built rating outcome from construction. The project is an initiative with the Australian Government, who contributed $30 million as part of the Education Investment Fund, and the cutting-edge facility features a diverse range of learning spaces and services supported by state-of-the-art technologies.

Applying a well proven Green Star Independent Commissioning Agent (ICA) approach during construction, A.G. Coombs Advisory worked closely with builders Hindmarsh Construction to ensure all building services at the Learning Centre were successfully installed and appropriately commissioned and documented. Designed by Bestec and incorporating sustainability advice provided by Umow Lai, the facility’s innovative HVAC system uses induction VAV technology – European technology that promises improved comfort control and energy efficiency – and heat recovery air handling systems. A complete design peer review by Advisory

was followed by the development of detailed commissioning and system tuning strategies. These enhanced the system’s efficiency and helped deliver ongoing operational and energy efficiencies through optimised system performance.

The A.G. Coombs Green Star ICA approach assured the required outcome and UniSA’s objective of developing a world-class learning facility that sets a sustainability benchmark for the University.

Operational outcomes are standard for many projects, but become critical when the facility demands high levels of safety and security from day one.

The Hopkins Correctional Centre Expansion Project (HCCEP) in Ararat, Victoria, is a public-private partnership (PPP) which includes a 350 bed expansion of Hopkins Correctional Centre and facilities maintenance of the adjacent 40 bed Corella Place transitional facility. The project incorporates new building construction, refurbishment of the existing facility and a requirement for phased construction and occupation.

A.G. Coombs Advisory acted as an advisor to builder Brookfield Multiplex for commissioning handover and the completion requirements of the project.

The key aim was to ensure that all facilities comply with the strict contractual requirements, or “Schedule 10”, as it is known. There was an emphasis on security and critical engineering systems and an understandable need for equipment to remain operational under a series of simulated failure modes such as network communications failure and mains failure. There are also particular standards around methodologies and deliverables that present challenges unique to prisons, including a “proven simultaneous load operation” requirement applied to a range of systems. The team even had to prove that the centre’s kitchen could deliver 900 meals simultaneously by undertaking a test cook!

Working with the Department of Justice and its PPP partner AEGIS, a plan to deliver integrated systems testing over sequenced phases of construction was put in place in addition to demonstrating fault free operation of the high-security facility following completion of commissioning.

Applying its experience in mission-critical facilities, A.G. Coombs Advisory devised the framework and processes for the testing and completion strategy. Neil Watson, Senior Services Manager of Brookfield Multiplex, said, “We are impressed with the team’s commissioning management capability in ensuring the optimal operational performance of this critical facility.”

It is no surprise that time outcomes are also important to building owners. Some projects simply cannot afford to overrun.

Melbourne’s newest shopping precinct, Emporium Melbourne, opened its doors to the public as planned; at 9am on Wednesday 16 April, 2014. The precinct features a mix of local and international designers, innovative concept and flagship stores and world- class architecture, and is considered to be the city’s premier retail centre.

Engaged as technical experts, A.G. Coombs Advisory acted as Commissioning Manager for builder Grocon on the project, providing a detailed and disciplined commissioning management approach to ensure the task was completed on time.

A key challenge was driving the completion of the Integrated Communications Network (ICN); the backbone for all communications, controls and monitoring systems in the precinct. Commissioning plans with tight schedules were developed for all services, including the critical life safety systems with their strict compliance requirements. Completion and full integration of the ICN supported the precinct’s achievement of its Certificate of Occupancy in time for doors to be opened to the public on schedule.

David Leggett, Services Manager at Grocon, said that, “A.G. Coombs’ commissioning management expertise was an integral part of our team to achieve the required operational performance of the building’s systems and cross the line in meeting our strict time targets.”

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The achievement of demonstrated performance outcomes is a major issue in the construction of many modern facilities. Whether it is ‘drop dead’ start-up dates, tough specialist certification requirements or turnkey operational performance, a sophisticated approach to managing commissioning is required to deliver these outcomes within tight construction budgets and timelines, particularly in challenging, highly technical projects.

MANAGING COMMISSIONING FOR TARGETED OUTCOMES

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HIGH ENVIRONMENTAL STANDARDSA comprehensive Environmental Program in place since 2005, together with continuous development to its Environmental Management System, has helped to ensure ongoing independent certification to the AS/NZS ISO14001:2004 Environmental Management Systems Standard for A.G. Coombs.

The Group’s Environmental Program features integrated policies, guidelines and activities that assure compliance with environmental legislation and work towards actively minimising the environmental impact of A.G. Coombs’ business operations and those of our clients.

Focusing on the use of materials and resources such as metals, refrigerants, fuel, consumable goods, energy and water, along with waste management, some of the Program’s initiatives include:

• Actively working with suppliers and subcontractors to reduce their environmental impact.

• End-to-end waste minimisation processes that optimise material usage, reduce rework and ensure efficient reuse or recycling of waste (all revenue from the recycling of materials is donated to charity).

• Vehicle fleet procurement, management and operation to minimise environmental impact.

• Investment in audio visual and other technologies to improve telecommunications and reduce need for travel between locations.

• Education, training and coaching to help A.G. Coombs staff and site personnel to minimise their personal environmental footprints.

Sydney Airport is one of the oldest continually operating airports in the world. The first flight took place in November 1919 when Nigel Love took off and circled the aerodrome.

It has grown to become Australia’s busiest airport. In 2013, it was used by nearly 38 million passengers – an average of more than 100,000 passengers each day. Eight kilometres south of Sydney’s CBD, it is also Australia’s largest international and domestic air freight hub, processing 550,000 tonnes of freight a year, and this is expected to double by 2033 to over one million tonnes.

In 2013, A.G. Coombs was appointed by Sydney Airport to carry out a range of mechanical services and Building Management & Controls System (BMCS) upgrades to key plant in International Terminal T1’s Central Services Building (CSB).

The CSB contains water cooled chillers and the primary and secondary chilled water pumping systems serving Terminal 1 (T1), along with the cooling towers and condenser water pumping systems.

Engineering reviews and on-site testing led by A.G. Coombs supported the chilled and condenser water system enhancements to the terminal building’s hydraulic distribution, and a functional upgrade to the BMCS control of the systems. In addition to the installation of new and reliable plant, outcomes have included improved water flow between the CSB and T1, which is separated by over three kilometres of pipework, and significant enhancements to the cooling system’s effectiveness and efficiency.

Stuart Naylor, A.G. Coombs’ Project Manager for Sydney Airport, said about the improvement works delivered to date, “The rectification of key plant and systems associated with the central chilled water supply to T1 has been delivered professionally and effectively by our team, with minimal disruption to Sydney Airport’s everyday operations and with no compromise to risk or safety. We are meeting our goals to design, construct and deliver effective solutions for optimum performance and improved energy efficiency at this critical facility.”

Subsequently, A.G. Coombs was commissioned by Sydney Airport to maintain the CSB plant and the large and complex mechanical and HVAC systems in Airport Terminals T1 and T2. Drawing on the Group’s experience at Melbourne Airport, and its technical capabilities, the team is ensuring ongoing operational efficiency as well as comfortable working conditions for the 28,000 plus people who work at the airport.

Sydney Airport’s Airport Environment Strategy 2013-2018 (AES) promotes the continual improvement of environmental management at the Airport.

Building on existing water recycling and reuse initiatives, A.G. Coombs is assisting with system controls maintenance including the maintenance of water treatment systems.

With more than 40 international, domestic and regional airlines operating into Sydney, maintaining air quality inside the terminals is a key consideration. HVAC system performance is closely monitored with stringent maintenance strategies in place to ensure the provision of continuous clean air for the safety and comfort of airport personnel and the general public.

The Airport is a 24-hour operation, and maintenance must continue through the Airport’s ‘curfew’ hours of 11pm to 6am to minimise risk of system failure, support the continuity of operations, and ensure no interruption to passenger services. Complex maintenance activities that may affect operations, such as integrated fire mode testing, are undertaken during these out-of-hours periods.

Airport security is an important consideration in maintaining this busy, critical facility. Strict protocols and procedures must be maintained and personnel inducted, trained and, for some activities such as driving airside, specially licenced.

Geoff Saggus, A.G. Coombs’ Service Contract Manager for Sydney Airport, is pleased with the team’s efforts and the Airport’s overall building system performance, stating that, “We are helping to assure fully functional, reliable systems, and are continually working with Sydney Airport to identify and deliver opportunities for improvement.”

Upgrading and maintaining critical plant and systems is always a challenging task, made more

complex by the strict operational, safety and environmental requirements at airports. At Sydney’s

award winning international airport, key plant improvements and maintenance is helping to keep

things cool, efficient and sustainable.

“We are meeting our goals to design,

construct and deliver effective

solutions for optimum performance

and improved energy efficiency at

this critical facility.”

Stuart Naylor – Project Manager for Sydney Airport,

A.G. Coombs

A.G. Coombs has been nominated for three prestigious safety awards for its innovative prefabricated services riser technology:

• National Safety Council National Safety Awards of Excellence; “Best Solution of a WHS Risk (Medium to Large Business).”

• NSW WorkSafe SafeWork Awards; “Best solution to an identified workplace health and safety issue.”

• Victorian WorkCover Authority Health and Safety Awards; “Best Solution to a Specific Workplace Health and Safety Issue.”

The National Safety Council and NSW WorkSafe award submissions were prepared jointly with Lend Lease, focussing on the Barangaroo South project, and the

Victorian WorkCover entry referenced the significant prefabrication works undertaken at a complex new university building in Melbourne. The awards will be announced in 2014.

The single biggest safety risk identified in the construction of many high-rise buildings is the installation of services risers, with the potential for falls from height and exposure to materials/debris falling from above. In the construction of a large building, A.G. Coombs’ prefabrication methodologies result in the transfer of thousands of hours of complicated site installation into a controlled factory environment, with the need to work at height in risers almost eliminated.

SAFETY INNOVATION

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UPGRADING SYDNEY AIRPORT

COO1

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A.G. COOMBS GROUP

The A.G. Coombs Group is a privately owned Australian group of companies that provides an integrated range of technical services for all systems in buildings, from design through to installation, commissioning, maintenance and ongoing operation and management. Operating for over 65 years, A.G. Coombs has a national capability with major operations on Australia’s eastern seaboard.

Melbourne 03 9248 2700 | Sydney 02 8020 6000 | Canberra 02 6217 5600 Brisbane 07 3854 2380 | agcoombs.com.au/profile/

A.G. COOMBS PROJECTS

A.G. Coombs Projects leverage a National Centre of Excellence approach, where teamwork and project management skills set the company apart. This approach also provides high-end engineering, project management and site personnel to deliver successful projects throughout Australia.

03 9248 2700 | agcoombs.com.au/projects/

A.G. COOMBS SERVICE

A.G. Coombs Service is a specialist provider of air conditioning, mechanical services, building controls and bundled services maintenance. Delivering 24/7 building support, the company is a preferred supplier to the Facilities Management Industry and provides professionally managed, highly qualified technical staff to achieve improved reliability, lower costs and regulatory compliance in commercial, retail and industrial buildings.

03 9676 4600 | agcoombs.com.au/service/

A.G. COOMBS ADVISORY

A.G. Coombs Advisory provides quality advice and consulting services across numerous disciplines including mechanical, electrical, hydraulics and fire protection services. A.G. Coombs Advisory is Australia’s leading provider of Green Star Independent Commissioning Agent (ICA) services for projects requiring Green Star ‘As Built’ Certification.

03 9248 2700 | agcoombs.com.au/advisory/

WALKER FIRE PROTECTION

Walker Fire Protection provides a range of fire protection and detection services, from high-end project engineering advice and consultancy through to concept and detailed design, installation of all types of fire detection and suppression systems, and ongoing inspection, testing, maintenance and regulatory compliance support.

03 9279 7100 | agcoombs.com.au/walkerfire/

INTEGRATED TECHNICAL MANAGEMENT

Integrated Technical Management is a high quality provider of Technical Facilities Management specialising in technically complex and critical facilities such as data and internet centres, major commercial complexes and sophisticated industrial plants.

03 9248 2700 | agcoombs.com.au/itm/

171 Collins St Melbourne