PGH Drier Rehabilitation

South Australia

Value: $1.5mil

Completion date: January 2022

The PGH brick and paver drier facility at Golden Grove was constructed in the 1980s from a series of brick walls and suspended slabs. Each of the four driers was approximately 60 meters long, 3 meters high, and 4 meters wide. Over the years, significant heat and moisture ingress into the concrete slabs caused the structure to become severely damaged, leading to its condemnation. It became critical for a full shutdown rehabilitation to take place to ensure the asset's continued operation and safety.

Portolesi were chosen from a national pool of contractors to carry out the initial report, scope of works, structural assessment, costing assessment, and repair methodology, ultimately winning the contract to perform the works. This selection highlighted Portolesi's expertise and reputation in the field of civil contracting, particularly in handling complex rehabilitation projects.

The remediation process was extensive and required careful planning and execution. It began with full propping to the underside of the suspended slabs to ensure stability during the repair process. New restraining slabs were then poured on top of the existing slabs to enhance the structure's integrity. This step was crucial in distributing the load and preventing further deterioration.

Hydro demolition was employed to remove the existing degraded concrete from the internal soffits. This method allowed for precise and efficient removal of damaged material without causing additional harm to the surrounding structure. Following this, reinforcement repairs were conducted, and repair mortar was spray-applied to the soffits. This process restored the structural strength and durability of the slabs, ensuring they could withstand the operational demands of the facility.

To further bolster the structure, structural steel lintels were installed to support the load-bearing sub-structure. These lintels provided additional reinforcement, ensuring the long-term stability and safety of the drier facility. The close collaboration with MLEI Structural Engineers was instrumental in ensuring the success of this phase. Their expertise in structural engineering complemented Portolesi's civil contracting skills, resulting in a seamless and effective rehabilitation process.

The first phase of works was completed on time, on budget, and to the absolute satisfaction of the client. The facility was back in full operation within three months, a testament to the efficiency and dedication of the Portolesi team. The successful completion of this phase demonstrated Portolesi's ability to manage complex civil contracting projects, balancing technical challenges with client requirements.

The second phase of works is due to commence in December 2021. This phase will likely involve further enhancements and maintenance activities to ensure the long-term sustainability of the facility. Portolesi's ongoing commitment to quality and excellence in civil contracting will continue to play a crucial role in the project's success.

Overall, the rehabilitation of the PGH brick and paver drier facility at Golden Grove showcases the importance of skilled civil contracting in maintaining and restoring critical infrastructure. The project's success is a reflection of Portolesi's technical expertise, strategic planning, and collaborative approach, setting a high standard for future rehabilitation efforts in the industry.