LIVE ENVIRONMENT

• Our initial approach combined the Stage 1 and Stage 4 works into one stage. This reduced preliminary costs and the overall program, whilst providing additional car parking for staff and visitors during the major Stage 2 construction.
• The safety of residents and staff was our highest priority. We staged all works in cohesion with the facility operators, executing decanting strategies to minimise disruptions. We broke down each stage into smaller sequences, which enabled areas to be handed over and occupied progressively.
• Dust, noise, and vibration were key concerns, addressed through adaptable demolition and construction plans that minimised disruption to residents.
  

SITE ACCESS

• All Stages: The site's dense bushland setting and proximity to an adjacent creek created significant access challenges, particularly during Stage 3.
• Stage 2: We built the new RACF wings around a protected heritage Yellow Box Eucalyptus tree, which limited crane/machinery access. To overcome this, we created a new loading zone north of the car park for lifting operations. This approach required three crane pad locations and precise coordination with our precast subcontractor. We minimised crane time by climbing the precast cores, which also fast-tracked the program.
• Stage 3: With only footpath-width access to one facade and a steep slope behind, we developed a complex temporary propping solution for installing large steel members. Without crane access, we prefabricated as much steelwork as possible, adapting to structural requirements uncovered during demolition. This allowed us to transport the prefabricated steel through the front of the site before building the driveway slab and façade.
• Stage 3: Our temporary propping solution also enabled ground floor refurbishment works to proceed without relocating residents above. When demolition revealed discrepancies in existing structural members, we worked closely with the design team, subcontractor, and temporary design engineer to adapt the propping and sequencing plan. We also developed a strategy for safely removing the brick façade and installing new windows while maintaining the stability of the first-floor structure, which housed resident bedrooms and a steel roof.
• Stage 3: To navigate the tight conditions along the western façade, we utilised smaller equipment such as duct lifters, scissor lifts, and mobile scaffolding, ensuring efficient and safe installation.

UNEXPECTED CHALLENGES

Our team’s ongoing design input and proactive approach to resolution management added significant value throughout the project.

• Connecting the Stage 2 extension (new RACF wings) with the existing buildings required detailed planning to ensure proper level alignment. We identified discrepancies between the existing floor levels and the proposed design. In collaboration with consultants, we developed a new sub-flooring solution that allowed for a seamless 0% threshold connection between the existing structure and the new extension.
• We adjusted our approach to the major fire services upgrade, originally planned for later in Stage 2, to ensure essential services remained operational. Recognising the need for earlier completion, we collaborated with our hydraulics engineer to re-sequence the works. This enabled a phased completion using temporary supplies, maintaining full coverage and uninterrupted service.
• We completely revised our program for Stage 3. In line with the program, we'd planned to occupy the entire Stage 3 construction zone from the start of the phase. It turned out this wasn't feasible, as it would have left residents without sufficient dining and leisure areas. To meet resident needs, we re-sequenced the stage into four separate areas and accelerated the fitout of the area containing the dining/servery and staff offices. Close coordination with the fire engineer and building surveyor ensured we met essential services and egress requirements before full completion.
• We managed a major upgrade of electrical supplies including the installation of a new authority kiosk. We ensured continuous power re-supply throughout the facility by implementing temporary supplies and strategies for essential services, life-saving devices, food storages, and security. Our detailed investigative works, methodologies and close coordination with facility staff ensured that day-to-day operations were not adversely effected.
  
  

COVID-19
Whilst already facing budget and program pressures, we navigated the effects of COVID-19.

• We implemented many strategies to improve safety and reduce risks during this time, including creating alternate access routes to operational areas so our workers were not entering the facility.
• The resultant material price increases had significant impact.
  We awarded all contracts in 2020 based on completing Stages 1-3 in full, but many subcontractors weren’t needed on-site until 2022/2023. As a result, several withdrew from their obligations during Stage 2, requiring us to re-let five contracts during the project.
  

Our key strategies to maintain and accelerate program included:

• Procuring materials and scheduling deliveries as early. We stored items in containers on site to ensure stock was ready and available as soon as it was required.  
• Large lead time items, such as lifts, were also procured early but stored off-site.
• We identified portions of Stage 3 that could be completed during Stage 2 and successfully advanced these tasks.

• As of January 2025, the expanded facility is at full capacity.
• The addition of more beds ensures greater access to aged care services for the community (134 beds to 182 beds).
• The improved communal spaces, including a commercial café, dining areas, and a revitalised courtyard, create a more welcoming environment for residents, families and visitors.
• Beyond expansion, this project preserves and extends the life of a facility with deep historical significance, ensuring it continues to serve future generations while maintaining its strong community connection.