University of Adelaide, Bonython Hall Modular

Combined Modular and Traditional Build

Due to the site constraints, the module structures were required to have traditional substructure footings, requiring close collaboration between the on-site construction and the off-site modular teams.
To meet the tight timeframe, site inspections were conducted over teleconference facilities, including Sarah’s subcontractors as required, and Sarah’s in-house Building Information Modelling (BIM) team provided digital models to coordinate the on- and off-site activities for seamless integration.

Designing to Suit Site Constraints

The 4-metre-wide site and load restrictions on the plaza slab precluded the use of normal heavy construction equipment such as piling rigs and cranes.
Sarah’s team modified the footing design and the steel substructure components to make use of alternative, smaller equipment.

For example, piers were designed shorter and wider than traditional piers to allow excavation using hydrovac methodology, and steel sections were spliced to be placed using smaller spider cranes.

Working within a Operational Educational Environment

With Bonython Hall immediately adjacent to functional learning environments and the Hall continuing to be used for events and graduation ceremonies, Sarah’s team worked closely with the University staff to understand the program of lessons and events, and plan for noise generating activities to be completed out of hours.

Fast Tracked Delivery

Even for a modular solution, the project’s timeline was very tight.

The team developed an accelerated design and construct program moving directly from structural steel concept sketches to shop drawings and engaged several factories to fabricate the structural steel, in parallel with the footing construction.
Sarah’s team invited the University’s Project team to its modular manufacturing facility to view the construction activities, giving them confidence in the delivery date and allowing for the early identification of changes, and Sarah’s team visited the steel fabrication factories to ensure the product would meet the program.

Managing Site Challenges

With the limited load rating on the plaza structure, Sarah’s team were unable to crane the modules into place from the same side as the building. Instead, units of up to 10T were delivered to the opposite side and lifted 57-metres over the imposing roof of Bonython Hall, after confirming clearances including existing heritage columns, trees and overhead cables, and the University’s Drone Club was enlisted to record the lifts.

Alternative Material Selection

To further accelerate the project timeline, Sarah’s team reviewed the lead times of all materials, and suggested several alternatives which were presented to the University’s Design Standard Panel for approval.

Sarah also recommended changing the specification of the timber-look aluminium product which reduced the lead time and ongoing maintenance costs, while retaining the architectural intent and integration with the existing building.

Flexible Working Hours

To meet the challenges of the timeframe and reduce construction impacts to the university’s normal activities, Sarah’s team adopted flexible working periods including working through weekends and after hours and leveraged their excellent relationships with subcontractors to have them do the same.