3D Scan Saves the Day for Retrofit Project of Jewel Fine Foods’ New Facility

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30 Jul
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The project scope for CSD Group Australia Pty Ltd (CSD Group) was to retrofit a 10,760m2 existing warehouse to host a food processing and packaging plant for Jewel Fine Foods. Known for catering the Sydney Summer Olympic Games in 2000, Jewel Fine Foods has seen significant growth since its arrival in Australia from India via New Zealand in 1997. Over 15 years, its personnel has grown tenfold. The company now delivers prepackaged meals to supermarkets throughout Australia, supplying major grocery chains such as Coles and Woolworths, as well as airlines requiring AQIS standards.

 

15 million ready meals hit supermarket shelves across the country. With the new food processing facility in Banksmeadow, Sydney, the growth could be further facilitated.

 

The highly complex facility fit-out included new cool rooms, cooking areas, production lines, high and low care facility areas, and infrastructure upgrades, including two new kiosk substations with lead-in cabling and a new gas main. The high-level services, refrigeration, and steam plant were hung from the roof or raised on gantries. The roof was reinforced to take the weight of the equipment, some weighing more than eight tonnes.

 

Retrofit Accuracy Checked by Laser Scanning

 

CSD Group’s ideal workflow included laser scanning for accuracy. A Robotic Total Station 3D scan was used, capturing over 505 million points to include all necessary objects within the warehouse: structural beams and columns, purlins, existing service pipes and fire water, electrical cable trays, concrete step-downs and joints, and precast wall slabs.

 

“The initial 3D scanning showed that the cambers had not been added during the original construction of the building, causing some rafters to sag over 110 mm in the middle and bow in the horizontal axis by up to 35 mm,” said Michael Williams, Managing Director of CSD Group. Additional steelwork was immediately supplied to rectify the structural rafters. A correction check survey was then conducted to ensure the building moved as intended.

 

The 3D scan ensured CSD Group could complete the project accurately and without clashes.

 

Optimized, Clash-Free Accuracy

 

Using the scan, the additional steelwork was modeled using macros and details with pre-positioned layout points to connect the existing steelwork and concrete.

 

“All steel lengths between existing rafters were bespoke, as no allowance for slotted holes was allowed to the hanging equipment frames. In addition, the rafter corrections did not allow for rectifying the horizontal bowing of steelwork,” said Mr. Williams.

 

CSD Group also utilized Tekla BIMsight and Trimble Connect alongside Skype for Business and DWG imports to bring in the new refrigeration components, aircon ducting, and services to eliminate on-site clashes.

 

Upon positional sign-off, while the 2D drawings were being processed, a team of two spent two days on-site with an RTS unit, laying out over 460 chemset locations for the column baseplates and 1,056 bolt locations for the existing 13-meter-high steel rafters.

 

Once the steelwork arrived on site, all 3,419 new assemblies fit into the 1,520 site-marked holes with millimeter precision and required no site alterations.

 

Project Facts

  • Existing structure scanned: 10,760m2 (approx. 140,000m3 of scanned data)
  • Scan size: 505 million points captured in 4 hours
  • Layout points (steel drillings): 1,056 (1 day on site)
  • Layout points (concrete chemsets): 464 (1 day on site)
  • Assemblies retrofitted: 3,419 assemblies supplied to be erected
  • Software used: Tekla Structures v2016, Trimble Realworks v10.1, Trimble Connect, Tekla BIMSight
  • Hardware used: Faro X130 scanner, Trimble Robot Total Station
  • Drawings: 1,340 assemblies, 1,877 parts, 98 general arrangements

 

Source: [Tekla] (https://www.tekla.com/resources/tekla-structures-steel-tips/3d-scan-saves-the-day-for-retrofit-project-of-jewel-fine-foods-new-facility)

 

At BuildingPoint, we are committed to providing you with the best solutions and support for your construction projects. Reach out to us today to learn more about how our expertise and tools like Tekla Structures can help you achieve your project goals.

 

Source: 3D scan saves the day for retrofit project of Jewel Fine Foods new facility (tekla.com)

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