In late 2022 Cunningham Construction were engaged by a client who was interested in transforming a 110 tonne beast of a scaffold into an even bigger beast for a different purpose. That purpose was to achieve one of Methanex NZ’s largest decarbonisation project and Taranaki’s biggest current work scope. With the Distillation 4 Column already fully scaffolded and enclosed while serving a current Corrosion Under Insulation (CUI) campaign CCL began designing a plan that would enable the key CUI project to continue while adding 140 tonne of scaffolding as well as an additional GEDA 1200 to permit the retray works to take place without impacting either project.
Managing SIMOPS was an integral part of this project which was built in half sections to create exclusion zones and access to both work fronts. An additional stair access was built as well as a pedestrian gantry to allow work crews to safely access the Geda 1200, whilst a secondary Geda was installed to be designated for the debottlenecking modification.
With CCL’s Toitu zero Carbon certification this project was close to our hearts and to be part of one of our major client’s carbon greenhouse gas (GHG) reduction projects is something special.
The design phase was extremely involved with deck heights changing and a wing required which created extremely unique engineering challenges. Rodrigo Winkler from Bluebarn was an integral piece of the puzzle and together with Layher’s design team led by Kelvin and Cunningham’s general manager Greg Lockley it was definitely the right team for the job.
This has been CCL’s most involved job in terms of time spent at the front end and even while the scaffold was going up there were changes to the design daily as new project information came to light. This included changing of scaffold load requirements when weights of the new tray components were confirmed. A massive thanks to Jayden and the CCL team on the ground for their patience, expertise, and leadership on this one. A job without incident and executed to the highest of standards.
Project Specifics:
Dimensions (metres) and gear:
- Height = 73m
- Width = 13.4
- Length = 16.5m
- Internal work area: 50m long by 16m wide
- Weight = 250 Tonne
- Geda = 2 X Geda 1200
- Keder wall brackets and sheets for bottom half
- Keder Roof installed at top.
- Layher Allround and associated bits and pieces
- Winches
- Duration of project: 6 Months
Innovation
Layher’s innovative solutions proved instrumental in achieving remarkable speed and efficiency during the construction phase. By utilising Layher’s Allround Lightweight Scaffolding and Layher Aluminium Beams, Cunningham Construction successfully erected a sturdy, free-standing scaffold towering 73 meters high. The scaffold design incorporated stair access all the way to the top, facilitating smooth and safe movement for maintenance crew and contractors.
One of the key advantages of choosing Layher was the ability to use Keder sheeting for containment purposes, streamlining the process further. This approach not only expedited the build time but also provided an effective containment solution during construction.
To ensure seamless assembly without the need for extensive cranage, Cunningham Construction employed a Geda 1200 Z/ZP 2 hoist. This powerful hoist system efficiently handled the entire construction process, except for lifting the Keder Roof components, which required the assistance of a crane.
Incorporating Layher’s 3D modeling technology proved to be a transformative addition. It played a crucial role in preventing major clashes between production piping and access platform steelwork. This proactive approach helped avoid costly delays and rework, enhancing overall project efficiency.
Throughout the construction, safety remained paramount. Double standards were strategically placed up to one-third of the scaffold’s height to account for environmental loads when encapsulated. Additionally, Guy wires and clump weights were meticulously installed as per PS1 guidelines, ensuring stability during extreme weather conditions. Our client continuously monitored weather conditions and forecasts to proactively respond to any potential challenges.
Layher’s comprehensive scaffolding solutions, combined with Cunningham Construction’s expertise and commitment to safety, resulted in a successful and streamlined construction process. The project exemplifies how collaboration with industry-leading partners and innovative technologies can elevate the efficiency and safety of large-scale construction projects.
“Distillation reconfiguration dramatically decreasing emissions. Our team of engineers are always looking for ways to reduce emissions and improve the efficiency of our plants. We’re currently reconfiguring our distillation capability. A multi-million dollar investment that’ll see improved technology in our distillation columns, alongside other critical modifications at our Motunui site. This has been undertaken to reduce carbon emission by over 50,000 tonnes, the equivalent of taking 25,000 cars off the road.”
Methanex NZ
"Blue Barn Consulting Engineers were the engineers responsible for the certification of the scaffold. This project involved modifications to the already existing scaffold erected around one of Methanex’s Distillation Column. The loading bay located to the side of the scaffold generated great challenges from an engineering point of view, it caused large displacements and torsional action under wind loading. Portions of the extension required strengthening, while additional restraints and wind limitations before shrink-wrap were to be removed. It was critical to ensure loads transferred to the column remained within the admissible levels, and several ground anchors were specified for extreme wind conditions. Constructability reviews and good communication between Blue Barn, Cunninghams and Layher were key to the success of the project. Blue Barn is proud of having been part of a project of this complexity and magnitude."
"As per the request from Methanex, CCL asked us to modify the design for D4 to make it work for the debottlenecking project. Even if the scaffold is not 100% fit for the new purpose, this still means Methanex have saved some money since most of the scaffold around the tower is already installed.
We have added bigger loading bays to allow for material to be lifted into position. We have also added lattice beams or diagonal braces to enable the cutting of standards to create wider openings/pathways for movement of materials.
This type of design modification is not ideal for everyone, but we were given enough information by CCL to produce a working solution for this second stage of the project."