Ingenia and Smart Fabrication identified a tender opportunity via ICN for the design, construct, supply and installation of purpose-built Access Towers and Utility Towers for use in the Osborne Naval Shipbuilding Precinct (ONSP).
The ONSP, located in Osborne South Australia, comprises of modern, state-of-the-art steel in, ship out shipbuilding facilities for the building and sustainment of naval ships and submarines. These include the Hunter Class Frigates, the Collins-Class Submarines, and the new Nuclear-Powered Submarines to be manufactured under the AUKUS agreement.
As part of being a state-of-the-art facility, the ergonomics and efficiency of access methods for shipbuilders during the construction, consolidation and “future-proofing” of the shipyard was of high priority. It was then identified that the design, supply and installation of purpose-built Access Towers and Utility Towers was required, which was then posted for tender via the ICN portal.
Ingenia were confident that we would provide a product and service that would exceed the high expectations of the defence industry, especially due to the Ingenia, Smart Fab, and Dematec Automation team having successfully completed multiple projects within the ONSP, for which we were nominated for the 2021 DTC (Defence Teaming Centre) Teaming Award.
Once awarded the tender, and after the excitement and realisation of the achievement set in, Ingenia proceeded with the mechanical and structural design phase of the project to include the multiple features required for the enhancement of the ergonomics and efficiency of shipbuilding for shipbuilders. This phase was closely designed with Dematec’s electrical engineering design to ensure an overall cohesive and practical design.
To manage the project efficiently, Ingenia split the scope of works for the design into 3 phases, namely, preliminary design, detailed design, and project closeout.
Design of Access Towers and Utility Towers
Preliminary Design:
Based on the initial concept provided during the tender process and through collaboration with the design team, Ingenia developed a preliminary design that met there requirements of BAE and the owner. This was achieved through innovative attachment methods for barriers and handrails, while also reducing the need for extensive bracing.
Once the preliminary design was completed which incorporated both structural design and mechanical design, a 3D digital twin was created and evaluated for operational, maintenance and lifecycle risks as part of a “Safety in Design (SiD) assessment.”
One of the key innovative features of this structural design is its free-standing construction, which is uncommon for access towers of this height. This design choice enhances flexibility and ease of installation, making it a standout solution for the project.
Detailed Design:
The detailed design included, but not limited to, the design of:
- Structural members, including calculations
- Connections and Joints
- Connection points for access between the towers and ship blocks
- Railings and mesh around the tower for ease of access and safety
- Structural support of pipework and electrical systems
- Lifting Design and Analysis.
- Flammable and no flammable pipework design and compliance to relevant standards.
- Detailed modelling and drawings.
Fabrication and Project Closeout:
As part of the fabrication and project closeout phase, to aid in the fabrication and installation, Ingenia compiled the following documentation:
- Workshop Drawings
- FAT Testing Plan
- SAT Testing and Commissioning Plan
- As-built drawings
- Installation Procedure
- O&M Manuals
Ingenia was also involved with on ground support during project close out, namely:
- Compliance Inspection and Testing
- Factory Acceptance Testing (FAT)
- Site Acceptance Testing (SAT)
Overall we are proud to have been a significant part of this project, with the successful delivery of the towers to ANI, BAE, and the wider defence industry.
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