Port Phillip Prison

A view of the Port Phillip Prison, project by Insulpak
inside view of the Alcoa Portland Plant, project by Insulpak
An inside view of the Port Phillip Prison, project by Insulpak
An inside view of the Port Phillip Prison room, project by Insulpak
An inside view of the Port Phillip Prison room, project by Insulpak
Client Ireland Brown Construction
Location Laverton
Scope Of Work Mechanical Services/HVAC
Schedule 2012-2015

Project Detail

HVAC Project Summary

To supply heating with individual AHU’s and fan coil units serving all cells and warden areas. This involved complete installation of new boilers, pumps, building automation and ductwork, also refrigeration systems using FCU’s and split systems to serve warden areas.

This project had minimal roof/shaft allocation for duct pipe’s, experienced drafting methods and personnel were used to co-ordinate all services to avoid clashes and provide for clear and safe access for future maintenance/service.

Skills and Equipment Used

  • Plumbing: welding, press fit, measuring and marking out, drawing, boilers, pump and coil setups, labour requirements etc.
  • Custom stainless security proof grilles complete with tamper proof screws were sourced, these were made to fit to cells and common areas for security.
  • Engineering: Design checks, schedules and re-engineering to ensure an efficient reliable system.
  • Insulation and metal cladding: Pipe and ductwork.
  • Drafting: Pre-cast penetration sign-off, sensors and switches.
  • Sheet metal: Ductwork, plenums, flashings, safe trays, etc.
  • Electrical and Controls: MSSB and DDC boards manufactured, wiring isolators, which had to be integrated with existing building controls systems.
  • NEBB: Commissioning and balancing specialists were contracted to meet the design intent and specifications.
  • Commissioning of Type B Gas boilers.
  • Commissioning and co-ordination of multi head refrigeration systems and automation on the building BMS.
  • Pre-fabrication of ductwork, pipes and boiler modules.
  • Managing Sub-contractors and other services along with co-ordination meetings with the builder to meet time frames.
  • Detailed onsite training of the HVAC system for all prison staff and provision of detailed operation and maintenance manuals to the client on completion.
  • Ongoing Service Maintenance was also completed by our service company GRS Commercial Air conditioning.

Challenges of the HVAC Installation

This project being a high security area, Insulpak had to seriously consider all safety concerns. All tools had to be listed/itemised and monitored upon entry and exit to prevent any lost items causing security hazards for workers and prison staff.

Staff security Checks took place on entry and exiting the prison.

An added challenge was to provide easy and safe access for future service maintenance.

Planning the logistics of cranage to lift 2000 pieces of duct, multiple pipe, FCU’s, condensers, AHU’s and boiler modules in place in a 2 day period, complying with  security, deliveries and time constraints.

Our specialist drafting team and project co-ordination on site before and during the project was integral to complete this project on time.

HVAC Project Outcome

On completion of this project. Insulpak subsequently awarded the next 2 projects at Port Phillip Prison totalling 5 years of work.

This clearly portrayed our professionalism, experience, co-ordination, competitive tendering and ability to deliver work of the high quality and standard that Insulpak prides itself on.