Lavarack Barracks gymnasium

The supply and installation of 43.9 metre lengths of LYSAGHT KLIP-LOK 700 HIGH STRENGTH® steel roofing for the Gymnasium Building (Stage 4 Redevelopment) at Lavarack Army Base in Townsville was accomplished with the precision of a military operation.

"This job was not without its challenges," Trevor Smedley observed wryly. Trevor is the Director of SPD Contracting, a specialist roofing firm of many years standing based in Townsville with extensive experience in installation work on the base. "Apart from the long lengths involved on this job, Lavarack is also a working defence facility with an expanding number of army base personnel and some special issues involving security protocol and access", he explained.

At first this roofing contractor looked at the possibility of producing these long lengths on site using Lysaght's special onsite rollforming rig. "In the end this proved too difficult due to restrictions imposed on movement of heavy equipment and machinery on the base," Trevor said. "That was when we learned that Lysaght also has a rear steer bogey extendable trailer located in Brisbane. This trailer can handle lengths up to 45 metres and it provided the answer for delivering these long roof sheet lengths to site."

The project architect, Scott Hardcastle, of BVN Architecture based in Brisbane, explained the roof design concept. "The roof details throughout Lavarack Stage 4 Redevelopment have a very strong exposed structural steel expression that we were trying to maintain," he said. "This meant no interference from steps due to expansion joints."

The roof runs overall were in excess of 40 metres so the option to use a concealed-fixed metal roof was considered.

LYSAGHT KLIP-LOK 700 HIGH STRENGTH® roofing was chosen because it is manufactured in Townsville, is fully LHL cyclone rated and due to the concealed clip fixings, it can accommodate large amounts of thermal movement without the need for expansion joints.

"The typical soffit detail also exposes the underside of the roof sheeting profile and this was a consideration as well," Scott added.

The Gymnasium roof is over eight metres in overall height above ground level so future access for maintenance is an important consideration for the Defence Department client. "Obviously concealed fixings and a joint-free sheeting solution reduce any chances for leaks in the tropical storms and heavy downpours," Scott explained.

"Further it provides a very low maintenance solution, with very few fixings exposed on top of the roof, which could be expected to reduce the requirements for maintenance access longer term," he said.

"Due to heavy security on the base anything that reduces potential for outside contractors to have to come and perform maintenance is definitely a bonus," Scott pointed out.

"So we believe that with the collaboration of the builder, roof installer and the supplier in achieving the design aims, we achieved a good outcome for all concerned," Scott concluded.

The Regional Manager of Lysaght in Townsville, Matt Hardy, stated that this was the longest roof sheeting that had been so far produced at his factory, located at Bohle. "It's not all that difficult to manufacture such long lengths at our facility but transporting them to site is quite an exercise in logistics" he said.

This was accomplished over two nights with an extendable rear steer trailer rig moving through the streets with an escort in the small hours of the morning. "A conventional trailer would not have been able to negotiate many of the intersections and other sharp bends." Matt pointed out. "That's where the rear steerable bogey wheels of this special long length trailer made all the difference.

Off-loading of 11 tonnes of roofing was accomplished on site with the use of a large site crane, spreader bar and slings. The roof fixer had a crew of 40 men and one supervisor on site. Up to 25 men per sheet were needed to lift these long sheets into position on the roof. The roof sheeting went down very quickly and was installed in one day. "I was surprised with how well it all went," Trevor Smedley said, "it was completed on time and on budget."