Cunningham Construction Limited were engaged by Methanex NZ to replicate our completed Distillation 3 (D3) scaffold on the neighbouring column Distillation 4 (D4). CCL had achieved some fantastic environmental outcomes with D3 and with the identical footprint CCL set out to conquer this one in the same starting fashion. This involved engaging local surveyors BTW for a full aerial survey and 3D laser scan of the column. From there, the 3D scan was sent offshore to decipher, clean up and format for use with our CAD designers. Once this was achieved Edgar from Layher was able to begin his magic resulting in the scaffold design overlay utilising the 3D model in all its glory.
Clashes (down to the millimetre) were eliminated which was front and centre right from the base out stage with the individual 84 screw jacks lasered in and set with our scaffolding crew working with the surveyors onsite.
Even though the mandate was to replicate what we had built on D3 we took the liberty to tweak things and improve things where possible. This was driven by both Willy Lane and Jayden Wilson at the coal face and executed perfectly by the Cunninghams boys onsite. Due to the scaffold having to avoid every bit of pipework coming off the column the design required us to fabricate 500 ledger to Keder rail components from a local manufacturer (Steelfab) this meant we could start in one corner coming off on an angle and use 4 keder sheets per side, with one custom sheet made at just over 2.316m to complete the 3 sides. We used Keder snake components on D4 to navigate the reboilers on the column allowing us to go top to bottom in the reusable Keder sheeting unlike D3 (where the bottom 20m was shrinkwrap).
110 tonne of Layher scaffolding with a intuitive way of managing the full containment by splitting the sheets for airflow. The scaffold has held up to Cyclone Gabrielle’s full force and the engineering and design behind this one make the job a really unique one that has created huge efficiencies for our client.
