Flinders Medical Centre

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Project Details

Client:

Flinders Medical Centre

Tags:

Commercial

Location:

Flinders Dr, Bedford Park SA 5042

Hey guys, Riley here from ProFab Engineering.

Project overview

This project involved the supply, fabrication, and installation of 18 stainless steel bollards and 40 linear meters of galvanised handrail. The bollards were made from 150 mm OD stainless steel pipe with a 6.4 mm wall thickness, providing both structural integrity and aesthetic appeal for the client. Each bollard was fully welded with a seamlessly finished cap at the top, and then linished after fabrication to achieve a perfect brushed finish on all external faces.
The galvanised handrail system was custom-fabricated on-site to meet the project’s specific requirements. Due to the winding nature of the concrete formwork and tapering steps, we needed to make precise on-site adjustments to the handrail’s design. This involved fabricating the system with perfectly notched joints to accommodate the varying angles of the steps and winding curves of the formwork. Once the handrails were assembled and welded, they were removed for hot-dip galvanising off-site, ensuring long-term corrosion resistance. After galvanisation, they were returned to site for installation, with welds touched up using epoxy zinc-rich primer and silver zinc spray to ensure seamless, uniform protection across the structure.
Throughout both aspects of this project, we adhered to relevant standards such as AS 4100 for steel structures and AS/NZS 4680 for hot-dip galvanising, ensuring that both the bollards and handrail systems met stringent safety, durability, and aesthetic criteria.

Key areas include quality control, customer satisfaction, employee involvement, and process optimization. Through TQM, we target higher consistency, reduced defects, and enhanced customer satisfaction, leading to better product reliability, reduced operational costs, and a stronger competitive position in the market.

Complexities:

The fabrication and installation of this project came with its own set of unique challenges:
On-Site Custom Fabrication for Handrails: The winding concrete formwork and tapering steps required the handrails to be fabricated entirely on-site. This meant that no pre-fabricated components could be used, and every joint had to be calculated and notched precisely to suit the angles of the steps and curves of the formwork. The on-site complexity made this part of the project time-consuming and demanded a high degree of precision.
Handling of Heavy Bollards: The 18 stainless steel bollards, each measuring 150 mm OD with a 6.4 mm wall thickness, were heavy and required careful handling during transportation and installation. The fully welded and capped bollards also needed to be linished after fabrication to achieve a smooth, uniform brushed finish — a process that added time but was crucial for achieving the desired high-quality aesthetic.
Logistical Challenges: Once the handrail system was fabricated on-site, it had to be removed, galvanised off-site, and then returned for final installation. This required coordination with the galvanising plant to ensure timely processing and a smooth turnaround.

Environmental Considerations: As with any external project, we had to contend with varying weather conditions, especially during the winter months. This added extra time for setting the finishes and ensuring that materials like epoxy primer and galvanising were applied under optimal conditions.
Despite these complexities, our team successfully met all deadlines and delivered a final product that met the client’s aesthetic and functional expectations while ensuring compliance with safety standards.

Materials:

150 mm OD Stainless Steel Pipe (Bollards): The bollards were fabricated from high-quality stainless steel with a 6.4 mm wall thickness. This ensured both strength and durability, offering corrosion resistance and visual appeal. The material was welded and finished with a seamless top cap, and the bollards were linished to provide a brushed finish on all external surfaces.

Mild Steel for Handrail Stanchions and Horizontal Members: The handrail stanchions and horizontal members were fabricated from mild steel to provide structural strength. These elements were custom-fabricated on-site and then hot-dip galvanised to ensure long-term corrosion resistance.

Hot-Dip Galvanising (AS/NZS 4680): Both the handrail system and bollards were hot-dip galvanised off-site, providing a long-lasting protective coating against corrosion, ensuring the longevity of the installation in external environments.

Epoxy Zinc-Rich Primer and Silver Zinc Spray: The welds on the handrails were treated with an epoxy zinc-rich primer and finished with a silver zinc spray to ensure the same protective and aesthetic quality as the hot-dip galvanised coating, matching the finish seamlessly.

Structural Bolts and Fixings: High-strength M12 structural bolts were used to securely fix the handrail stanchions to the concrete base, ensuring the stability of the handrail system.

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