20 Industrial Factories located in Altona. Commenced early 2019 and is currently under construction.

THE CONSTRUCTION PROCESS

Aylesbury consists of 20 industrial factories on a two-acre site located in Altona, Melbourne.

This complex project has very challenging soil conditions, in which Galea Build worked closely with architects, engineers and geo-technical consultants to achieve a very structural and cost-effective outcome.

The project itself consisted of a combination of H5 timber treated piles that were core-drilled through the challenging soil conditions into the natural ground below and rammed into stable ground until refusal to depth of 4.2m then continuous concrete footings were placed on top.

The ground preparation was key to this development’s success. The first stage was to engage a Broons BH 1300 Impact Roller and a vibration monitoring device to ensure no damage was made to the neighbouring properties. The ground needed to be raised which was constructed in layers using a pad foot roller and water cart, which when tested, gave a compaction of 98.5% – 99.5% well above the geo-technical requirements.

The crushed rock sub-base which is 100mm thick was roller vibrated and watered, and once tested, achieved a compaction rating of 99.5% – 102.5%, again, well above the geo-technical requirements.

The driveway sub-base was constructed in the same manner as the slab, although the driveway size was 200mm thick, SL81 mesh and 40 MPA vibrated concrete.

The slab is supported on the footings with starter bars at 600mm centres cast into the footing to form a monolithic slab. The concrete was 32 MPA and when tested, achieved 35.5 MPA at 27 days.

All factory walls are constructed out of tilt panel 32 MPA vibrated concrete which are designed to stay standing even after a fire. The panels have extra reinforcement for vehicle or forklift impact.

CONSTRUCTION PROCESS GALLERY

View our gallery of progress images of the construction of Aylesbury.