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oolacotts have been collaborating with BlueScope Steel since December 2023 as Head Consultant to deliver a complete design package for the Plate Mill Modernisation Project at Port Kembla. Woolacotts’ involvement across the site involved a wide range of architectural, structural, civil, hydraulic, mechanical, electrical, wet fire, dry fire, ESD and specialist Piling design solutions.

The project involved installation of a new Walking Beam Furnace (WBF) within BlueScope’s existing reheat plate mill located in Port Kembla. The structural design work has included shoring system design suitable for deep excavation up to three levels on a site subjected to tidal water table and slag. Other foundation design items included critical furnace components, including support for hearth structures, roll tables, bumpers, transfer frames, charging and discharging areas, integration with the existing structures, cooling systems, and deep foundation system for 40-meter-tall stack tower. Woolacotts engaged industry leading experts to develop an extensive deep piling and shoring system which is sympathetic to site restraint and suitable for installation whist site is operational.

Additionally, we have designed structural elements for access platforms, basements, and support areas for hydraulic and electrical rooms, following precise load-transfer and geotechnical specifications.

The services scope also covered exhaust system, gas suppression system, including floor waste systems, fire extinguishers, and emergency showers, along with civil work for stormwater drainage and courtyard pavements. Mechanical systems design has focused on natural and mechanical ventilation, extending the Building Management System, and air conditioning, while electrical work has included power distribution, lighting, and data infrastructure. Woolacotts have provided dry fire system designs and comprehensive acoustic reviews to ensure compliance with noise policies, with clear exclusions for specialized exhaust, high-voltage fire sprinklers, primary electrical infrastructure, and site-wide acoustic assessments for the new furnace.

Throughout the project, Woolacotts managed design coordination, delivering Revit models, 4 D sequencing, clash detection, and Bill of Materials estimates.

We are excited that the project has now entered the construction phase, which is expected to be in the order of 18 months. During this time we will be supporting Bluescope with ongoing services including design verifications, drawing reviews, and RFI responses and construction inspections to verify that the design intent is adhered to.