Fireproofing an iconic boutique hotel in Melbourne’s CBD

About Melbourne Place

Melbourne Place is a boutique hotel in the heart of the city. The $75 million building project involves the demolition of three existing buildings and the construction of a two-level basement and a fourteen-level hotel on Russell Street.

Design Phase - Working from height

ADCO, working in partnership with Longriver, were contracted with the project, which included demolishing three buildings and erecting a bespoke boutique hotel, featuring a floating mezzanine lobby. The client wanted the fireproofing to be visible, which meant that all workmanship needed to be of the highest standard. PROFINISH was entrusted with the job, and immediately set about solving the issue of having to fireproof the mezzanine area before the flooring had been built. The team confidently took on the project with their solution-based approach.

Design Challenges

• No floor or ceiling upon arrival.
• Fireproofing and steelwork were installed concurrently.
• Fireproofing requirements included curved beams.
• The builder required a 2-way fire protection system for 120 minutes from above the flooring and below the ceiling

Because of our experience, every team member had the ability to work from height. The team would need to be rappelled from the existing structure to begin the job until the flooring could be built in. In addition, we needed to find a solution to bring the fireproofing material into the mezzanine without a surface to place it on.

Design Solutions

• The team worked from harnessed anchor points.
• Curved beams received a specialised fireproofing system.
• Specialised mobilising equipment to get material into the designated working area.
• Fireboards installed to a neat finish to allow a painted finish.

The team, who all have Working From Heights tickets, were required to work in harnesses until the floor had been built. Our team used an electrical jack and flatbed scissors to raise the boards up to the team, as they were installed. Although the team needed to work in harnesses, this didn’t impact their expert craftsmanship, ensuring that the boards were installed in an aesthetically pleasing way, which the client had asked for. To ensure that the curved steel beams were effectively fireproofed, the team decided to use a system featuring two 15mm boards at a time, to achieve the FRL (Fire Resistance Level), while ensuring that the board was flexible enough to cover the curve of the steel beams effectively.

Building & Documenting - Expert flexibility and problem-solving

Building & Documenting Challenges

• Steelwork changes meant uninstallation and reinstallation of fireproofing
• Changes made to plans during the build included two additional large penetrations
• Site in CBD with minimal space, leaving no space for tools or material storage
• The team was required to work while suspended in the absence of a structural floor

The PROFINISH team needed to work flexibly to allow changes to be made underneath installed fireproofing boards, which meant reinstallation on a few occasions. Adding a kitchen beneath the mezzanine level meant the team had to redesign the fire system to include two large penetrations.

Building & Documenting Solutions

• Difficult design and timeframe, meaning PROFINISH had to work closely with the steel fabricators onsite.
• Mechanical duct through fire-rated flooring system
• Staggered delivery of material to the site
• QA’s and ITP’s completed throughout the project

The team worked alongside the steelworkers, navigating a difficult design and build, which meant a high level of coordination and planning was required, which they carried out efficiently, and timeously. The team had designed the fire system to include two large penetrations to take the addition of the newly added kitchen into account. They solved the issue quickly and effectively, installing the new system without losing any time. With no space for tools or material to be stored, the team staggered the delivery of fireproofing material, using 6 different deliveries to cover the project’s requirements over the course of the job. The team also ensured they brought their tools and equipment off-site at the end of every day.

What was installed

• Fully fireproofed floating mezzanine lobby
• Fully wrapped steel structure in Promat board systems
• Vermiculite to mechanical duct
• All fireproofing was installed to be visible and aesthetically pleasing

How PROFINISH made the solution possible

The team overcame many challenges, and completed the job on time and effectively. Our flexibility and expertise meant that working alongside other teams, and in spaces with no flooring, was achievable. The PROFINISH team needed a quick turnaround to begin the job within 2 days of notice, which we achieved. The builder turned to the PROFINISH team for guidance and assistance on fire-related issues and decisions throughout the project.

Results

The project was completed to the client’s satisfaction. All certifications were received, and all systems were installed per the testing requirements. Considering the long list of changes, the team managed to complete the job within the contractor’s desired timeframe.

Future Plans

PROFINISH proved, once again, that our expertise and flexible ways of working meant that almost any issue could be solved.

The team has been contracted to fireproof the mechanical ducts of the building with vermiculite spray. This project features several ducts on various levels throughout the building to be effectively fireproofed, which the PROFINISH team has confidently taken on. We look forward to taking on another challenging and rewarding project with ADCO.

If you’re looking for an expert passive fire protection team, PROFINISH has the experience and expertise needed for even the most difficult projects. Our team has years of experience in passive fireproofing, covering every part of a project – from design to installation, and even certification. Get in touch with PROFINISH today, and trust us to get it done.

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