Scenario Cockram have successfully completed many Design and Construct Rockwork projects for the Themed Environment Sector.
Our scope includes the Design and 3D modelling of Rock Work form and production of metal fabric from which the Rock Work takes its shape. On site duties include structural steel installation to support the Rock Work form, Cementitious applications and final Painting of the Rock Work. Contracts include trade partnership in Integrated Project Delivery IPD contracts and D&C contracts, with projects as large as 700,000sq ft of Rock Work.
Cockram Scenario was the first vendor to be substantially complete with the show set scope of work at the Shanghai Disney Resort on Pirates of the Caribbean. Cockram was also engaged in various contract models to deliver the Main Entry and Gardens precinct of the Disney Shanghai Project.
Cockram Scenario managed over 500 workers (Sub Contractors and Direct Employees) by Management resources and provided specialty craftsman from China and the Asia region in order to achieve the quality and schedule requirements of Disney.
Treasure Cove was the largest show set scope within the park
- Project – TREASURE COVE SHANGHAI
- 24 Months – for Design and Production
- Delivered on schedule and in budget
Cockram was asked to grow the base contract and take on the following additional scopes
- Fiberglass icon characters for Hotels 1&2 Production / Installation
- Treasure Cove Signage Production / Installation
- Show action doors and platforms Fabrication / Installation
- Treasure Cove (term contract)
- Fantasyland Signage Production / Installation (term contract)
- Main Entry Garden (Program / Construction Management)
- Main Entry Gardens (term contract – Construction)
- Woodland Gardens Rockwork (term contract – Construction)
- Mickey Avenue (term contract – Construction)
Lights, Camera, Action
Universal Studios Singapore
Role: Turn Key Show Contractor – production and installation
Scope: Design Development, BIM Management and integration, Shop Drawings, Manufacturing, Show Control, SFX, Animatronics, SAE, Lighting, AV (Audio Video), Installation Supervision, Testing and Commissioning and Handover and close out to Owner.
Project Description & BIM Usage:
- Design development from 2D concept to fully integrated 3D models & detailed shop drawings.
- All show elements were modelled and coordinated in 3D.
- Fully lit and textured 3D guest point of view animation was used for creative coordination and definition of art direction intent
- Fire and water effect particle and fluid simulations were carried out to define show experience
- Weekly big room meetings were held with all project participants (contractors and specialty trades like Audio, Video, Lighting, Special Effects, Show Control).
- Technical drawings were derived directly from the 3D models to guarantee spatial accuracy.
- BIM was used during installation (survey of as built conditions and clash detection carried out to anticipate issues and find solutions before hitting the field)
Cockram have provided Project Management Services for the Bio-Pharma sector since 2001. Currently we are providing services into the Themed Environment, Data Centre and Pharma-Bio sectors.
Cockram have completed Project management services in Bahrain for Health care and completed with the Scenario company themed environments projects in UAE
Cockram are installing modular data centres in USA.
Metronode Derrimut MEL-2 Expansion Stage 2
The construction of the Metronode at Derrimut included the fitout of ten high density data halls, shell space provision for another two data halls, two Point of Presence (POP) rooms, support technical spaces, offices, amenities, storage spaces, security offices, site wide services infrastructure, external works including road and pathways, car parking, loading dock, perimeter security fencing and landscaping.
ANSTO Security and Main Entry Building
Works included the construction and fit out of a multi level security building, separate stores receivables building and guardhouse, installation of automated security gates, booms and high impact retractable bollards, complex surveillance and security installations, road works and landscaping. The security building for the Australian Nuclear Science and Technology Organisation contains a public reception area, training rooms, federal police offices, sophisticated security monitoring room and equipment, interview/holding rooms, armoury store and amenities. The project was delivered within an operating environment where continuity of operations and site security was paramount. Integrated site controls and procedures were developed in cooperation with ANSTO representatives.
Hilleman Labs R&D Centre
This was a fast-tracked Research and Development facility in an operational university building, with construction commencing whilst the design was being finalized. The 1860m2 fitout comprised of International standard finished labs, fume hoods, offices, canteen, IT rooms and reception. Services included 1000 meters HT cable, DG sets, transformers and panels, HVAC, DMW systems, PA/CCTV/EPBAX, BMS, automatic doors and installation of Goods and Passenger lifts.
International Flavors & Fragrances Flying Dragon Project
A new plant on a Greenfield 38,500 m² site. The plant consists of the major buildings including Powder and Liquid Manufacturing Building, Raw Material and Finished Goods Warehouse, Utility Building, Administration Building, Flammable Warehouse, Tank Farm, Waste Water Treatment Centre, Recycle Waste Shelter and Fire Fighting Tank and Pump Room.
Givaudan Kuai Project
This project was completed on a Greenfield site in three phases. The Production Building has a total area of 11233m2, includes three level steel reinforced concrete structure containing production rooms, a two- level Office Room, two-level Utility Room, warehouse with steel beams and columns, insulated double skin metal panel wall and roof. Also included in the scope of works were a Packing Room, Buffer Room, CIP Room, Process Flavour Room, Blender Room, SD Room,Weight Room, Blender Dumping, PAL and Liquid Room.
Dow Chemicals R&D Centre
Three buildings comprising Dow’s 88,000m2 R&D Centre. The larger buildings are the R&D building and the Administration building and the smallest is the Central Utilities Building (CUB). The R&D and Administration buildings include undercover car park, 64 light laboratories and 1 heavy laboratory, offices, a 700 seat restaurant, Gymnasium, Presidents suite and Badminton court. The building has an open area through the center with a glass atrium roofprotecting the space.
The CUB building houses the High Voltage and Low Voltage Electrical rooms, Boiler room, Ice chiller tank, Chillers and Fire protection room and holding tank etc.
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Alcan Cable Project
A new light industrial facility for Alcan Cable Tianjin Co., Ltd for the production of high technology, flame retardant cable products based on new alloy technology. The facility was constructed on a land parcel in the Tianjin Airport Industrial Park and consisted of two phases of approximately 35,000m2 in total. The project was completed on time and within budget to an international level of quality.
International School of Tianjin Phase 2
A 20,000m2 extension to the existing school campus in Tianjin. The new facility includes the elementary and secondary education areas including a 470 Seat Theater, Class Rooms, Science Labs, Library, Muli-Media Rooms, IT Rooms, Music Rooms (Acoustically Formed), Teacher & Student Lounges and New Utility Rooms.
Johnson & Johnson Renaissance Project
Project Renaissance is a Brownfield project with site area of 9,778 m2, which will provide additional manufacturing capacity for J&J’s liquid pharmaceutical products to meet increased market demand. The manufacturing facility will include raw materials handling, washing, liquid pre-mix and mixing processes and filling / packaging lines. The new site will also include utilities, general office areas, staging area and an existing canteen to support the manufacturing operations. Manufacturing capacity from both the SJJP facility and the J&J Xian (XJP) facility will be moved into the new liquids manufacturing plant.
Eisai New Injection Project
This Brownfield project of approximately 50,000m2 is for a new pharmaceutical injection plant. The project comprises three buildings including the two-level plus basement and mezzanine injection production building, annex building housing steam plant and pump station and a class A hazardous goods storage building. Level 1 of the production building houses a production workshop and storage, level 2 is dedicated to laboratories, utility room and offices.
Kraft Project Picasso
A c.41,000m2 expansion to an existing facility for processing granular sugar, flour, palm oil and glucose. Operations consist of ingredient dumping, mixing, forming, baking, cream filling addition, cooling and packaging (2-stage). it is intended to develop the site to double production capacity over two phases. To achieve this, Cockram is constructing additional buildings, utilities and site infrastructure. An extension to the existing staff amenities building is also being undertaken as part of the project.
AstraZeneca Broad Market Manufacturing Site Project
AstraZeneca, one of the world’s leading Pharma companies, is establishing a new pharmaceutical manufacturing facility in Jiangsu Province, China. Known as China Broad Market Manufacturing Site, in the China Medical City, Taizhou, the 51,000m2 project comprises Sterile dry powder filling for injectable Cephalosporin products, and Oral Solid Dosage products. Phase 1 of the $230M project was recently completed and Phases 2 and 3 are progressing well.
Boehringer Ingelheim Panda Project
Shanghai - China
This 17,000m2 project includes an Ampule and Solids packaging building (APP), which houses QA/QC offices, general offices and multiple packaging lines. The APP Building is linked to a fully automated lights out High-Bay Warehouse (HBW). At 22m high this warehouse is equipped with a European racking system and demands strict tolerances in base building construction. The 3-level Centre of Competence (CoC) houses high quality lab and working offices.
Associated works include Hazardous Goods store, Pumphouse and Firefighting Water Tank, Waste, Gate Houses and upgrades to the existing infrastructure including a new 4000KVa substation, underground services, ring road and packing areas.
Cockram have completed design management works and project supervision works in Europe.
Hunter Medical Research Institute - New Research Facility
Newcastle, NSW - Australia
Located within the Rankin Park campus adjacent to the John Hunter Hospital in Newcastle, the 16,000 m² building consists of two five-storey wings (east & west) linked together by a two-storey elevated glass entry pod. The partnership development between Hunter Medical Research Institute, Hunter New England Health and The University of Newcastle represents a significant capital investment at the John Hunter Hospital Precinct and shall provide for 450 leading researchers under the one roof. The project consists of the following key features: PC2 laboratories, specific pathogen free zones, clinical trial support unit, animal holding areas (bio resource facility), outdoor semi enclosed recreation and barbeque area for the staff, workstations and generic open plan laboratories, lecture theatre and associated support staff offices and amenities. Construction of a three tiered open deck car-park for 250 vehicles is also part of the construction works to be undertaken.
Elizabeth Macarthur Agricultural Biosecurity Upgrade Works
NSW - Australia
The $56 million ($43.0M construction) upgrade of biosecurity facilities included the construction of a large new secure laboratory precinct. It will include high-containment certified PC2 and PC3 laboratories for virology, bacteriology, microbiology and molecular biology; refurbishment of existing animal and plant health laboratories, and an upgrade of electrical and safety systems.
Cockram Construction was engaged in an early tender involvement (ETI) process with NSW Public Works which essentially required us to provide feedback on documentation and potential design issues/risks. At this time we identified one of the key issues for the client was the programme and at tender time proposed a temporary PC2 certified laboratory structure to house researchers between moves so as not to disrupt their research. This in turn also cut 12 months off the practical completion date.
Melbourne Centre for Nanofabrication
As the main facility of the Victorian Node of the Australian National Fabrication facility, this project links seven university-based nodes to provide researchers and industry access to state of the art fabrication facilities. Based at Monash University Science Research Park, the 3,800m2 building is made up of three main functional pavilions. The research pavilion is one level plus a dedicated mezzanine plant room with trafficable ceiling. The pavilion contains Class 10,000 clean rooms, Class 100 clean rooms, PC2 laboratory, general labs and associated offices and amenities. Cockram was subsequently awarded the Class 100 clean room fitout and we worked closely with the client to ensure minimal disruption to the operation of the newly completed facility. The Class 100 area is of the highest standard of clean room construction.
Winner – Master Builders Excellence in Construction Awards 2011 Industrial Buildings
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Baxter Healthcare Expansion Project
Guangzhou – China
The Baxter Healthcare facility produces sterile renal products in soft plastic bags. Cockram’s project scope included a full development of two new filling lines and the construction of a multi-level manufacturing building approximately 20,000m2 with associated facility and utility systems and a new 2nd floor office adjacent. The facility will have full sprinkler protection and will be required to meet both local Fire Code and Factory Mutual standards requirement.
Sanofi Minsheng Relocation Project
Hangzhou – China
This Relocation Project is a joint venture between Hangzhou Minsheng Pharmaceutical Co., Ltd. and Sanofi-Aventis.
The facility specializes in manufacturing OTC items such as vitamins and health products, predominantly coated and non-coated tablets, capsules and soft gelatin capsules, including packing of the products in bottles or blister packaging. The existing plant will continue production during the relocation phase. Major equipment will be relocated and started up in the new facility so as not to affect the supply to market.
Sanofi-Aventis Lotus Relocation Project
Located within the Rankin Park Campus adjacent to the John Hunter Hospital in Newcastle, the 16,000 m²building consists of 2 five storey wings (east & west) of solid elements linked together by a two storey elevated glass entry pod. This project is a green-field facility in Hangzhou for Sanofi-Aventis designed to replace the current production facility. The site has a total area of 49,587m2 of which the new plant will be approximately 30,000m2. The new facility will comprise areas including manufacturing, distribution centre, warehouse, solvent store, energy centre, administration, laboratory and amenities.
Novo Nordisk Filling Plant Project
Located on a Greenfield site of approximately 98,000 sqm, the project was constructed in two phases. The completed facility has enabled Novo Nordisk to meet the rapidly expanding demand for insulin products in China. This filling site comprises formulation, filling, inspection and packaging of Penfills, and some packaging of FlexPen (pre-filled insulin pens), in addition to vial packaging.
CSR Gyprocket Project
VIC – Australia
The CSR Gyprocket Project incorporates the design, fabrication, supply and construction of buildings and associated roadways and laydown for the manufacture of plasterboard.
Awards – 2010 MBAV AWARD WINNER
EXCELLENCE IN CONSTRUCTION OF COMMERCIAL BUILDINGS
Pfizer Utilities Infrastructure Project
Mumbai – India
Infrastructure upgrade throughout Pfizer’s 23 Acre Mumbai facility. Included was Roads, drains, paths, lighting and landscaping, a gatehouse security building, meter room to house the incomers for the 22kV site power from the local authorities and a cable, 350m from the meter room to the Panel room which houses all the site wide electrical distribution panels and transformer, a pipe rack runs throughout the site providing services to all buildings. Adjacent the panel room are 2 1200kVA diesel generators for 100% power backup, a fuel oil tank farm provides fuel oil for the generators, diesel fire pump and boilers.
A 750m3 water tank and a pump-house supply water to the site and fire sprinkler and fire hydrant systems to all of the buildings throughout the site. A utilities building houses the Soft water filtration system and associated plant and equipment, services are provided from this building to all the others. This project was not required originally as all services were provided from the adjacent facility however part way through construction all services to the site were terminated which made this project a necessity.
Pfizer PSB 2
Mumbai – India
A 2 level Pharmaceutical Sciences building of approximately 7,000m2. The facility includes laboratories for process chemistry and safety, Hydrogenation, Scale up unit, QC Lab and Analytical, BMS and IT server rooms and stability ovens and technical space including 30 air handling units, 11 Scrubber units for fume extraction, UPS with battery back-up and Vacuum skid. Two atria provide natural light to laboratories.
The building also houses meeting rooms and Conference room with Audio visual facilities, staff amenities, canteen, document storage and an acoustic treated training room.
Pfizer API Pilot Plant
Mumbai – India
With a floor area of 5,000m2 over four levels this facility produces API (Active Pharmaceutical Ingredients) for animal health and comprises laboratories and clean rooms with HEPA filtration and warehousing, DCS and BMS Control rooms, technical service areas, filter dryers, UPS reactor halls with nine reactors, of which six are glass lined and three are Hasteloy, transfer panels and drum transfer stations, office and warehousing.
Externally there is a cooling tower, below ground slurry tanks, Organic and Aqueous tanks, and a Blast proof room with Hydrogenation, nitrogen generation plant, Solvent storage tank farm and drum storage area.
Lilly Plant Demolition
Mayaguez - Puerto Rico
Cockram was engaged by Lilly to represent the client and provide Construction Management services for the Mayaguez Equipment Salvage Facility Recovery. Our team provided the management & implementation of our safety and environmental program and provided project accounting services on behalf of Lilly.
The project consisted in demo all production building that were not going to be in operation any more, also all tanks from the tank farm area were removed, all the equipment from the building also were removed before the building was demo. More that the half of the plant was demo.
Our team prepared and direct weekly Environmental Health and Safety meetings, were responsible to preparing monthly reports, approving EQB manifests, storm water control program, waste disposal management plan, performed the audits to identify noncompliance areas and implement corrective actions. Conduct regulars Safety and Health audits and inspections to the construction site and contractors workshops to report findings.
Lilly API Plant Retro fit
Guayama – Puerto Rico
Cockram provided the full range of services over the 3 phase project program to retrofit an idle existing API facility. The scope of projects included in demolition, rooms retrofit, new equipment installation, new pipe rack, utilities upgrades and instrumentation
modifications. Cockram role commenced with client representative leading the Engineering phase of the project. We also provided Full Agency CM for phase 1 and 2 of the project. The general scope for Phase 1 included demolition, equipment installation, piping, instrumentation modifications, and architectural modifications around the existing charge room & filter dryer room. The Phase 1 scope also included the necessary tie-ins and planning for future Phase II scope to minimize shut downs and interference when Phase I is in production. Phase II scope includes new structural & architectural alterations and installation of 4 new reactors, filter dryer and conveying & charging systems. To support the increase in capacity for Phase II the following changes will be required: We provided quality assurance and cost controls for the phase 3 project.
McCain Foods French Fry Manufacturing Facility
Harbin – China
Design and construction of McCain’s Greenfield French fry processing facility in Harbin Heilongjiang Province, capable of producing 7.5 tonnes of French Fries per hour.
Roche Head Office and Conference Centre
NSW – Australia
The project for Roche Products included the construction and fitout of a multi level commercial building with gross floor area of 4,800sqm, refurbishment of the existing administration building and cafeteria, car parks and modifications to warehousing buildings, complete with complex building and process services installations. Key to the project is the integration of environmentally sustainable initiatives with the design and operation of the facility. The project was delivered in an operating facility. Continuity of the existing operations was paramount thus an integrated operations and construction schedule was developed in cooperation with Roche Products. The site is also a highly secure facility which required project conformance to various security procedures and protocols. Cockram developed special training and induction programs with Roche Products.
Scholle Packaging Facility Fitout
Suzhou - China
Scholle Industries appointed Cockram to undertake the general construction services for its leased facility. The main scope of Cockram’s services included: general construction services, local project construction permits and approvals, quality controls, program controls, construction management and safety controls, project completion and as-built documentation.