Total Construction is nearing completion on Stacked Farm’s automated vertical farming facility at Melbourne Airport.
Building an automated vertical farm inside an airport precinct was never going to follow a conventional construction path. Partnering with Stacked Farm and Melbourne Airport on an automated indoor farm, food and beverage building specialist Total Construction worked to cut through the noise, delivering a holistic approach to lower risks and blowouts while redirecting focus.
“Our goal was to allow the food producer to focus on what they’re good at as opposed to worrying about issues with the build,” said Rob Blythman, group general manager, food & beverage group at Total Construction.
The vertical farm, which spans more than 11,000 square metres, is expected to produce 3.4 million kilograms of fresh herbs and leafy greens annually. For the company, the project has involved balancing evolving technology, airport regulations, logistics challenges and controlled growing environments, while maintaining program timelines on the project.
Now approaching completion, the project is entering its final stages, with Stacked Farm beginning installation of its racking systems ahead of planned production later this year.
“We are tracking well ahead of the anticipated programme and Stacked Farm is getting some massive benefits from that,” said project manager Don Peteranna.
Part of the benefits derive from collaborating under an Early Contractor Involvement (ECI) model. Total has been involved in the project from its inception, enabling proactive risk management and efficient project delivery.
“Because of early involvement with us the builder during the design phase, the project now is ahead of schedule as a lot of the problems were foreseen way back as opposed to when you’re doing the build,” said Blythman.
This approach has allowed the team to plan for predicted challenges.
Challenges
Constructing inside an airport environment introduced a range of site restrictions and regulatory considerations. One constraint involved a microwave communication link running only metres above the finished building height between Melbourne Airport and Essendon Airport.
“You can’t pass a crane through it or anything. It’ll break the communication link,” said Blythman.
The facility itself also introduced unique structural and logistical demands. Large grow room components arriving from overseas as assembled units need to be manoeuvred into position inside the building after the facade is completed, according to design manager at Total, Paul O’Brien.
“This process takes a lot of planning,” said O’Brien. “We also had to ensure a controlled environment, which demands high levels of sealing, hygiene and temperature control.”
The climate-controlled environment allows for the continuous production of crops year-round. The facility benefits from faster crop cycles than traditional farming, with crops ready to harvest in 16 to 31 days compared to the traditional 45 to 80 days. Creating the built environment for those conditions require coordination between construction, mechanical systems and fit out planning.
The power requirements also added another layer of complexity. As sustainability is central to the facility’s design, it was planned to install lighting systems that are 47 per cent more energy efficient than traditional farming systems. This meant the facility required underground cabling connected to substations and switchboards that support the automated growing systems and lighting infrastructure.
Managing heat generation from the power distribution network became a complex engineering consideration during construction.
“Managing the amount of cable, power, heat and how you distribute that heat took a fair amount of workshopping,” said Peteranna.
The project has become a learning process for both Stacked Farm and Total. Through close collaboration and discussion, they have been able to overcome technical challenges to build a unique agri-tech system, laying the foundation for future vertical farming developments.
“We want to be able to grow with the client,” said O’Brien. “By growing the relationship, we can improve on the next project.”
Where the focus should be
Part of Total’s role was allowing Stacked Farm to focus on its production systems rather than construction management. Blythman highlighted that future projects would benefit from keeping the focus firmly on production outcomes rather than architectural features.
“Instead of focusing on how the building will look, we shift the focus on what it’s got to do,” said Blythman. “At the end of the day, it’s a machine that’s got to make a product.”
With an “agnostic” approach, the company does not shy away from redirecting clients back to the original objective. A slight amendment outside of planning can create a web of impacts. Trust is an imperative factor in keeping the project on track.
“We’ve gone through years of experience to provide knowledge when customers ask questions about construction, delivery management, and coordination,” said Peteranna.
“Projects like these are difficult and can pose a real challenge,” added O’Brien. “But it’s a challenge that we enjoy solving.”
After the racking system is installed, practical completion of the main building is expected shortly thereafter. Once complete, the facility will provide a local supply of produce while also acting as a reference point for future automated farming developments.
For Blythman, the unpredictable nature of the project has been part of what made it rewarding.
“There’s never been a boring day,” he said. “To learn and work on something new every day has been the best part about the build.”
