InfraBuild Construction Solutions – PFX

Overview

PFX

PREFAB SOLUTIONS FROM LIBERTY REINFORCING

PFX, the name of Australia's prefab experts.

At PFX, we're raising the bar in prefab solutions, with a comprehensive product range that delivers quality, improved safety, efficiency and cost effectiveness.

At every step of the prefab process – planning, manufacturing and delivery – you can rely on our team of dedicated experts for outstanding service delivery. Furthermore, with Liberty Reinforcing’s 80 years’ plus experience behind us, we offer the reassurance that nothing less than excellence is good enough.

About us

InfraBuild Construction Solutions

Building Possibilities with the prefab experts

InfraBuild Construction Solutions (formerly LIBERTY OneSteel Reinforcing) has been helping build Australia for over 80 years. During that time, InfraBuild Construction Solutions has not only reinforced all kinds of structures, but also its reputation as a reliable and innovative supplier.

Product quality is second to none, thanks to world-class manufacturing facilities and logistics expertise.

Plus, InfraBuild Construction Solutions’s national branch and distributor network delivers unmatched service right across Australia.

Dedicated experts

As Australia’s prefab experts, we’re raising the bar in prefab solutions. At every step of the prefab process – planning, manufacturing and delivery –you can rely on our team of dedicated experts for service, quality, safety and innovative thinking.

Expert sales team – PFX’s expert sales team evaluate alternative concepts and identify value engineering opportunities.

Expert technical service – Our technical service experts stand behind our safety and quality standards and product buildability.

Expert commercial solutions – Dedicated commercial solutions experts advise on final cost structures.

Expert schedulers & detailers – Our schedulers and detailers capture materials content and essential build detail in CAD format for final approval.

Expert planners – PFX’s expert planners are the key to developing accurate timelines so you can be confident your project will be delivered on time.

Expert fabricators – Our fabricators turn your approved CAD drawings into finished and fully compliant product.

Expert product managers – Right through the project, our project managers will work with you to ensure seamless delivery and service excellence.

Product solutions

Six core PFX product ranges reinforce our reputation for innovation and quality.

All comply with relevant Australian standards AS/NZS 1554.3, AS/NZS 4671, AS 3600 and AS 5100, offer Green Star and Infrastructure Sustainability credits. Lifting certificates are available. Being manufactured in our InfraBuild Construction Solutions factory environments, they deliver enhanced on-site safety and reduced on-site labour costs and dependency on favourable weather conditions.

1. PROPILE™

PROPILE is our solution for the bored pier and ground support market.

Fabricated using machine and manual processes, PROPILE™ provides accuracy, flexibility and robustness. Plus, downtime on site is reduced because off-site fabrication isn’t weather dependent.

Technical information

Markets – Commercial, Civil & Infrastructure, Residential, Industrial

Applications – Bored piers, precast piles

Technical info

  • Cage Diameter: 250 – 1950 mm (machine-made)
  • Cage Diameter: 160 – 2500 mm (manual fabrication)
  • Cage Length: up to 15 m
  • Bar Diameters: 12 – 40 mm
  • Spiral Diameters: 10, 12 & 16 mm
  • Spiral Pitch: 50 – 300 mm

Certification – Lifting certification available upon request

Note: Please check with your local PFX representative for availability of products & services and to discuss your requirements.

Benefits

  • Enhanced quality – made in controlled environment
  • Improved efficiency
  • Reduction of waste and on-site labour
  • Speed and simplicity of construction
  • Increased site safety
  • Customised to meet project requirements

Case study

PROJECT – Blackburn Level Crossing Removal Project

CUSTOMER – Wagstaff Piling

CHALLENGE – Piling work during railway line shutdown, 7-day duration (24/7), 200+ pile cages

Pile requirements – 17m long instead, 5 tonnes each, Integrated coupler systems

Solution

  • PFX simplified design proposal adopted
  • PFX PROPILE lifting design
  • Material savings via special length bar, N40 at 17m (no lap/coupler)
  • 24/7 delivery service
  • Pre-production combined with logistics/storage solution


2. PROCAGE

PROCAGE is typically used in columns, footings and beams.

Customised to suit project specific requirements. Off-site fabrication using optimal weld patterns.

Technical information

Markets Commercial, Civil & Infrastructure, Residential, Industrial, High Rise

Applications – Columns, beams, footings, walls, pile caps

Technical info

  • Cage Configuration: Round, Square, Rectangular
  • Cage Length: up to 15 m
  • Bar Diameters: 10 – 40 mm

Certification – Lifting certification available upon request

Note: Please check with your local PFX representative for availability of products & services and to discuss your requirements.

Benefits

  • Enhanced quality – made in controlled environment
  • Improved efficiency
  • Reduction of waste and on-site labour
  • Speed and simplicity of construction
  • Increased site safety
  • Customised to meet project requirements

Case Study

PROJECT – Eureka Tower VIC – the world’s tallest apartment development.

CHALLENGE

  • Fast tracked design and strict construction schedule
  • Crane time 88 storey, 300 m tall tower
  • Innovative climbing floor formwork system
  • Column design critical to structural efficiency
  • Confined site

SOLUTION 

  • PFX PROCAGE column reinforcement
  • Coupler systems integrated into PROCAGE – provides flush face to accommodate climbing floor formwork system
  • PFX CAD modelling of PROCAGE to identify and overcome issues prior to on-site installation
  • Double height column cages – reduced crane lifts
  • 500+ PROCAGE columns


3. ROMTECH®

ROMTECH® is an innovative tunnel support system of rebar lattice girders.

Suitable for use in hard rock or soft ground conditions, ROMTECH® lattice girders provide a high strength-to-weight ratio. Manufactured to your bespoke design in specialised jig, the lightweight sections simplify transport and handling and the simple connection details makes them easy to install on site.

Technical information

Markets – Civil & Infrastructure

Applications – Strata control, tunnel & ground support (hard rock and soft ground conditions)

Technical info – Custom-made

Certification – Lifting certification available upon request

Note: Please check with your local PFX representative for availability of products & services and to discuss your requirements.

Benefits

  • Customised to meet project specific requirements
  • High strength to weight ratio
  • Simplified transport & handling due to lightweight sections
  • Ease of installation due to simple connection details


4. CUSTOMCAGE™

CUSTOMCAGE™ is used in all aspects of reinforced concrete construction, including beams, walls columns and footings.

Factory fabricated using manual processes, CUSTOMCAGE™ is customised.

Technical information

Markets – Commercial, Civil & Infrastructure, Residential, Industrial, High Rise

Applications – Columns, beams, footings, diaphragm walls

Technical info

  • Cage Configuration: Custom shape
  • Cage Length: up to 15 m
  • Bar Diameters: 10 – 40 mm

Certification – Lifting certification available upon request

Note: Please check with your local PFX representative for availability of products & services and to discuss your requirements.

Benefits

  • Customised to meet project specific requirements
  • Enhanced quality – made in controlled environment
  • Reduction of waste and on-site labour
  • Speed and simplicity of construction
  • Increased site safety
  • Improved efficiency

Case study

PROJECT

  • 8 Chifley Square, Sydney
  • 30-storey boutique premium grade commercial building
  • Five-storey high entrance at street level
  • 3,000 tonnes of reinforcing steel
  • 450 tonnes of customised prefabricated columns – CUSTOMCAGE
  • CUSTOMCAGE weight approximately 15 tonnes

CUSTOMER – Mirvac

CHALLENGES

  • Supply, prefabrication, handling, delivery and installation of four mega columns for the abutments
  • Complex abutment cages
  • Intensive scaffolding, numerous labour resources and longer time to manually fix the reinforcing steel
  • High safety risk to do scaffolding and steel fixing in elevated heights
  • Road restrictions on transportation and delivery time

SOLUTION

  • Off-site fabrication
  • CAD modelling of cages to avoid bar clashing and allow for ease of placement on site
  • Provided lifting design and certification forsafe handling and installation
  • On time delivery of CUSTOMCAGE™ within the council and road authority requirements

PROJECT REFERENCES

TORRE DEVELOPMENTS – NEWSTEAD QLD

Torre Developments Director, Michael Cavallucci commented “With InfraBuild Construction Solution’s wealth of experience to draw on, the PFX team was able to identify various complications during the process that, once identified and overcome, allowed the  CUSTOMCAGE™ solution to proceed to installation seamlessly.”


5. BARMAT®

BARMAT® is our customised prefab bar solution for reinforced suspended slab construction, precast panels and culverts, retaining walls, road parapets, diaphragm walls and shotcrete walls.

BARMAT® is fabricated off-site, using automated machine manufacturing that allows steel to be prefabricated with variable bar diameters and spacing in a variety of mat shapes, configurations and sizes.

Technical information

Markets – Precast, Commercial, Civil & Infrastructure, High Rise

Applications – Precast panels & culverts, parapet, diaphragm walls, shotcrete walls, suspended slab

Technical info

  • Machine-made
  • Mat width: up to 4 m
  • Mat length: up to 12 m
  • Configuration: any shape, with penetration (if required) to suit requirements
  • Bar Diameters: 8, 10, 12 & 16 mm (Class N), 8 & 9 mm (Class L)
  • Bar Spacing: variable to suit, bespoke
  • Add On: trimmer and additional bars to suit design

Certification – Lifting certification available upon request

Note: Please check with your local PFX representative for availability of products & services and to discuss your requirements.

Benefits

  • Enhanced quality
  • Improved efficiency and reduction of waste
  • Speed and simplicity of construction
  • Increased site safety

Case study

CLIENT

  • Nucon Design & Construction Pty Ltd
  • Precast Concrete Panels

CHALLENGE

  • Business improvement
  • Increase daily precast panel output within existing facility constraints
  • Improve cost certainty
  • Streamline processes to improve efficiency

SOLUTION

  • BARMAT® custom manufactured to suit each precast panel produced.
  • Eliminate reinforcement preparation areas
  • Release additional space for more casting beds
  • Simplified manufacturing and supply process
  • Locked in pricing by project and/or per precast panel
  • Technology to improve accuracy & reduce issues


6. BAMTEC®

BAMTEC® is utilised in suspended and slab-on-ground applications, continuously reinforced concrete pavements, precast panels, topping slabs and large foundations.

Machine manufactured BAMTEC® is the world’s fastest steel fixing system and a revolutionary approach to placing concrete reinforcing steels. By simply rolling out ‘carpets’ of reo detailed to fit designated areas, installation time is slashed, accuracy is improved, and fewer onsite fixers are required.

Technical information

Markets – Commercial, Civil & Infrastructure, Industrial, Precast

Applications – Slab on ground, suspended slab, CRCP, wind farm foundation, precast panels

Technical info

  • Machine-made
  • Carpet Length: up to 12 m
  • Carpet Mass: up to 1.5 tonnes
  • Bar Diameters: 10 – 32 mm
  • Bar Space: variable to suit, bespoke

Certification – Lifting certification available upon request

Note: Please check with your local PFX representative for availability of products & services and to discuss your requirements.

Benefits

  • Design efficiency – fabricated to specified bar centres
  • Reduction of waste and on-site steel fixers
  • Speedy, efficiency and accuracy of site installation
  • Increased site safety
  • Enhanced quality

Case study

PROJECT

  • Bunnings Warehouse, Rockdale, Sydney
  • 10,000 m2 floor area
  • 270 mm thick slab
  • 400 tonnes BAMTEC®
  • Up to 12-metre carpets 1 tonne per carpet

CUSTOMER – AVM Constructions

CHALLENGE – Poor ground condition meant that earthworks took a lot longer and the whole project was severely behind schedule

SOLUTION

  • Installed 400 tonnes of BAMTEC® in under a month, four steel fixers and a mobile crane
  • It would have taken more than three months using conventional steel fixing
  • Use of continuous bar chairs aided the speedy rollout of the BAMTEC® carpets
  • Material cost was reduced using different bar diameters at different spacing
  • Overall cost saving on reinforcement of around 10%

PLAN – It starts with proactive planning, a collaborative process where we set out to meet each project’s specific needs, assessing buildability and lead time, and taking lifting, safety and risk management factors into account.

Detailed drawings ensure the customer can see exactly what will be fabricated and delivered.

MAKE – Once CAD drawings are approved, we make the materials in a controlled factory environment using a team of qualified welders.

To further reduce risk, rigorous quality checks in the factory ensure prefab product delivers consistent reliability, enhanced safety and compliance with Australian Standards.

DELIVER – At PFX, we’re raising the bar when it comes to delivery too. We deliver the right product, on time as agreed. Our processes are designed to minimise lifting and handling processes.

Prefab offers the safety reassurance of lifting certification. Product is delivered in-sync with customer’s construction program. To ensure it all goes according to plan, PFX project management is your point of contact every step of the way.

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