Australia Post Automated Parcel Sorting Facility, Bayswater, VIC

NDY was engaged by Australia Post to retrofit and upgrade an existing 25,000 m² facility, integrating a state-of-the-art automated parcel sortation system. We played a crucial role during both the tender and construction phases working with Australia Post, ensuring a seamless transition to modern technologies.

The facility’s design features automated sorting systems for incoming and outgoing goods, establishing it as a key distribution hub for the eastern suburbs. Given the existing structure, extensive upgrades were necessary to meet current fire and life safety codes, which required a careful assessment of systems originally installed in 1980. NDY collaborated with the project team in the initial stages to gather baseline data through compliance audits and council searches, identifying areas that needed improvement.

In the electrical design, our team implemented innovative highbay luminaires with a 5000K colour temperature that closely mimics natural daylight, enhancing worker focus and alertness. This lighting solution not only boosts productivity but also provides market-leading energy efficiency, reducing overall energy costs. We also introduced a smart wireless Exit and Emergency Lighting system with active monitoring, a modern approach that simplifies installation, minimises re-cabling needs and lowers annual maintenance costs.

The mechanical design focused on optimising efficiency and comfort across both the warehouse and office spaces. A notable innovation is the spot cooling system in the warehouse, tailored for the internal truck cargo area during unloading. This system employs ducted split air conditioning and telescopic spiro supply ducts that extend into the truck, ensuring precise cooling during operations. Roof-mounted exhaust fans function as a combined car park exhaust and smoke spill system, while local battery exhaust systems are in place for forklift charging stations, effectively managing air quality and safety.

In the office areas, a ducted variant refrigerant flow (VRF) air conditioning system supplies consistent comfort across all conditioned spaces. For the server equipment room, specialised computer room air conditioners maintain optimal conditions for sensitive equipment. Additionally, exhaust systems were installed in amenities areas to comply with ventilation and air quality regulations.

NDY was also able to introduce significant cost-saving measures, such as performance-based smoke hazard management systems to ensure compliance with building codes and suitability for final use. Given the age of the existing building, many fire systems were unsuitable for the new fitout.

Our assessment of the building infrastructure identified the need for new high hazard sprinkler pumps and tanks, particularly due to vehicle movements into and out of the facility, which posed a risk for false smoke signals. To mitigate this, our engineers specified a multi-aspirated smoke detection (MASD) system throughout the facility to prevent false alarms.

The structural design was executed in two major phases. The first phase comprised a detailed condition audit of the existing structure to confirm that the new works could be integrated with only minor modifications. This phase also included geotechnical testing of the current structural footings to ensure safe installation of the new automated sorting systems.

In the second phase, NDY focused on designing and constructing new structural elements aligned with the Australia Post fitout requirements. This involved steel strengthening, the construction of new external canopies, development of new structural footings and obtaining all necessary certifications.

Through expert collaboration, NDY made the most of the existing infrastructure, modernising it to meet the unique retrofit requirements of Australia Post. The upgraded facility is now a vital part of the network, supporting faster and more efficient package delivery to Melbourne’s eastern suburbs.