Perth Mint PVD Room: Concurrent Fit-Out and Structural Works Inside a Live Production Facility

The Perth Mint needed a Physical Vapour Deposition (PVD) system installed on the first floor. That required two things to happen at the same time: structural works underneath to support the first-floor slab for the heavy new equipment, and a full fit-out of the room above to create the completely airtight environment the PVD system requires.

The structural scope covered internal demolition, concrete footings, and installation of structural steel columns and beams. The fit-out scope covered demolition, new stud walls and suspended ceiling, epoxy flooring, airtight windows and sealed doors, and alterations to mechanical ducting and PVC pipework within the ceiling space.

The structural design changed twice during construction. The original engineer’s design used a single column to support the loads. Due to access constraints, that was revised to two columns fabricated in shorter sections. Then during construction, the existing supporting beam — initially assumed to be reinforced concrete — turned out to be a concrete-encased steel I-beam. The design was revised again to four support columns.

The overall completion was also delayed by approximately five weeks due to client-organised works. The Perth Mint’s mechanical contractor was delayed by about three weeks, which prevented the ceiling works from progressing as programmed. That had a knock-on effect — a further two-week delay while the Mint rearranged crane hire and road closures to install the PVD system.

Throughout all of this, dust mitigation was critical. Adjacent production areas stayed fully operational, so contamination from construction dust was not an option.

A temporary sealed enclosure was installed to isolate the work area from the surrounding production environment and prevent dust migration.

When the structural design changed, we worked closely with the client and their engineers to assess the revised conditions and get updated details for fabrication and installation. A variation for time and cost was raised to cover the structural redesign, which was driven by site conditions outside our control.

When the client’s mechanical contractor was delayed, we stayed flexible. We helped where we could with the crane lift, and once the PVD system was installed, we completed the remaining mechanical works before finishing the ceiling. The Perth Mint has stringent security requirements — all personnel completed these well in advance to avoid delays.

Two concurrent contracts, multiple design changes, client-side delays, and a live production environment. Delivered to scope with full stakeholder alignment throughout.