Fleetwood Defence Case Studies

DEFENCE CASE STUDIES

In-depth analysis of modular defence building projects and outcomes

HOLSWORTHY BARRACKS, NSW MEDICAL ADMINISTRATION & AMBULANCE STATION

PROJECT OVERVIEW AND KEY FACTS KEY FACT

DETAIL

Modules

6 modular units

Programme

30 Nov 2020 – 2 Apr 2021

Operational Context

Live, security-controlled Defence base

Design Feature

Elevated structure enabling ambulance parking

Value

$471,904.00

Client

Push Constructions/ ADFSSO Medical Cell

Fleetwood delivered a purpose-built medical administration building with an associated ambulance station within an active Defence base environment.

The solution was configured as a modular facility to accelerate delivery and reduce disruption to ongoing base operations.

CHALLENGE AND FLEETWOOD SOLUTION Project Challenges The project faced challenges like strict access protocols and limited space for ambulance movements.

DfMA Methodology Fleetwood used Design for Manufacture and Assembly to fabricate modular units off-site ensuring faster delivery.

Efficient Installation Modules were craned in during scheduled windows facilitating precise placement and minimal disruption.

Operational and Safety Benefits Reduced on-site labor, minimized security risks, and quick commissioning supported Defence priorities.

DEFENCE RELEVANCE SUMMARY Quality and Security Control Fleetwood demonstrates exceptional quality and security management in Defencecritical infrastructure projects.

Reduced On-Site Labour Exposure The project minimizes on-site labour, enhancing safety and maintaining operational continuity under Defence constraints.

Innovative Modular Design Elevated and modular building designs optimize space efficiency and function within constrained Defence sites.

Off-Site Manufacture Compliance Off-site manufacturing ensures consistent quality and compliance regardless of site restrictions.

LANCELIN DEFENCE TRAINING FACILITIES, WA DEFENCE ACCOMMODATION

PROJECT OVERVIEW AND KEY FACTS KEY FACT

DETAIL

Value

$625,000 (publishable)

Location

Coastal Defence Training Area, WA

Delivery Model

Construct, Supply & Install

Environmental Challenge

Wind, sand, corrosion risk

Value

$625,000

Client

Australian Army

Fleetwood delivered robust bunkhouse accommodation to support Defence personnel at a coastal training environment. The accommodation was designed for resilience and low maintenance, suitable for repeated use over many training cycles.

CHALLENGE AND FLEETWOOD SOLUTION Environmental Challenges Remote coastal conditions include abrasive winds, airborne sand, and high corrosion risks requiring durable solutions.

Modular Delivery Strategy Fleetwood used off-site fabrication to ensure quality control and reduce on-site environmental impact during construction.

Construct, Supply, and Install Model Coordinated civil works, services integration, and rapid on-site module installation optimised efficiency and reduced risks.

Improved Site Usability New pathways connected accommodation to existing facilities, enhancing circulation and usability for Defence personnel.

DEFENCE RELEVANCE SUMMARY Alignment with Defence Priorities The project supports Defence goals of delivery certainty, operational safety, and infrastructure resilience in challenging environments.

Off-site Manufacturing Benefits Extensive off-site manufacturing reduces on-site labour and safety risks, minimizing disruption to Defence operations.

Logistics in Remote Environments Fleetwood effectively manages complex logistics to deliver infrastructure enhancing training readiness and personnel welfare.

Compliance and Asset Durability Modular construction ensures quality control and compliance with Defence housing standards, supporting long-term durability.

BORDER PATROL FACILITIES, SOLOMON ISLANDS MODULAR PATROL OUTPOST

PROJECT OVERVIEW AND KEY FACTS ASPECT

DETAIL

Facility Type

Modular patrol outpost

Deployment Environment

Remote tropical region

Delivery Approach

Export-ready modular fabrication

Key Goal

Reduce reliance on local trades

Value

NA

Client

Pacific Division/ICON-Reeves/Border Force

Fleetwood developed a custom modular patrol outpost concept for international deployment, comprising accommodation, offices and dining facilities.

The project highlights Fleetwood’s capability to design and deliver exportable modular infrastructure suitable for remote operations.

CHALLENGE AND FLEETWOOD SOLUTION Remote Environment Challenges The patrol outpost required support for security in remote tropical areas with limited local resources and logistics.

Off-site Manufacturing Quality Modules were pre-completed in controlled Australian facilities to ensure high quality and consistent performance.

Ease of Transport and Installation Design included container compatibility and simple erection to simplify international transport and rapid deployment.

DEFENCE RELEVANCE SUMMARY Deployable Modular Infrastructure Modular designs enable secure, transportable facilities suitable for remote or austere Defence operations.

Support for Rapid Deployment Modular construction supports Defence missions requiring quick setup and operational readiness.

Enhancing Sovereign Capability Export-ready modular infrastructure demonstrates sovereign manufacturing capabilities for Defence needs.

Supporting Indo-Pacific Partnerships Modular infrastructure enhances Australia's ability to support partners in the IndoPacific region.

HMAS PENGUIN, NSW SCEC-RATED ADMINISTRATION FACILITY

PROJECT OVERVIEW AND KEY FACTS KEY FEATURE

DETAIL

Facility Size

~612 sqm

Security Rating

SCEC 2 (admin), SCEC 3 (meeting room)

Compliance

BAL-FZ bushfire rating

Delivery Method

DfMA volumetric modular

Value

$1,900,00.00

Client

Push Constructions

Fleetwood delivered a secure, modular administration facility for the Department of Defence, providing modern office, meeting and support spaces within a Defence base setting.

The project demonstrates Fleetwood’s ability to deliver security-rated environments with high quality finishes and rapid delivery.

CHALLENGE AND FLEETWOOD SOLUTION Construction Challenges HMAS Penguin faced strict security and bushfire compliance amid live base operations requiring careful construction planning.

Modular Off-Site Manufacturing Fleetwood used DfMA volumetric modular solutions, manufacturing modules off-site to enhance quality and control security risks.

Design Integration and Security Secure rooms, concealed beams, and durable cladding were integrated to meet Defence standards and operational needs.

Minimized On-site Disruption Reducing personnel and onsite work minimized disruption in the sensitive Defence environment during construction.

DEFENCE RELEVANCE SUMMARY High-Assurance Infrastructure Project demonstrates delivery of secure infrastructure aligning with stringent Defence protocols and SCEC-rated secure spaces.

Controlled Off-Site Manufacturing Off-site manufacturing reduced on-base security risks and improved schedule predictability in Defence project delivery.

Regulatory Compliance and Resilience Compliance with bushfire resilience standards shows integration of complex regulations within modular frameworks.

Relevance to Defence Programmes Project supports Defence programmes needing secure administration, command, or training facilities with minimal disruption.

MULTIPLE CORRECTIONAL CENTRES, NSW HIGH INTENSITY PROGRAM UNITS (HIPU)

PROJECT OVERVIEW AND KEY FACTS KEY ATTRIBUTE

DETAIL

Delivery Context

Live custodial operational environments

Delivery Approach

Standardised modular units

Security Requirement

Strict protocols, controlled access

Relevance

Comparable to Defence secure-site delivery

Value

NA

Client

NSW Police

Fleetwood delivered High Intensity Program Units (HIPU) across multiple NSW correctional centres, demonstrating repeatable, secure modular delivery in operational environments.

CHALLENGE AND FLEETWOOD SOLUTION Operating in Secure Environments Fleetwood managed strict security protocols and limited access windows within live correctional facilities effectively.

Standardised Modular Solutions Modular units were standardised and produced off-site to reduce disruptions and enable efficient installation sequencing.

Secure and Robust Manufacturing Units were manufactured with secure finishes and robust materials tailored for custodial environments.

Logistics and Compliance Transport and cranage were carefully planned to meet strict handling and access requirements, ensuring compliance.

DEFENCE RELEVANCE SUMMARY While this is not a Defence asset, this work is highly relevant to Defence for its security controls, staging and live-site delivery requirements.

Controlled Delivery in Secure Sites HIPU projects demonstrate controlled delivery within operationally sensitive sites with strict access protocols.

Standardised Modular Designs Standardised, secure modular designs enable scalable and consistent infrastructure across multiple locations.

Alignment with Defence Needs Methodologies align with Defence needs for risk mitigation, schedule certainty, and repeatable design.

REGIONAL POLICE STATIONS, QLD & VIC HOLDING & ADMINISTRATION FACILITIES

PROJECT OVERVIEW AND KEY FACTS ASPECT

DETAIL

Delivery Scope

Holding, admin, amenities facilities

Regions

QLD & VIC

Delivery Model

Turnkey modular solution

Operational Context

Active police stations

Value

NA

Client

QLD and VIC Police

Fleetwood delivered holding, administration and amenities facilities across multiple regional police stations, providing a turnkey solution suitable for live operational environments.

CHALLENGE AND FLEETWOOD SOLUTION Project Challenges Challenges included multi-state approvals, compressed installation windows, and varied site constraints requiring coordination.

Turnkey Solution Approach Fleetwood provided design, construction, and project management in a turnkey model across all operational sites.

Modular Construction Benefits Off-site fabrication of secure areas reduced on-site footprint and minimized risks during installation.

Minimized Operational Disruption Installation sequencing was tailored to site operations to ensure minimal impact on policing activities.

DEFENCE RELEVANCE SUMMARY Modular Infrastructure Delivery Turnkey modular approach ensures rapid installation with minimal disruption to ongoing operations.

Continuity of Service Demonstrated ability to maintain continuous service under tight operational constraints.

Multi-site Coordination Expertise in coordinating projects across multiple locations and navigating regulatory requirements.

Durable and Secure Facilities Facilities designed for high usage, meeting Defence’s requirements for security and durability.

AUSTRALIAN EMBASSY, MOROCCO SECURE INTERNATIONAL FACILITY

PROJECT OVERVIEW AND KEY FACTS KEY SPECIFICATION

DETAIL

Facility Size

~450 sqm

Security Requirements

DFAT-level security and acoustics

Manufacturing Location

Smithfield, NSW

Shipping Certification

CSC-certified for export

Value Client

Fleetwood delivered robust bunkhouse accommodation to support Defence personnel at a coastal training environment. The accommodation was designed for resilience and low maintenance, suitable for repeated use over many training cycles.

CHALLENGE AND FLEETWOOD SOLUTION Security and Acoustic Requirements The solution met stringent security and acoustic standards necessary for sensitive embassy use.

Structural Robustness for Transport Modules were designed for structural integrity to withstand long-distance ocean shipping.

Off-site Manufacturing and Quality Control Fleetwood used off-site modular construction for quality, security, and compliance assurance.

Pre-export Fit-out and Installation Ease Complete fit-out before export reduced on-site labor and simplified installation overseas.

DEFENCE RELEVANCE SUMMARY Sovereign Capability Demonstrates ability to deliver complex and mission-critical infrastructure for overseas Defence use.

Modular and Export-Ready Design Embassy’s modular format aligns with Defence needs for deployable headquarters and operational hubs.

Compliance and Quality Assurance Manufactured in Australia with high-security standards ensuring minimal host-nation reliance and quality control.

Defence Confidence Project builds confidence in delivering sensitive, secure infrastructure predictably and rapidly internationally.

WACOL GUN RANGE TRAINING FACILITY, QLD AMENITIES BLOCK

PROJECT OVERVIEW AND KEY FACTS PROJECT ELEMENT

DETAIL

Delivery Window

Completed in 3 weeks (5 weeks allocated)

Key Features

Anti-vandal finishes, amenities, secure fencing

Scope

Demolition + new construction + services

Operational Context

Secure training environment

Value

NA

Client

NA

Fleetwood delivered a state-of-the-art amenities block for a secure training environment, demonstrating rapid delivery under tight on-site windows. The project combined demolition, new construction and secure finishes suitable for high-use operational settings.

CHALLENGE AND FLEETWOOD SOLUTION Project Challenges Replacing ageing amenities in a secure, constrained environment required safety and minimal operational disruption.

Modular Construction Approach Fleetwood used off-site modular construction and just-in-time delivery to reduce onsite congestion and speed installation.

Durability and Security Use of anti-vandal materials and high-durability finishes matched the facility’s demanding usage profile.

Coordinated Parallel Works Services integration, external works, and secure fencing were staged in parallel to quickly restore operational readiness.

DEFENCE RELEVANCE SUMMARY Applicability to Defence Training The project skills apply to Defence environments requiring secure, robust infrastructure and minimal disruption during delivery.

Rapid and Safe Delivery Fleetwood demonstrated fast three-week delivery without compromising safety or compliance in infrastructure projects.

Durable Anti-Vandal Finishes Use of durable, anti-vandal finishes meets Defence needs for resilient and long-lasting training facilities.

Modular and Controlled Construction Modular construction and precision sequencing reduce on-site exposure and ensure high-assurance delivery in controlled settings.

LEARMONTH DEFENCE ACCOMMODATION, WA REMOTE DEFENCE HOUSING

PROJECT OVERVIEW AND KEY FACTS KEY ATTRIBUTE

DETAIL

Delivery Model

Construct, Supply & Install

Project Value

$726,000 (publishable)

Environment

Remote, harsh Western Australian conditions

Partner

Ventia

Value

$726,000

Client

NA

CHALLENGE AND FLEETWOOD SOLUTION Project Challenges Extreme heat, remote access, limited infrastructure, and high logistics costs created substantial risks for accommodation delivery.

Off-site Modular Strategy Fleetwood completed most construction off-site in controlled facilities, minimizing on-site work and safety hazards.

Construct, Supply, Install Model Coordinated civil works, service connections, and modular placement enabled fast installation and integration on-site.

Enhanced Delivery Resilience This approach improved delivery resilience and ensured reliable, well-built accommodation for Defence personnel.

DEFENCE RELEVANCE SUMMARY Remote Environment Delivery Learmonth project shows capability in delivering accommodation in remote, resource-constrained Defence locations.

Workforce Safety and Efficiency Fleetwood’s off-site manufacturing reduces large onsite workforces, improving safety and delivery predictability.

Defence Standards Compliance Accommodation meets Defence standards for durability, comfort, and maintainability in challenging conditions.

Strategic Partnerships Partnership with Defence-affiliated Ventia validates expertise in Defence contractual and operational frameworks.

CONCLUSION AND STRATEGIC ALIGNMENT

OVERALL DEFENCE CAPABILITY SUMMARY Secure Operational Capability Fleetwood operates effectively within secure and active defence environments, maintaining strict compliance and security protocols.

Off-site Modular Manufacturing High schedule certainty is achieved through off-site modular manufacturing, minimizing on-site labour and enhancing predictability.

Remote Logistics Management Fleetwood manages logistics efficiently in remote and constrained environments, ensuring operational continuity and timely delivery.

Specialised Defence Facilities Fleetwood meets specialised requirements including SCEC ratings, ballistic protection, and support for internationally deployable infrastructure.