Callide B Power Station

Suspended Boiler Access Platform

APS Industrial Services designed and installed an innovative suspended access platform for CS Energy during a planned outage at Callide B Power Station.

The solution enabled maintenance activities above and below the platform to proceed concurrently, improving outage efficiency and reducing the critical-path scaffold dismantling program.

The Project

Location: Callide B Power Station, Queensland
Client: CS Energy
Contract Type: Design and Installation
APS Scope: Suspended Boiler Access Platform

Callide B Power Station required safe access to the boiler’s superheater elements for planned remedial and maintenance works.

Traditionally, these works would rely on a full-height boiler scaffold, requiring the lower scaffold to remain in place until every activity above had been completed. APS developed an alternative approach using its Technitruss suspended access system to separate the work areas and enable parallel workflows.

The Scope

APS designed and installed a full dance-floor access platform inside the boiler. The Technitruss platform was assembled at a lower level, lifted into position and dead-hung beneath the superheater elements and boiler nose.

The completed platform supported:

A 30-tonne birdcage scaffold constructed above the platform
Safe access to the superheater elements for remedial and maintenance works
A full boiler scaffold constructed below the platform by another subcontractor
Simultaneous work activities above and below the suspended platform
Use of the platform as an engineered safety deck between the two work zones

Innovation and Delivery

This was the first time this access methodology had been implemented within a black-coal-fired boiler.
By creating an independent suspended safety deck, the Technitruss platform allowed work above and below to proceed at the same time. It also protected personnel working beneath the platform while maintenance was undertaken on the superheater elements above.

Quality assured and on-time delivery – All platforms were designed, engineered and manufactured in accordance with relevant Australian Standards and project specifications. Careful logistics planning and staged deliveries ensured efficient material handling within the highly constrained laydown and access areas beneath the bridge.
Complex platform installation execution – Specialist rigging methodologies and innovative installation techniques were developed to safely position platforms in difficult-to-access locations, including over live traffic corridors, marine environments and structurally constrained areas.
Programme certainty and operational efficiency – Platform installation, relocation and removal activities were consistently delivered within, and in many cases ahead of, the alliance programme requirements, enabling remedial works to progress without delay.

The Outcomes & Delivery

The works beneath the platform were completed ahead of the maintenance activities above. Because the suspended dance floor provided separation between the work zones, the majority of the lower boiler scaffold could be dismantled before the upper works were finished.

Without the Technitruss platform, dismantling of the lower scaffold would have been delayed until all overhead work was complete.

The project demonstrates APS Industrial Services’ capability to engineer specialised temporary access solutions that improve safety, productivity and outage performance in complex industrial environments.

Key project outcomes included:

Parallel workflows above and below the platform
Improved separation and protection between work areas
Earlier dismantling of the majority of the boiler scaffold
Reduced pressure on the outage’s critical path
An estimated saving of approximately two to three shifts
Successful delivery of a first-of-its-kind access solution for a black coal boiler

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