The SAAB Secure Facility is one of Tomkins’ most technically complex industrial projects to date. Designed to operate 24 hours a day, seven days a week, the facility supports SAAB in delivering cutting-edge deployable military and humanitarian equipment to the Australian Defence Force (ADF). Its proximity to RAAF Base Amberley enables rapid global deployment of ADF equipment from the site.
The 35,816m² facility comprises two 6,000m² warehouses — an Operations Warehouse and a Storage Warehouse — linked by a 2,150m² super awning. The facility also includes 950m² of offices, workshops, training spaces and a reception, along with 15,500m² of heavy-duty concrete hardstand and access secured by 12-metre automatic security swing gates.
The Operations Warehouse was the technical centrepiece of the project, purpose-built to ADF Type 1 and Physical Security Requirements. It includes:
- A fully certified Central Sterile Supply Department (CSSD) Room, built to hospital-grade sterilisation standards with controlled air pressure, zero air leakage, compliant surface finishes and integrated specialised services
- Temperature-controlled cold stores and a Bond Store Area/Pharmacy
- Tent Assembly Areas and an HVAC Assembly Area
- A Maintenance Hub and outdoor exercise space for ADF operational medical team familiarisation
- Full temperature control across the entire warehouse (20°C to 24°C), with all mechanical plant roof-mounted and a Building Management System (BMS) monitoring conditions every 15 minutes
Three gantry cranes were installed within the Operations Warehouse to support the movement of large containerised military and humanitarian equipment — two 5-tonne cranes and one 15-tonne crane, all on 25-metre spans. The installation required meticulous planning due to the warehouse having only four central columns.
The Storage Warehouse features a fully integrated heavy-duty racking and services system, providing high-volume, organised storage for ADF equipment and supplies.
The ADF’s fitout scope was substantial — with fitout works totalling only $2 million less than the overall contract value. Tomkins successfully completed both the full construction and extensive fitout within a 12-month programme, achieving Practical Completion on the agreed contractual date. Early access was provided to the ADF ahead of PC to enable a smooth transition into the production phase.
Construction of the CSSD Room presented a series of engineering and quality assurance challenges. Tomkins engaged a qualified external consultant to review and approve the design, installation and certification process, with continual inspections conducted throughout the build. Achieving the air tightness required to sustain positive and negative pressure differentials, across a large-footprint industrial building, required precise detailing of all material junctions and service penetrations.
Stakeholder management was a key element of delivery. Tomkins maintained formal and informal weekly meetings with Walker Corporation project managers, SAAB representatives, Ipswich City Council, Urban Utilities, Energex and NBN to keep the project on programme and ensure all end user requirements were incorporated. All stakeholders, including the ADF, were satisfied with the project outcome.
