Months of Planning. Minutes in the Air.

52 helicopter lifts. Three hours. Six months of preparation.

Photo Credit: Joel Strickland

Ever wondered what it takes to lift several tonnes of HVAC equipment onto the roof of a shopping centre by helicopter?

It’s not simply a matter of attaching a load and taking off. Every kilogram counts. Every movement matters. And long before the helicopter arrives, there’s an enormous amount of work happening behind the scenes.

That was the challenge facing our AE Smith team during a recent rooftop HVAC plant replacement at a major shopping centre in Mt Gravatt, Brisbane.

Engaged as principal contractor for a significant HVAC plant upgrade, AE Smith was tasked with replacing ageing infrastructure across the facility. The broader project involved the removal of 13 existing units, installation of six new packaged air-conditioning (PAC) units, replacement of the mechanical services switchboard (MSSB), a building management system (BMS) upgrade and installation of new plant decks.

But accessing the rooftop plant presented a significant challenge. With no conventional crane capable of reaching the required locations, a specialist helicopter lifting operation was the only viable solution.

Behind the scenes

From the first safety briefing at sunrise to the helicopter arriving overhead, the radio communications between crews and the final placement of the units, our project video captures the operation in action.

Hear from AE Smith Project Manager Scott, Precision Rigging’s Luke and Parker Aero pilot Brendan Parker as they share what really goes into a helicopter lift of this scale.

Watch the full operation unfold below.

Precision in the air. Expertise on the ground.

Six months of preparation came down to a three-hour window on Sunday, 11 October.

The operation involved 52 helicopter lifts, including three landings for refuelling. With every kilogram affecting the aircraft’s lifting capacity, each new HVAC unit had to be reduced in weight from approximately 1,300 kg to 800 kg before it could be lifted.

And the logistics extended well beyond the rooftop.

To safely undertake the lifts, the shopping centre needed to be completely empty, with exclusion zones established across all levels beneath the lifting areas.

From load calculations and fuel management to lifting configurations, radio communications and ground crew positioning, there was little room for error.

Working alongside specialist partners Precision Rigging and Parker Aero, AE Smith oversaw the operation, which was completed as planned, allowing the shopping centre to reopen for trade that Sunday morning.

More than just the lift

While the helicopter operation was a major milestone, it was just one part of a much broader HVAC upgrade.

With the new equipment positioned on the rooftop, AE Smith’s team continued the installation works, supported by specialist contractors across electrical services, automation and mechanical systems.

The wider project brought together AE Smith and delivery partners including 888 Electrical, Precision Rigging, Austec Automation, Parker Aero and Conform.

It’s projects like these that showcase what goes into delivering complex infrastructure upgrades. Not just the technical expertise and problem-solving, but the people and partnerships that make it possible.

A reminder of what’s possible when we work as one team. Together, we go Further Together.