Industry embraces feature-packed 2024 ASI Australian steel convention
Best and brightest recognised at 2024 steel excellence awards
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ABOUT THE ASI
Steel Australia is published by the Australian Steel Institute (ASI)—the peak national body of the steel industry.
The ASI works to increase the awareness of the benefits of steel and promote Australian made steel as the material of choice. Increasing the competitiveness of the Australian steel industry and its member companies is central to that vision. The organisation conducts engineering seminars and disseminates relevant, timely and detailed information. Expert technical advice, a library and a resource centre are available to all members, along with a range of other member benefits. For information, visit: steel.org.au
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FROM THE CHAIR
This edition of Steel Australia showcases our collective industry excellence as evidenced by our Steel Excellence Awards. The state winners were announced on 23 October 2024, and the national winners were announced at our gala dinner in Sydney on 21 November 2024. This year’s nominations astounded us all with the breadth of creativity, design freedom and community amenity arising from the innovative use of steel that provides society with community outcomes. The entire Australian steel industry can feel proud to have contributed to these wonderful outcomes that will provide many generations of Australians with the flexibility of lifestyle that we treasure so much.
While our awards provide industry-wide recognition to individuals and firms, they also serve another purpose for our industry. Each nomination adds to the public historical record that illustrates the unique contribution steel has made to the economic and social progression of our country and all who live here. We hope that these awards motivate and enthuse school children to aspire to a wonderful career in our industry. The career options transcend design, architecture, engineering, skilled trades, supply chain management, procurement, finance, human relations, manufacturing, distribution, safety and supporting professions. They are careers where success is determined by contribution, work ethic, co-operation, collaboration and innovation.
Therefore, and on behalf of the ASI board of directors, I acknowledge the focus areas of Australian Steel Institute chief executive Mark Cain and the outstanding ASI team who work tirelessly to progress our industry on behalf of all members, with the aim of creating a more prosperous future.
In terms of challenges, our manufacturing members are facing considerable headwinds because of global factors influencing the industry due to significant Chinese overcapacity and resulting trade issues. Our fabrication industry is experiencing significant hardship from fully imported fabricated structures exported from countries seeking outlets for excess production. Mark and his team are advocating for fair and transparent trade in acknowledgement of the multi-factor flow on effect, if segments of our industry are disadvantaged from competing fairly and equally with international sources.
From an opportunity perspective, Australia has a significant pipeline of infrastructure projects waiting to be released for project commencement. The ASI is proactively promoting the capability, capacity and flexibility of the domestic supply chain to be well-credentialled participants in delivering the future to which Australians aspire.
In terms of society’s aspiration towards a lower carbon future, Mark and his team are proactively endeavouring to demystify the carbon credentials of Australian steel visà-vis inter-material substitutes in a manner that is factual, understandable and believable. This understanding is critical in providing designers and architects with the confidence to leverage steel to deliver the structures of the future.
Turning our mind to renewable energy, our domestic industry has a unique role to play in helping Australia realise its ambitions – ambitions that will take decades to achieve. Again, advocating across all levels of government policy formation with respect to sovereign capability, supply chain flexibility, and industry commitment in terms of investment, is paramount in presenting our domestic industry as an enabler for Australia to achieve its aspirations.
All this work is centred on one core objective: to provide all those who follow us with a steel industry that is vibrant, energised and acknowledged by all as contributing to the continued health and vitality of Australian society. Delivering on this objective is my focus, and the focus of many. We have a changing world and a changing geopolitical environment. We have an imaginative and passionate industry that we can leverage to provide the end users of our collective efforts with outstanding outcomes irrespective of short-term challenges.
Tony Schreiber Chair, ASI
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FROM THE CHIEF EXECUTIVE
2024 Australian Steel Convention
With the theme of What it takes: sustainable building and infrastructure , the 2024 Australian Steel Convention was held from 8 to 10 September at the Pullman Brisbane King George Square.
More than 200 attendees heard from an exciting line-up of presenters and panels that examined: cost-effective, sustainable, and resilient steel solutions; case studies showcasing steel’s versatility, reusability, and traceability; demands and opportunities of the Australian infrastructure initiatives and projects pipeline; and the current and future requirements and capabilities of the Australian steel supply chain. For further details, see the article on page 8.
2024 Australian Steel Excellence Awards
The feature of this edition of Steel Australia magazine is the 2024 Australian Steel Excellence Awards. Held every two years, the awards celebrate and recognise innovative steel projects, designs and people. They highlight collaboration throughout the Australian steel supply chain—from architects, structural engineers, and building contractors, through to steel fabricators and steel detailers—using steel as the primary building product.
A gala event at Doltone House in Sydney on 21 November saw 48 state and territory winners vie for national honours in six categories. The national winners were:
Buildings (Large Projects): Sydney Modern Project at the Art Gallery of NSW
Buildings (Small Projects): Rozelle Interchange
Engineering Projects: Hay Point Shiploader
Steel Clad Structures: Melbourne Quarter Tower Innovative Cold Form Steel Building: Glenelg Primary School Young Achiever: Mohammed Kassira
I would like to congratulate this year’s national and state winners and finalists. I would also like to thank all of our judges and sponsors, without whom the awards would not have possible. For further information, please see the article on page 16.
Securing robust supply chains with strong local content
Our ongoing efforts to secure robust supply chains with strong local content have yielded significant progress, particularly in Victoria. Over the past few months, we have engaged with the Victorian Department of Energy, Environment and Climate Action to gain better visibility of government funded renewable energy projects and the Victorian Energy Policy and Investment Overview.
The ASI continues to advocate for local steel content via the Office of the Local Jobs Commissioner on behalf of fabricators quoting on steel bridge work (girders, foot bridge, gantries) on the North-East Link Eastern Freeway Upgrade project.
At the federal level, ASI briefed industry minister Ed Husic on the significance of the imported fabricated steel issue, and requested a meeting to discuss the problem. As a result, we met with the Anti-Dumping Commissioner.
In Western Australia, we met with Department of Jobs to discuss the state’s wind farm strategy, which is at a crossroads with
both onshore and offshore wind farms facing protests and urgent demand from new industrial developments such as the Murchison Hydrogen Project. ASI advised the Department that steel supply is critical for the state’s ambitions and that OEMs should be encouraged to engage with the industry.
In New South Wales, we compiled a database of local steel producers, fabricators and manufacturers capable of supplying wind, solar, transmission and pumped hydro componentry and infrastructure for Australian Energy Market Operator (AEMO) Services to use when evaluating tenders for energy supply projects.
The ASI attended a ‘Meet the Buyer’ event organised by the South Australian Office of Industry Advocate and engaged with numerous government agencies including the Office of Northern Water Delivery, Office of Industry Advocate, Office of Hydrogen Power and the Housing Authority to promote the local Australian steel supply chain and gain a better understanding of the South Australia’s major projects.
Industrial decarbonisation and green metals panel
I am pleased to report that I have been appointed to the industrial decarbonisation and green metals panel. The panel is a commitment under the Federal Government’s Future Made in Australia agenda to support investment in green metals and help the industry decarbonise iron, steel, alumina and aluminium. The panel members will give strategic advice on opportunities for a sustainable green metals industry. The panel’s insights will also help inform the Federal Government’s Industrial Net Zero Sector Plan.
Mark Cain Chief executive, ASI
INDUSTRY EMBRACES FEATURE-
PACKED 2024 ASI AUSTRALIAN STEEL CONVENTION
Expert commentary on steel’s move to net zero, a featurepacked exhibition space and cuttingedge virtual reality: this year’s ASI Australian Steel Convention in Brisbane had it all.
More than 200 attendees witnessed sustainable steel solutions up close while hearing from expert speakers from Australia and abroad on the industry’s sustainable future at the ASI Australian Steel Convention. With the theme of Sustainable Building and Infrastructure: What It Takes, the three-day convention kicked off on Sunday 8 September. Sponsored by Combilift, the welcome reception was held at Brisbane’s Sixteen Antlers Pullman’s rooftop bar.
The night’s festivities provided those in attendance with the opportunity to chat informally, and compare notes ahead of the formal convention program. Attendees were welcomed by ASI chief executive Mark Cain and heard from Chris Littlewood, Combilift’s Australian country manager.
The convention welcome reception at Sixteen Antlers
Chris Littlewood, Combilift’s Australian country manager
Day One
The first day of the convention boasted a feature-packed speaker lineup, kicked off by a welcome address from chair of the ASI Tony Schreiber. There were invited presentations by chief executive Australian steel products at BlueScope Tania Archibald and chief executive officer of InfraBuild Francisco Irazusta.
Demographer Bernard Salt delved into the role and opportunity for Australian steel in building a better future. Bernard provided demographic insights and highlighted important trends shaping the nation and impacting the steel supply chain.
Stuart Wilson from AustralianSuper and Phil Hodgson from Calix discussed Australia’s clean energy transition and investment pipeline.
A design for deconstruction panel proved to be a hit, with expert speakers including Alex Edwards from ARUP, Al Baxter from Populous, Hannah Jones from TTW Engineers and Ed Bond from Robert Bird Group.
Associate professor at Coimbra University Helena Gervasio provided an overview of the environmental sustainability of steel in the building and construction industry, focused on recycling and reuse of steel in life-cycle analysis.
The day was closed by an insightful and inspiring session from Tom Nash—a quadruple amputee. Tom spoke about the links between being forced to think differently to solve problems, and the lateral thinking methods involved in overcoming challenges.
Tom Nash
Francisco Irazusta
Bernard Salt
Tania Archibald
Tony Schreiber
Design for deconstruction panel
Day Two
Day two saw the return of the always popular case studies. Associate structural engineer at Arup Michaela Brown presented a case study on the Art Gallery NSW extension project. Rowan Dillon from the Fitzroy Bridge Alliance presented a case study on the Fitzroy River Bridge project.
The day also included presentations on the use of artificial intelligence (AI) in construction and steel supply chain applications by David Porter from Octant AI; the Australian infrastructure landscape and opportunities for the local steel industry by Adam Copp from Infrastructure Australia; and a practical approach to repurposing steel by Jeremy Hawkes from Bowhill Engineering.
The last formal session of the convention was a popular panel that discussed the opportunities for the steel supply chain associated with the Brisbane 2032 Olympic Games. Panel members included Sheree Taylor from BlueScope, Bradley Wood from GHD, Joseph Pirrello from Aurecon and Michael Whitehead from the Brisbane 2032 Olympic and Paralympic Games Organising Committee.
The ASI would like to thank its platinum partners BlueScope and InfraBuild; its major partners BlueScope, Combilift, Australasian Certification Authority for Reinforcing and Structural Steels (ACRS) and the Queensland Government; its supporters AA Steel Works, DuraGal Profiles and Southern Steel; and all the exhibitors.
The convention dinner
Olympic opportunities for the steel supply chain panel
Jeremy Hawkes
David Porter
Adam Copp Michaela Brown
AI the way of the future?
AI and robotics not only save time, but also potentially save lives by minimising human error and ensuring a safer working environment, Professor Cori Stewart told day two of the convention.
Significantly, AI and robotics accelerate the creation of novel capabilities and the potential to create a step change in Australia’s global competitiveness, she said.
Professor Stewart is the founder and CEO of the Advanced Robotics for Manufacturing (ARM) Hub, Australia’s leading AI, robotics and design-formanufacture industry innovation hub. She is helping drive productivity in Australian manufacturing through technology commercialisation using AI and robotics.
“In the highly competitive steel industry, AI and automation is helping Australia realise business growth and competitiveness, commercialise research and development, address skills shortages, and compete in an economy that is rapidly decarbonising,” Professor Stewart said.
According to Professor Stewart, growth in the manufacturing industry— including steel—was likely because of the baked-in demand for green energy. However, accelerated AI and automation was required to ensure
Australia’s competitiveness. “We want these technologies to be instrumental in creating higher-value products and services that are meeting customer demand. Australian productivity is the worst it has been in 60 years and that is clearly at the centre of our global competitiveness challenges.”
“Currently Australia owns another poor productivity statistic that out of 38 developed countries we rank 35th in robot population density, but after some time declining we may be starting gradually to inch our way up. Getting ahead will require more than ‘business as usual’. It will require disruption and innovation. AI and robotics provide that opportunity.”
Professor Stewart said Australian successes in AI and robotics include Boeing Australia’s delivery of the Ghost Bat autonomous warfighting aircraft and the automation of more than 700 Caterpillar, Komatsu and Hitachi haulage trucks in the Pilbara mines.
“This is the kind of high-value, highly skilled industry Australia needs. We need it to back our steel industry and therefore we need to nurture our local tech capability. We also need to keep Australia’s data local and monetise its value here. When I travel overseas and visit manufacturers, one thing you don’t see is them giving their data away to other companies or other countries,” Professor Stewart said.
Professor Cori Stewart
Phil Casey
Mark Cain
SOVEREIGN MANUFACTURING CAPABILITY FOR INFRASTRUCTURE SUPPLY
In an era of growth and influence of global supply chains, the importance of local manufacturing cannot be overstated.
BlueScope’s $70 million investment for Orrcon Steel Manufacturing to commission a state-of-the-art pipe and tube mill in Unanderra, New South Wales, demonstrates its confidence in growing Australia’s local manufacturing capability.
The investment showcases the critical role that domestic production plays in Australia’s economy, and will help ensure the sovereign capability needed to supply infrastructure growth over the next 10 years.
Orrcon’s Unanderra facility is located at the former stainless steel production plant. It has been transformed into a hub of automation and robotics, and is now the most advanced of its kind in Australia. The state-of-the-art mill, featuring advanced robotics and automation, can produce up to 90 metres of tubular product per minute, including large circular, square,
and rectangular hollow sections up to 10 inches in diameter.
The new mill will supply critical inputs for commercial-sized solar farms, directly contributing to the nation’s energy transition. By supporting such projects, Orrcon Steel Manufacturing is not only advancing its own capabilities but also fostering the development of downstream partners, encouraging them to participate in this pivotal shift towards renewable energy.
General manager of Orrcon Steel and chair of the Australian Steel Institute Tony Schreiber said this is about positioning Orrcon Steel Manufacturing as a humble, yet invaluable, supply chain partner for the long haul - one that can be relied upon not just today, but 30, 60 years into the future.
This ethos is what sets Orrcon Steel Manufacturing apart. The recruitment of local talent, not solely for their technical expertise but for their integrity, collaboration and dedication, underscores a commitment to building a team that reflects the values of
the community it serves. According to Tony, “The team at our Unanderra tube mill exhibit all the traits of cooperation, collaboration, work ethic, work standards and they are very modest people. Like most of us in this industry, all we want to do is say to our customers, ‘we will work hard for you. We will do our best!’”
BlueScope, through its Orrcon Steel Manufacturing business, has not just built a facility to produce tube, but has further strengthened the foundation of Australian industry and supported local communities where we all live to continue to thrive.
This article was supplied as part of a paid advertising package.
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NEW CHANGES TO SUPER THAT IMPACT BUSINESSES
The Federal Government’s superannuation changes for the financial year 2025 (FY25) bring important updates that employers need to understand to ensure compliance and support their employees’ retirement savings. These changes, aimed at strengthening the superannuation system, involve adjustments to the superannuation guarantee (SG) rate and contribution caps
Increase in superannuation guarantee rate
One of the most significant changes in FY25 is the increase in the superannuation guarantee (SG) rate. Since 1 July 2024, the SG rate has risen from 11% to 11.5%, as part of a phased approach to reaching the target rate of 12% by July 2025. This increase requires employers to adjust their payroll systems to reflect the new rate, ensuring that employees receive the correct superannuation contributions.
Failing to comply with the updated SG rate could result in penalties for employers, including additional charges and interest on unpaid contributions. Therefore, it is crucial for businesses
to stay ahead of these changes by reviewing their payroll processes and making necessary updates well before the deadline.
Concessional contributions cap
For FY25, the concessional contributions cap has increased to $30,000 up from $27,500. Concessional contributions include compulsory employer contributions, salary sacrifice contributions, and voluntary contributions for which an employee claims a tax deduction. While the cap has increased, it remains important for employers and employees to be aware of it to avoid exceeding the limit, which could result in additional tax liabilities. Employers may wish to communicate this information to their employees, particularly those who are making voluntary contributions, to ensure they understand the implications of exceeding the cap.
Payday super
While payday super is not yet legislated, it is proposed to start for employers on 1 July 2026. Under payday super, employers will be required to pay their employees’ super at the same time as
their salary and wages.
Before it comes into effect, there’s an opportunity for businesses to prepare for any changes, including looking at the impacts on business cashflow of super being paid at the same time as the regular pay cycle.
Staying informed and compliant
Staying informed about these superannuation changes is essential for employers to manage their obligations effectively and support their employees’ financial well-being. AustralianSuper recommends that employers regularly review their payroll systems, contribution processes, and communication strategies to ensure compliance with the updated regulations.
The FY25 superannuation changes introduce key adjustments that require attention from employers. By understanding and implementing these changes—such as the increase in the SG rate and the awareness of the concessional contributions cap will ensure businesses are prepared as these changes come into effect.
This article was supplied as part of a paid advertising package.
Disclaimer
Sponsored by AustralianSuper Pty Ltd, ABN 94 006 457 987, AFSL 233788, Trustee of AustralianSuper ABN 65 714 394 898.
This information may be general financial advice which doesn’t take into account your personal objectives, financial situation or needs. Before making a decision about AustralianSuper, you should think about your financial requirements and refer to the relevant Product Disclosure Statement available at australiansuper. com/pds or by calling 1300 300 273. A Target Market Determination (TMD) is a document that outlines the target market a product has been designed for. Find the TMDs at australiansuper.com/tmd.
FORGING FUTURES: The ASI’s 2024 student awards and scholarships
The Australian Steel Institute (ASI) is pleased to announce the winners of the 2024 undergraduate steel design awards. Sponsored by the ASI each year, the awards recognise students across the country who have achieved the highest grade in their third-year steel design subjects. The awards play a vital role in fostering the next generation of architects and engineers.
Each year, the Australian Steel Institute (ASI) offers awards to the students who achieve the highest grade in their third-year steel design subjects at Australian universities across the nation.
Students are assessed by their own university based on the results of their steel related subjects. The winning students receive an eLearning voucher, so that they can take advantage of the ASI’s diverse range of online courses.
According to ASI chief executive Mark Cain, “The ASI’s Undergraduate Steel Design Awards play an important role in building a relationship with the next generation of engineers and architects. These high performing students usually go on to be employed in design or engineering positions with high profile engineering consultants due to their academic ability.”
“As the nation’s peak body representing the entire Australian steel supply chain—from the manufacturing mills right through to end users in building and construction, heavy engineering and manufacturing—it is vital that we foster the academic and professional careers of these individuals.”
“In the future, these students may be in a position to influence a decision to use steel in a structure due to their familiarity with steel design. It’s important that the next generation does not perceive steel design as a difficult process. Through initiatives such as these awards, the ASI is helping to provide tools and education to promote the use of steel in Australia,” said Mark.
“Supporting the work of Australian universities is also important. Universities are hotbeds of innovation and entrepreneurship.”
They help provide students with the skills to compete in increasingly global workplaces and shape the minds of the future,” said Mark.
The ASI would like to congratulate all of the winning students for 2024:
James Cook University (March 2024): Angus Luxon
UNSW Sydney (March 2024): Tsz Ling Tang
Victoria University (April 2024): Divay Vijaykumar Khimji Patel
University of Sunshine Coast (April 2024): Rebecca Stevens
Curtin University (April 2024): Ramudhi Kottage
University of Newcastle (May 2024): Nicholas Curren
University of Wollongong (May 2024): Jeremy Tyssen
Monash University (July 2024): Gokul Sridaran
University of Technology, Sydney (August 2024): Sathejan Kulenthiran
Griffith University (September 2024): Viet Thang Nguyen
CQ University (October 2024): Ira Kromer
Queensland University of Technology (October 2024): Nour Obaid
Student scholarship awarded to fourth-year QUT student
Congratulations to Julian Alber, the first-ever recipient of the ASI Student Scholarship valued at $10,000. Funded by Orrcon Steel Manufacturing, this scholarship aims to support university students in their steel-related studies, foster stronger relationships with the steel industry, and highlight steel as a key design solution.
A QUT (Queensland University of Technology) Dean’s Scholar and fourth-year student, Julian will use this scholarship to focus on his thesis project on Screw in Steel Piles (SiSP) under the supervision of Professor Mahendran.
The Australian and New Zealand residential screw piling market has grown exponentially with much of this growth coming from the replacement of concrete bored piers. With a significant correlation between torque and pile capacity it is critical to not only understand the point at which the pile can perform to the design capacity but also when the pile may reach its elastic and torsional yield capacity.
Julian’s thesis project includes conducting an in-depth analysis of screw-in steel piles, exploring installation variable and capacity, and developing better methods through finite element modelling and physical experimentation. It will also focus on enhacing the reliability and performance of Orrcon Steel’s product in residential and light commercial applications.
This scholarship is offered by the ASI in conjunction with Orrcon Steel Manufacturing to assist students in pursuing studies focused on steel, facilitating advancements in steel research, and cultivating a comprehensive understanding of steel as a practical design solution.
Steel plays a pivotal role in Australia’s construction, infrastructure, and manufacturing sectors, making significant contributions to innovation, employment, and overall capabilities in both urban and regional areas.
Nour Obaid and John Gardner (ASI)
John Gardner, Angus Luxon and Dr John Ginger
Sulfianda Soeleiman (ASI) with Gokul Sridaran
Ramudhi Kottage shown with James England (ASI) and Richard Shedlock (AMOG Consulting)
Jeremy Tyssen with Gursel Alici from the University of Wollongong
BEST AND BRIGHTEST RECOGNISED AT 2024 STEEL EXCELLENCE AWARDS
The best and brightest in Australian steel were recognised at the Australian Steel Institute’s National Steel Excellence Awards in Sydney on 21 November. Forty-eight state and territory winners competed in six award categories. Highly regarded by industry, the awards provide an outstanding opportunity to showcase the collaboration and achievements of project teams and individuals.
NATIONAL AWARD WINNERS
The winner of the large buildings over $10 million category in the ASI national steel excellence awards was the Art Gallery of NSW Sydney Modern Project (see page 20). Judges praised the project’s steel solution as vital to meeting the challenges of the project site, being partially located on a land bridge over critical infrastructure. The Kangaroo Point Bridge and Adelaide Marriott Hotel projects took out high commendations.
The small buildings category was won by the Rozelle Interchange project (see page 22). Judges said the complexity of the geometry was evident on the project, creating a head-turning structure.
The engineering category was won by Hay Point Shiploader (see page 24). Judges said building information modelling and the adoption of a fully modularised fabrication and installation methodology delivered significant safety, cost and schedule benefits. A highly commended award went to the New Fitzroy Bridge Project.
The steel-clad category was won by Melbourne Quarter Tower (see page 26). Judges said the fabricators and designers produced a compelling solution that takes into account the construction complexities of building at height.
The cold-form category was win by Glenelg Primary School (see page 28). The use of cold-formed structures ensured the design and modular construction criteria was met.
The young achiever award was won by Mohammed Kassira from Robert Group (see page 30). Mohammed’s passion for the industry, his community involvement and drive for success were clear.
Art Gallery of NSW Sydney Modern Project
STATE AND TERRITORY AWARD WINNERS
New South Wales and ACT
Buildings - Large Projects
Winner: Art Gallery of NSW Sydney Modern Project, submitted by Arup
Buildings - Small Projects
Winner: Rozelle Interchange, submitted by Studio Chris Fox
Highly commended: Parramatta Light Rail Stage 1, submitted by Icon Metal
Innovative Cold Formed Steel Buildings
Winner: Hungry Jacks Warrawong Retail Centre, submitted by TopSteel Solutions
Engineering Projects
Winner: Sydney Gateway Arch Bridges SB51, submitted by S&L Steel
Highly commended: Sydney Gateway Launch Nose, submitted by Alfabs Engineering
Highly commended: Sydney Gateway, submitted by BG&E
Steel Clad Structures
Winner: Project Broccoli/Coles, submitted by Costin Roe Consulting
The Sydney Modern Project has transformed the 152-year-old Art Gallery of New South Wales into a two-building art museum campus. The expansion has almost doubled the exhibition space, and created new art and cultural experiences, with seamless connections between indoor and outdoor spaces.
“An example of how site-based constraints resulted in a thoughtful design outcome. This is also backed by the careful consideration of materials and expression of the steel structure. The steel solution was critical to meeting the challenges of this project location, being partially located on a land bridge over a critical piece of Infrastructure.” ~ Judges
Japanese architectural firm SANAA designed the Art Gallery of New South Wales Sydney Modern Project building to respond to the site’s topography and integrate with existing infrastructure. The project site is on a steep escarpment in The Domain in Sydney, north of the original art gallery building. The new and original buildings are separated by a ‘land bridge’ over a multi-lane motorway, the Eastern Distributor. Adding complexity was a pair of decommissioned Navy fuel tanks below the site, built during WWII in a former sandstone quarry. The new building is formed from interlocking art pavilions nestled into the landscape over five levels, resting lightly on the land bridge and the fuel tanks. Each pavilion connects with the outdoors, via roof terraces, walkways, and landscaped gardens.
SANAA’s concept was for a light and expansive design that provides new types of spaces to enhance the presentation of art, performance and learning facilities. With increased space, the art gallery can showcase more of its outstanding collection and attract more of the best national and international exhibitions to Sydney. A particular feature is a new prominent destination for Aboriginal and Torres Strait Islander art and culture, both inside the new building and across the campus including a major commission in the art garden that links the new and original buildings.
The building’s structure consists of a series of linked steel-framed structures, built over a reinforced and post-tensioned concrete podium structure, set in a deep excavation into the steep hillside. Much of the new building is founded on existing structure. This includes the fuel tanks, constructed of reinforced concrete in 1941, and the land bridge, constructed in 2000 from in-situ and precast reinforced and pretensioned concrete elements.
The design transforms the southern of the two fuel tanks into a unique art space of 2,200m2. The intent of the art gallery was for this space to be left ‘raw’, with the only spatial interventions being a new floor and drainage, new openings cut into the walls for egress, and a spiral stair inserted through a circular penetration in the roof.
Designed by SANAA, the new building was realised through a collaboration between the art gallery and Infrastructure NSW. The project’s executive architect is Architectus, with Arup providing multi-disciplinary engineering including structural, civil, acoustic, fire, hydraulics and services, lighting, security and traffic. It was delivered by lead contractor Richard Crookes Constructions (RCC), with the building’s structural steel fabricated and erected by Samaras Structural Engineers. Secondary steel elements formed part of the façades and the landscaping, which were delivered by subcontractors Kingston Group and Landscape Solutions respectively. Elmasry Steel Design & Detailing was responsible for the steel detailing.
PROJECT TEAM
Entering Organisation: Arup
Architect: Architectus, SANAA
Structural Engineer: Arup
Head Contractor: Richard Crookes Constructions
Steel Fabricator: Samaras Structural Engineers
Steel Detailer: Elmasry Steel Design & Detailing
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ROZELLE INTERCHANGE
“The complexity of the geometry was evident on this project, creating a structure which will surely turn heads. The fabricator’s planning in the assembly and erection methodology ensured meeting the tight deadlines and achieving the design intent.” ~ Judges
The landmark urban artwork at Rozelle Interchange interweaves between the ventilation towers servicing the underground motorway as part of Sydney’s WestConnex project. The form of the work is derived from mappings of previous, current and future ecologies and envelops three concrete monoliths which stand at 40m to 42m heights and 9.8m to 13.8m diameters to transform and soften their form. These mappings generate patterns of sculptural looping and interweaving that provide a framework for nature to take over.
Situated on the land of both Gadigal and Wangal clans of the Dharug language group, the three landscaped monoliths take ground above a new parkland on the edge of Rozelle Bay. The area that was once bursting with vibrant ecosystems has transformed over millennia; previously mudflats and mangrove forests, more recently characterised by industrialised maritime and rail use. This integrated landscaped artwork looks to this history and its continued stories.
Modulated zinc panelling and a twisting steel structure reference the turbulent air flow of the facility and projected spatial movements by inhabitants of the vast subterranean road network below. Enveloping the towers, this living system extends as bridge forms above pedestrians and cyclists, whilst biophilic green-wall modules further integrate the structures into the parklands and transform this vast infrastructure into a habitat for urban biodiversity.
The artwork was designed by Studio Chris Fox in close collaboration with structural engineers Bollinger+Grohmann, to fluently emerge as a sprawling structure supporting concepts of movement and nature taking over the infrastructure. Fixed to the top slab of the cut and cover structure, the encompassing main steel framework of columns and beams of the artwork follow a repetitive radial spacing.
The interstitial space between the concrete and the framing allow for manual maintenance of the concrete outlet with air monitoring and sampling ports that are located at elevated sampling platforms. The platform structures at a height of 33m surround each outlet with stairs and are utilised in combination with beams in laterally pinning the structure to the outlets.
Governed and organised by this repetitive steel framing, steel vines and bridges are the key design elements of Rozelle Interchange. The wrapping, twisted rope elements weave through in connecting all components of the structure, giving it its dynamism and rigidity. Bridging elements connecting the three tower frames to form a single coherent structure.
The series of vine-like elements twist and weave around the entire structure adding to the architectural intent, while also being crucial to the global stability of the bridging elements. These interacting elements are integral in the holistic performance of the structure. The final modulated zinc panelling and biophilic green wall modules are distributed across the framework to create a porous and dynamic façade treatment.
Rozelle Interchange is situated with the aim of transforming the built environment, bridging disciplines of art, architecture and engineering. It is delivered as a complex large-scale art and architectural design project to a total approximate tonnage of 300t of sustainable steel.
Between strategic art-thinking and computational processes, design improvements and structural enhancements were identified and incorporated through the project in creating a more efficient and robust structure integrated into the urban landscape, architecture and story of place.
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PROJECT TEAM
Entering Organisation: Studio Chris Fox
Architect: Studio Chris Fox
Structural Engineer: Bollinger+Grohmann
Head Contractor: John Holland, CPB Contractors JV
Distributor or Manufacturer: United Steel
Steel Fabricator: TSS Engineering
HAY POINT SHIPLOADER
The Hay Point Shiploader—one of the largest shiploaders ever to be built globally—isn’t just a static structure; it is a complex machine with intricate moving parts that reinforce Hay Point’s ability to deliver coal to customers into the future. The shiploader’s completion required strategic planning to address complexity for seamless execution of construction, as well as optimal performance upon completion.
Aurecon’s trade-off studies proposed an acceleration of design and construction to de-risk the project schedule, due to its complexity and possible schedule delays. The methodology involved overlapping workfronts of engineering design, detailing and fabrication.
Utilising parallel direct-to-detail and direct-to-fabrication workfronts minimised risk, improved schedules, and boosted cost efficiency. By integrating Aurecon’s engineering team with DBM Vircon’s construction modelling and detailing team, a single detailed engineering and fabrication model was delivered. This approach enhanced productivity, saved time, and ensured that constructability and crucial fabrication details were considered from the outset.
Digital analysis and modelling techniques allowed the design of the structure to consider complex geometries and manage the interfaces between mobile and static structures (such as the shiploader traversing and operating on the berth).
Construction featured in-workshop fabrication of the entire structure, including structural platework and mechanical items, and the use of custom-built jigs and temporary welds to ensure precision. Over 1,100 tonnes of steel plate from BlueScope was used, demonstrating substantial use of Australian steel. Extensive pre-weld and post-weld surveying, including third-party verification, ensured correct tolerances and high-quality assembly. This collaborative and unconventional approach was a success, with the complex machine fully assembled and shipped to the berth on budget and ahead of schedule—despite the project running during the COVID-19 pandemic.
To achieve the shiploader’s on-time completion, modularisation was used to streamline construction, ensuring that shop-built components were assembled efficiently. By fully detailing all services and brackets at the modelling stage, all services could be pre-fabricated and fitted in the shop with confidence that the arrangement would be clash free. The need for development of site-run services was eliminated and disruption to paint finishes was minimised.
Utilising bolted connections instead of welding for services brackets and modules ensured better control and quality for application of paint, contributing to reduced corrosion, and enhanced longevity and reliability of the machine. Rigorous examination and implementation of dissimilar metals and corrosion isolation strategies were undertaken, ensuring long-term durability and minimised maintenance.
PROJECT TEAM
Entering Organisation: DBM Vircon
Structural Engineer: Aurecon
Distributor or Manufacturer: BlueScope
Steel Fabricator: Civmec
Steel Detailer: DBM Vircon
Coatings Supplier: International Paints
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BIM modelling and the adoption of a fully modularised fabrication and installation methodology has delivered significant safety, cost and schedule benefits. Environmental considerations were made throughout the project design and delivery.” ~ Judges
MELBOURNE QUARTER TOWER
The Melbourne Quarter precinct is among one of the largest mixed-use urban regeneration developments to occur in the city. Sited across from the Southern Cross Station, the objective behind the precinct is to activate and connect a previously underutilised gap between the CBD grid and Docklands. The Melbourne Quarter Tower, at 130m tall, is the largest of three office and residential towers in the precinct, reaching 35 levels.
The tower features a unique roof design that enables maximum floor volume in line with council requirements. The roof consists of 700t structural steel framing from Level 28 to the plantroom area on Level 35. Given the 28-degree pitch roof, the steel framing was designed to enable a large portion of the steel, roofing, skylight framing and services to be constructed off-site and lifted into place safely and efficiently.
“ The fabricators and designers have produced a compelling solution that takes into account the construction complexities of building at height and ensuring the majority of work can be handled off site for safety and efficiency.” ~ Judges
The Melbourne Quarter Tower roof was separated into two stages: the modular roof section encompassing 53 modular cladded frames, five x 20t central spine frames, locally fabricated box section columns (up to 1.2m deep x 16m tall) and locally procured WB primary beams; and the hull plantroom framing which included 10 modular cladded frames, BMU garage, cooling tower platforms and pergola framing.
The hull plantroom required extensive coordination with several trades. By staging the elements into 16 areas, ArcStructural was able to develop a safe, efficient strategy with Lendlease and all contractors. The wall framing was temporarily engineered with propping to support screens being fixed to the structural steel. Given the columns were 13.5m high and in some instances 16m high the screens could not be supported by the slabs. The upper roof framing was modularised with roof cladding, roof access safety systems and temporary handrails.
Some hockey sticks were set-up in ArchStructrual’s off-site cladding facility so that all fire board, roofing and speedpanel could be installed prior to erection. The BMU garage was assembled in two primary frames weighing 15t each. This garage housed a 40t BMU which tracked down the central spine frames on a winch system along large CHS rails. Cooling tower platforms were assembled in six modules off-site. Access was extremely difficult with these areas situated above a 40-degree fully clad roof and services skids. Pergola frames also had to be assembled into four frames in the site loading dock. Pergola frames were 8m wide x 12m long when fully assembled. By assembling these on the ground required less access points above services, cooling towers and steel to navigate.
The project comprised over 60 modules and various other assemblies with over 26,000 documented welds—equivalent to over 70km of deposited weld. This included specialised welding sequences and preparations for several connection plates on the spine frames comprised of Z-25 grade plate. This required controlled pre-heat and run sequences to avoid the possibility of lamellar tears in the thick material.
GLENELG PRIMARY SCHOOL
As part of the South Australia Government’s Department of Education upgrade program, Glenelg Primary School underwent a $7 milion upgrade. A new facility was built along the eastern boundary of the grounds, including three modular classrooms, as well as additional teacher preparation rooms and breakout facilities.
The classrooms meet the most up-to-date standards in an education facility in terms of the natural light, and sound reverberation controls. The curved corners of the building’s architecture added visual interest while softening the form of the structure overall. The new modular classrooms bound extensive covered areas where students can continue their learning outdoors.
The new education spaces were delivered in the form of three buildings covering an area of approximately 825m2. Each building is comprised of prefabricated modules that were assembled at site. The builder for the project, Sarah Build contracted MYT Framing Solutions to design and fabricate the wall, floor and roofing cassettes.
The adoption of light gauge steel framing in the design resulted in less steel being used within the project overall, improving the life cycle assessment for the project. A standard width of 3.4m was adopted for each module to ensure ease of transport to site with only the length of the modules varying from 10.5m up to 12.4m. Each roof module was constructed with four or five trusses, each of which weighed between 75kg and 140kg. This allowed the 17 tonnes of light gauge steel framing required for the project to be delivered in smaller, more manageable pieces minimising site costs and reducing on-site labour requirements.
With collaboration between the architect, builder and the consulting engineer, the shop drawings were finalised, and engineering confirmed over a six-week period. The use of 3D modelling software ensured that clashes between the structures and services were resolved well in advance of manufacture, allowing for efficient installation on-site. The structure was designed with openings of up to 2.7m wide for windows and doors, which were completely supported by lintels made from light-gauge steel. Beyond that dimension, some structural steel was incorporated into the structure. Light gauge steel framing was also used to achieve the curved 2.7m high walls, ensuring that the walls are dimensionally accurate and consistent.
PROJECT TEAM
Entering Organisation: MYT Framing Solutions
Architect: JPE Design Studio
Structural Engineer: Ginos Engineering
Head Contractor: Sarah Build
Distributor or Manufacturer: BlueScope
Steel Fabricator: MYT Framing Solutions
Steel Detailer: JP Drafting Services
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The prefabrication of some of the elements ensured for an efficient use of materials and less disruption to the school due to decreased construction time. The use of cold-formed steel ensured the design criteria were met and lends itself to modular construction.”
MOHAMMED KASSIRA
Mohammed Kassira’s journey in the engineering world is one marked by ambition, expertise, and a commitment to innovation and sustainability. Currently a structural design engineer at Robert Bird Group, Mohammed’s contributions to key infrastructure projects position him as a formidable young talent in the construction industry.
Mohammed Kassira graduated from the University of New South Wales in 2022, joining Robert Bird Group Sydney as a structural design engineer.
Mohammed has been instrumental in the design and development of highimpact projects during his tenure at Robert Bird Group, including the Sydney Metro Western Sydney Airport (SSTOM) line, Seven Hills High School Vocational Education and Training (VET) Facility, and the Crows Nest Metro Station.
His work on the SSTOM project, specifically within the stabling and maintenance facility package, showcases his proficiency in complex structural analysis and design. Tasked with creating structural components like 90m long platform galleries and a 40m wide steel masonry security building, Mohammed’s role required coordination with multidisciplinary teams to meet tight project deadlines while ensuring design accuracy.
Before his role at Robert Bird Group, Mohammed gained invaluable experience at Bayside Council. Starting as a student engineer, he quickly became a development engineer, working on extensive projects like multi-use developments of over 700 units. This early exposure equipped him with practical insights into sustainable construction, stormwater management, and traffic impact assessment, skills that have become foundational in his approach to environmentally conscious design.
Mohammed’s commitment to sustainability is a defining trait of his career. Believing that structural engineers have both the opportunity and responsibility to reduce carbon impact, he strives to optimise designs for material efficiency. This commitment extended to his role at Bayside Council, where he helped draft specifications promoting sustainable urban infrastructure, including electric vehicle accommodations and enhanced public transport access.
Alongside his technical expertise, Mohammed demonstrates strong project management skills. At Robert Bird Group, he managed updates for construction documentation on the Crows Nest Metro Station project, coordinating closely with architects and project stakeholders to ensure precise execution.
His leadership experience is further evidenced by his involvement with Global Consulting Group at university, where he managed pro bono projects, gaining skills in risk and time management.
Equally passionate about giving back, Mohammed has been involved in multiple not-for-profit organisations. In particular, Mohammed was heavily involved with the UNSW branch of Engineers Without Borders (EWB), holding key positions over the years including Vice President - Marketing. Mohammed volunteered for EWB on various occasions particularly through their School Outreach Program, which involved running STEM workshops and
promoting engineering careers to school aged students. Mohammed was also involved in various other capacities, including as a researcher for accelerating energy access in Cambodia with EWB Australia.
Mohammed continues to volunteer in similar capacities, most recently having been involved in Engineers Australia EngineersinClassrooms program, attending workshops at the University of Sydney and East Hills Girls High School.
His influence as an educator extends into his role as a project management tutor at the University of Technology Sydney, where he helps budding engineers grasp essential project lifecycle concepts.
With a career driven by technical excellence, sustainability, and community service, Mohammed exemplifies the qualities of an emerging leader in the field of engineering.
“ Mohammed’s passion for the industry, his community involvement and drive for success were clearly outlined in his submission. His future is undoubtedly bright.” ~ Judges
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