Sydney Metro is Australia’s largest ever public transport project. It will extend Sydney’s Metro rail into the CBD and beyond to Bankstown, with new stations delivered at Crow’s Nest, Victoria Cross, Barangaroo, Martin Place, Pitt Street and Waterloo, along with the new underground platforms at Central Station.
As a result, by 2030, Sydney will have four metro lines, with 46 stations and a 113km standalone metro railway system.
The $1.3 billion transformation of Sydney’s Central Station will revitalise Australia’s busiest commuter hub. Prior to the COVID-19 pandemic, more than 270,000 people used Central Station every day, with that number expected to rise to 450,000 over the next two decades.
The location of the metro platforms at Central Station will facilitate a critical interchange, fully connecting the station with suburban, intercity and regional rail services, buses, coaches and light rail.
A new entrance on Chalmers Street will provide direct access to Central Station for customers from the Surry Hills catchment area and a direct interchange for passengers from the CBD and South East Light Rail. The new Central Walk pedestrian concourse will better connect passengers to trains, light rail and the new Sydney Metro underground platforms.
The project also includes: new underground Sydney Metro platforms at Central beneath platforms 13, 14 and 15; escalators directly to suburban platforms 12 to 23 for the first time; and an upgraded northern concourse complete with pedestrian thoroughfares and a feature roof.
Over the course of two and half years, Valmont Coatings galvanized 700 tonnes of structural steel for Central Station. Galvanizing has not only ensured a 100-year lifespan for the station but also overcome challenges association with design, logistics, and site constraints.
GALVANIZING CENTRAL STATION’S STRUCTURAL FOUNDATIONS
Galvanized steel forms the core of the basement hanging structures at Central Station. It supports intricate flooring systems and edge forms, vital for the station’s functionality. The basement also benefits from this robust steelwork, upholding the precast hollow core plank flooring system. Notably, the steelwork extends to cladding support along metro walls and escalator support, ensuring seamless integration of modern amenities.
Galvanized steel supports precast walls, floors, and roof systems for the southern and northern vent building structures. The incorporation of removable floor grating demonstrates a thoughtful approach to infrastructure design, allowing for monorail access across levels.
Finally, galvanized steel underpins the flooring systems and control room roofs, illustrating its adaptability. The cladding support framework here exemplifies the material’s strength and reliability in high-traffic areas.
The choice of hot dip galvanizing for this project was strategic. With over 450,000 daily commuters anticipated in the coming decades, the need for a durable, long-lasting solution was paramount. Alternative coatings paled in comparison to galvanizing’s promise of a century-long lifespan.
OVERCOMING CHALLENGES: DESIGN AND LOGISTICS
A Dynamic Design
The project’s evolving design necessitated frequent steelwork modifications, including stripping and re-galvanizing.
According to Tony Kalesovski (Sales Manager NSW, Valmont Coatings), “With some of the design changes being made while the installation of steelwork was being carried out, the need to expedite the stripping and re-galvanizing work was critical to allow the project to flow. The off-site expedited treatment was crucial to meeting the project’s design life, showcasing galvanizing’s flexibility under pressure.”
Valmont Coatings undertook shift work to meet project milestones and delivery expectations. Reworks after required modifications were completed in a timely manner and the end-product was indistinguishable from unmodified steel.
A Logistical Labyrinth
Transfer between fabricator and coating specialist, and then forwarding to the install location takes significant planning and coordination on any project—let alone one the size of Central Station.
“Due to the nature of the project and changes in the installation sequence, logistics were constantly evolving, which meant that storage was also a big factor. The close working relationship between Industrial Maintenance & Fabrications (IMF)—the fabricators on the project—and Valmont Coatings played a major role in overcoming this challenge,” said Kalesovski.
Construction and installation were time-critical; disruptions to the day-to-day operations of Central Station had to remain minimal. This meant that project timelines and milestones were often constrained by planned rail possessions. In addition, the site is located in the heart of Sydney’s busy CBD, making access difficult.
“We worked flexibly to adjust schedules to meet site demand and used our facilities to store a large percentage of finished items when programs changed,” said Kalesovski.
“Daily communication and coordination between Valmont Coatings and IMF were key. This synergy ensured adherence to stringent timelines, exemplifying the critical role of teamwork in large-scale projects like Central Station.”
MARKET GROWTH AND SUSTAINABILITY
As a pivotal node in Sydney’s transport network, Central Station represents both a market growth opportunity and a showcase of sustainable resource utilisation for Australia’s galvanizing industry. Galvanized steel, with its 100-year lifespan, recyclability and minimal waste production, stands out as an environmentally conscious choice.
Galvanizing enabled innovative design, rigorous adherence to timelines, and logistical prowess for Central Station. The project demonstrates galvanizing’s unmatched ability to meet contemporary demands while promising longevity, sustainability, and efficiency.
PROJECT TEAM
Developer and Owner: Sydney Metro
Architect: GHD
Engineer: Aurecon
Head Building Contractor: Laing O’Rourke
Steel Fabricator: Industrial Maintenance & Fabrications (IMF)
Steel Detailer: Revision Zero
Galvanizer: Valmont Coatings