Sydney Football Stadium

Sydney Football Stadium

Sydney Football Stadium Sydney, NSW   Project Details Location: Moore Park, Sydney, New South Wales Scope: Roof Nosing Edge Completion Year: 2022 Architect: Cox Architecture Builder/Contractor: John Holland Group Façade Engineer: Aurecon ShapeShift Product: ShapeShell™-RT Develop Premier Sportainment Venue The original Sydney Football Stadium, opened in 1988, had become outdated, with aging infrastructure and inadequate facilities. In November 2017, the New South Wales Government announced plans to demolish and rebuild the stadium to meet modern standards, enhance spectator experience, and maintain Sydney’s status as a premier destination for sporting and entertainment events . The redevelopment aimed to create a world-class, 42,500-seat venue with improved accessibility, safety, and amenities. Project Challenges Structural Complexity: Designing and constructing a large-span, synclastic diagrid shell roof posed significant engineering challenges, requiring precise coordination between architects, engineers, and contractors. Construction Timeline: The project had to be completed within a tight schedule to be ready for major events, including the 2022 NRL Grand Final. Material Integration: Incorporating various materials such as PTFE and ETFE membranes, along with GRP bullnose fascia panels, demanded meticulous planning to ensure seamless integration and performance. Solutions To address these challenges, the project team employed advanced digital modeling and parametric design techniques, facilitating efficient planning and execution of the complex roof structure . The use of GRP bullnose fascia panels with integrated gutter systems provided a lightweight, durable, and aesthetically pleasing solution for the roof’s edge, effectively managing rainwater runoff and enhancing the stadium’s sleek appearance. Collaborative efforts among Cox Architecture, Aurecon, and John Holland ensured that the project met its structural, functional, and aesthetic goals within the stipulated timeframe. Shapeshift Contributions Design, engineering, manufacture, supply and installation of roof nosing edge elements around the stadium perimeter using ShapeShell-RT, a fibre-reinforced thermoset material developed by ShapeShift Technologies Technical Highlights Material: ShapeShell-RT Lightweight & high strength Handles complex geometries (double curves, organic shapes) Non-corrosive, impact-resistant, chemically inert 50-year warranty on structure, 25-year warranty on colour retention Recyclable and lower embodied energy than traditional materials Design & Construction Considerations Nosing edge follows the entire stadium perimeter. Monocoque structure divided into manageable 7m panels Attached to steel tension ring with cleats using Orbi-plates Designed for ease of onsite installation, including allowance for some elevated installation (30% of panels at height) Integrated ferrules for strip lighting attachment (778 fixing points)   Structural Design The roof encompasses approximately 26,000 square metres and is characterised by a diagrid steel framework supported by four corner “super columns” or derrick structures. These columns uphold large-span inner arched trusses measuring about 140 metres and 90 metres in length. An encircling outer tension ring, approximately 680 metres in circumference, connects the trusses, forming a stable and efficient structural system. Cladding Materials The roof’s cladding comprises 48 PTFE (polytetrafluoroethylene) fabric panels, each up to 14.5 metres wide and over 40 metres long, providing durability and weather resistance. Additionally, 96 ETFE (ethylene tetrafluoroethylene) transparent panels cover the inner ring, allowing natural light to reach the playing surface, promoting turf growth while offering protection to spectators. Acoustic and Environmental Considerations The roof’s design includes a “cloud-like” steel structure that reflects noise back into the stadium, enhancing the auditory experience for spectators and minimising sound dispersion into the surrounding community. The stadium has achieved a LEED Gold certification, incorporating sustainable features such as solar panels and water harvesting systems integrated into the roof structure. Construction and Engineering Collaboration The project was a collaborative effort involving Cox Architecture, engineering firms Aurecon and Schlaich Bergermann Partner, and construction company John Holland. The use of digital modelling and parametric design facilitated efficient planning and execution, ensuring the roof’s complex geometry was accurately realised. Discover More About Our Cladding Solutions This proposal establishes ShapeShift’s capability to deliver a complex, high-performance façade element—the stadium’s perimeter roof nosing—through a highly integrated design-to-installation process. ShapeShell-RT offers aesthetic, structural, and environmental advantages, with logistics and installation strategies that minimise risk and support program efficiency.   Contact Us Discuss Your Needs

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UNSW Health Translation Hub

UNSW Health Translation Hub Randwick, NSW   Project Details Location: High Street & Botany Street, Randwick, NSW Scope: Comprehensive façade development, integrating innovative safety and design features. Completion Year: 2024 Architect: Architectus Builder/Contractor: Hansen Yuncken Façade Consultant: Acor Consultants Pty Ltd ShapeShift Product: ShapeShell™-RC advanced Glass Fibre Reinforced Concrete (GRC) façade panels Delivering High-Performance Architectural Façades for UNSW’s Landmark Health Innovation Hub The UNSW Health Translation Hub (HTH) aims to deliver a state-of-the-art facility that unites health education, clinical training, and medical research in a single location, directly connecting with acute healthcare services at the Randwick Health and Innovation Precinct. The project’s vision is to improve health outcomes by co-locating researchers, clinicians, students, and industry partners to enable collaboration across disciplines and deliver real-world patient benefits. Project Mission The mission of the UNSW Health Translation Hub (HTH) is to establish a world-class facility that brings together researchers, educators, clinicians, and industry partners to accelerate the translation of medical research into real-world health outcomes. Designed as an integrated space for health education, clinical training, and translational research, the HTH aims to strengthen partnerships between the university and the Randwick Health & Innovation Precinct. Beyond its internal functions, the project aspires to deliver a highly accessible public precinct, featuring landscaped plazas and pedestrian connections that foster community engagement. By achieving architectural, environmental, and operational excellence, the UNSW HTH will serve as a catalyst for future-focused health innovation, benefiting the broader NSW community. Project Vision and Architectural Significance Delivering the UNSW Health Translation Hub required addressing a combination of technical, architectural, and logistical challenges. One of the primary challenges was meeting the demanding aesthetic and performance expectations for the external façade, particularly the complex GRC solar hoods and spandrel panels with sculptural fluting. Maintaining batch-to-batch colour consistency across more than 7,200 m² of façade panels proved critical to achieving a seamless visual outcome. In addition, the façade system needed to integrate multiple performance requirements, including thermal efficiency, acoustic control, durability, and fire compliance, while accommodating movement joints, structural tolerances, and maintenance access. Working within the congested healthcare precinct, with strict working hours and pedestrian safety constraints, further added to the complexity of fabrication, delivery, and installation. These factors required collaborative engineering, material innovation, and precise execution to meet the project’s high standards. Advanced Application The application of the product and work is described as follows: Primary System:ShapeShell™-RC (Glass Reinforced Concrete – GRC) Façade Cladding Architectural Elements Covered: Fluted Panels – featuring either off-form or light acid wash finishes. Flat Panels – also offered in different finish options for cost and aesthetic alignment. High-Performance Façade Elements – durable, impact-resistant, and environmentally safer with an option for silica-free Green GRC. Functional Use: External Façade Cladding of UNSW Health Translation Hub. Provides architectural texture and depth through fluted geometry. Delivers a durable and sustainable skin for the building envelope. Allows visual consistency through sample batch testing. Supports installation efficiency with engineered attachment systems. Finish Options Provided for Consideration: Off-Form Finish:Smooth, moulded surface resembling precast concrete. Light Acid Wash Finish:Textured surface with reduced reflectivity and visible depth. Project Purpose Alignment: The façade serves to visually anchor UNSW’s health precinct while enhancing environmental performance, including durability against Sydney’s weather conditions and supporting lifecycle efficiency.   Our Role and Contribution ShapeShift Technologies played a key role in realising the architectural vision of the UNSW Health Translation Hub by supplying advanced ShapeShell™-RC Glass Reinforced Concrete (GRC) façade systems. Working closely with the façade consultant and builder, ShapeShift provided design input, prototyping, and batch sample testing to help resolve critical challenges such as surface finish selection and colour consistency for the project’s signature fluted solar hoods and spandrel panels. ShapeShift’s vertically integrated design-to-manufacturing process, supported by large-scale CNC tooling and rigorous quality assurance, ensured the production of lightweight, high-strength panels that met the project’s durability, fire safety, and environmental requirements. With engineered fixing and installation systems designed for on-site tolerance adjustment, ShapeShift also contributed to reducing installation risk and improving on-site efficiency. Through this partnership, ShapeShift helped deliver a façade solution that combines architectural impact with long-term performance. Outcome & Legacy The successful delivery of the UNSW Health Translation Hub marks a significant advancement in the integration of health, education, and research infrastructure in New South Wales. The building stands as a landmark within the Randwick Health & Innovation Precinct, distinguished by its architecturally expressive façade, where ShapeShift’s GRC solar hoods and spandrel panels play a defining role in achieving both aesthetic and environmental performance. The outcome reflects a collaborative effort that balanced design excellence, sustainability, and practical constructability, setting a new benchmark for future health precinct developments. Beyond its physical presence, the HTH will serve as a catalyst for medical innovation, fostering partnerships between academia, healthcare providers, and industry. Its legacy lies in enhancing patient outcomes, accelerating translational research, and creating a publicly accessible urban precinct that connects people, knowledge, and community for generations to come. Discover More About Our Cladding Solutions ShapeShift provides innovative, sustainable, and high-quality cladding solutions for modern architectural projects. If you’re ready to bring your vision to life with ShapeShell’s advanced GRC materials, contact us today!   Contact Us Discuss Your Needs

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Brisbane Girls Grammar School

Home Brisbane Girls Grammar School Brisbane, QLD Architect: m3architecture Builder: Lendlease Product: ShapeShell™-RC Surface Area: Over 100 double curvature panels Application: Central Void & Soffit Panels Responsibility: Design, Engineer & Manufacture of Feature Elements –

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Marvel Stadium Melbourne

Marvel Stadium Melbourne Melbourne, VIC Project Details Location: 740 Bourke Street, Docklands, Melbourne, Victoria 3008 Scope: Comprehensive façade redevelopment, integrating innovative safety and design features. Completion Year: 2024 Architect: Grimshaw Architects in collaboration with Smartform Architecture Builder/Contractor: John Holland  Façade Engineer: Aurecon  ShapeShift Product: ShapeShell™-RC advanced Glass Fibre Reinforced Concrete (GRC) façade panels Transforming sportainment spaces with ShapeShell™ RC Marvel Stadium is a dynamic multi-purpose venue in Melbourne’s Docklands precinct, revitalised with ShapeShell™-RC façade panels. These innovative, high-performance GRC panels by ShapeShift Technologies enabled a bold architectural vision, featuring seamless curves, exceptional safety, superior durability, and significantly reduced environmental impact—enhancing the stadium’s iconic presence and ensuring lasting resilience.  The ShapeShell™ – RC Integration at Marvel Stadium Marvel Stadium, a landmark sports and entertainment venue located in Melbourne’s Docklands precinct, underwent a transformative redevelopment designed by Grimshaw Architects in collaboration with Smartform Architecture. The project aimed to revitalise the stadium’s identity, enhance its connectivity with Melbourne’s vibrant urban landscape, and significantly upgrade its safety and performance standards.  Project Vision and Architectural Significance The vision was ambitious: seamlessly integrating bold, contemporary architecture into an existing iconic structure. The new design demanded innovative solutions to realise sweeping curves, sleek façade lines, and stringent safety and performance standards required for large public venues.  Advanced Performance & Safety ShapeShell™-RC panels are certified non-combustible (AS 1530.1) and were independently tested to demonstrate exceptional blast resistance, effectively absorbing and dissipating high-impact energy. This critical safety advantage greatly enhanced public safety standards at Marvel Stadium, meeting and exceeding stringent compliance requirements. Structural Efficiency & Visual Impact With approximately half the weight of traditional precast concrete and significantly increased stiffness compared to standard GRC panels, ShapeShell™-RC substantially reduced structural reinforcement requirements. This structural efficiency allowed Grimshaw and Smartform to incorporate dynamic, complex façade geometries, delivering a visually striking, modern architectural with minimal structural impact.  Long-Term Durability & Sustainability The panels feature a protective hydrophobic coating, significantly improving durability by resisting weathering, abrasion, and corrosion. Precision manufacturing through digital fabrication further ensured seamless, high-quality finishes with minimal joints and crisp architectural detailing. Environmentally, the ShapeShell™-RC panels substantially lowered the project’s carbon footprint compared to traditional construction materials, contributing positively to sustainable urban development practices.  Outcome & Legacy The integration of ShapeShell™-RC panels transformed Marvel Stadium into a contemporary urban landmark, significantly improving its aesthetic appeal, visitor experience, and safety standards. The innovative use of ShapeShell™-RC established a new benchmark for architectural excellence, sustainable design, and safety in public venue construction. This project reinforces ShapeShift Technologies’ position as a leader in providing advanced composite façade solutions that meet complex design visions and rigorous performance demands.  Discover More About Our Cladding Solutions ShapeShift provides innovative, sustainable, and high-quality cladding solutions for modern architectural projects. If you’re ready to bring your vision to life with ShapeShell’s advanced GRC materials, contact us today! Contact Us Discuss Your Needs

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Victoria Pride Centre

Home Victoria Pride Centre Melbourne, VIC Architect: Grant Amon Architects & Brearley Architects + Urbanists Builder: Hansen Yuncken Product: ShapeShell™-RT & ShapeShell™-RC Surface Area: – Application: Architectural Responsibility: Design, Engineer & Manufacture of Feature Elements Details ShapeShift Technologies designs, engineers, and manufactures complex architectural structures. ShapeShift worked on the engineering, design, and manufacture of arched roof vaults for Levels 2 and 5 and the stunning ‛egg’ shaped feature installed in the central lobby. ShapeShell-RC (Reinforced Concrete), an advanced GRC product was used for the exterior elements with a finish of off-form grey to suit surrounding precast and in situ elements. The ‛egg’ was made of ShapeShell-RT (Reinforced Thermoset), an advanced fibre-reinforced thermoset material ShapeShift has developed specifically for the construction industry.

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Spanda

Home Spanda Perth, WA Artist: Christian de Vietri Builder: Adam Mitchell Product: ShapeShell™-RT Surface Area: – Application: Public Installation Responsibility: Design, Engineer & Manufacture of Feature Elements Details ShapeShift Technologies worked with artist Christian de Vietri from the inception of the Spanda project, initially providing the required feasibility study and backing for his artwork submission as the major works of the Elizabeth Quay upgrade.  Spanda is a series of six aligned nested rings that vary exponentially in size about a central point, each tapering as it reaches the sky. The largest of the rings is 29m high. Following Christian’s success in his proposal, ShapeShift Tech completed all the design, engineering, project management, manufacture, installation and certification of the large Spanda artwork. Given the size and cantilever of the structure, a detailed engineering analysis was required. The engineering analysis utilised finite element analysis to determine static performance and normal modes of the structure. In addition, a detailed analytical and finite element analysis was conducted to review the structures response to vortex-shedding phenomenon. To ensure the structure met performance specifications, a high-strength ShapeShell-RT was required and developed through use of analytical calculations and physical testing. The resulting material was tested to a UTS of 660MPa. We also collaborated with civil engineers to design the foundation and completed internally all the engineering of the connections into the foundation. To install the units within the site constraints, it was required to lift each of the rings as one entire unit. This meant the largest lift was a ring unit of almost 30m high and 6m across. This lift was completed in a similar manner to the stepping of a mast. All the design and engineering required to prove this out was also completed in-house.

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West Gate Tunnel

West Gate Tunnel Melbourne, VIC Project Details Location: Footscray Road, Melbourne, Victoria Scope: Comprehensive bridge cladding, integrating innovative safety and design features. Completion Year: 2025 (on going) Consultant: Transurban Architect: Wood Marsh Builder/Contractor:CPB Contractors and John Holland Engineer:Aurecon and Jacobs Joint Venture ShapeShift Product: ShapeShell™-RC advanced Glass Fibre Reinforced Concrete (GRC) façade panels Transforming Civil Infrastructure The West Gate Tunnel Project is a significant infrastructure development in Melbourne, Australia, designed to enhance traffic flow between the city’s western suburbs and the central business district. Upon completion, the West Gate Tunnel is expected to provide a vital alternative to the West Gate Bridge, reduce congestion, and improve freight efficiency by removing thousands of trucks from local streets in Melbourne’s inner west. The Big Plan The West Gate Tunnel Project is a transformative infrastructure initiative designed to alleviate congestion, improve connectivity, and provide a modern alternative to Melbourne’s West Gate Bridge. The project encompasses several key components:​ Widening the West Gate Freeway: The freeway is being expanded from 8 to 12 lanes, including the addition of express lanes between the M80 Ring Road and the West Gate Bridge, to reduce congestion and improve traffic flow.  Twin Tunnels: Two tunnels are being constructed beneath the suburb of Yarraville, connecting the West Gate Freeway to the Maribyrnong River and the Port of Melbourne. These tunnels aim to divert traffic away from residential areas and provide a more direct route for motorists and freight.  Maribyrnong River Crossing: A new bridge over the Maribyrnong River will link to an elevated road along Footscray Road, facilitating quick access to Melbourne’s northern central business district and alleviating congestion on existing routes. ​ Elevated Roadway: An elevated road is being constructed above Footscray Road, improving connectivity to CityLink, Dynon Road, and Wurundjeri Way, thereby enhancing access to various parts of the city. ShapeShift Contributions ShapeShift Technologies supplied over 1,000 two-storey-tall ShapeShell™ RT panels for bridge cladding. These panels were engineered with four simple connection points for fast and efficient installation, and the installation contractor for the panels was FacadeX, a specialised cladding installation firm renowned for precision and efficiency in large-scale infrastructure projects. Our expertise ensured the seamless integration of the ShapeShell™ RT panels, adhering to the project’s tight timelines and high-quality standards. Featuring a net-inspired lattice structure, they provided both durability and an aesthetic connection to Melbourne’s maritime and industrial heritage. The panels also served functional roles, offering noise attenuation and resilience against the city’s dynamic climate. ShapeShift technologies worked in collaboration with Wood Marsh architect and the CPBJH JV construction team, employing advanced moulding techniques to create lightweight, robust panels that aligned with the project’s functional and design objectives. Outcome & Legacy ​ShapeShift Technologies played a pivotal role in the West Gate Tunnel Project, contributing to its innovative design and functionality. The project’s outcomes and conclusions, reflecting ShapeShift’s involvement. The bridge cladding within the West Gate Tunnel Project exemplifies a thoughtful integration of engineering and architectural design. By selecting appropriate materials and designs, the project achieves structures that are not only functional and durable but also contribute positively to the visual and environmental context of Melbourne’s infrastructure landscape. Discover More ShapeShift provides innovative, sustainable, and high-quality cladding in civil solutions for modern architectural projects. If you’re ready to bring your vision to life with ShapeShell’s advanced FRP materials, contact us today! Contact Us Discuss Your Needs

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Blacktown Exercise Sports and Technology Hub

Blacktown Exercise Sports and Technology Hub Rooty Hill, NSW Project Details Location: 25 Blacktown Olympic Avenue. Rooty Hill, New South Wales 2766 Scope: Comprehensive façade redevelopment, integrating innovative safety and design features. Completion Year: 2023 Architect: ARM Architecture Builder/Contractor: Buildcorp  ShapeShift Product: ShapeShell™-RC advanced Glass Fibre Reinforced Concrete (GRC) façade panels Shaping Sport Excellence with ShapeShell™ RC The Blacktown Exercise Sports and Technology (BEST) Hub is a state-of-the-art sports, health, and education precinct located within the Blacktown International Sports Park (BISP) in Rooty Hill, New South Wales, Australia. The project is spearheaded by Blacktown City Council as part of its long-term strategic vision to enhance community well-being, sports performance, and educational research.  The ShapeShell™ – RC Integration at BEST Collaborating with ARM Architecture and Buildcorp, we supplied 1,000 precision-engineered ShapeShell™–RC (the next generation of GRC/GFRC) external facade panels that not only seamlessly blend intricate geometry with a lightweight structure for efficient installation, but also provide a sustainable high-performance solution.    Finished in a striking high-gloss automotive coating, our ShapeShell™–RC external facade panels played a crucial role in bringing the architect’s vision to life, drawing inspiration from diverse cultural architecture, including Indian temples and Turkish bathhouses.  Project Vision and Architectural Significance Located in the world-class precinct of the Blacktown International Sports Park, the Blacktown Exercise Sports and Technology Hub (BEST) is set to become yet another premier resource in the heart of Western Sydney Blacktown City Council.  The state-of-the-art complex combines advanced sports science, physiotherapy, and rehabilitation facilities with cutting-edge amenities, including a strength and conditioning gym, indoor running track, lecture theatre, and recovery pools with a sauna.  Partnering with the Australian Catholic University, Sydney West Sports Medicine, WentWest – Western Sydney PHN, and the AFL – Australian Football League, BEST benefits teams and organizations based at the Sports Park, such as the Western Sydney Wanderers FC, GWS GIANTS, Sydney Blue Sox, Sydney Thunder, NSW Breakers, and the Young Matildas.  Collaborating with ARM Architecture and Buildcorp, we supplied ShapeShell™-RC (the next generation of GRC/GFRC) external panels for the striking high-gloss black façade, ensuring the intricate geometry aligned with the architectural vision while also delivering on buildability, durability, sustainability, and low maintenance.  The ShapeShell™-RC Solution Innovative Design: ShapeShell™ RC – Reinforced Concrete has been instrumental in BEST Hub’s striking façade, which is inspired by diverse cultural architectures, including Indian temples and Turkish bathhouses. The material’s adaptability has enabled a design that stands out as a local landmark, reflecting the spirited community of Blacktown.   Technical Superiority: The lightweight yet robust nature of ShapeShell™ RC allowed for a re-engineered building structure, optimising the use of space and resources. This innovation added an extra floor to the project and expedited the construction timeline, marking significant gains for both the developer and the builder.   Cultural Synergy: The design intricacies facilitated by ShapeShell™ RC at BEST Hub resonate with the facility’s mission to serve the wider community, promoting inclusivity and physical literacy. The material’s versatility has supported the creation of spaces that encourage physical and mental well-being.   Sustainable Solutions: ShapeShell™ RC’s utilisation in BEST Hub underscores a commitment to sustainability with designs that foster energy efficiency and environmental consciousness. This reflects ShapeShift’s dedication to integrating high-performance materials with green building practices.   Community Impact: Using ShapeShell™ RC, the BEST Hub has become a nexus for sports science, health, and community engagement, enriching the lives of Blacktown residents and positioning the facility as a cornerstone for athletic and health excellence. Outcome & Legacy The Blacktown Exercise and Sports Technology Hub (BEST) has won GOLD in the ‘Architecture – Public and Institutional’ category of the 2024 Sydney Design Awards. Our ShapeShell™-RC (the next generation of GRC/GFRC) external wall panels for the striking black façade, blending design innovation with sustainability.  Commissioned by Blacktown City Council as part of their award-winning Transformational Projects Program, BEST was designed by ARM Architecture, with landscape architecture by Architectus (formerly Scott Carver). CO.OP Studio was executive architect, with contractors Buildcorp.  Discover More About Our Cladding Solutions ShapeShift provides innovative, sustainable, and high-quality cladding solutions for modern architectural projects. If you’re ready to bring your vision to life with ShapeShell’s advanced GRC composite materials, contact us today. Contact Us Discuss Your Needs

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Powerhouse Museum Parramatta

Home Powerhouse Museum Parramatta Parramatta, NSW Architect: Genton Builder: Lendlease Product: ShapeShell™-RC Surface Area: Facade Panels Application: Standard Facade Panels Responsibility: Design, Engineer & Manufacture of Feature Elements Details The Powerhouse Museum Parramatta is an iconic cultural landmark set to redefine contemporary museum design with its impressive architectural exoskeleton. ShapeShift is proud to have contributed to this visionary project by providing advanced Glass Reinforced Concrete (GRC) façade systems. Our role in design, engineering, manufacturing, and supply ensured the successful realisation of the complex architectural forms. Feldspar, a key mineral, is incorporated into our ShapeShell RC/GRC panels, enhancing durability, strength, and a natural stone-like quartz finish, delivering a visually striking and sustainable façade.  ShapeShift Technologies played a crucial role in the Powerhouse Museum Parramatta project by delivering robust Glass Reinforced Concrete (GRC) façade systems tailored to meet the project’s demanding requirements. Our expertise in design, engineering, manufacturing, and supply ensured the seamless installation of the museum’s intricate architectural exoskeleton. 

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One Sydney Harbour

Home One Sydney Harbour Sydney, NSW Architect: Renzo Piano Builder: Lendlease Product: ShapeShell™-RC Surface Area: Facade Panels Application: Standard Facade Panels (72 floors) Responsibility: Design, Engineer & Manufacture of Feature Elements Details

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