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
The original Sydney Football Stadium, opened in 1988, had become outdated, with aging infrastructure and inadequate facilities.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.
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.
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.
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
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
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)
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.
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.
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.
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.
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.
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