XLERPLATE® Kicks A Goal For MCG

Location:	Melbourne, Victoria
Country:	Australia
Project Size:	A$425 million
Builder:	Grocon Construction Pty Ltd
Fabricator:	Alfasi Steel Constructions
Products Used:	AS/NZS 3678 - 250 XLERPLATE® AS/NZS 3678 - 350 XLERPLATE®

One of Melbourne's biggest construction projects is staying ahead of the game, with the help of established Melbourne-based steel fabricators, Alfasi Steel Constructions, and BlueScope Steel.

The redevelopment of the northern end of the Melbourne Cricket Ground will see about 55% of the ground rebuilt, with a new Northern Stand replacing the existing Ponsford Stand, Olympic Stand, and Members Pavilion.

Due for completion prior to the 2006 Melbourne Commonwealth Games, the A$425 million project will increase the capacity of the stadium to over 100,000. The new Northern Stand consists of nearly 135,000 square metres of built area, with 55,000 seats. It also includes new dining facilities, spectator services and concession areas.

All structural steel work for the new stand is being supplied by Alfasi Steel Constructions. "We are fabricating and erecting all the structural steel work for the new MCG grandstand, including the bowl, or seating area, and the roof," says Gill D'Vier, Director of Alfasi Steel Constructions.

"We've been involved in the job for about a year now," he adds. "The MCG is still in use while the project is proceeding, so the job is being completed in stages, to allow a certain number of seats to remain available. We are currently completing Stages One and Two, with Stages Three, Four and Five to go. The entire project must be finished prior to the Commonwealth Games in 2006."

A family owned and run business, Alfasi Steel Constructions was established in 1982, by Avri Alfasi. The business has come a long way from its modest beginnings, and is now one of Australia's leading structural steel fabrication and erection companies, with over 200 employees.

"It's a big project for us," says Gill. "We were awarded the A$33 million contract by Grocon - largely due to our previous experience in similar projects, such as Colonial Stadium."

The new roof for the Northern Stand is a cable net structural system with structural steel supports and concrete filled beams provided to assist uplift. Alfasi has developed a methodology which enables the completion of the roof panels on the ground, including all secondary steel, roof sheeting, soffits lining and insulation and services. The completed panels are then lifted into place, complete with required safety fixings and handrails.

The main roof rafters of the new grandstand are 40 metres long and weigh up to 32 tonnes. The rafter is fabricated in two halves, which are then bolted together on the ground prior to erection.

"We had to put a lot of thought into the erection methodology for the roof of the stand," explains Gill. "It's a highly architectural cable stayed roof with pretty complex steelwork, so we put a lot of work into the technical aspects of the erection. The roof consists of very large components and unusual shapes - and it's very high up in the air - so safety is imperative."

"It's been a matter of determining how to stabilise the roof temporarily before the cables are fixed, and the best way to lift the roof panels. The fabrication process for the steel work was also very involved - due to the complexity of the job," he adds.

All the steel work is being fabricated in Alfasi's workshop in Dandenong. "All up, we are supplying 4,500 tonnes of structural steel for the project," says Gill. "All steel used on the project is from BlueScope Steel. We are using XLERPLATE® in 250 and 350 grade, depending on what strength is required for particular sections."

According to Gill, flexibility of supply, especially when it comes to non-standard lengths of plate, was a good reason to choose BlueScope Steel. "We would always prefer to use an Australian product," he says. "Using a local supplier gives us the flexibility to order special lengths of plate, which we've done with the XLERPLATE®."

Reliability of supply is key, says Gill. "Obviously the timing is crucial to the fabrication and erection programme, particularly on a high-profile job like this. The quality of the steel has to be perfect and it has to be the right grade. There is absolutely no room for error."