Category: Projects

At TEK1, we believe great detailing is more than just precision—it’s about understanding real-world challenges and turning complexity into clarity.

The Challenge

The Great EMU in the Sky project presented one of the most unique and technically demanding structures we’ve ever worked on—a 30-metre-wide globe made up of 128 intricate “star nodes” connecting the bracing members.

These nodes weren’t ordinary joints. Each featured 5 or 6 connection points and came in three different CHS sizes, with every arm set at unique, non-repeating angles.

For the fabrication team, this posed a significant challenge:

• 128 Complex Star Nodes, each with custom angles
• Inconsistent geometries
• Time-consuming and difficult to fabricate accurately

Even with precise 3D modelling, the practicality of fabrication was proving to be a serious bottleneck. Something had to change.

The Turning Point

That’s when TEK1 took the initiative.

Rather than simply delivering a model and walking away, we engaged directly with the fabricator to understand the issue from their perspective. We realized that even the most accurate detailing wasn’t enough—what the team needed was smarter, fabrication-friendly solutions.

The Solution

Our detailing team re-engineered how the star nodes were documented, presented, and ultimately fabricated. Key solutions included:

• ✅ Custom fabrication jig design: We developed a dedicated jig that allowed star nodes to be fabricated with greater ease and precision, regardless of the angle configuration.
• ✅ Standardized node sub-groups: We grouped similar nodes together to reduce variation and streamline production.
• ✅ Detailed templates: For common angle types, we provided accurate templates to guide fabrication.
• ✅ Visual fabrication aids: Clear drawings showing exact cuts, welds, and orientations for every node.

The Result

• ⚡ Faster fabrication times
• 🎯 Improved accuracy and alignment
• 🔁 Reduced rework and error rates
• 🤝 Stronger collaboration between design and workshop teams

Most importantly, the fabricators were able to work with confidence, knowing each node would come together exactly as intended.

Taking Detailing to the Next Level

This project reinforced one of TEK1’s core values: true excellence in detailing comes not just from precision—but from empathy. When we truly understand the needs of the people building the structure, we unlock practical, buildable solutions.

The Great EMU in the Sky is more than a globe—it’s a powerful example of what happens when detailers and fabricators work together as one team.

📢 Call to Action:

🚀 Have a complex structure or fabrication challenge? Partner with TEK1—where technical expertise meets buildability.

TEK1 is proud to be part of an iconic project—the ‘Great Emu in the Sky’ sculpture, a monumental 30-meter-high emu nest that will stand as a cultural landmark along Sydney’s M12 Motorway.

A Symbol of Dharug Heritage

The peanic structure celebrates the Dharug Community’s sacred creation story of the Great Emu constellation.

A Landmark Visible from Land & Sky

Positioned for maximum visibility, the sculpture will be seen by:

• Road users
• Pedestrians
• Sydney Metro passengers
• Even planes approaching and departing Sydney Airport

Blending Art, Culture & Engineering

The steel artwork will take on different forms depending on the time of day and viewing angles:We look forward to seeing this one-of-a-kind sculpture take its place in Sydney’s landscape, honoring history while welcoming the future.

• By day, it will resemble an emu nest, crafted from signature steel “sticks” that reflect the natural landscape and traditional materials of the Dharug people.
• By night, it will illuminate and reveal two emu forms, visible only from certain perspectives—mirroring the Great Emu constellation as it shifts throughout the six Aboriginal seasons.

TEK1’s Role in Detailing the Sculpture

A lot of technical challenges were navigated to ensure that this complex structure, could be fabricated and erected, cheaply and efficient. We will document this on our blog if you’re interested.

Please refer to the below video which represents the various stages of on-going erection

TEK1, we recently had the opportunity to detail GRC panel brackets for a section of the Sydney Metro Tunnel, utilizing a point cloud survey to ensure precise alignment and installation.

Project Overview

The client provided a point cloud survey of the tunnel, allowing us to accurately determine the placement of GRC panels and their supporting brackets. Since tunnel walls are rarely perfectly straight—often featuring irregularities, ups, and downs—extra attention was required to ensure each bracket was positioned correctly for a seamless fit.

Challenges & Solutions

Efficient Coordination – By leveraging point cloud technology, we minimized potential site adjustments, streamlining the installation process for our client.

As-Built Adjustments – The natural deviations in the tunnel wall’s shape meant that standard placements wouldn’t work. The point cloud data helped us fine-tune the bracket positions to match real-world conditions.

Precision Detailing – Each steel bracket was meticulously detailed to accommodate the GRC panels, ensuring a secure and uniform installation.

Conclusion

Working with as-built tunnel walls requires high accuracy and adaptability, and this project was a great example of how TEK1 effectively integrates advanced technologies like point cloud surveys into our detailing process.

Check out the snapshots below to see how the GRC panels are securely fixed to the tunnel wall using custom steel brackets.