Category: Steel Detailing Projects

Steel Detailing projects Show case projects details by Tek1 pty ltd

  • TEK1 Brings the ‘Great Emu in the Sky’ Sculpture to Life for Sydney’s M12 Motorway

    TEK1 Brings the ‘Great Emu in the Sky’ Sculpture to Life for Sydney’s M12 Motorway

    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

  • SYDNEY METRO CITY & SOUTHWEST TUNNELGRC PANELS & ITS BRACKET

    SYDNEY METRO CITY & SOUTHWEST TUNNELGRC PANELS & ITS BRACKET

    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.

  • TEK1’s Steel Detailing for Sydney Metro – Resolving Design Challenges – 2

    TEK1’s Steel Detailing for Sydney Metro – Resolving Design Challenges – 2

    In the last blog in Sydney metro project , we discussed about the design issue regarding angle weld. https://www.tek1.com.au/steel-detailing/tek1s-steel-detailing-for-sydney-metro-resolving-design-challenges-1/

    Here we are going to discuss about the member placement issue.

    The design specified two PFCs on both sides of a column.Column was surrounded by fireproofing sheets. However, the PFC flanges clashed with the fireproofing sheets, making installation difficult. Additionally, the bolts connecting the PFCs would interfere with the fireproofing.

    To resolve this, TEK1 planned a simple yet effective adjustment—changing the orientation of the PFCs. This allowed for seamless fireproofing installation without compromising the structural integrity.

    If we have followed the design , then the erection team will have difficulties to provide the fireproofing sheets.By identifying and addressing potential clashes early in the detailing process, TEK1 saved significant time and costs for the client, ensuring a smooth execution on-site.

    Stay with TEK1 for more updates on steel detailing challenges and solutions in our upcoming blogs.

  • Erection Issue Eliminated Through Suggested Changes in the Splice Connection During Detail Engineering

    Erection Issue Eliminated Through Suggested Changes in the Splice Connection During Detail Engineering

    Issue Identified During Detail Engineering

    • During detail engineering, it was identified that the design specifies both-side web plates, with shop weld on one side and field bolts on the other.
    • This would have created a field erection issue, as the shop-welded web plate on both sides prevents secondary beam placement.

    Proposed Solution: Fully Bolted Connection

    • Use bolted connections on both sides instead of welding one side.
    • This allows the web plate to be shipped loose, making field installation easier.
    • At the site, the secondary beam can be placed first, followed by the web plate installation and bolting.
    • Factory-drilled holes ensure precise alignment and better quality.
    • Eliminates on-site welding hazards and inspection issues.

    Client Approval

    • The client accepted the suggestion due to its practical benefits and ease of installation.
    • The change improves efficiency, cost-effectiveness, and safety.

    Conclusion

    • Switching from welded-bolted to fully bolted improves constructability.
    • Ensures stronger, safer, and more efficient structural connections.
    • Small design changes can greatly impact project success.
  • TEK1’s Steel Detailing for Sydney Metro – Resolving Design Challenges – 1

    TEK1’s Steel Detailing for Sydney Metro – Resolving Design Challenges – 1

    TEK1 is currently engaged in steel detailing for the Sydney Metro project, working with a reputed organization in Australia. During the detailing process, we have encountered several design challenges. Here, we will share one such issue and how we resolved it.

    The Issue

    A design required two unequal angles welded to a small hanger with 10mm packer plates. This left insufficient weld space, making fabrication tough.

    Recognizing this issue early, we raised a query with the concerned team. Our initial proposal was to cut both angles to create the required weld space.

    After reviewing our concern, the team suggested an alternative solution that involved reducing the packer plate thickness from 10mm to 4mm. This adjustment allowed for a 6mm weld clearance on both sides without significantly affecting the design.

    If this issue had gone unnoticed and we had followed the original design, it would have caused complications for both the fabricator and the designer. By identifying the problem early and addressing it proactively, we saved time and costs for the client.

    Stay Tuned for More Insights

    This is just one example of how TEK1 ensures seamless steel detailing by resolving design issues efficiently. Stay with TEK1 for more updates on steel detailing challenges and solutions in our upcoming blogs.

  • Melbourne Airport Gantry

    Melbourne Airport Gantry

    At Melbourne Airport, a gantry supporting a signboard spans 26 meters between laced columns without intermediate supports. The box gantry alone weighs 8 tonne. Since the gantry would bend because of to its self weight, pre-camber of 170mm was provided at the middle.


    For accurate representation, two models were created: one with pre-camber for assembly drawings and another without for general arrangement (GA) drawings. This approach ensures clarity in fabrication and erection, maintaining structural integrity while achieving the desired final alignment.

  • Grain Chutes

    Grain Chutes

    Input information was an Inventor model and pdf drawings

    We have extracted the information from inventor, cross checked with pdf drawings, Checked constructurability, Resolved design details so that items can be fabricated at lowest cost.

    These chutes were submitted for approval, and was approved without any issues.

    Eventhough these chutes are for grain transfer, mining projects have similar requirements.

    CHUTES
  • KAMAY FERRY-LA PEROUSE WHARF

    KAMAY FERRY-LA PEROUSE WHARF

    This was a complex project, but we successfully delivered it. Our scope included the balustrade around the bridge, which needed to be provided in multiple panels. By utilizing advanced modeling techniques, we were able to complete it within a significantly shorter timeline.

    Since the structure is above the sea, we provided several cost-saving ideas for both erection and fabrication to optimize the process.

    This was drawn by Tek1 (Vignesh), if you want shop drawings for a project you are working on, feel free to call Koshy on: (03) 9560 6397.

  • Beautiful Planters

    Here are some planters we have detailed for Straight UP. There are some steel planters and brick planters here. Each planter brings a unique aesthetic and functional appeal to your garden or patio.

    Steel Planter
    Brick Planter
    Brick Planater
    Brick Planter