In keeping with this sense of community and connection, Wood Marsh, the architects commissioned to design Bell Station, drew inspiration from the heritage-listed housing surrounding the site. The suburb’s roofscape inspired the three-dimensional pattern which forms both the concrete facade that dominates the building, and the imposing glazed feature walls that provide natural light into the station’s interior concourse.

It’s these glazed feature walls that would present a significant challenge for the building’s facade contractor, Casello. Their extensive experience working with NWPA on many previous rail projects made them acutely aware of the need to minimise network disruption, according to Sam Goldberg, Casello’s Business Development Manager.

“Major transport infrastructure projects, that include ‘occupation shutdowns’ are particularly time sensitive, so alternate building solutions like the prefabricated light gauge steel (LGS) framing used on this facade, expedited the construction process without compromising the architects original design intent”.

Sam Goldberg Business Development Manager, Casello

This facade was originally designed and specified to be constructed entirely on-site using a ‘stick-build’ method incorporating structural steel components. However, according to Dan Thomson from CMG Frames, the company Casello contracted to build the prefabricated modules, “on site construction of the complex multi-faceted, articulated, angular framework added risk to the project timeline”. Dan added, “the accuracy of prefabricated and engineered LGS framing meant that the bespoke, imported windows could be ordered in advance, confidently knowing that they would fit perfectly into the frames on arrival”.

The prefabricated LGS framing used on this project was designed and engineered by CMG Frames using 3D modelling software to achieve seismic, wind and load requirements. Selected for its high strength-to-weight ratio, G550 grade TRUECORE® steel with a base metal thickness (BMT) of 1mm was selected for the structural framing within the project.

Despite the extreme complexity of these unique frame structures, 3D modelling facilitated the dimensional accuracy of every component, including all bracing, fixing point, mounting plates, and support bracket to deliver the modules’ required structural integrity.

In total, 36 prefabricated light gauge steel modules were manufactured for the Bell Station project, with each elevation incorporating 18 modules varying in size from a massive 5.3m high x 2m wide, with the smaller modules measuring 2m x 2m. When complete, these modules were transported to the site entirely configured and installed in a sequenced process by a small crew using only a mobile site crane. Demonstrating yet another key benefit of utilising an LGS solution rather than the alternative approach that would have necessitated costly perimeter scaffolding and may have caused a lengthy, longer and disruptive installation process.