The Victorian Government’s Level Crossing Removal Project is the most extensive infrastructure program of its kind, ever undertaken in the state’s history. Its clear objective is to improve road and rail safety while reducing congestion. To date, 84 dangerous level crossings have been removed and 48 new commuter stations built or refurbished.
As part of this project, light gauge steel (LGS) framing made from TRUECORE® steel was specified and manufactured by CMG Frames, to construct the multi-dimensional façade of the new Bell Station in the Melbourne suburb of Preston. This helped the time-critical project to stay on track during construction.
The efficiency of a prefabricated LGS framing solution proved beneficial for this project, where prolonged or unintended disruption would have a negative impact on a public transport network.
The use of LGS framing enabled each module of the façade to be made to exact tolerances. To ensure structural integrity, CMG Frames’ 3D modelling software was used to ensure the frames met 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.
In turn, this enabled other elements, like the stained-glass windows, to be pre-ordered and manufactured concurrently, saving time and minimising the need for on-site measuring. According to Dan Thomson from CMG Frames: “The accuracy of prefabricated and engineered LGS framing meant that the bespoke, imported windows for example, could be ordered in advance, confidently knowing that they would fit perfectly into the frames on arrival.”
In total, 36 prefabricated LGS 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, to 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.
The use of prefabricated LGS framing made from TRUECORE® steel provided key benefits including:
- Engineered structural integrity
- Dimensional accuracy
- Timely and efficient installation
- Less site disruption