Australian steel exported for global architectural landmark

It's a mark of distinction for XLERPLATE® steel to be a component of the astonishing architectural achievement of Marina Bay Sands – Singapore's new luxury resort and hotel development.

And it's not just a mark of distinction for XLERPLATE® steel. Its utilisation in Marina Bay Sands is also recognition of the exacting quality control that exists at BlueScope Steel's Port Kembla Steelworks (PKSW).

For this project, PKSW had to achieve Factory Production Control accreditation through an audit process by global independent quality assurance company, Lloyds Register, to certify that BlueScope Steel's quality control systems were good enough to ensure that material supplied met the relevant European Standard. This requirement was part of Singapore's BC 1 Design Guide, which has been recently implemented to safeguard high standards of building construction.

Other aspects of XLERPLATE® steel that led to its choice for this project was the technical support that comes with the product and its diverse product range. A range of EN 10025 grades of XLERPLATE® steel were supplied, including EN 10025-2- S355J2 and EN 10025-4-S355M, which were custom made according to project specifications. These grades are impact tested, high strength structural steel grades. The material requirements for the project also called for comprehensive steel cleanness (to ensure structural integrity) and surface quality to meet the exacting standards required for such a high profile project.

Marina Bay Sands' trademark three towers and 340 metre long Sands Skypark, featuring the longest cantilevered public observation deck in the world. This project uses XLERPLATE® steel.

XLERPLATE® steel was used for the one kilometre long canopy above the Marina Bay Sands retail promenade. The fabrication was undertaken in Melbourne by Alfasi Steel Construction Pty Ltd, one of Australia's leading construction and engineering groups.

The retail canopy utilised 1,000 tonnes of XLERPLATE® steel in 54 rafters that were 33 metres long. Steel was supplied in 11 metre lengths and welded into rafters onsite. XLERPLATE® steel was also used in 26 mast (tapered cone-ended) columns, 13 metres long, to support the rafters.

"We had BlueScope Steel specially roll the XLERPLATE® steel for us," explained Elad Zohar, Alfasi's Marina Bay Sands Retail Promenade Project Manager – Supply of Steel. "The product was chosen because it achieved the required engineered performance. After fabrication – which included cutting to size, bevelling, welding and testing – the XLERPLATE® steel was spliced and painted onsite, then erected."

The XLERPLATE® steel was also rolled into round sections for use in the tubular-shaped rafters by Alfasi, as well as for cones which were fitted to the ends of the masts.

Elad said this project presented a number of engineering challenges to Alfasi. "The rafter was an arch shape; therefore splice joint tolerance had to be kept to a minimum so there was no misalignment. An architectural finish was also specified for the project, so we applied a customised linishing process to the plates to achieve the desired smooth, aesthetically pleasing surface finish."

In fact, said Elad, "Alfasi's Melbourne workshop was partly chosen for this job because it had previously, and successfully, undertaken projects that required a similar, high-attention-to-detail linishing".

One of the unique aspects of the project involved its transportation, Elad outlined. "The XLERPLATE® steel was sea freighted on special flat racks. These racks are very difficult to get hold of and they sit in an open container. The steel sections were lashed onto the rack with chains and were subject to special marine survey loading restrictions.

"BlueScope was advised six weeks ahead when every piece of steel plate was being called up," continued Elad. "And it successfully delivered the product to Alfasi every time. BlueScope Steel's capability to deliver the product from Australian mills saved Alfasi the freight lead time that would have applied if the steel was imported."

In addition to the project scope described in this case study, unique engineering elements of Marina Bay Sands, when it is fully complete, will include:

• three 60-storey hotel towers
• a two acre sky park bridging across the towers, consisting of a garden, swimming pool, jogging paths, spas and ‘floating' crystal pavilions
• three underground storeys that will house 2,600 hotel rooms/suites and a 4,000 car garage
• a lotus-shaped science museum
• exhibition halls and a convention centre that will have capacity to host over 45,000 delegates.

Download Steel In Touch Issue 18, Summer 2011 (655 KB)