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Hot Dip Galvanizing Services from Nepean Building & Infrastructure

thornleigh golf centre

Case Study: From pit to prestigious sports centre

Hot dip galvanizing (HDG) applied to the entire structure of a driving range and practice facility at a brand new golf centre in Sydney's northwest, transformed what was a disused and derelict industrial brick pit and waste site into a modern and enduring sporting venue.

hot dipped galvanized staircase The $5 million Thornleigh Golf Centre facility features 56 hitting bays over two levels with automated ball return complementing a mini-golf facility, clubhouse and 15,000m2 driving range.

As the golf centre is located on a clay-capped filled site, an adjustable design was required for the two-tiered driving facility to overcome differential site settlement associated with engineering constraints onsite, demanding a lightweight protective coating.

The structure therefore incorporates a system to adjust deck levels and a lightweight HDG steel superstructure was chosen. HDG was applied to the entire two tiers of the structure comprising 80 tonnes of structural steel portal frame supporting a steel clad roof and two levels of pre-cast concrete flooring.

The HDG structural steelwork includes universal beams and columns, parallel flange channels as well as rectangular and circular hollow sections.

Challenges and Solutions
The most significant challenge was the need for an architectural finish from what is basically an industrial process to ensure an end surface finish which is completely uniform and unblemished with no wire or touch up marks.

The second biggest challenge was to provide the high quality galvanizing within a very tight schedule required by the builders for items to arrive onsite ready for erection without delay, which was met through tight teamwork between the galvanizer, steel contractor, owner, engineer and architect.

The vast majority of outdoor sporting facilities use paint as the preferred type of protective coating. Thornleigh Golf Centre made a conscious decision to use HDG steel due to its durable, cost-effective and aesthetic properties. The vast quantity of galvanized steel for the golf centre is clearly visible.

Already promoting sustainability and environmental awareness through land renewal, the use of galvanizing on this project was the most appropriate finish as HDG does not leach, nor require maintenance or further product applied during its lifetime.

hot dipped structural steel at thornleigh golf course

This project scored a real hole in one for golfing enthusiasts and even resident rabbits which still thrive on the grounds.

The HDG solution was not only a lot cheaper than stainless steel or other alternatives it provided superior weathering capabilities in the exposed outdoor setting with no touch ups required at erection and minimal maintenance costs going forward.

Eight Reasons to Choose Hot Dip Galvanizing

1. No hold ups due to weather - steel can be galvanized in any weather conditions
2. Speed - modular design compatibility to speed up construction
3. Tough coating system - reduces transport damage & minimises on-site repairs
4. Inbuilt durability - minimises in-service damage from vandalism & accidental knocks
5. Withstands UV - the surface is immune to damage from the extreme Australian sun
6. Superior corrosion protection - provides initial and lifetime cost savings
7. Aesthetics - natural good looks
8. Sustainable - Zinc and steel are 100% recyclable

In addition to being a finalist in the 2013 Galvanizers Association of Australia Sorel Awards, the project also attracted a High Commendation in the Small Building projects category of the 2012 Australian Steel Design Awards organised by the Australian Steel Institute.

Project Team
Developer/Owner: Steve Aisbett for Thornleigh Golf Centre
Architecture: OPRA Architects
Structural Design: Kneebone and Beretta Consulting Engineers
Project Managers: Darren Comin, Paul Comin and Ron Comin (Combell Steel Fabricators)
Main Contractor: DBHE Building Services
Hot Dip Galvanizer: Galserv® Galvanising Services (by NEPEAN Building & Infrastructure).

thornleigh golf club

NEPEAN B & I Profile

02 9707 5088

117-153 Rockwood Road, Yagoona, NSW, 2199

NEPEAN B & I Profile

02 9707 5088



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