Innovation Takes Flight at Western Sydney Airport
Western Sydney International (Nancy-Bird Walton) Airport (WSI) development has been spoken about for decades; environmental assessments began in 2015-16, community engagement followed, the construction plan was finalised by late 2016 and construction of the terminal and related infrastructure by Multiplex officially began in November 2021.
When WSI opens in the second half of 2026, it will be only the second new major international airport in Australia since Melbourne’s Tullamarine Airport opened in 1970.
With the new airport desperately needed to cater to Sydney’s rapid projected aviation growth, which is expected to double over the next 20 years.
The new airport (pictured top) is a major undertaking and one that must remain functional and relevant well into the future. Given the project’s importance, it’s no wonder that Western Sydney Airport Co Limited (WSA Co)—the company that was formed in 2017 to oversee the construction and operation of the airport—is seeking to achieve best practice across all aspects of the build.
The Fielders Design Solutions Group (DSG) was formed with the same best practices objective—to provide an industry leading customer experience that provides real value and support to building design and construction professionals across Australia.
From concept to completion, the DSG team leverage their subject matter experts to provide design solutions and technical support throughout all stages of a project.
DSG began working with Multiplex over two years ago to understand the WSI terminal’s key success metrics and technical requirements.
This early collaboration enabled DSG to recommend an efficient structural solution using Fielders SlimDek 210 composite decking, saving months in construction time and delivering major program efficiencies unattainable with conventional methods.
SlimDek 210 features a unique trapezoidal shape and deep rib profile geometry that enables large unpropped spans up-to 7m to be achieved.
This capability allowed DSG national engineering manager Marko Stankovic to propose a completely new structural twin-beam design for the terminal buildings, replacing conventional concrete beams and slabs with large span SlimDek 210 composite slabs supported on welded beams manufactured from BlueScope’s XLERPLATE steel for a cleaner, more efficient structure.
In addition to the large unpropped spans enabled by SimDek 210, the product can also deliver other advantages during construction, including enabling immediate fitout of floors below, a requirement for less equipment, materials and workers on-site as well as faster construction times leading to earlier hand-over.
DSG presented this innovative solution to Multiplex, demonstrating its ability to meet complex structural performance requirements while saving significant time.
Following a detailed assessment by ARUP, the design was adopted for detailed development.
About 32,000sq m of Fielders SlimDek 210 and 25,000sq m of KF57 were specified, with DSG’s Marko and Jack Huang providing ongoing technical support throughout the project’s design and construction phases.
Fielders DSG developed a bespoke construction solution, the first of its kind in Australia and possibly the world.
Marko and Jack continue to support Multiplex onsite, ensuring best-practice SlimDek 210 installation.
Their dedication reinforces Fielders’ reputation as innovative, solution-focused partners delivering exceptional value to the construction industry.
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