Sydney International Airport Terminal 1 Arrivals Car Park New South Wales

E610 free spanning 4.65mtr

This recently completed project will help you understand the benefits of our 74mm polycarbonate system.

Everbright E610 clear was used on this project as a skylight on the 9th level of the Car Park in this new $500 million dollar upgrade to the Sydney International Airport Terminal 1. The skylight is visible from the Car Park Lobby where visitors will leave the arrivals hall at Sydney International Airport. On this project E610 free spanned 4.65mtr incorporating Locking System 2.5. Locking System 2.5 simply means there are 5 aluminium locking bars required out of every 6 chambers. See design loads, which shows you in more detail the different locking systems available.

These panels were extruded, and supplied in complete 9.525mtr lengths and in 600mm wide configurations. For this development our panels only required one intermediate support. The panels simply clip together making the installation process very rapid, as our product only requires to be joined every 600mm on site. Delivered to site were 50 panels at 9.525mtr length x 600mm, the total area was 285.75sqm, and width of the roof was 30mtr.

Installation time for this project took eight hours from start to finish and there were four tradesmen available and on site. Due to safety issues on the site and the flexibility of our panels, it was decided that the panels where fixed to the steelwork on the ground and then craned up in three different bays of 10mtr width. Then each bay was then bolted when in position.

The roof was set at a 3 degree pitch and some extra precautions where taken (see below) as normal recommendations are for a minimum 5 degree pitch.

  1. apply silicon to the underside of the washer.
  2. apply silicon to the actual screw.
  3. Drip nose to be extended to 100mm as opposed to 75mm to discourage capillary action on a low pitched roof.

The clients brief due to the size and height of the car park was for a skylight that would minimize the structural requirements, and make use of all the natural light available, which was of paramount importance. The car park is nine stories high, so it was imperative to have as much light as possible flooding down to all the levels below. Service and maintenance were an important consideration for the Airport, during the selection process for all materials. E610 is trafficable and is a material which has a very high impact strength. Should any person fall onto our polycarbonate panels they will not break or separate, due to the unique design of our three layer 74mm polycarbonate system, E610 it's self acts as the safety net. Safety netting however would be recommended for the process of construction, however this would only be a temporary item that should be removed when all the roof works are completed. This made our system a great selection for this development, as permanent safety net's aren't necessary for any maintenance work.

Another key factor was a product which had a long life span. Makrolon 1243, is the material used in our polycarbonate roofing system which is part of the worldwide Bayer Group and Everbright E610 comes with a manufactures worldwide 10 year warranty and our panels have a life expectancy in excess of 30 years.

The specification was to make use of all the natural light available and they also required a system that had superior thermal performance. Therefore Clear was the colour selected due to a 73% light transmission for visible light and a thermal performance of 1.85W/mK (see test results).

Our polycarbonate system give a seamless and continuous line, with no steel frame work spoiling the visual effect. E610 Integral locking bars hide the aspect of where a panel starts and where it finishes, so it becomes a continuous system giving a uniformed and conformed design feature. Creating an architectural flare, that isn't possible with any other polycarbonate system available on the market. Our system only needs to be secured with washer and screw fixings provided to both the lower and higher end of the panels, all the joints are self sealing once the integral locking bar is fitted. Other systems would necessitate the need for a framed grid work support system across the entire roof. Since less structure is required with our system less shadows are created, and as such the natural light translucency is at it's full potential, which was of paramount importance for this development.

E610 polycarbonate panels incorporate an excellent safety factor. All loading criteria are based on 0.75kN/sqm and a 50% safety factor as part of a standard specification detailing.

As you can see from the images contained in this section, E610 is a very light weight product, that can be easily manoeuvred on site during the installation process. Our 74mm polycarbonate panels are also fully trafficable, which makes a huge difference to construction time, and helps with general service and maintenance of the roof.

The construction process with E610 is very simple and is less time consuming to install on site.

Upgrade Sydney Airport Terminal 1 Car Park

Everbright E610 major advantages at a glance:

  • Rapid installation
  • Superior free span (see design loads)
  • Can be extruded to a maximum 20.5mtr
  • Minimal additional structure required with our system
  • Strongest translucent material in the world (74mm profile)
  • 100% fully trafficable
  • Passed the AS1562.3-2006 sand bag test
  • Impact resistance
  • Intruder resistance
  • Cyclone rated
  • Superior thermal/ acoustic performance
  • Long life span
  • Coextruded UV protection layer
  • Australian manufactured
  • Unique jointing arrangement
  • Self cleaning dome shape
  • Light weight product

This project is located at Sydney International Airport Terminal 1 Arrivals Court Car Park, Mascot NSW 2022, New South Wales
The project can be viewed should site visits be required and adequate notice is given.

The Installation Visually

  •  View finished roof 8th level

    View finished roof…

  • View finished roof 8th level

    View finished roof 8th…

  • View finished roof 8th level

    View finished roof 8th…

  • View finished roof 9th level

    View finished roof 9th…

  • View finished roof 8th level

    View finished roof 8th…

  • View finished roof 9th level

    View finished roof 9th…

  • E610 free spanning 4.65mtr

    E610 free spanning…

  • Safety harnesses used in construction

    Safety harnesses used…

  • View underneath finished roof level 4

    View underneath…

  • View underneath finished roof level 4

    View underneath…

  • One complete bay level 4

    One complete bay level…

  • View underneath finished roof level 4

    View underneath…

  • E610 free spaning 4.65mtr level 4

    E610 free spaning…

  • View underneath finished roof level 4

    View underneath…

  • View underneath finished roof level 4

    View underneath…

  • Complete development front view

    Complete development…

  • Complete development side view

    Complete development…

  • Complete development rear view

    Complete development…

  • Ground level view E610 skylight

    Ground level view E610…

  • E610 skylight closer picture

    E610 skylight closer…

  • E610 skylight closer picture

    E610 skylight closer…

  • Complete development arrivals view

    Complete development…

  • Complete development arrivals view

    Complete development…

  • E610 skylight closer picture arrivals

    E610 skylight closer…

  • Car Park North Entrance arrivals

    Car Park North…

  • View underneath finished roof level 9

    View underneath…

  • E610 30mtr wide skylight level 9

    E610 30mtr wide…

  • E610 30mtr wide skylight level 9

    E610 30mtr wide…

  • View above level 9 facing city

    View above level 9…

  • View above level 9 facing airport

    View above level 9…