Sydney Football Stadium

The Sydney Football Stadium is a world-class, 42,500-seat venue built on the site of the former Allianz Stadium. With a total investment of $830 million, the redevelopment was part of a broader urban renewal initiative aimed at enhancing transport connectivity and public spaces around the precinct. Officially opened in August 2022, the stadium serves as the home ground for Sydney FC, the NSW Waratahs, and the Sydney Roosters, and was delivered in time for the 2022 NRL Grand Final and the 2023 FIFA Women’s World Cup.

Designed by Cox Architecture, the stadium features a striking diagrid roof supported by four corner “super columns,” with large-span inner trusses and an encircling outer tension ring. The design offers superior sightlines, complete roof coverage, and world-class amenities. It has also achieved LEED Gold certification, featuring a roof that uses 40% less steel than the reference design, solar panel integration, water harvesting systems, and significant green space and habitat creation.

DBM Vircon’s Scope of Work:

DBM Vircon was engaged across two key phases of the Sydney Football Stadium redevelopment, supporting both the early design coordination effort and the delivery of fabrication-ready steelwork.

Design Assist Engagement (under John Holland):

In the early stages of the project, DBM Vircon was engaged by the main contractor, John Holland, to support a design assist initiative aimed at resolving engineering and constructability challenges ahead of fabrication. Working in close collaboration with Cox Architecture, Aurecon, and steel fabricator S&L Steel, DBM Vircon played a pivotal role in identifying connection design constraints, resolving spatial and geometric clashes, and aligning design outputs with practical fabrication and erection methodologies. This proactive engagement helped streamline downstream steel detailing, reduce rework, and mitigate delivery risk.

Stadium Roof Steelwork Detailing (under S&L Steel):

Following the design assist phase, DBM Vircon was engaged by S&L Steel to undertake detailed construction modelling and shop detailing for the stadium’s complex roof structure. Key components included:

• Four Super Columns (Derricks): Iconic vertical support structures at each corner of the stadium, central to the roof’s architectural and structural identity.
• Ten Arch Trusses: Large-span structural elements extending between the Derricks, measuring approximately 140m on the East and West stands, and 90m on the North and South.
• Outer Tension Ring Steelwork: Perimeter steel ring supported by underlying columns, forming the stadium’s outer roof boundary.
• Interconnecting Diagrid Net: A complex web of curved CHS and RHS members forming the roof’s internal net structure, requiring detailed coordination to address geometric tolerances and connection variation.

Temporary Works Steel Structures:

In parallel, DBM Vircon collaborated with BG&E Engineering and S&L Steel to develop and detail a range of complex temporary works required for construction staging and assembly. This included access platforms, jacking frames, lifting assemblies, ladders, handrails, and grating. The team worked to integrate design and detailing efforts wherever possible, reducing duplication and improving cost and schedule efficiency.

Throughout the project, DBM Vircon’s teams in Perth and Chennai coordinated closely using Trimble Connect and Tekla Structures, leveraging internal job management systems to automate drawing production and enhance quality control. The result was a high-performing digital delivery that supported one of Australia’s most prominent stadium developments.

Project Highlights & Challenges:

• Scale and Complexity: DBM Vircon produced over 25,000 shop fabrication drawings to support fabrication and delivery, covering approximately 2,300 tonnes of steelwork and more than 7,000 primary steel members.
• Geometric Complexity: The highly intricate roof geometry — including pre-cambered arch trusses and a tension ring with movement considerations — required precise 3D modelling and shop detailing. Many connections were bespoke, each demanding a tailored approach to fabrication.
• Technology and Automation: Leveraging Tekla Structures, DBM Vircon deployed our internal Job Management Systems (JMS) and smart drawing templates to automate production workflows. Complex 3D etching marks on pipe sections were modelled to aid accurate fabrication of non-standard connections.
• Collaboration Amidst COVID-19: Despite pandemic-related constraints, DBM Vircon’s Perth and Chennai teams maintained daily collaboration with the wider project group — including Cox Architecture, Aurecon, John Holland, and S&L Steel — using Trimble Connect for real-time model sharing, mark-ups, and progress tracking.

The Sydney Football Stadium project underscores DBM Vircon’s ability to deliver at scale on technically demanding, architecturally iconic infrastructure through proactive collaboration and precision digital delivery.

Industry Recognition:

The project has received significant industry recognition, including:

• Winner of the 2022 Australian Steel Institute (ASI) Steel Excellence Award in the Buildings – Large Projects
• Winner of the ANZ Tekla BIM Awards 2021 in the Sports and Recreation category, recognising the innovative use of BIM and digital engineering throughout the delivery process.