At ALDI’s new distribution centre in Tarneit, Victoria, BARMAT® prefabricated reinforcing mesh helped recover valuable time in the construction schedule, supporting the project team to maintain momentum on one of Australia’s largest logistics developments.

InfraBuild Reinforcing supplied BARMAT® through ARC to Calibre Concrete Group, the concrete contractor responsible for delivering more than 183,000 square metres of concrete works across the site. ARC helped deliver this project end-to-end.

Project at a glance

• 102,000m² distribution centre
• 183,000m² of concrete works delivered
• 500+ tonnes of prefabricated reinforcement installed in suspended slabs
• 32 days recovered across the suspended slab programme

Supporting one of Australia’s largest distribution centres

Located within the Tarneit Logistics Hub in Melbourne’s west, the new ALDI Distribution Centre spans 102,000 square metres and represents a significant investment in Victoria’s supply chain infrastructure.

Developed by Charter Hall and constructed by Qanstruct, the fully automated facility features ultra high-bay warehousing, temperature-controlled storage and advanced logistics technology capable of processing close to 2.3 million pallets annually.

As part of the project, Calibre Concrete Group delivered:

• 70,000m² of warehouse floor slabs
• 85,000m² of hardstands
• 28,000m² of suspended slabs

The scale of the concrete package demanded a solution that could support productivity while helping the project team meet critical delivery milestones.

A programme under pressure

Like many major construction projects, the Tarneit development faced unforeseen challenges during delivery.

Delays in structural steel installation and formwork reduced the time available to complete suspended slab works, placing additional pressure on the construction programme.

Traditional suspended slab reinforcement requires significant on-site labour to place, tie and assemble individual reinforcing bars. With the programme already compressed, the project team needed a faster and more efficient approach.

Delivering productivity through prefabrication

To help recover lost time, the project team adopted BARMAT® prefabricated reinforcing mesh.

Manufactured off-site as pre-assembled reinforcing panels, BARMAT® eliminates the need to tie reinforcement bar by bar on site. Panels are lifted directly into place by crane, allowing installation teams to work quickly and efficiently across large slab areas.

For the Tarneit project, the results were significant.

Each suspended slab was completed approximately one day faster than would have been achieved using traditional reinforcement methods, resulting in a total programme saving of 32 days across the suspended slab package.

“Switching to BARMAT® on the suspended slabs gave us back control of the programme. Eliminating the need to tie over 500 tonnes of steel on site made a significant difference to our sequencing and productivity, and the prefabricated panels installed efficiently with crane access across the site.

The solution worked great at Tarneit, especially with the large, open and consistent slab layouts.”

Ryan Wong, Senior Project Manager, Calibre Concrete Group

Designed for large-scale construction

BARMAT® is particularly effective on large, open slab areas where reinforcement layouts are consistent and repetitive.

The suspended slabs at Tarneit were ideally suited to this approach. With crane access across the site and a uniform reinforcing design, panels could be installed in sequence with minimal handling and reduced site labour requirements.

By prefabricating reinforcement off site and accounting for laps during manufacture, the solution also reduced on-site coordination and supported a smoother installation process.

Building more with less

The Tarneit project demonstrates how prefabrication can help improve construction productivity and support project teams when programmes come under pressure.

While BARMAT® was introduced as a response to a scheduling challenge, its impact extended beyond programme recovery. By reducing on-site labour requirements and accelerating installation, it enabled the concrete team to maintain progress without compromising quality.

“Supplying BARMAT® through ARC, who delivered to a project of this scale, demonstrates how prefabricated reinforcing can help improve productivity on site. When programmes are under pressure, reducing installation time and on-site labour can make a meaningful difference to project outcomes. Recovering 32 days on a project of this scale is a strong example of the value prefabrication can deliver.”

Rupinder Saraan, Account Manager, InfraBuild Reinforcing

Delivering practical outcomes

As Australia’s industrial and logistics sector continues to expand, project teams are increasingly looking for ways to improve productivity, reduce complexity and maintain programme certainty.

The ALDI Tarneit Distribution Centre highlights how prefabricated reinforcing solutions such as BARMAT® can help deliver practical outcomes on large-scale projects, supporting faster construction and helping customers build more with less.

Please contact us to learn more about how BARMAT® can support your next project

The post How prefabrication improved construction productivity at ALDI Tarneit appeared first on InfraBuild.

Delivered as part of the Victorian Government’s Level Crossing Removal Project (LXRP), the upgrade replaced two level crossings with new road bridges, improving connections between Diggers Rest, Sunbury and surrounding suburbs and helping future proof one of Melbourne’s fastest expanding corridors.

InfraBuild Reinforcing partnered with Civil Infrastructure Group to support the delivery of reinforcement across key structures on the project, contributing both to the physical build and to how the project was delivered.

A smarter way to deliver steel

Diggers Rest was not just a construction project. It also became the pilot site for an industry first initiative to digitise the reinforced steel supply chain, led by the Level Crossing Removal Project, GS1 Australia and project partners including InfraBuild Reinforcing.

As the primary steel supplier, InfraBuild trialled the use of:

• Digital delivery dockets and invoices
• Improved site to office tracking for steel deliveries

This created a more connected and transparent way to manage materials, improving accuracy, reducing manual handling and supporting better coordination between site and office teams.

By helping lead this trial, InfraBuild contributed to a smarter approach to supply that reduces errors, minimises waste and limits contract disputes.

“Being part of the Diggers Rest pilot allowed us to demonstrate what a connected supply chain could look like, one where material traceability, document accuracy and on-site efficiency all improve through better data sharing. It’s a strong step forward for the entire industry.”
 — David McNeil, Customer Experience Manager, InfraBuild

Local steel, delivered with certainty

InfraBuild Reinforcing supplied a total of 478 tonnes of reinforcement to the project, including:

• 415 tonnes of loose bar
• 63 tonnes of prefabricated cages
• An additional 25 tonnes scheduled for final delivery

All steel was 100% manufactured locally, supporting Australian industry and meeting project requirements for local content.

At peak construction, up to two truckloads per day were delivered to align with critical build windows, helping keep the program on track and avoid delays.

Faster installation through prefabrication

Prefabricated pier columns were manufactured at InfraBuild Reinforcing’s Sunshine facility in Victoria and delivered directly to site, reducing on-site labour and improving installation speed.

This approach allowed reinforcement to arrive ready for installation, improving safety and helping maintain momentum during key construction phases.

“Working closely with the delivery teams on Diggers Rest, our focus was on removing friction from site operations. Through consistent scheduling, prefabrication support and daily coordination, we helped keep the project moving at pace while ensuring quality and compliance every step of the way.”
 — Ricardo Angola, Project Manager, InfraBuild Reinforcing

Working through complexity

Like any major infrastructure project, Diggers Rest presented challenges, including compressed timelines and complex reinforcement requirements.

Working closely with the builder and design teams, InfraBuild provided:

• Experienced detailing support to resolve complex drawings, queries and RFIs, improving reinforcement layouts and speeding up approvals
• Just in time delivery coordination aligned to site needs
• Prefabrication solutions with strict lifting specifications, reducing congestion and labour time on site

Productivity that drives better outcomes

By improving how materials, data and schedules were managed across the project, the team reduced rework, minimised steel waste and shortened construction time.

These productivity gains also support better environmental outcomes, with fewer delays, less waste and more efficient use of materials.

A stronger future, built together

The successful removal of the Diggers Rest level crossings shows what can be achieved through strong partnerships, practical solutions and Australian made steel.

By combining local manufacturing, prefabrication and a more connected supply approach, InfraBuild Reinforcing helped deliver both the infrastructure and a better way of working for future projects.

For more information on how we can support your project goals, get in touch with our team.

The post Partnering for Progress at Diggers Rest: Smarter Supply, Stronger Outcomes appeared first on InfraBuild.

Located in Queensland’s Southern Downs region, it includes 162 wind turbines with a generation capacity of 923MW. As part of a broader renewable energy zone, the project is helping strengthen Australia’s energy network while supporting long-term decarbonisation goals.

InfraBuild Reinforcing partnered with ACCIONA to deliver reinforcement across turbine foundations and associated civil works, contributing not just to supply, but to how the project was delivered.

Scaling supply to match an ambitious program

Delivering a project of this size required more than volume. It required consistency, coordination and the ability to keep pace with a demanding construction schedule.

InfraBuild Reinforcing supplied approximately 18,000 tonnes of steel, maintaining delivery rates of up to 1,500 tonnes per month to support continuous activity across multiple work fronts.

Through careful planning and close alignment with site requirements, reinforcement was delivered when and where it was needed, helping maintain momentum and avoid disruption.

As Mike Jostsons, InfraBuild Business Development Manager – Energy, explains:

“On a project of this scale, it’s not just about how much steel you supply, it’s about how reliably you can deliver it. Consistency across the program was critical to keeping construction moving.”

Setting the project up early

One of the key contributors to the project’s performance was early engagement during the design phase.

By working closely with the client and design teams, InfraBuild Reinforcing supported accurate modelling, detailed reinforcement design, and constructability reviews before the first delivery reached site.

This approach reduced the typical delays seen in early-stage steel fixing and allowed the project to progress with greater certainty from day one.

“Getting involved early meant we could resolve challenges in the model, not on site,” says Mike. “That makes a significant difference to productivity once construction begins.”

Smarter solutions for faster, safer installation

Beyond supply, the project demanded practical solutions that improved efficiency on site.

InfraBuild Reinforcing partnered with the client to introduce engineered J-Bar solutions, reducing labour requirements and improving installation productivity across turbine foundations.

A tailored delivery approach was developed, to significantly reduce unloading time on site, while supporting compliance with strict safety requirements.

These changes helped remove friction from site operations, enabling teams to work more efficiently and safely.

Managing complexity through coordination

The scale and technical requirements of the project introduced several operational challenges, including high-volume supply across multiple processing locations, complex reinforcement configurations, and strict compliance requirements for lifting systems.

These were addressed through structured planning and close coordination across all stakeholders. Early alignment with operations teams ensured production capability matched project demand, while targeted investment in plant, jigs and processes supported specialised fabrication requirements.

“There was a lot of complexity behind the scenes,” Mike explains. “But with the right planning and coordination, we were able to keep supply aligned to the program the whole way through.”

Improving constructability through 3D modelling

The MacIntyre Wind Farm also marked a step forward in how reinforcement is detailed and delivered on large-scale renewable projects.

For the first time in this context, a full 3D modelling approach was applied to reinforcement detailing. This enabled early clash detection, improved constructability, and more accurate production documentation.

By resolving issues before materials reached site, the project reduced rework, improved sequencing, and created a more efficient construction process overall.

A model for future renewable projects

The MacIntyre Wind Farm demonstrates what can be achieved when large-scale supply, early engagement and practical innovation come together.

By combining detailed planning, smarter delivery methods and a collaborative approach, InfraBuild Reinforcing supported a project that is helping shape Australia’s renewable energy future.

The learnings from this project, particularly around early engagement and 3D modelling, are now informing how wind farm projects are delivered moving forward.

Talk to our team

To learn how InfraBuild Reinforcing can support your next project, get in touch with our team.

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The Bairnsdale Regional Health Service (BRHS) Workers Accommodation project in regional Victoria was designed to support essential workforce housing, with a clear focus on construction efficiency and delivery certainty.

InfraBuild Reinforcing partnered with Metro Precast to supply BARMAT® reinforcement for precast concrete panels. The approach prioritised off-site manufacturing to reduce on-site labour, improve build speed, and create a more repeatable construction process.

By shifting key activities into a controlled precast environment, the project team aimed to streamline delivery without compromising quality.

The challenge: keeping design and programme aligned

The main constraint on the project was not material supply. It was design readiness.

Delays in finalising and approving shop drawings created a bottleneck, slowing the transition into fabrication. Without approved drawings, production timelines could not move forward, putting pressure on the overall construction programme.

This is a common challenge in precast construction. Speed relies on tight coordination between design, fabrication and supply. When one stage is delayed, the flow-on impact can affect the entire build.

The solution: BARMAT® enabling efficient precast production

Once shop drawings were approved, InfraBuild Reinforcing responded quickly to manufacture and deliver reinforcement, helping the project regain momentum.

BARMAT® provided a structured reinforcement solution that supported:

• Faster precast panel production
• Reduced manual handling on site
• Lower labour intensity during installation
• Consistent reinforcement placement across panels

Equally important was the responsiveness of supply. Fast turnaround and reliable delivery ensured that delays in the design phase did not continue into fabrication and installation.

The outcome: improved productivity and smoother delivery

The project achieved its core objective of reducing on-site labour and improving construction efficiency through the use of precast systems supported by BARMAT®.

InfraBuild’s role extended beyond supply. It provided confidence that once the project was ready to move, reinforcement would be delivered on time and to specification.

Key outcomes included:

• Rapid turnaround following design approvals
• Consistent product quality for precast integration
• Reliable delivery aligned with production schedules
• Improved workflow across fabrication and site installation

The result was a more predictable build, with fewer disruptions and better overall productivity.

“This project shows how important timing and coordination are in precast construction. Once the drawings were approved, we were able to move quickly and keep production on track. BARMAT® helped simplify the reinforcement process, but just as importantly, it gave the team confidence that supply would keep pace with the build.”

Rupinder Saraan, Account Manager, InfraBuild Reinforcing

The outcome: scaling precast with BARMAT®

The success of the BRHS Workers Accommodation project has strengthened the partnership between Metro Precast and InfraBuild Reinforcing, with further collaboration already identified on future projects including Beaconhills College in Pakenham.

While reinforcement design remains the responsibility of the structural engineer, this project reflects a broader shift across the industry.

Precast construction, supported by systems like BARMAT®, is helping builders reduce labour dependency, improve build speed, and deliver more consistent outcomes.

This project demonstrates a simple but important point. When design alignment meets reliable supply, construction becomes faster, more efficient and easier to deliver at scale.

What is BARMAT®?

BARMAT® is a prefabricated reinforcement system that improves construction efficiency by replacing traditional loose bar installation with pre-assembled reinforcement mats.

Designed to support faster, safer and more consistent concrete construction, BARMAT® is manufactured off-site under controlled conditions and delivered ready for installation. This reduces the need for on-site bar tying and helps streamline both labour and programme timelines.

BARMAT® is well suited to precast concrete panels, slabs, footings and large-scale civil and building projects, where repeatability and speed are critical to delivery.

Key benefits of BARMAT® reinforcement:

• Faster installation compared to loose bar reinforcement
• Reduced on-site labour and manual handling
• Improved safety through less handling and congestion
• Greater consistency and accuracy in reinforcement placement
• Supports precast and prefabricated construction methodologies
• Helps improve overall construction productivity and programme certainty

By shifting reinforcement work off-site and into a controlled manufacturing environment, BARMAT® helps project teams reduce variability, improve coordination, and deliver more predictable outcomes.

The post BARMAT® supporting faster precast construction at Bairnsdale Regional Health Service appeared first on InfraBuild.

From the foundations to the frame, our steel helps support reliable infrastructure across regional Australia. This video showcases the scale, quality and craftsmanship behind WRL’s sheds, built to meet the needs of the ag sector.

The post Built to Last: Supplying Steel for WRL Engineering’s Grain Sheds appeared first on InfraBuild.

Watch how this partnership supports fast-paced fabrication and keeps projects moving for Metalmorphic’s customers across the region.

The post Supporting local fabrication on the Sunshine Coast appeared first on InfraBuild.

InfraBuild is proud to be a key contributor to this project, supplying Australian-made steel. Working closely with Engineering Fabricators Newcastle (EFN), InfraBuild provided a diverse range of materials including welded beams, structural sections, tubular materials, and merchant bar.

“This project is not only a huge step forward for Newcastle’s infrastructure, but it’s also an important showcase of local talent and resources,” said Nigel Buckton, Account Manager from InfraBuild. “Our steel is playing a critical role in shaping a terminal that truly reflects the region.”

The new terminal, designed by Cox Architecture, draws inspiration from the Hunter Valley’s sand dunes and beaches. The design also reflects the region’s commitment to inclusivity, welcoming people of all abilities and celebrating the stories of the Worimi people.

“Our partnership with EFN has allowed us to deliver materials that meet the unique requirements of this project,” said Nigel. “We’re pleased to contribute to a project that not only serves the growing needs of the region but also honours its natural beauty and cultural heritage.”

Set for completion in mid 2025, the terminal will aim for a 5-star Green Star rating, a testament to its focus on sustainability. The project is expected to generate more than 500 construction jobs and provide long-term benefits for the community.

“From its design to the materials used, this terminal is a reflection of what makes Newcastle special – its environment, its people, and its future,” added Nigel. “We’re proud to be part of a project that’s set to leave a lasting impact on the region.”

The post Newcastle Airport Upgrade: Building for the Future with InfraBuild’s Local Steel appeared first on InfraBuild.

Chris discusses how our stock availability at our Sunshine Coast steel centre supported him and his business as the demand for gym equipment peaked throughout and post COVID.

Going from strength to strength, Maverick remains dedicated to providing quality equipment at fair prices, driven by Chris’s extensive experience in fitness.

Take a look at the partnership below…

The post Customer Spotlight: Maverick Strength & Conditioning Equipment appeared first on InfraBuild.

Array Technologies used 2,000 tonnes of torque tubes from InfraBuild to support the solar panels, structure, and main drive shafts for Array trackers, one of the world’s largest Tier 1 utility-scale solar tracker manufacturers.

The new products would normally take years to perfect but through commitment of our strong distribution network across Australia, we were able to manufacture, test and deliver in just eight months.

Take a look at the partnership below…

The post Customer Spotlight: Array Technologies appeared first on InfraBuild.

A standout feature of Melbourne Quarter Tower is its distinct curved roof, which uses Steelforce’s rectangular hollow sections (RHS) to form unique beams and showcase the building’s contemporary design.

Meet Andrew Moir, Managing Director at ArcStructural, who attributes collaboration and reliability a core component of this partnership.

Take a look at the partnership below…

The post Customer Spotlight: ArcStructural appeared first on InfraBuild.

“My name’s Ashley Palmer and I’m a structural design manager at Hutchinson Builders. We build everything from the smallest residential building, all the way up to the largest skyscrapers.

“We’re at one of our new sites at the moment which is 600 Coro Drive or Moana as it’s known. So it’s two 15 story premium level apartments. 3D modelling, it just gives more detail and it’s a really nice visual aid for myself and the schedules and the site team.

“3D modelling just streamlines the whole RFI process. It takes it from what it would have been which is emails and markups and sketches and allows you to visually see and work out what you need to do to make the design intent right.

The result of the 3D modelling saves potential time lost in rework because again we’ve sorted those problems out in the officer and the scheduling before it gets to site.”

Take a look at the partnership…

Read more about our 3D modelling here.

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We are proud of our long-standing and ongoing role in contributing to Australia’s built environment, and continuing to support and stand with the construction industry and partners as the revitalisation of our towns and cities is underway. We’re also proud of our teams and the skills and capability of our people who bring their expertise to these projects around the country.

Here are the major projects we’re celebrating.

NSW

Western Sydney International airport – Baggage Handling System (BHS) & Passenger link bridges (PLB) – Australia’s first modern baggage handling system will be a game changer for anyone catching a plane from Western Sydney International (Nancy-Bird Walton) Airport when it opens in late 2026. Western Sydney Airport CEO Simon Hickey said the baggage handling system will help deliver a fast and easy experience for passengers and airlines and make Sydney’s new airport one of the most advanced airports in the world. InfraBuild is set to supply over 1800 tonnes of structural, tubular and plate steel.

QLD

Maroochydore Road and Mons Road Interchange – Another milestone in the delivery of Queensland’s Bruce Highway upgrade has arrived with the commencement of the Maroochydore Road to Mons Road Interchange package of works. The project includes a new, 4-lane eastbound bridge over the Bruce Highway from Nambour Connection Road to Maroochydore Road, converting the roads’ existing roundabout to a signalised interchange, and upgrades, relocations, and removals of existing off and on ramps. Partnering with John Holland Seymour Whyte Joint Venture, InfraBuild will provide 2,000 tonnes of reinforcing steel to the project which, upon completion in 2022, will signal the beginning of the final push in the 15-year long delivery of the $12.6 billion Bruce Highway project.

Queens Wharf – InfraBuild has kept the Queen’s Wharf project ahead of program by accelerating its supply of reinforcing steel to site for two of the project’s large raft slabs. Approximately 700 tonnes of reinforcing has been used in the two slabs, which form a base for two of the four towers that will make up Brisbane’s $3.6bn Queen’s Wharf Brisbane Integrated Resort Development.

VIC

Melbourne Metro Tunnel – This major project is set to deliver five new underground stations to increase capacity by 504,000 passengers during its seven year construction timeframe. Its aim is to alleviate the city’s congested City Loop by diverting its busiest line through the new twin tunnels. InfraBuild has been collaborating closely with the Cross Yarra Partnership to supply Australian-made reinforcing steel. From specialised diaphragm wall cages which allowed TBMs to breakthrough without damage, to large scale prefabrication of slab inverts, station columns, and roof beams requiring 3D BIM, InfraBuild has been an essential partner in the delivery of the project’s new underground stations.

WA

Yanchep Rail Extension and Thornlie-Cockburn Link – Following the successful supply of reinforcing steel to the Forrestfield-Airport Link, InfraBuild is proud to continue to be a part of Western Australia’s rail infrastructure development by partnering with the NEWest Alliance to deliver 14 000 tonnes of reo to the Yanchep Rail Extension and Thornlie-Cockburn Link. Improving public transport for Perth’s growing northern corridor and facilitating more flexible train travel for the city’s southern suburbs respectively, the Yanchep Rail Extension and the Thornlie-Cockburn Link are the latest package of works to be commenced as part of the State Government’s METRONET program.

Image (L-R): Queens Wharf (Image courtesy Destination Brisbane Consortium) & Melbourne Metro, Melbourne Metro (Image courtesy: Metro tunnel)

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