Aurizon Rail Yard

Introduction

Incon was engaged by Aurizon Bulk Central Pty Ltd to deliver structural engineering design and documentation for a proposed steel-framed veranda (awning) at the Gillman Rail Yard site in South Australia. The project involved the design of a lightweight canopy structure attached to an existing gatehouse building, supporting operational functionality while ensuring structural adequacy, durability, and constructibility within an active industrial environment.

Project
description

The scope of works included:

Structural design of a steel-framed veranda / canopy
Design of supporting columns using SHS sections
Use of lightweight steel framing (C-sections) for roof structure
Design of isolated pad footings for new column supports
Preparation of engineering drawings and documentation for construction

The canopy was intended to provide weather protection and functional coverage to the existing site office/gatehouse facility.

Site and Architectural Context

Based on architectural documentation:

The gatehouse forms part of a site office facility with internal workspaces, amenities, and access points
The layout includes:

Offices and workstations
Male and female amenities
Circulation areas and entry points

The building utilises:

Lightweight steel framing systems
Cladding and roofing systems (e.g., Smartspan roofing on purlins)
Modular construction typical of transportable/site office structures

This context required the new awning to integrate seamlessly with the existing lightweight structural system.

Challenge

The awning needed to connect to an existing lightweight building without overloading or compromising its structural integrity.
The rail yard environment required:

Robust yet simple design
Minimal disruption during installation

Achieving adequate strength and stability using:

C-section members
Slim SHS columns

Footings had to be designed conservatively while remaining cost-efficient.
The solution needed to be straightforward for rapid fabrication and installation.

Solution

Incon provided a practical and efficient engineering solution tailored to site conditions:

Designed a lightweight steel canopy structure using:

Cold-formed C-sections for rafters and framing
SHS columns for vertical support

Optimised member sizing to balance:

Structural performance
Cost efficiency
Ease of fabrication

Designed SHS columns to support vertical and lateral loads
Developed connection details for:

Column-to-beam connections
Interface with existing structure (where applicable)

Designed isolated pad footings for each column location
Considerations included:

Bearing capacity assumptions
Uplift resistance due to wind loading
Stability under combined load cases

Outcome

The project was successfully completed with:

Fully engineered and documented awning structure
Efficient lightweight design aligned with site requirements
Constructible solution suitable for rapid installation
Compliance with relevant Australian Standards

The design enabled Aurizon to proceed with construction, enhancing the functionality and usability of the gatehouse facility.

Key Engineering Value Delivered

Cost-effective lightweight structural solution
Seamless integration with existing building
Fast turnaround design delivery
Practical footing and connection design
Fit-for-purpose solution for industrial rail environment

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