The Centenary Bridge Upgrade is a $353.5 million infrastructure project designed to increase capacity and improve safety on the Centenary Bridge.
Key features of the project include:
- A new three-lane northbound bridge
- Rehabilitation of the existing bridge to provide three southbound lanes
- Upgraded active transport connections to improve accessibility for pedestrians and bike riders.
The bridge forms part of the Centenary Motorway, which is the main link between Ipswich, Queensland's fastest growing area, and the Brisbane central business district. It also connects the Brisbane central business district to the national road networks.
The project required a durable, efficient void panel system for the precast bridge girders forming the new northbound bridge decks. Traditional materials, such as plywood and fibre cement sheeting, posed issues with weather resistance, weight and labour requirements.
Seeking a more effective solution, the Georgiou/BMD Joint Venture selected Fielders KingFlor® 40 (KF40®).
The Fielders Solution
KF40® was selected for its strength, lightweight properties and cost-saving benefits. Unlike traditional void panels, KF40® delivers:
- Lightweight efficiency: At 8kg/m², KF40® is significantly lighter than plywood (13kg/m²), making it easier to handle and install.
- Weather resistance: Galvanised steel resists moisture, eliminating the risk of warping, rotting, or weakening over time.
- Concrete savings: KF40®’s unique trapezoidal profile reduces concrete volume by up to 40kg/m² (16mm of slab depth), cutting costs and material usage.
- Precision cutting: Pre-cut to exact lengths, KF40® minimises on-site modification, reducing labour and waste.
- Advanced design features: SquashCut™ ends eliminate the need for end caps and provide a rigid construction platform.
“Plywood can’t withstand prolonged exposure to Queensland’s weather,” explained Jack Huang, Structural Manager of the Fielders Design Solutions Group. “It rots, softens and requires more manual cutting on-site. KF40® is light, durable and pre-cut to exact lengths, reducing labour and installation time.”
To ensure the product met regulatory requirements, KF40® underwent a comprehensive approval process with the Department of Transport and Main Roads (TMR).
Project Execution
Before KF40® could be installed, it had to meet TMR’s strict regulatory standards.
“All material supplied to QLD infrastructure projects must be pre-approved by TMR prior to being considered by main contractors,” explained Jack. “Before the Bruce Highway upgrade in Gympie, no metal deck system had been approved by TMR for this application.”
Fielders worked closely with Georgiou and BMD Group over a 12-month approval process with TMR, which included:
- Trial installations at a local precast yard to assess real-world application.
- Confirmatory laboratory testing at BlueScope’s NATA-accredited facility to verify KF40®’s load-bearing capacity.
- Technical documentation and approval submissions, outlining system specifications, installation procedures and compliance with performance requirements.
Following six months of rigorous assessment, TMR officially approved KF40® on 3rd February 2022.
Fielders continued to provide on-site support to ensure a smooth transition, including:
- Pre-installation meetings to brief site teams.
- Technical guidance to optimise installation efficiency.
- A tailored supply strategy to maximise transportation efficiency and reduce costs.
Outcomes
Fielders has played a key role in supporting construction efficiency on site.
“Our local team in Queensland worked closely with the TMR to develop a supply strategy, ensure efficient transportation and provide ongoing site support, including pre-install meetings and technical guidance,” said Jack.
To date, approximately 1,000m² of KF40® has been installed for the Centenary Bridge Upgrade project in Jindalee. The lightweight (8kg/m²), pre-cut steel decking helped reduce manual handling, on-site cutting and installation effort, making it a practical and effective alternative to traditional plywood, which is heavier, absorbs moisture and deteriorates in wet conditions.
KF40®'s shallow trapezoidal profile also saves the equivalent of 16mm of concrete from the overall slab depth by concrete volume when compared to conventional concrete slabs.
KF40® has also been supplied for other major Queensland projects, including the Gympie Highway Upgrade (2022) and Rockhampton Ring Road, Stage 1. As civil projects continue to demand faster, more efficient construction methods, KF40® is increasingly being chosen for its practical advantages on-site.
Learnings
The Centenary Bridge Upgrade highlighted three key lessons for future infrastructure projects:
- Engaging regulators early streamlines approval - Securing TMR approval required extensive planning, technical validation and collaboration with key stakeholders.
- Innovative materials drive efficiency - KF40®’s lightweight, precision-cut design reduces installation time, labour costs and material waste.
- Thorough testing helps guarantee reliability - Field trials and NATA-accredited laboratory assessments played a critical role in proving KF40®’s suitability for large-scale infrastructure projects.
Conclusion
The Centenary Bridge Upgrade demonstrates how fit-for-purpose materials, regulatory compliance and technical support can contribute to more efficient outcomes on major infrastructure projects.
KF40® provided a lightweight, moisture-resistant, and pre-cut void panel solution that helped reduce labour requirements, minimise on-site adjustments and support smoother installation across the bridge girders.
Its successful TMR approval sets a new benchmark for bridge construction in Queensland, opening the door for broader adoption in future infrastructure projects.
As demand for stronger, more efficient transport networks continues to grow, KF40® stands ready to support the next generation of high-performance infrastructure projects. For more information on how KF40® can enhance your next project, visit Fielders.com.au.
Fielders® and KingFlor® are registered trademarks of BlueScope Steel Limited. All rights reserved.
