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Lightweight TRUECORE® steel speeds up construction of next generation childcare centre

An engineered, light gauge steel (LGS) framing solution expedited the construction of this distinctive childcare centre in Mermaid Waters, QLD, delivering significant time and cost savings.

Architecture & Design Team

18 Feb 2025 • 6m read • View Author

Sunkids Childcare Centres have a holistic approach to early childhood education, where parents are honoured as the ‘first teachers’, early childhood professionals are the ‘second teachers’, and the physical environment is the ‘third teacher’, providing a safe space where children are allowed to learn, play, grow and explore.

With this core philosophy in mind, architect Hooman Jaffar from Realspace Creative had a clear objective when designing this benchmark facility. He set out to create a space with a sense of gathering and community where families and staff can come together in a shared environment to support and encourage early childhood development.

This design vision would be physically represented by two sweeping curves, which Hooman suggests take their cues from human notions of embrace and nurturing. These curved structures would house the centre’s learning areas, activity rooms and amenities, and encircle the central courtyard’s global village, a playscape that would introduce ‘the world’ to these young, curious minds.

The centre was initially designed to be constructed with concrete blocks as the predominant walling material and a suspended concrete slab for the roof. However, when Riaz Rezvani from 9 Constructions suggested an alternative, Realspace Creative and the client were keen to explore other options.

9 Constructions had extensive building experience using light gauge steel framing made from TRUECORE® steel and believed there was an opportunity to incorporate prefabricated LGS frames in the build without compromising the design and still maintain the building’s thermal, acoustic, and structural integrity. Using prefabricated LGS framing also helped minimise on-site waste and create a safer work environment. Framing was delivered to the site in packages, which reduced worksite congestion and supported the meticulously planned delivery and installation schedule.

A collaborative team was then formed with Australian Framing Solutions (AFS). They provided engineering and design expertise using their 3D modelling software to develop a prefabricated solution that delivered tangible benefits to the project, including an increase in floor area due to the smaller footprint offered by LGS framing. Additionally, by modelling the centre in 3D, Sunkids’ early childhood professionals were able to assess and contribute to the design of the open-planned, interactive spaces, ensuring the childcare centre was purposefully designed to support and meet the needs of their young clients and centre staff.

“By using prefabricated LGS framing made from TRUECORE® steel to replace the suspended roof slab and masonry walls, we achieved significant cost savings on the project. Furthermore, we could reduce the overall construction timeline by at least two months, ensuring the project was completed on time, efficiently and cost-effectively,” said Riaz Rezvani, founder of 9 Constructions.

As an end-to-end design, engineering, manufacturing, and installation company, Australian Framing Solutions (AFS) was an integral partner in the development and construction of this project. They ensured design challenges were expeditiously turned into design solutions, while maintaining the building’s architectural intent.

The most notable of these design challenges was related to the complexity of the circular roof structure. AFS’ solution featured over 300 individually engineered roof trusses, uniquely fabricated to deliver the roof’s striking shape and structural integrity. Each custom-made truss was approximately 14 metres long, spanning the entire width of the building and had to be precisely positioned using mobile site cranes. The correct placement of these trusses was crucial to the project’s timeline and only made possible because of AFS’ detailed 3D modelling, precision manufacturing, thorough site plans, and clearly marked frames and trusses.

These trusses provide the supporting framework for the specialised, tapered, standing seam roof profile used on the project. Fielders Freeform® profile was selected and roll-formed on site. Fielders Mobile Mill® expedited the installation process by tapering each roof sheet in a continuous length to eliminate joins and perfectly align with the complex concave geometry of the roof.

One of the other challenges that needed to be resolved related to the massive shade sails covering the central courtyard. AFS needed to overcome the significant lateral forces these expansive sails would generate, particularly during high wind periods. AFS’ engineered solution included a customised connection that allowed all lateral forces to be transferred back to the structural steel posts without impacting the adjacent lightweight steel framing structure.

Sunkids Mermaid Waters was designed and built as part of a new precinct called ‘The Lanes’, with a topography featuring an expansive waterways system synonymous with Gold Coast living. This environment contributed to TRUECORE® steel being specified for the framework of the childcare centre and, incidentally, the adjacent townhouse development.

“Undoubtedly, this has been one of the most exciting early learning centre projects we have ever participated in. The structure featured five zones and incorporated over 300 trusses, each spanning more than 14 metres. The frame for this 2,000-square-metre facility was constructed entirely out of TRUECORE® steel in just 25 days by a team of five dedicated individuals. Collaboration was key to this success; AFS worked closely with the architect, builder, engineers, and other stakeholders to effectively problem-solve throughout the project,” said Jake Gundry, Australian Framing Solutions (AFS) Managing Director.

Key benefits delivered

Prefabricated light gauge steel roof trusses and wall framing made from TRUECORE® steel delivered the following project benefits to this unique QLD childcare facility:

Fast, cost-effective installation

According to Riaz Rezvani from 9 Constructions, using a prefabricated light gauge steel framing solution engineered, manufactured, and installed by Australian Framing Solutions (AFS) streamlined and reduced the overall project timeline, while delivering tangible cost savings that would not have been possible using the originally specified masonry construction materials and associated wet trades.

Lightweight, yet strong

With its impressive strength-to-weight ratio, the frames and trusses made from TRUECORE® steel used in this development, starkly contrast with the suspended concrete slab roof and masonry block wall construction initially specified for this project. It offers an uncompromising lightweight building solution that would significantly benefit this project timeline and budget while maintaining the building's structural integrity and design intent.

Precision-engineered solution

Australian Framing Solutions (AFS) designed and fabricated this project's complex circular roof structure using its 3D modelling software. Over 300 uniquely engineered roof trusses were prefabricated and incorporated into the build, ensuring the integrity of the roof structure while maintaining its intricate design and distinctive aesthetic.