Queenscliff Ferry Terminal
Project Overview
This project involved a design with structural assemblies larger than any galvanizing bath in Australia, but that didn’t stop J. Furphy & Sons Group from delivering an award-winning project that ticked all the boxes of the original plans with a new and innovative approach. Searoad Ferries in Queenscliff, Victoria required a corrosion protection system capable of achieving a 20-year life to first maintenance on 170 tonnes of structural steel, installed in a fully enclosed building directly exposed to a C5 coastal environment. We delivered architectural and engineering excellence in what is now a national and international award-winning ferry terminal.
The Challenge
The original design called for large pod-like assemblies that exceeded the capacity of every galvanizing bath in Australia which would require a complete structural redesign while preserving the architectural intent. A controlled road closure on the Bellarine Peninsula also meant site deliveries operated within rigid windows with any coating delay shutting down the entire construction programme. With the terminal sitting directly on the surf break at Queenscliff, the structure would be constantly exposed to a C5 marine environment during both the six-month erection phase and its entire operational life, requiring the highest quality corrosion protection. 170 tonnes of steel across a complex modular structure and to strict compliance requirements meant there was absolutely no room for non-conformance.
Our Solution
We supplied 170 tonnes of hot dipped galvanized steel across a complex modular system of beams, canopies, outriggers and connection details, all processed at our Geelong facility with every shop drawing reviewed against AS/NZS 4680 before processing began. The original pod-like assemblies were completely redesigned around our 9.5m bath and double-dipping capability to remove the original size complications with the team problem-solving at every challenge posed. Sandblasting was applied to a significant number of components to reduce pickling times and lift average coating mass, while custom venting and draining solutions were developed for complex sections that would otherwise have required splicing. The zinc-metallic alloy was selected specifically for its ability to withstand C5 marine exposure with a 20-year life to first maintenance, outperforming the paint systems that were also evaluated. Our Geelong facility operated almost solely as a dedicated facility to this project, maintaining 2–3-day turnarounds across the full production run, ensuring every piece arrived within the controlled road closure windows on the Bellarine Peninsula.
Technical Specifications
170 tonnes
9.5 metres
Structural steel
Hot dip galvanized
AS/NZS 4680, C5 Coastal rating
Exceeded specification
2-3 days
Sandblasted components
- Modular bolt-together design
- 20 year life to maintenance
The Outcome
This highly successful project delivered:
- An architecturally brilliant and structurally sound terminal for a high-traffic coastal town
- 170 tonnes of structural steel processed to AS/NZS 4680 with coating thicknesses exceeding the standard’s requirements
- Every component delivered within the controlled site windows despite cascading delays on the Bellarine Peninsula
- Five-to-six months of near dedicated production without a single programme-breaking delay
- A 20-year life to first maintenance in a harsh C5 coastal environment
- A structure robust enough to handle breaking surf conditions during its six-month erection
- Long-term durability by eliminating weather-related coating delays
- Efficient installation by enabling erection direct from the delivery trailer
- A terminal announced as the winner of the 2023 Architectural MasterPrize “Best of the Best” in Transportation, the 2024 Victorian Master Builders Excellence in Construction award, and the 2024 National Master Builders prize for Commercial/Industrial Construction
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