METRONET New Bayswater Station

Vertex Facades designed, fabricated, and installed 2,600m² of bespoke prefabricated aluminium cladding for the METRONET Bayswater Station project. This case study outlines how a collaborative approach led to an engineered aluminium solution that honoured the original architectural vision while significantly reducing the structural load on the bridge. The system was independently tested to five times the project's required pressures in a NATA-accredited facility.

Project Overview

Understanding the Design Challenge

The METRONET Bayswater Station project required a bespoke cladding solution for the rail-over-road bridge structure — a highly visible piece of public infrastructure requiring a finish that was architecturally compelling, structurally sound, and lightweight enough to avoid imposing additional dead load on the bridge.

The original design intent called for GRC (Glass Reinforced Concrete) casting to achieve the required fluted, stone-like profile. While GRC can deliver the desired aesthetic, it carries significant weight — a critical concern for a bridge structure with defined load limits. Vertex Facades was engaged early to workshop alternatives that could honour the architectural vision without compromising structural performance.

Engineering a Lighter Solution

Through close collaboration with the design team and principal contractor, Vertex Facades developed a fabricated aluminium solution capable of replicating the complex fluted profile originally intended for GRC. The engineered aluminium system delivered a dramatic reduction in panel weight compared to GRC casting — significantly reducing the implied dead load on the bridge structure without any compromise to the architectural outcome.

Achieving the Stone-Like Finish in Aluminium

One of the key challenges was replicating the natural, stone-like texture and colour of the original GRC intent using powder-coated aluminium. Vertex Facades developed a prototyping programme to work through finish options with the client, producing full-scale powder coat samples that were reviewed and approved before committing to production.

Full-Scale Mock-Up and Client Review

Prior to committing to full production, Vertex Facades produced a full-scale mock-up of the cladding system. The mock-up was installed in its intended location on the structure, allowing the client to review the powder coat finish, fluted profile, and overall aesthetic in context — at full scale and in natural light — before sign-off.

NATA-Accredited Pressure Testing

To validate the structural performance of the bespoke system, the cladding panels were subjected to independent pressure testing at a NATA-accredited test facility. The panels were tested to the full project-specified pressures — and then beyond. Testing continued until failure, which occurred at five times the project's required pressure. This result provided the client and design team with a high level of confidence in the system's performance and safety margin.

Scope of Works

Vertex Facades' scope on the Bayswater Station project included the design, fabrication, and installation of all secondary steel supporting the cladding system, as well as the bespoke feature cladding panels themselves. The prefabricated approach — with panels manufactured offsite and installed in a controlled sequence — reduced on-site labour time and programme risk on a live infrastructure project.