Custom Fabricated Curved Bolts

Allfasteners manufacturing capabilities were leveraged in the latest works at Arden Station in Melbourne’s Metro Tunnel project. 6.15-meter bolts were thread rolled, galvanised & rolled into a radius and installed to create the impressive Arden Arches.

The North Melbourne metro station is part of Victoria’s Big Build initiative that will provide more access, more regularly, to more Melbournian residents across the city and its suburbs. An essential aspect of these new metro stations is their location and connection to the culture of the suburb.

Homage Paid: Arden Station

North Melbourne has a rich history of construction and industry, dating back to the early days of European settlement. The Arden Station design pays tribute to this history, with clay brick mixed with a modern concrete design reflecting the area’s heritage.

Forty-five thoughtfully designed segments are currently used to make 15 arches in the cut-and-cover project, weighing between 48 and 60 tonnes. Each arch requires the sides to be secured to the ground and then the keystone cap to be connected to those side segments. The design challenge was the curve in the upper segments and how to secure them.

Bolting it all Together

Allfasteners was tasked with helping to literally bring it all together with a unique bolting system. Our industrial and engineering team have a complete fabrication process for making special fasteners, including these unique curved bolts. And the crew were ready for the task at hand.

Starting with a special order bar length, our team rolled thread on each end of the massive 6150mm bars, ready for galvanising. After the galvanising was completed, the bars were passed through a rolling process to achieve a very fine tolerance radiused curve, to meet the site requirements.

Each machine process was completed in our controlled industrial workshop to ensure a perfect result every time. Due to the very long bar length a special galvanising process was required to achieve a conforming finish on such a length.

Once delivered to the site, the rods were inserted through special voids in the concrete segments, and custom square washers with a nut assembly were tensioned to the appropriate torque to achieve the correct pre-load and clamping force. Critical lead times were  required, Allfasteners was able to bring special length bars, critical galvanising and forming processes together with coordination to achieve a successful delivery to site on time.

Keystone Moments

Arden Station is a truly unique and innovative design that captures the essence of North Melbourne’s history and culture. The design also includes encapsulation by a larger building to be filled with cafés and terraces for dining. The use of these traditional materials gives the station a unique character that is reminiscent of the area’s industrial past.

Allfasteners is proud to be a part of a modern and historical build that will not only change how commuters access the city but also pay homage to one of Melbourne’s oldest suburbs.

Our Capabilities: Custom Rolled Bolts

At Allfasteners, we have a long history of helping our customers find unique solutions for their projects.

We roll, cut, weld, fabricate, curate, and deliver fastening solutions for the most challenging projects. Our team of experts is always on hand to advise and support you with your project, no matter how big or small.

Our in-house fabrication capabilities are second-to-none, and we always find a solution to a challenge. Contact us today for more information about our capabilities or to discuss your next project.