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Zero-carbon aluminium: Distant dream or inevitable reality? Network Architectural weighs in

Gadigal Station interior with curved aluminium ceiling and wall panels

Gadigal Metro Station, Sydney NSW

Aluminium is the quintessential material of modern architecture. Light, strong and endlessly versatile, it’s allowed the industry to push the architectural envelope in ways that were impossible a century ago. It is, by all accounts, a material of the future. However, as one of the building sector’s most significant carbon culprits, aluminium’s undeniable brilliance has also come at a cost which, for decades, has seemed manageable. The industry has focused on incremental gains, celebrating recycled content while framing the immense energy required for primary production as an impenetrable challenge, positioning the concept of zero-carbon aluminium as a distant dream.

But it’s becoming abundantly clear that this environmental price tag is one the industry – and the planet itself – can no longer afford. And according to industry expert Steven Fraser, Ceiling Systems Manager at Network Architectural, that entire perspective is now obsolete.

“The assertion that aluminium’s high energy intensity renders zero-carbon production a distant dream is increasingly outdated,” he says. “While aluminium smelting is indeed energy-intensive – accounting for approximately 3% of global electricity consumption – advancements in technology, renewable energy integration and supportive policies are making zero-carbon recycled aluminium a tangible goal.”

And while Steven admits there isn’t an easy, single solution, the pathway forward is an actionable industry blueprint anchored by the strategic integration of robust, existing and emerging solutions. In fact, he is confident that by combining large-scale recycling with renewable energy and innovative smelting technologies, a transition to zero-carbon recycled aluminium that is not only technically possible but also economically advantageous is at our fingertips.

Nan Tien Institute, NSW – Architectural project featuring aluminium façade

Nan Tien Institute, NSW

Real challenges or dangerous excuses?

Steven is crystal clear: the challenges ahead are not insignificant. The industry rightly points to high capital costs for upgrading smelters, the technological maturity of innovations like inert anodes, and the logistical and infrastructure hurdles of shifting to renewables. Plus, the global supply chains are dominated by coal-powered production.

“China produces about 60% of the world’s aluminium, much of which is powered by coal,” Steven explains. “And efforts to relocate smelters to regions with cleaner energy sources, like Yunnan province, face challenges due to inconsistent hydropower availability.” This is also compounded by the varying environmental regulations and policies across different countries that can either hinder or accelerate decarbonisation initiatives.

These certainly are real and serious considerations, but to dismiss them as permanent roadblocks is not just a failure of imagination but a rejection of responsibility. As we collectively face profound environmental consequences, loyally clinging to the operational status quo is no longer a viable option because, as Steven points out, the stakes are simply too high. “Fundamentally, if we don’t start aiming to decarbonise aluminium production, we’re on track for the planet to lose a food bowl due to climate change,” he warns, emphasising the stark reality that to some seems too abstract to take seriously. “Food bowl regions are critical to global food security and their loss would have profound economic and humanitarian impacts and may lead to higher food prices and potential continental mass migrations.” With the gravity of inaction as a sobering backdrop, Steven points to strategic integration of key areas that can help make the technical and economic feasibility of zero-carbon aluminium possible by transforming the material’s lifecycle from linear and carbon-intensive to circular and clean.

The Bond, NSW – sustainable commercial building featuring aluminium façade

The Bond, NSW

Infinite recycling

He says that the most accessible and impactful tool at industry’s disposal is recycled aluminium and, rather than a niche solution, it’s the primary low-carbon resource stream.

“Recycling aluminium requires significantly less energy – up to 95% less, in fact – than producing primary aluminium, leading to reductions in energy consumption and associated costs,” Steven explains. “Plus, the International Aluminium Institute reports that recycling aluminium can save up to $2 billion annually in energy costs across the global industry.” He adds that because aluminium is infinitely recyclable, it should never end up in landfill, which can help minimise disposal costs too. “It’s one of a handful of building products where business will pay you to remove it from the site as it has an intrinsic value as scrap,” he explains.

Naturally, harnessing this potential involves policy support, enhanced collection systems and – crucially – advanced sorting technologies to ensure high-quality scraps can be reintegrated into a closed-loop system. “These are not simple scrap yards,” Steven clarifies. “Modern facilities now use sophisticated methods like X-ray transmission and near-infrared sorting to accurately separate different aluminium alloys, preserving their quality for high-grade architectural applications.”

Kirribilli, NSW – Aluminium cladding detail on residential building

Kirribili, NSW

From grid burden to green partner

Steven also points out that the decarbonisation of aluminium is intrinsically linked to the decarbonisation of our electricity grids, and the material’s robust energy requirements can be transformed into an asset in a renewables-led system.

“Transitioning to 100% renewable energy is pivotal for achieving zero-carbon aluminium production,” he says. “Given that aluminium smelting is highly energy-intensive, the carbon footprint of aluminium is closely tied to the energy sources used. Shifting to renewable energy sources like hydropower, wind and solar can drastically reduce emissions.”

With smelters like Tomago in NSW consuming up to 10% of the state’s electricity, the scale of the challenge is evident. But it’s also an opportunity – these facilities can act as robust industrial batteries, providing services that stabilise grids with high penetrations of intermittent solar and wind power.

Government support – like Australia’s $2 billion commitment in production credits to assist aluminium smelters in transitioning to renewable energy by 2036 – is already galvanising this transition. And Steven points to Rio Tinto’s Boyne smelter in Queensland, which has signed a 20-year agreement to be powered primarily by solar energy, as an example of this broader industry shift. “This single initiative is expected to meet about 80% of the smelter’s needs, resulting in a substantial reduction in carbon emissions and demonstrating that the large-scale shift to renewables for aluminium production is already underway in Australia.”

Kingswood TAFE, NSW – Modern educational building with aluminium finishes

Kingswood TAFE NSW

Smelting without the smoke

The other piece of this intricate puzzle is eliminating the emissions inherent in the smelting process. Groundbreaking smelting technologies are moving from the lab to commercial-scale reality, fundamentally reimagining the chemical equation of aluminium production. Steven explains that innovations like ELYSIS’s inert anode, Hydro’s HalZero process and Molten Oxide Electrolysis (MOE) share a common, revolutionary outcome.

“This innovation eliminates all direct greenhouse gas emissions, emitting only pure oxygen as a byproduct,” he says, using the joint venture between Alcoa and Rio Tinto, ELYSIS, which replaces traditional carbon anodes with inert materials in the smelting process. “A demonstration plant is underway at Rio Tinto’s Arvida smelter in Quebec, aiming to produce up to 2,500 tonnes of commercial-quality aluminium annually without direct emissions.”

MOE, on the other hand, is an emerging technology that uses electricity to extract aluminium from ore without carbon emissions. “It offers a pathway to fully decarbonised aluminium production,” Steven notes. And, most importantly, when combined with a 100% renewable power source, it encourages a move past just low-carbon and towards zero-carbon aluminium.

Trilogi Apartments, VIC – Multi-residential project with aluminium façade

Trilogi Apartments, VIC

Sustainability: The new profitability

The argument that this transition is too expensive is based on an outdated economic model that fails to factor in carbon risk, market demand or brand value. And Steven stresses that a genuinely sustainable product is no longer just an ethical choice – it’s a significant competitive advantage too.

“As global demand for sustainable materials rises, aluminium produced with low or zero-carbon emissions can command premium prices,” he explains. “Manufacturers and consumers are increasingly open to paying more for sustainably produced materials, recognising the long-term environmental and economic benefits.”

Plus, early adoption of zero-carbon positions companies ahead of inevitable compliance requirements, potentially avoiding future costs associated with regulatory changes, strengthening supply chains against volatile fossil fuel markets – and attracting investment in a world increasingly guided by ESG principles.

The specifier’s power

However, this transition will not be driven by producers alone. Architects, designers and specifiers are the gatekeepers of material selection, and their decisions send powerful signals to the entire supply chain. This influence starts with immediate carbon savings through material specification.

“Before we even get to how the aluminium is produced, we should consider how we can use less of it,” Steven urges. “This is where material efficiency becomes a powerful tool for decarbonisation. Using a product like ALPOLIC™– aluminium cladding with a non-combustible mineral core, which is known for superior flatness and durability – means we can achieve the same architectural results with significantly less material volume than solid sheeting. It’s a simple, immediate choice that can have a direct and positive impact on a project’s embodied carbon.”

The same principle applies to other aluminium-based architectural elements – including high-performance ceiling systems, which often utilise lightweight panelised solutions designed for extended lifespans, easy installation and full recyclability. “Choosing ceiling systems that incorporate recycled aluminium and are designed with disassembly in mind can make a meaningful contribution to a project’s overall sustainability profile,” Steven notes.

This principle of efficiency, combined with a commitment to demanding better products, forms the basis of a powerful specification strategy that can actively drive the market forward. “Prioritise sustainable materials: select aluminium products with verified low-carbon footprints for construction projects,” Steven highlights. “And, crucially, incorporate circular design principles – design structures that facilitate the reuse and recycling of aluminium components at the end of their lifecycle.”

“This push for sustainable specification must be supported by a parallel industry effort to standardise carbon footprinting,” he adds. “This will ensure architects have transparent and reliable data to compare products.” Underpinned by industry-wide commitment to transparent reporting and education about the benefits of low-carbon aluminium in construction, specifiers have genuine power to accelerate this change. “Starting today,” Steven adds.

The Bond, NSW – Commercial development showcasing sustainable aluminium design

The Bond, NSW

The inevitable future

The poignant message emerging from Steven’s robust analysis is an optimistic one: the era of carbon-intensive aluminium is genuinely drawing to a close. The fusion of large-scale recycling, abundant renewable energy and revolutionary smelting technology sets a technically viable path to a decarbonised future for this essential material. And considering the disastrous alternative, the towering challenges on this journey now seem more like fundamental milestones than impenetrable barriers. Especially because industry pioneers like Network Architectural, who keenly promote industry-wide adoption of sustainable building materials and practices, are here to help overcome the hurdles.

“As a leader in commercial architectural products, we can significantly influence the adoption of low-carbon aluminium,” Steven sums up. Network Architectural offers aluminium building products that utilise low-carbon or recycled aluminium, collaborates with suppliers committed to sustainable aluminium manufacturing practices and – crucially, bringing both sustainability and profitability back into one conversation – advises clients on the environmental and economic benefits of choosing low-carbon aluminium for their projects.

A Station Like No Other: Gadigal’s Bespoke Metal Ceilings Brought to Life

Entrance of Gadigal Metro Station

In the heart of Sydney, beneath one of the busiest intersections in the CBD, lies a new icon of modern transport infrastructure — Gadigal Station. As part of the Sydney Metro City & Southwest project, this underground marvel is not only a feat of engineering and urban design but also a cultural and architectural landmark. Formerly known as Pitt Street Station, it has been renamed to honour the Gadigal people of the Eora Nation, reflecting a powerful commitment to truth-telling and Indigenous recognition.

But beyond its cultural importance and transport function, Gadigal Station is also a design masterpiece — particularly in the stunning, bespoke metal ceilings that grace its interiors. Developed through an extraordinary collaboration between durlum, Foxville Projects, and Network Architectural, the ceiling system is one of the most complex and ambitious durlum has ever undertaken. It’s a testament to design innovation, flexibility, and the tireless service behind the scenes.

Delivered by CPB Contractors, Gadigal Station is part of an Integrated Station Development (ISD) running between Park and Bathurst Streets. The platforms sit approximately 17 to 20 metres below ground, making it the shallowest station on the City & Southwest line. With over 10,000 workers contributing to its construction, and 9,000 commuters expected to pass through each morning peak, the scale and impact of Gadigal Station are immense.

The project was led by Foster + Partners as the design lead in collaboration with Cox Architecture, with significant contributions from Sydney Metro’s internal teams and design consultants. Their shared vision focused on creating an experience that was as inspiring as it was functional, incorporating Indigenous heritage, world-class infrastructure, and modern aesthetics.

Gadigal Metro Railway Station with Durlum Metal Ceilings

A Metal Ceiling Design Without Limits

Within this extraordinary build, the bespoke ceiling system stands out as both a structural and artistic achievement. Developed and delivered by Network Architectural using durlum metal ceilings, the solution spanned more than 5,000 square metres — covering the platform tunnels and pedestrian adits with intricate architectural detail.

“This was one of the most complex projects we’ve ever worked on,” said Paul Sheehan, Ceilings Division Manager at Network Architectural. “It wasn’t just about supplying a ceiling — it was about co-creating a solution in real-time with the installer and design team, piece by piece, to ensure every millimetre delivered on the vision.”

Foxville Projects, one of Australia’s premier ceiling installers, led the installation. Their collaboration with Network Architectural began after successful work on Victoria Cross Station. In early 2021, Foxville invited Network Architectural to “take a look” at the Pitt Street build. What followed was nearly three years of design refinement, prototyping, and hands-on support — a level of service Network Architectural is known for.

Gadigal Metro Railway Station Train Entrace with Durlum Metal Ceilings

Bringing Gadigal Metro Station Bespoke Ceiling to Life

At the heart of the ceiling design was a commitment to customisation and precision. The project was divided into three major design elements:

The PSD Elements: These included the walls, custom louvre, bulkheads and bullnoses, and integrated lighting panels — with every fourth panel designed as an access point for maintenance. Above the platform screen doors, curved bronze bulkheads raked down to the floor, providing both visual continuity and functional form.
The Signature durlum Tubes: Running the full length of the interior space, these 63mm metal tubes were meticulously aligned with the GRC wall panels, both vertically and horizontally. The backing panels featured perforation for acoustic ceiling performance, while also maintaining accessibility. “We ensured every join in the tubes aligned precisely with the joins in the GRC panels — the attention to detail was second to none,” Paul explained.
The Boom Panels: These ceiling panels in the adits (walkways) concealed essential services such as lighting, ventilation, and fire systems. Featuring three-dimensional curves — not only upwards but also outwards — these panels required advanced manufacturing to meet the design complexity. Their seamless finish masked the underlying infrastructure while contributing to the station’s unique visual rhythm.

Design flexibility was key throughout the project. Network Architectural’s in-house design team worked in lockstep with Foxville’s Design team, iterating via 3D drawings and physical prototypes. “This project was being designed on the go. Some areas took weeks to finalise due to the complexity of the radius curves and the integration with concrete walls. But the end result speaks for itself,” Paul noted.

The station is also a canvas for Indigenous storytelling. The name “Gadigal” is not just symbolic; it signifies a powerful truth-telling initiative. Councillor Yvonne Weldon of the City of Sydney described it best: “The first step of that truth telling is making sure that we are heard, we are seen, and we are recognised — and that’s what we have in Gadigal station.”

Art installations, including massive 12.5-metre murals titled The Underneath by Callum Morton, enhance the immersive design. Inspired by historic tunnels and local waterways, they echo both the natural and industrial history of the site. More than 10,000 handmade porcelain enamel tiles were used in the entrance areas, reinforcing the tactile, human scale of the design.

World-Class Design, World-Class Collaboration

For Network Architectural and durlum, delivering this project wasn’t just about fulfilling a brief — it was about enabling vision at scale. By embedding their team into the design and installation process, they ensured that the ceilings not only matched the architectural intent but elevated the entire experience.

“This was a massive undertaking, and the project would not have succeeded without true collaboration between the installer, the design team, and our internal design manager,” said Paul. “We were constantly adjusting, solving challenges, and ensuring every detail came together.”

With over 5000 sqm of bespoke metal ceilings, countless design hours, and dozens of prototypes, the finished ceiling is a testament of what’s possible when flexibility, craftsmanship, and service come together.

As commuters descend into Gadigal Station, they are met not just with a world-class transport hub, but with an architectural experience that tells stories — of the city, of culture, of design excellence. The bespoke metal ceiling plays a central role in creating this identity.

From sweeping bulkheads to three-dimensional curves, every element was purpose-built to contribute to the beauty, functionality, and durability of this space. It is a station built for generations — a landmark not only of infrastructure but of what thoughtful design and expert execution can achieve.

durlum metal ceilings in Gadigal Metro Railway Station

Network Architectural & Bespoke Metal Ceilings

Whether the project is large-scale and complex or smaller in scope, bespoke metal ceiling solutions demand collaboration and precision. Network Architectural’s in-house architectural team partners with designers, builders, and installers from concept through to completion — ensuring every metal ceiling system is expertly tailored and flawlessly executed. To see how our team has brought other standout projects to life, explore our projects — and if you’re planning a project of your own, get in touch with us today to start the conversation.

Recladding for Safety and Style: ALPOLIC™ NC/A1 Transforms Top Ryde Residential Tower

ALPOLIC™ NC/A1 non-combustible mineral core aluminium cladding in timber pattern and Black finishes on apartment building facade

Non-combustible mineral core aluminium cladding delivers compliance, confidence and seamless colour matching at scale

When the residential apartment buildings above Top Ryde City Shopping Centre were issued a fire order to replace all non-compliant cladding, it set in motion a carefully managed recladding project that would need to balance aesthetic continuity with compliant safety standards.

The brief was clear: remove all combustible cladding materials and replace them with a compliant solution that would meet the strict requirements of the NCC 2019 and deliver a long-term, low-maintenance result. But with multiple buildings and finishes across the site, the complexity of the recladding job was far from simple.

When it came time to address the fire order, Diagnostech brought their trusted expertise to the table, working alongside Network Architectural—the exclusive distributor of ALPOLIC™ NC/A1, a non-combustible mineral core aluminium cladding solution designed for superior performance and compliance.

Diagnostech, who led the diagnostics and specification phase, explained the urgency of the project:

“The building was issued with a fire order requiring the removal of all non-compliant combustible cladding. Our role was to ensure that the replacement not only achieved compliance but would future proof the building against further risks.”

The team selected ALPOLIC™ NC, a non-combustible mineral core composite panel that meets the fire compliance requirements of AS 1530.1 and is compliant under NCC 2019 Deemed-to-Satisfy provisions.

“We specifically chose ALPOLIC™ NC over solid aluminium due to its superior flatness and reduced risk of oil canning,” Tom Mackay, Director from Diagnostech. “It allowed us to maintain the building’s original look without compromising fire safety or design intent.”

The technical complexity of the job was no small feat. With multiple towers in varying colour palettes and cladding configurations, ensuring a smooth transition and same aesthetics was essential.

Llewellyn Regler, Technical Manager at Network Architectural, worked closely with all project partners throughout the recladding process.

“This project involved replacing around 6,500sqm of cladding across a number of connected residential towers. Each building had different finishes and colours, and our ability to match those existing colours precisely with ALPOLIC™ NC was a major advantage,” he said.

“From a compliance and visual perspective, the result is exceptional. The panels look sharp and clean, and everyone—from the client to the consultants—was really happy with the outcome.”

Black ALPOLIC™ NC/A1 non-combustible mineral core aluminium cladding on apartment building balcony

Certified Safety and Superior Façade Finish

ALPOLIC™ NC/A1 is manufactured in Japan by Mitsubishi Chemical Infratec Co., Ltd and is a next-generation cladding material that combines the lightweight benefits of composite panels with DtS non-combustibility, exceptional flatness, and a high-performance Lumiflon™ FEVE paint system that comes with a 20-year full cover warranty.

“We were particularly drawn to the strong warranty provisions, which include cover for material, labour and rectification costs,” said Diagnostech. “That level of assurance is above industry standard, and gave the client added peace of mind.” ALPOLIC™ does not require any ongoing maintenance in order to maintain the warranty, which represents a significant cost saving to the building owner.

The product’s durability and low-maintenance finish were further deciding factors in its selection.

“This project demanded a long-term solution. ALPOLIC™ NC delivers just that—robust performance, minimal maintenance, and a finish that lasts.”

One of the key challenges in the project was material availability and cost control.

“Procurement was a concern—especially with price escalations occurring across the market,” said Diagnostech. “We were able to work collaboratively with the builder and Network Architectural to pre-order the panels at a locked-in price, ensuring materials were delivered on time and within budget. That coordination was invaluable.”

Network Architectural’s full-service support was a key part of the project’s success.

“From initial consultation to final delivery, their service was professional, responsive and solution-oriented,” Diagnostech noted.

Modern multi-residential building featuring ALPOLIC™ NC/A1 non-combustible mineral core aluminium cladding in timber pattern finish framed by palm trees

For Network Architectural, supporting clients through the recladding process is about more than just supplying compliant materials—it’s about providing clarity, guidance and a proven process from start to finish.

“We work closely with consultants, builders, fabricators and clients to ensure everything is compliant, coordinated and clear,” said Llewellyn. “That’s especially important in recladding projects where there’s a lot of pressure to deliver safely, quickly and within the rules.”

For the Top Ryde residential towers, the completed project is a case study in how recladding can be done right—with no aesthetic compromise, no compliance concerns, and no delays.

“The clean finish, colour consistency and sharp detailing really elevate the building while preserving its original identity,” said Diagnostech. “It’s a true example of how non-combustible mineral core aluminium cladding like ALPOLIC™ NC can deliver both form and function.”

“We would confidently use Network Architectural’s products again and recommend them to others in the industry.”

ALPOLIC™ NC/A1 is a non-combustible mineral core aluminium composite panel that meets the highest global fire safety standards, including AS 1530.1 and Euroclass A1 classification as defined by EN 13501-1. It combines advanced fire resistance with design flexibility, flatness and durability. Manufactured in Japan by Mitsubishi Chemical Infratec Co., Ltd and exclusively distributed in Australia and New Zealand by Network Architectural, ALPOLIC™ NC is the premium choice for recladding and façade projects requiring absolute compliance.

Network Architectural offers a complete façade solution—from product supply to compliance documentation, colour matching, and technical support. With decades of industry experience we help architects, builders and consultants deliver safe, striking and compliant buildings, every time. For more information or help with your next project contact us today.

The Cladding Conversation: Facade Engineers Shouldn’t be an Afterthought

People are waking up to the need to engage Facade Engineers early on rather than reactively, says Associate Director at Total Building Engineering Solutions and former National Facade Lead at ACOR, Mario Mey.

Network Architectural’s National Technical Manager Llewellyn Regler agrees, saying previously clients and builders were engaging Facade Engineers too late in the project and “people got stung too many times”.

Both credit the introduction of the Design and Building Practitioners Act (DBP) as having a positive impact on safer facade design.

“Everybody is now encouraged to get Facade Engineers engaged from an early stage, which obviously renders much better designs, better coordination and a stronger focus on the compliance and long term performance,” Mario says.

Llewellyn says those doing anything in cladding at all should consider joining The Society of Facade Engineering to support the work they do to get more recognition, understanding and advocacy.

When considering some of the major issues being uncovered in poorly completed cladding projects, a lack of waterproofing and condensation are ongoing problems.

“Every time you do any remediation work commercial, residential whatever it is and you take it [the cladding] off it’s pandora’s box … it’s like what are you going to discover,” Llewellyn says.

One project where a lot of damage was sustained was in a building in Lilyfield that was just five years old and they had used furring channel instead of top hat to attach the cladding.

“It was rusted, it looked like someone had left it in the ocean and it was five years old,” Llewellyn recalls.

“The waterproofing and condensation it comes down to understanding what the system is. Some architects don’t want weep holes in the panels …but the water has to get out,” he says.

“People think the cladding panels themselves are what’s keeping the water away from the building but it’s just not true it’s the sarking or its the weatherproofing membrane you have behind it that is the waterproof”.

Both Llewellyn and Mario are advocates for ALPOLIC cladding with Mario saying “it outperforms the other bonded laminates with regards to fire safety, durability and it’s just a good product overall”.

“When you have a warranty for a Mitsubishi product and it’s 20-year full cover…it’s stand alone in the building industry,” Llewellyn adds.

“Mitsubishi actually did a special warranty for Project Remediate for the NSW Government.”

“We’ve had a few years of using solid aluminium and these kinds of things but now we are going back to composite materials because they work and one of the biggest things with the ALPOLIC as well is no colour fade”.

When it comes to the future of facades Mario expects it will look like “education about the importance of facade engineering as a whole, sustainability, safer facades and lower carbon materials”.

“It should always be constant improvement, you do that through education and understanding what Facade Engineers do. At the end of the day you’re doing a building that someone is going to be using. The goal should be better than the construction code not just building to it,” Llewellyn adds.

This podcast was brought to you in association with Architecture & Design. Listen to this episode of Talking Architecture & Design here.

The Case for Customisation: Getting the Most Out of Metal Ceilings

Custom metal ceilings offer far more than aesthetic appeal—they can play a key role in achieving functional, compliant and efficient building designs. Despite common misconceptions around cost and complexity, tailored solutions are often just as practical as standard systems.

The Case for Customisation: Getting the Most Out of Metal Ceilings explores how bespoke ceiling designs can enhance aesthetics and acoustic performance, integrate essential services and reduce long-term maintenance. It also highlights how early collaboration with suppliers can minimise delays and streamline approvals. Discover how customisation can become a strategic advantage in modern architectural projects.

Network Architectural is committed to supporting architects throughout every phase of the design and construction process. Their durlum Project Design Lifecycle provides a structured, expert-led approach to metal ceiling systems that guides projects from initial concept through to final installation. This comprehensive framework ensures that each stage—whether design development, compliance or implementation—is managed with precision and a deep understanding of architectural intent.

Download this whitepaper to learn how custom ceiling solutions can optimise performance, simplify integration and bring your architectural vision to life.

Bespoke durlum Metal Ceilings Elevate Altis Consulting’s High-End Office Fitout

When Altis Consulting set out to transform their office into a premium, high-end workspace, every detail was meticulously planned to reflect luxury, innovation, and functionality. This ambitious commercial fitout, led by Komad, a Sydney-based expert in commercial fitouts and project management, and designed by studiobb, known for their human-centered approach to architecture, required a ceiling solution that would seamlessly blend aesthetics with performance. That’s where Network Architectural and durlum bespoke metal ceilings stepped in to deliver an exceptional result.

The Vision: Luxury Meets Functionality

The objective of the project was to remove the existing office fitout and create a high-end workspace that would impress both clients and employees. Studiobb, renowned for their focus on user experience and sustainability, envisioned a space that would evoke an emotional response while maintaining functionality and elegance.

“The brief for the design was to create a high-end office space, and the use of gold blended perfectly with the opulent feeling we were trying to achieve,” said Susie Bryden, from studiobb.

durlum’s Bespoke Metal Ceilings: A Key Design Feature

One of the standout elements of the Altis Consulting office was its main lobby ceiling, designed to be a visual masterpiece. The metallic gold perforated S7 ceiling panels from durlum were chosen to elevate the space, creating a stunning, contemporary aesthetic. Network Architectural worked closely with studiobb and Komad to ensure that the ceiling design met the project’s high standards.

Key features of the ceiling installation:

Rapid Sample Turnaround – Within eight days, two samples were provided for sign-off, demonstrating durlum’s flexibility and efficiency.
Precision in Colour Matching – The final ceiling panels were carefully colour-matched, ensuring a consistent and flawless finish.
Customised Solutions – durlum adapted to evolving design requirements, including providing touch-up paint for a perfect final result.

During the installation process, the original plan was to have exposed concrete sections between the gold perforated panels in the lobby. However, once installed, it became clear that the effect was not as visually appealing as anticipated.

Recognising this, Network Architectural and durlum swiftly adapted by designing and supplying bespoke infill panels that blended seamlessly with the rest of the ceiling. The result? A dramatic improvement in the overall aesthetics, proving Network Architectural’s commitment to delivering the best possible outcome for their clients.

“It was important for us to work with someone who understood the brief and had the attention to detail we required. Network Architectural delivered this, and their flexible and innovative approach made all the difference,” said Susie Bryden.

The Town Hall Space: A Hub for Collaboration

Beyond the main lobby, the “Town Hall” space was another crucial element of the fitout. Designed as a dynamic, open-plan area where employees could collaborate, socialise, and innovate, this space required a gold perforated ceiling solution that matched the lobby while also incorporating customised transition channels.

The biggest challenge? A tight plenum space that required a unique suspension solution. durlum engineered a custom approach, ensuring the transition between ceiling sections was both seamless and structurally sound, maintaining the premium aesthetic of the entire office.

“Creating a great environment for staff to work in is critical to productivity and well-being. The elegant, well-designed ceiling enhances the space, making it both visually striking and functionally effective,” said Joe Cacic, Forman from Komad.

The Power of a Beautiful Office Space

Research has consistently shown that workplace design directly impacts productivity and employee satisfaction. Studies suggest that:

Natural and high-quality materials contribute to improved focus and well-being.
Aesthetic office spaces foster creativity and innovation.
Flexible, well-lit environments encourage collaboration and efficiency.

By investing in high-end materials like durlum metal ceilings, Altis Consulting has not only enhanced the look and feel of their workspace but also created an environment where employees feel motivated and engaged.

Why Choose Network Architectural & durlum?

Bespoke Design Expertise

Network Architectural specialises in tailor-made ceiling solutions, offering a wide range of standard and customised metal ceilings that blend durability with striking modern design. Whether it’s a complex installation or a high-end fitout like Altis Consulting, no project is too challenging.

Full In-House Service

From the initial design phase through to installation and post-install support, Network Architectural ensures consistency, efficiency, and quality throughout the entire process.

Quality Without Compromise

Working with durlum’s premium metal ceiling systems means quicker timelines, superior materials, and expert craftsmanship that stands the test of time.

End-to-End Project Support

Network Architectural’s ability to pivot and problem-solve in real time was a critical factor in the success of this project. Our commitment to delivering tailored solutions, maintaining high-quality service, and adapting to changing project needs makes a great choice for high end commercial fitouts.

The Altis Consulting office transformation showcases what can be achieved when exceptional design, expert craftsmanship, and premium materials come together. With Komad’s precision in execution, studiobb’s visionary design, and Network Architectural’s expertise in bespoke metal ceilings, the project has resulted in a workspace that is both sophisticated and functional.

For architects, builders, and designers looking to elevate their commercial projects, Network Architectural metal ceilings provide the ultimate combination of aesthetic excellence, durability, and flexibility, contact us today for your next project.

Download this case study here.

A Bespoke Metal Ceiling With A Story: How durlum Integrated Indigenous Art Into A Multi-Use School Hall

When Matthew Pearce Public School embarked on the construction of a multifunctional hall and sports centre, they sought more than just a functional space—they wanted a structure that would reflect the cultural heritage of the community while delivering outstanding acoustic and visual quality. Network Architectural, in partnership with Stephen Edwards Constructions and indigenous artist Jamie Eastwood, brought this vision to life with a stunning custom-designed durlum metal ceiling.

Matthew Pearce Public School’s new facility was designed as both a school hall and a fully functional basketball court and sports centre, requiring a ceiling solution that was not only durable and high-performing but also aesthetically striking. Network Architectural supplied and customised durlum’s S7 metal ceiling system, incorporating intricate indigenous artwork that honoured the school’s connection to Country.

“This project was unique because of its strong cultural significance. We needed to ensure that the ceiling design was not only beautiful but also practical, blending acoustics, lighting, and services seamlessly into the architecture.” Paul Sheehan, Ceiling Division Manager, Network Architectural.

The ceiling’s design centered around indigenous artwork created by Jamie Eastwood, a celebrated Dharug artist. Each custom-perforated panel represented a different year group, from Kindergarten to Year 6, forming an interconnected story across the ceiling.

Matthew Edmonds from Stephen Edwards Constructions explained the process: “We engaged Jamie early on to ensure the artwork was an integral part of the ceiling. The challenge was converting his intricate designs into perforated patterns that worked within the ceiling panels while maintaining their cultural significance.”

Network Architectural’s ability to customise durlum’s S7 system proved critical. While many manufacturers struggle with custom perforations on pre-perforated panels, Network Architectural delivered a flawless result, ensuring the designs were accurately translated into the metal surfaces.

Internally, the hall’s ceiling incorporated a combination of perforated panels with campfire and shooting star motifs, symbolising knowledge-sharing and community. The panels were backed with black acoustic SoundTex, pre-assembled with adhesive fixing to enhance sound absorption and reduce echo—an essential feature in a multi-use school space.

Externally, non-perforated white durlum S7 panels were used for the soffit, ensuring a clean, modern finish. In areas where perforations formed indigenous artwork, black aluminum backing was placed behind the panels to make the designs stand out.

The installation, led by Auzoom Projects, initially presented several challenges, including tight plumbing spaces and the integration of lighting, sprinklers, and fans within designated non-perforated panels. However, these challenges were overcome with precision and expertise. Paul highlighted the attention to detail, stating, “The service channel was incorporated into every fourth panel, strategically designed to accommodate lighting and other fixtures while maintaining a sleek and cohesive aesthetic.”

The completed ceiling has been met with fantastic feedback. Teachers, school infrastructure teams, and project managers have all commented on its quality and seamless integration into the space. The bright white finish helps to enhance natural light, while the perforated design improves acoustics, making the hall a more comfortable and functional environment for students.

Matthew Edmonds reflected on the project’s success: “The quality of the product was outstanding. The design process took longer than expected due to the detailed artwork conversion, but the final result was worth it. The panels blended perfectly, and the artwork transitioned smoothly from one panel to the next. The client was thrilled with the outcome.”

Beyond functionality and aesthetics, the project represents the importance of integrating indigenous culture into contemporary educational spaces. Jamie Eastwood’s artwork ensures that every student who enters the hall is reminded of their connection to Country and the rich history of the community.

“This was the showpiece of the build,” said Matthew Edmonds. “It gave the school a sense of identity and cultural significance that will last for generations.”

The Matthew Pearce Public School project exemplifies the craftsmanship, flexibility, and innovation that durlum and Network Architectural brings to every build. From the technical precision required to integrate indigenous artwork into metal panels to the seamless installation process, the project highlights our expertise in creating high-quality, visually striking bespoke ceiling solutions.

Network Architectural and durlum’s expertise extends far beyond educational projects. Our expertise spans commercial, transport, healthcare, and hospitality sectors, delivering high-performance architectural ceiling solutions tailored to each project’s unique needs. With a full in-house team managing every step from initial concept to installation, we ensure seamless execution and outstanding results for architects, designers, and builders alike.

To learn more about how Network Architectural can support your next project, contact us today.

Download this case study here.

Engineering Resilient Facades

Australia’s rising temperatures are intensifying heatwaves, compromising the structural integrity of facade materials through accelerated wear and thermal expansion. These shifting climate conditions present significant challenges for the built environment, demanding facade solutions that can withstand extreme weather while ensuring occupant safety, comfort, and long-term performance.

Engineering Resilient Facades: Performance and Compliance for Australia’s Diverse and Demanding Climate helps architects and specifiers navigate these challenges as it delves into the critical aspects of designing resilient facades, with a particular emphasis on the relevant codes and standards governing weather resistance. Meeting facade performance compliance and testing standards is essential to ensuring buildings can withstand increasing environmental stresses.

Available from Network Architectural, ALPOLIC™ panels are a superior choice for architects aiming to address the challenges of Australia’s extreme climate. Engineered with high-quality aluminium and advanced Lumiflon FEVE paint coating technology, ALPOLIC™ panels maintain their structural integrity, aesthetic appeal, and resistance to denting and thermal expansion for up to 50 years, even under harsh environmental conditions.

Download the whitepaper here.

Metal Ceilings: The Sky is the Limit

Metal ceilings offer excellent design flexibility and aesthetic and performance benefits, making them a popular choice for transport hubs.

Network Architectural Ceiling Systems Manager, Steven Fraser, says metal ceilings have ample benefits, including being fire-safe, durable, low-maintenance, and easy to take apart.

“And you can customise it to the nth degree, so you’ve got an unlimited scope of design and flexibility on aesthetics as well, which is such a bonus…You can colour it any colour available, bend it in 3D forms, the sky is the limit”.

While metal’s carbon footprint is initially high, the material is “infinitely recyclable”.

“Once it’s in the solid form of aluminium, it uses up to 95% less energy if you recycle that panel than it did the first time around. The circularity of metal ceilings means it’s infinitely reusable and probably one of the only building products out there that people will pay you to remove off-site,” Steven says.

Network Architectural Ceiling Division Manager Paul Sheehan adds that metal ceilings in transport hubs such as underground stations and airports also provide good acoustics.

“With aluminium systems, we can perforate, have it slotted, and create any acoustic number that the acoustic requirements call for. We can add insulation to the back of panels and deaden the noise,” he says.

A striking example of the incredible versatility of metal ceilings can be seen throughout Terminal 3 at Singapore’s Changi Airport, where the anodised aluminium panels inspired by butterfly wings move to adjust to natural light.

“There are operable panels on the roof of the building and flexible reflector panels underneath in the terminal space, and that allows natural light to penetrate the space,” Steven explains.

“The flaps on the top can open and shut depending on the location of the sun, so there are actually sensors on the roof of the building that know the angle of the sun and open and close the panels accordingly, so what it does is allow natural light into the building, but it also reduces the amount of heat that gets into the building so we are reducing the amount of air conditioning that we need,” he says.

“By controlling the amount of natural light that comes in, we are also drastically reducing the amount of artificial light we need in the building space. Being exposed to natural light while you’re transiting through can reduce the effects of jetlag. So not only is it reducing the amount of carbon and operational energy of the building, it is also improving the wellbeing of the users moving through the building”.

Paul adds that many of the new train stations around Australia are opting for metal ceilings instead of plasterboard or fibre cement.

“With aluminium, you can fold it, shape it, curve it,” he says.

He says this flexibility came in handy while constructing the ceilings for Gadigal Station in Sydney, where every corner is curved. Network Architectural made intricate moulds to form them in the correct shape.

“A lot of the panels are curved in two directions. You don’t have that design capability with many other products or any other products, as far as we are aware.”

When it came to designing the ceilings for Victoria Cross Metro Station in North Sydney the client wanted “a real big wow factor.” They wanted it to be bright, so light reflectance was key.

“With the light reflectance, in particular, we can do any gloss level. We can do a really high gloss level or a really dull matt finish, depending on what that space calls for,” Paul says.

As demand for metal ceilings continues to grow Network Architectural expects the next 10 years are going to be “very busy”.

Listen to the full podcast here.

Podcast: The Advantages of using Metal Ceilings in Transport Infrastructure Hubs

Transport infrastructure projects, such as airports and railway stations, are among the most complex building types, requiring durability, longevity, and high functionality. These hubs operate around the clock, enduring heavy foot traffic and constant wear while needing to maintain both aesthetic and operational excellence.

Metal ceilings provide an ideal solution, offering design flexibility alongside acoustic, lighting, and performance benefits. Available in various forms—planks, panels, curved beams, and perforated options—metal ceilings not only enhance the architectural appeal of transport hubs but also contribute to a functional and comfortable environment.

But how do metal ceilings meet these demands? How do they manage acoustics, integrate lighting, and seamlessly conceal mechanical and electrical services while supporting the daily operations of busy transport hubs?

In this episode of Talking Architecture & Design, Paul Sheehan, Ceiling Division Manager, and Steven Fraser, Ceiling Systems Manager at Network Architectural, discuss these questions and more.

This podcast was brought to you by Architecture & Design as part of the Talking Architecture & Design series. Listen to the episode here.