1. Concrete Design and Construction Issues for the MCG
Redevelopment
Mark Sheldon
Senior Associate, Connell Mott MacDonald
60 Albert Road, South Melbourne, Vic, Australia, 3205
Erik Guldager-Nielsen
Arup
Level 17, 1 Nicholson Street, Melbourne, Vic, Australia, 3000
Steven Richardson
Project Manager, Grocon Constructors
MCG Site, Yarra Park, Vic, Australia, 3002
Abstract
The design and construction of the MCG Redevelopment, scheduled for completion for the 2006
Commonwealth Games, has presented numerous challenges for the design and construction team.
The $400 million project is being constructed by Grocon Constructors, working closely with the
novated consultant team lead by MCG-5 Sports Architects, a joint venture between Daryl Jackson
Architects, HOK Sport+Venue+Event, Cox Architects, Tompkins Shaw + Evans and Hassell
Architects. The engineering consultancy is a joint venture between Connell Mott MacDonald and Arup
(CMMA).
Immediately upon novation of MCG-5 and CMMA to the successful tenderer, Grocon, the design team
set about incorporating the preferred concrete solutions. High on Grocon’s priority list was the need to
expedite the construction. This led to the adoption of a variety of structural systems on site, each
chosen for their ability to overcome particular constraints at each location. The typical system
incorporates a concrete superstructure with hollowcore planks utilising a purpose built beam formwork
system. High strength precast columns were used extensively throughout the superstructure, as well
as bored pier retention systems.
Other interesting aspects of the design of the MCG include the concrete counterweight to the roof
structure and the construction staging methodology developed for the site.

2. The Project
The Melbourne Cricket Ground (MCG) is one of Australia's most famous sporting icons, and has been
undergoing a major redevelopment in the last 3 years. The three original stands on the northern side
of the ground (the Ponsford and Olympic Stands and the Member’s Pavilion) have being demolished
to make way for a new single stand. The only portion of the stadium left standing after the progressive
demolition was the Great Southern Stand, which was designed by Connell Mott MacDonald in the
early 1990's, although even this has had some modifications to accommodate enhanced lighting and
sound equipment.
Whilst the 150+ year old ground has hosted AFL matches in the past with 120,000+ spectators, the
introduction of seats to replace standing areas had whittled the capacity down to just over 96,000,
with many seats in the older stands having restricted viewing and uncomfortable timber slatted seats.
To maintain its reputation as Australia’s premier sporting venue, the Melbourne Cricket Club (MCC)
realised that a major redevelopment was essential.
Following an extensive feasibility study completed in December 2000, the MCC and the MCG Trust
confirmed it would proceed with a redevelopment of the aging stadium based on the following
criteria:-
• There should be no loss of public seating or overall capacity
• Sightlines should be of world standard
• Individual seating spacings should be at least equal to that in the Great Southern Stand
• The number of under-cover seats should be optimised
Through careful planning by the design team, the original capacity criteria has been exceeded, as the
capacity of the new stadium when complete will again exceed the magic 100,000 number.
Another key component of the architectural design was the concept of opening the stadium out to the
parklands north of the ground. This is a different philosophy to the Great Southern Stand which had a
relatively unattractive vista overlooking the busy Brunton Avenue and the rail yards. With its proximity
to Yarra Park, it was decided to make more a transparent wall in the new stand to engage
approaching patrons as they arrive at one of the three major entry points. Each entry features a grand
atrium behind large glass facades, serviced by escalators taking patrons to the upper levels.
Whilst the “front-of-house” areas essential for a stadium are critical for the MCG, there are other
features of the redevelopment that will not become obvious until the facility is fully opened to the
public. Whilst there is no net increase in corporate seats (considered an important criteria by the MCC
to maintain the MCG’s mantle as “The People’s Ground”), dining room capacity will almost double.
Large, deep rooms will enable tenant sports and clubs to accommodate up to 500 guests and the
MCC Members Dining Room has a similar capacity. Large new changerooms, press facilities and
coaches boxes will service the needs of both football and cricket. The stadium will have extensive
catering facilities, and will have nine passenger lifts and 13 escalators to supplement stairs.
A major feature of the redevelopment is the relocation of the Australian Gallery of Sport as part of a
seven day attraction, featuring interactive devices and a museum precinct. This will be linked to the
MCC’s library, which boasts the world’s finest repository of sporting literature. And, of course, the
famous Long Room in the Members Area will be recreated, complete with the memorabilia that made
it much loved by generations of Victorians.

3. Staging
In the latter part of 2001, the consultant team working for the MCC, issued tender documents for a
“Novation” style contract. These were not full “for construction” documents, but rather a preliminary
design issued to identify to the tenderers the client’s expectation for the project and a way in which
the stadium could be completed. Grocon Constructors commenced on the project in mid-2002, and
immediately set about directing the consultant team to modify elements of this partially completed
design to suit their preferred construction techniques. The final documentation was then completed by
CMMA and MCG5 based on Grocon’s preferred methods of construction.
All construction techniques, when evaluated, had to address the requirement that the stadium had to
remain operational throughout the AFL and cricket seasons, with a minimum number of seats to be
available for major events.
The old Ponsford Stand was the first to be demolished, immediately after the 2002 AFL Finals. This
western end of the new stand was then the first portion to be constructed, with patrons occupying this
for the 2003 AFL Grand Final. Following the 2003 Finals, the Members Pavilion was taken down. Half
of the Olympic stand went next, with further new seats made available for the 2004 AFL Grand Final.
Following this event, the remainder of the Olympic Stand was demolished and the final portion of the
stand could commence.
Much of the engineering design by Connell Mott MacDonald Arup was completed at a site office
working along side the MCG-5 Sports Architects and Grocon Constructors. Speed of construction has
been high on the design team’s agenda, driven by Grocon’s tight construction program.
The new Northern Stand itself is expected to be completed by the end of 2005 in time for the 2006
Commonwealth Games. Between the 2005 AFL Grand Final (in late September) and Boxing Day, the
entire playing surface will be stripped off and essential track and field base works will be completed,
prior to the turf pitch being reinstated for the traditional Test match. Then between January and April
2006, the turf will be removed again and the track must be set up, as well as data, communications
and electrical conduits installed for the events and ceremonies. Once the games are finished, the
whole stadium must then be turned back into an AFL ground for the balance of the 2006 AFL season.

4. Ecologically Sustainable Development (ESD)
A key criteria for the entire MCG redevelopment project was to introduce world-class sustainability
criteria in the building and managing of the stadium. The onus for the engineering design team was to
reduce the demand for energy, use building systems that provided optimum operational and resource
efficiency, and incorporate innovative and environmentally sustainable initiatives into the
redevelopment where feasible.
The architects coined a phrase on the outset – MCG Green – which has been part of the driving
philosophy behind a lot of the work. For example, trying to minimise the impact on the MCG's
surrounding parkland has taken into account the whole precinct concourse redevelopment and
interaction. As part of this aim, the main entry points for the new Northern Stand will be three atria that
will take advantage of passive ventilation for cooling. The engineering team used daylight studies and
thermal modelling to achieve this. The shading design has been optimised to provide sufficient solar
heat gain control, but at the same time letting in sufficient daylight and controlling glare in the space.
Through sophisticated computer simulation, CMMA have also predicted the air flow, air temperature,
surface temperatures, radiant heat, daylight levels and contrast glare in the space. As a result, the
three atria have a series of louvres, each differently arranged to give the best control of light within the
space. Apart from the thermal modelling, the simulations also addressed openings and access to
passive air flow. As a result, mechanical cooling is only needed in heavy use and high heat areas like
the food court.
As another part of the new sustainability measures, CMMA looked at storm water quality improvement
initiatives from the site and reuse of water. Previously all the water that came off the site was
discharged to the stormwater system, which went to the Yarra River. The new Northern Stand has a
1.5ML tank to collect water that falls on the 1hectare roof. This harvested water will be treated and
used for seating plat wash down.
The Structural Frame
The completed new Northern Stand will effectively be a 400m long seven-storey high building, with
two basement levels. The team looked at many alternative structural schemes before adopting a
solution of what is effectively five buildings, separated by movement joints. Within each of these
buildings, shear walls have been incorporated in the radial direction to provide stability and maximise
ceiling zones for reticulation of services around the stand. In the circumferential direction, however,
shear walls would hamper viewing areas, so beams have been provided, working with the columns as
a sway frame. This assisted with support of the floors, as Grocon's solution was for hollowcore planks
spanning radially for typical suspended floors of the stadium – a win-win situation.

5. Another aspect of the project where concrete has been used extensively is in the retention system to
the double basement. Bored piers by Wagstaff Piling were drilled from the surface level and shotcrete
panels sprayed between the bored piers progressively during excavation. Interestingly, wherever
possible large diameter bored piers are designed to cantilever out of the base in the temporary
condition, rather than smaller diameter piers restrained by temporary ground anchors.
The Floor System
With over 10hectares of floors to construct, Grocon elected to use a number of different flooring
systems throughout the project. Examples of the types used, and the reasons for selecting these
systems are summarised below: -
STRUCTURAL SYSTEM LOCATIONS USED
CONVENTIONAL CONCRETE
CONSTRUCTION (FORMWORK,
REINFORCEMENT & INSITU
CONCRETE)
Areas with large penetrations or where floor plate
was curved in plan.
Cantilevered slab edges or slabs requiring cast in
plates.
Main circumferential beams which support the
Hollowcore precast floor planks on Levels 1-4.
Inclined columns in the 3 main entry Atria
Level 1 seating plats using Grocon Lubeca jigs to
form up the seating plats incorporating BAMTEC
reinforcement system.
PRECAST FLOOR PLANKS (Hollowcore) Typical level 1-4 suspended slab areas with
minimal penetrations in the floor plate.
POST-TENSIONED PRECAST
CONCRETE SEATING PLATS
All seating areas on Levels 2, 3 and 5.
BONDEK SLABS Areas with very high soffits, such as bar over
Members Atrium.
Areas with tight floor-to-floor height, such as Long
Room Mezzanine.
Areas with sloping soffits not suitable for
Hollowcore
Non-typical areas where the architectural finish to
the soffit was not a driving issue
PRECAST WALLS All Goods and Passenger Lifts shaft walls
throughout the project, integrated with surrounding
concrete structure.
All Vomitory walls leading to Level 1 & Level 5
seating.
PRECAST COLUMNS All areas from LB2 to Level 3.
Level 1 tapered columns fully integrated with steel
rakers and tensioned concrete back-spans
supporting Level 2 precast concrete seating plats.
The typical grandstand circumferential beams are post-tensioned and span approximately 16m. To
maximise services zones, the design incorporated haunches in these beams, with depths of 900mm
at columns stepping down to 600mm at mid-span. Beam depths were set to maximise the use of
standard forms, recognising that to speed up construction the hollowcore planks were to be supported
by the formwork prior to the beams being poured. Considerable coordination was undertaken by the
project team, particularly at the many floor set-down areas, to achieve this goal. This enabled the
hollowcore planks to be used as a working platform for installation of reinforcement and
post-tensioning tendons in the circumferential beams. The structural topping to the hollowcore is
poured simultaneously with the beams, to minimise construction time on site. In a co-operative
approach, the floor system was designed in conjunction with Hollowcore Pty Ltd to be continuous
construction. Hollowcore were responsible for the design of the planks, with CMMA responsible for
the top flexural reinforcement over supports. Particular attention was paid to the shear characteristics
of the planks in zones of negative bending.

6. The Seating Tiers
A feature of the stadium evident to all spectators is the large cantilevering rakers that support the
upper seating tiers. The largest of these cantilever approximately 11metres and are spaced
approximately 12metres apart.
Carrying folded precast concrete seating plats with crowd loading, it is easy to see that a significant
steel beam is required. What is not so evident is the fact that we needed to design these elements for
more stringent dynamic performance criteria than what was appropriate when the Great Southern
Stand was designed.
Our team developed an analysis methodology that modelled the interaction of the steel beams, the
concrete supporting frame and the precast seating plats. Tweaking the relative stiffnesses of the
respective elements and researching to develop a rational design criteria meant we were able to save
the client over a million dollars compared to other stadia designed using a less sophisticated ‘deemed
to comply’ approach. Even with this reduction, steel beams up to 2.7metres deep with 80mm thick
flanges were still required.
The upper level seating tier consists of 36metre long boxed steel girders supported on sloping
tapered columns, and carries considerable forces from the roof down to the superstructure. Because
of the large horizontal thrust forces, up to 18No x 15.2mm dia post-tensioned strands are coupled to
the steel’s baseplates and traverse the top floor at each grid to counterbalance the opposing forces.

7. A similar challenge was how to connect the 2.7metre deep steel cantilever beams at level 2 back to
the concrete frame. Typically 36No x 15.2mm post-tensioned strands are anchored though a 3metre
deep concrete backspan beam into the superstructure. These required careful detailing to avoid
significant congestion of reinforcement at the junction with the columns.
Precast Columns
In keeping with Grocon’s philosophy for the project of prefabrication for speed of erection, many of the
columns are precast concrete. Strengths of up to 80MPa are being used to enable the sizes of
columns to be standardised, reducing the number of moulds. The use of precast columns expedited
site construction times, but required additional input from the design team coordinating levels prior to
fabrication.
Foundations
One of the areas of risk Grocon identified early in the design phase was potential delays associated
with excavation for footings on a site with a history of previous buildings. It was also known that a
dyke of weaker material traversed the site, the extent of which was not fully known. As a result,
Grocon instructed the team to reduce the number of columns through the structure in the final post-
novation design. This increased the spans of the circumferential beams and the stability moments in
the columns, but reduced the number of footings. Allowable bearing pressures were increased on the
basis that significant additional inspections by the geotechnical engineer were undertaken, allowing
the footing sizes to be reduced.
In the vicinity of light tower 1, unusually soft ground conditions due to the dyke were encountered,
requiring pile foundations instead of the usual pad footings.
The External Concourse
The concrete paved concourse to the west and north of the new stand provides a link to the
surrounding parkland and access to the ticket booths and entrances.
The choice of a structural system was dictated by the need to maintain existing underground services
in the area, noticeably a 66 kV power cable, which transverses the site in close proximity to the new
structure. It was necessary that a 6 metre wide corridor around this cable be kept free of all
construction work, including excavation. It was further agreed that engineered filling should be kept to

8. a maximum depth of about 1 metre, to avoid time-consuming operations of placing and compacting in
thin layers.
Thus the structural system evolved as parallel walls on each side of the power cable, with the outer
wall designed as a free-standing retaining wall. The deck over the cable is a hollow-core slab, with a
heavy in-situ topping, designed as simply supported, to allow removal in parts for repair of the cable
should that be necessary. Inside the cable corridor the slab is conventional in-situ concrete, generally
slab and band-beams. This structure is supported on the shoring piles around the basement under
the stand, but separated from the main structure by a movement joint. Outside the corridor a concrete
slab is constructed on compacted fill.
A major complication arose in the area where two columns, supporting one of the external services
pods, landed within the cable corridor. Here it was necessary to construct a temporary hollow-core
slab with minimum clearance over the ground, acting as support for an 1100mm deep transfer slab,
which carried the column load to piles placed outside the restricted zone.
A Novel Use of Concrete
The brief for the main roof over the new Northern Stand was for an elegant, light and transparent roof
structure, which maintained the MCG’s iconic status and complemented the Great Southern Stand
(GSS) without replicating it.
The Engineering team developed several options for the roof structure, and tested each against
architectural, cost and staged construction requirements. Some of these options included a large,
single mast within Yarra Park, a roof structure suspended from 2 different arch trusses or a
suspended roof utilising individual masts.
The adopted solution involves an innovative tension structure with rafters suspended from cable stays
running over individual masts. Utilising counterweight to resist uplift wind forces, the structure also
makes use of a cablenet to distribute peak wind loads determined from wind tunnel modelling. CMMA
were then able to engage a large portion of roof weight to resist uplift winds - which occur in peak
zones - resulting in a very efficient and light structure. The cablenet also serves the purpose of
restraining the top of the individual masts, eliminating the need for a bulkier bracing system.
The primary roof structure is comprised of fabricated steel box section rafters ranging in length from
37m to 42m. The rafters are concrete filled to provide counterweight against uplift wind and to further
assist this, a front hoop beam, consisting of a 600 square fabricated steel box section, was placed
towards the front of the roof and also concrete filled. The fabricated steel masts are tapered to give
their appearance a further element of slenderness and vary in height from 13m to 28m.
Grocon initiated prototyping to determine how the members providing counterweight for the roof can
be filled with concrete. This showed that the specially engineered concrete can be poured in through
holes in the top of the steel beams without vibration.
Another benefit of this scheme over other options, is its suitability to staged construction, as it could
be built bay by bay with minimal temporary support required.

9. Great Southern Stand Extension
One aspect of the project already “forgotten” by the public is the fact that, to maintain symmetry of the
stadium, the redevelopment also included the extension of the Great Southern Stand (GSS) by one
bay and the two main stands will be separated by large scoreboard structures at each end. This was
essential due to limited space on the site due to the proximity of Brunton Avenue and the rail yard.
The techniques for the construction of this extra bay were a hybrid of those used in the original stand
and those proposed to be used for the new stand.
Top Down Construction
The normal construction activities continuing around from west to east meant that the last portion to
be commenced would be the difficult interface with the Great Southern Stand, including working
around the existing Light Tower No 2 and Tower Crane No 9. This also included the non-typical last
two bays which feature the large electronic scoreboard. The significant retention systems supporting
these structures presented a challenge from both a construction and programming point of view.
To expedite the construction on site, Grocon initiated a ”jump start” construction methodology to the
eastern end of the project. The easternmost two bays were redesigned to enable construction after
the 2004 Finals to commence at concourse level. Columns through the basements previously
designed as precast concrete were replaced by bored piers installed from ground level. Construction
began at the eastern end at concourse level and continued upwards as the excavation for the
basements continued to work its way eastwards. The excavation then continued under the completed
concourse and the basement structure formed and attached to the newly rendered piers. Ramp
access into the two-basement hole for excavation vehicles required considerable coordination with
concourse construction activities particularly in the vicinity of the retention system to the light tower.
This “top and tail” technique saved considerable time in Grocon’s construction program by removing
the retention/ excavation off the critical path of the works.

10. Summary
The MCG redevelopment features many different examples of the uses for concrete in the
construction of major buildings. Due to the enormity of the task, Grocon Constructors, Connell Mott
MacDonald Arup, and MCG5 developed a series of different structural systems, each chosen to be
the right solution for that particular set of circumstances.
The primary system used for the main superstructure was post-tensioned concrete circumferential
beams poured in purpose built steel forms able to support hollowcore planks and the structural
topping. Other areas featured conventional reinforced concrete, some using the OneSteel “Bamtec”
reinforcing mats. Areas of slabs were also formed using Bondek, whilst significant program benefits
were gained by maximising the use of precast elements, such as the precast, pretensioned seating
plats that span up to 16metres. A significant number of bored piers were installed to provide the
perimeter retention system, and as footings in areas of weaker bearing material. A novel use of
concrete is in the main roof rafters, which are concrete filled steel boxes. The concrete provides
deadweight to resist the dominant uplift loads as well as adding rigidity to the steel wall plates.