Towering 200 meters above the heart of Sydney’s CBD, the 1 Elizabeth Dome Roof represents the cherry on top of the Sydney Metro Martin Place North Tower, part of an ambitious integrated station development. Galserv played a pivotal role in ensuring this iconic structure is equipped to endure for decades to come.
Galserv has been a trusted name in Sydney’s infrastructure landscape since 1963. As one of the largest hot-dip galvanisers in Australia, they offer tailored solutions that provide long-lasting corrosion protection for steel used across diverse industries. Operating from their facility in Yagoona, Galserv ensures projects are completed efficiently and effectively, with their 24/7 operation allowing them to meet even the tightest deadlines.
Part of NEPEAN Building & Infrastructure, Galserv brings the expertise and resources of a larger group while maintaining a hands-on, client-focused approach. Over the years, Galserv has become synonymous with quality and reliability, protecting Sydney’s most iconic structures, from Sydney Airport to the Scenic Railway – and their latest project, which saw them crown a new development destined to become a defining feature of Sydney’s skyline.
The 1 Elizabeth Dome Roof is a standout feature of the Sydney Metro Martin Place integrated station development, a transformative urban project combining transport infrastructure with commercial and public spaces.
The success of the 1 Elizabeth Dome Roof hinged on the collaborative efforts of a variety of stakeholders, led by the asset owner, Macquarie Group. Designed by JPW, engineered by ARUP, fabricated and installed by Wexford Welding, painted by NEPEAN Engineering, galvanised by Galserv and overseen by Lendlease, the dome roof marks the final stage of the Sydney Metro Martin Place North Tower, adding a distinctive architectural flourish to the skyline.

The challenge: Lofty heights, high standards
The 1 Elizabeth Dome Roof presented a unique set of challenges, largely due to its location 200 meters above street level. At this height, access is severely limited, and any future maintenance would be both costly and logistically complex. Safety risks associated with working at such an elevation further complicated matters, making it imperative to minimise the need for ongoing maintenance.
To meet these demands, a 25-year warranty for life-to-first maintenance was required. Compounding the challenge, ARUP specified the need for a duplex coating system, combining hot-dip galvanising with a paint finish to provide a secondary barrier. While this system would offer the necessary durability, it raised concerns about the compatibility of paint over galvanised steel – specifically about whether the paint would adhere properly. These concerns were significant enough that some suppliers declined to participate in the project, deeming the system too risky to implement.
With the project operating under an immovable deadline due to stringent occupancy requirements, any delay would have risked severe financial penalties and potential contractual breaches for the asset owner.
Galserv was engaged to deliver a solution that would meet the warranty standards, address the perceived risks of the duplex system, and ensure the project remained on track.

The solution: Galserv’s duplex flex
Galserv championed a collaborative approach, bringing together stakeholders and fostering an environment where expertise and ideas flowed freely. This spirit of teamwork was crucial to navigating the high-stakes challenges posed by the duplex system and delivering a solution that met the project’s exacting requirements for durability and reliability.
Adam Chessell from Galserv played a key role in reassembling the project team, working closely with NEPEAN Engineering, Wexford Welding and other stakeholders to address complex technical challenges. Galserv acted as a central coordinator, facilitating a detailed plan to resolve paint adhesion concerns and meet the critical 25-year warranty requirements.
Their strategy began with grit blasting prior to galvanising. This increased the steel surface area, enabling a thicker galvanised coating for enhanced corrosion resistance and a more robust foundation for the paint system.
Building on this groundwork, NEPEAN Engineering applied a specialised three-coat paint system supplied by Akzo Nobel. Formulated specifically for use over galvanised surfaces, this solution mitigated the risks of coating failure and ensured seamless integration between the galvanising and paint layers.
Recognising the immovable deadline for the 1 Elizabeth Dome Roof project, Galserv deployed their Gal Express service to address the critical time constraints. This enabled Galserv to expedite the galvanising process, reducing completion time.
This swift and efficient approach safeguarded the project from substantial costs and legal complications, reinforcing Galserv’s reputation as a dependable partner under pressure.
A dome built to last
The duplex coating system delivered exceptional durability and corrosion resistance, achieving the critical 25-year warranty and equipping the 1 Elizabeth Dome Roof to endure the challenges of its elevated location 200 meters above street level, while reducing the need for costly and logistically complex maintenance.
Beyond economic benefits, the project demonstrates a commitment to environmental and social responsibility. The duplex system’s longevity contributes to public safety by ensuring the structure remains secure and stable for decades to come, and directly contributes to a reduced carbon footprint by minimising the environmental impact associated with future maintenance, repair materials and transportation.
Galserv’s use of locally manufactured and applied coatings further underscores the project’s support for Australian industry, showcasing the value of domestic expertise in delivering high-profile infrastructure projects.
And as the 1 Elizabeth Dome Roof takes its place in Sydney’s skyline, it challenges industry misconceptions about the compatibility of paint over galvanised steel. By demonstrating that a well-executed duplex system can meet stringent durability requirements, this project opens the door to broader adoption of similar solutions in the future.
The 1 Elizabeth Dome Roof sets a benchmark for durability and innovation in modern urban development – and Galserv’s contributions to this project reinforce their status as leaders in galvanising, with a reputation for going above and beyond.