Harbord Diggers Club at Freshwater

The Challenge

Harboard Diggers consisted of approx. 100,000m2 of formwork quantity. Typical basement floor plates being 15,000m2 alone. The scope consisted of formwork to common basements one and two, plus the lower ground and upper floors, followed by all levels to buildings A to D and F in Stage 1, with Bldg E completed in Stage 2.

Builder: Ganellan               Contract Value: $9.8M    
Completed: Mar 2019

Our Approach

60% of the Harbord Diggers project consisted of basement, carpark and commercial club space.  These areas were mostly high strutting areas with particularly deep beams and structural elements. A major challenge was to maintain the right flow of labour and resources to meet programme requirements. Our team consisted of a Senior Project Manager who managed the contract conditions including 1st point of communications with Ganellen, Safety Management & Resource Management. He lead four team Supervisors on site with total  manpower at times reached 100-150 workers.

Calcono utilised a mix of systems for the project including the KingFlor™ Metal Decking System, which was used for all slab areas in the basements and commercial levels. The system helped to minimise labour and material resources for these particular challenging areas. Beams were formed using our Faresin Alufort system, which was also utilised to form slabs to apartment levels, with conventional formwork to balconies to achieve the appropriate class of finish.

Stair and lift cores were formed using a pre-made conventional shutter system, while external walls that reached from lower ground up to apartment levels, were completed using a mixture of AFS Rediwall and Dincel wall systems. The Dincel system allowed Calcono to achieve the specific radii required for the curved design of the walls.


Harbord Diggers Club was successfully completed and opened to the public in June 2018. Calcono is proud to have worked along side Ganellen on such an iconic project for Sydney’s Northern Beaches.