Blogs

Seismic, prefabrication and vibration engineering solutions from KUSCH for Western Sydney International Airport. Western Sydney International Airport brings together some of the world’s most respected design and engineering teams to deliver a project with national significance. The project was developed by Zaha Hadid Architects in partnership with Cox Architecture and Woods Bagot, combining global design capability with deep local knowledge. From its modular layout to its consideration for long-term sustainability and performance, the project sets a new benchmark for major infrastructure in Australia. The airport is positioned to become a core economic and transport hub for Greater Western Sydney. Its delivery spans...

At NEXTDC S3 Sydney, KUSCH engineered the structural design of 54 prefabricated cooling towers—each nearly 9 metres tall and IL4-rated for seismic and wind loads. Delivered in modular components and lifted into place with Roborigger technology, the system accelerated installation by design. With 26 towers now operational, this project showcases how prefabrication and precise engineering keep critical infrastructure cool, efficient, and on schedule.

KUSCH brought engineering precision to pure adrenaline with Vertigo—the Southern Hemisphere’s first free-fall ride of its kind. Designed for Rotorua’s Velocity Valley Adventure Park, the 43-metre drop ride features a custom mechanical cable system and support frame, engineered to safely decelerate riders mid-fall. From FEA to fabrication drawings, we ensured strength, safety, and compliance—all while embracing the fun side of engineering.

The L29 chiller plantroom at Wynyard Place was prefabricated into 15 SUPA modules and craned into place over a single weekend—compressing the mechanical program by 12 weeks. Seismic requirements were fully integrated into the prefabricated frames via BIM, eliminating the need for on-site bracing and demonstrating how prefabrication can accelerate complex builds without compromising compliance.

When a new school needed to be built before the start of term, conventional construction methods simply couldn’t meet the timeline. Prefabricated building manufacturers were also at capacity—so the project team had to think differently. By designing the structure as prefabricated, transportable steel modules, KUSCH enabled the use of local steel fabricators and traditional trades to complete the build. This smart hybrid approach shortened the construction schedule by around 10 weeks, delivering the project on time without compromising quality or compliance.

Understanding your building’s Importance Level under AS1170.4 is critical to achieving seismic compliance without unnecessary complexity or overengineering. Each Importance Level—from IL1 to IL4—comes with its own set of design obligations that can impact everything from anchor selection to certification pathways. In this post, we break down why getting this right matters, using our work on the Lyell McEwin Hospital Expansion as a real-world example of how smart, IL4-compliant design can meet strict performance requirements while remaining efficient and buildable.

Incorrect installation of AS5216 seismic screw anchors can compromise structural integrity and lead to costly failures. Our latest blog post breaks down the most common installation mistakes—including overdriving, incorrect hole depth, and stripped concrete—and provides practical solutions to ensure compliance and load capacity. Learn how to avoid these errors and install screw anchors correctly for safe and reliable performance.

A recent air leakage test on one of our Passive House projects achieved 0.24 ACH@50 (air changes per hour at 50 pascals pressure), well under the 0.6 ACH@50 required to achieve Passive House certification! Compared to the typical range of 5.0 to 15.0 ACH@50 for houses constructed under the energy efficiency requirements of NCC2019, this high-performance home is one of the most thermally efficient buildings in Australia. Pursuit of thermal efficiency without adequate expertise and experience can result in dangerous condensation and mould issues, so it’s essential to engage a registered Passive House consultant when pursuing this level of performance. Passive...

Significant challenges were encountered in the design of this 100m tall Ø600mm pipe riser, with the initial 1000kN pipe anchor loads (gravity + bellows thrust) exceeding the limits that could be supported by the existing concrete building core. A detailed analysis of pipe thermal effects, construction sequencing and design building movements enabled a reduction in the bellows displacement demands, while the constraints on anchor loads led to the exploration of ways to accommodate movements without generating thrust loads. Articulated bellows were found to be a viable solution with multiple benefits. The bellows were able to be repositioned out of the vertical...