"Our modular boardwalk system made it easy for Deicorp to solve the challenges they had while working on this residential development.
Our system made it possible to create safe and durable boardwalks catering to the unique contours of the site."
ENCAT was engaged to design, manufacture & construct a modular boardwalk system and viewing platform for major developer Deicorp for their residential project located in John Whiteway Drive in Gosford. This extensive project involved the full design, adaptation and construction of our unique modular boardwalk system together with an adjoining viewing platform that would enable residents and visitors to take in the sweeping views over Brisbane Waters.
- The boardwalk spans 140 metres in length and is 1200mm wide.
- It has steel balustrading on both sides to ensure maximum pedestrian safety at all times.
- At the southern end, we constructed a 6m x 2.4m viewing platform, giving residents a tranquil space to appreciate the natural surroundings.
- With 8 metres of elevation change across the site, the boardwalk was designed to closely follow the land’s natural contours, incorporating stepped sections to comply with AS2156 – the Australian Standard for Walking Tracks.
- Our team utilised a TOPCON robotic theodolite to carry out precise surveying, ensuring every gradient and riser met the standard requirements.
The client’s landscape architect had several unique specifications, which we addressed through multiple design iterations and practical modifications to align with both aesthetic and compliance needs.
Unlike traditional bespoke builds, our modular steel system (hot dip galvanised after fabrication) offered a more cost-effective and durable solution, while maintaining the flexibility required for the challenging terrain of the site.
Construction on-site was completed in just three weeks, and the project was finalised with a structural engineering certificate for the footings design and installation. The result was a high-quality, AS2156-compliant boardwalk that met all client expectations.
Deicorp was extremely satisfied with the finished product, both in function and finish.
New boardwalk for a residential development project
As you can see from the photos this was quite an extensive project due to the size of the site and the terrain. Two of the factors that the developer needed to consider were;
a) Safety of residents and visitors; they needed safe pathways for pedestrians to walk safely in all weather conditions, remain even and could be easily replaced if elements were were damaged.
b) Long term maintenance costs; any type of pathway that was to be installed had to provide relatively low maintenance costs over the lifetime of its installation. While some pathway materials can be very low cost to install initially, over a long period of time the monthly or annual repair costs can outweigh the use of it in the first place.
Deicorp decided to use our modular boardwalk system which has been used in other locations like Minnumurra Rainforest , Maloney’s Beach or The Tallawarra pathway.
For each of these locations our modular system can cater to changing gradients, different directions and the stainless steel construction means it can last for years, withstanding moisture and harsh winds.
Designing a modular boardwalk system
As mentioned earlier, the design process for the boardwalk began with a detailed site survey using our TOPCON robotic theodolite, which allowed us to accurately map the terrain and identify elevation changes across the 140-metre alignment.
From there, our engineering team developed the modular layout that followed the natural contours of the land, minimising environmental impact and earthworks. Working closely with the client’s landscape architect, we proposed several design options to address aesthetic preferences, access requirements, and structural considerations.
Once a preferred concept was selected, we refined the design to incorporate stair sections and landing points in accordance with AS2156, ensuring safe and accessible transitions across the 8-metre elevation change.
Each module was engineered for strength, durability, and ease of installation, with detailed footing designs tailored to site conditions. All elements were fabricated off-site from steel and hot dip galvanised, streamlining the on-site installation process and reducing disruption to the surrounding area.
For any architect, civil engineer or civil works contractor that is tendering for projects like this it makes sense to consider the use of a modular boardwalk system made out of stainless steel instead of a traditional methods like installing a concrete footpath.
Some of the reasons include’
Durability and Longevity:
Galvanised steel is known for its exceptional durability and resistance to corrosion. This makes it an ideal material for outdoor applications, particularly in areas with high moisture, saltwater, or harsh weather conditions. Unlike concrete or timber, which can crack or deteriorate over time, a stainless steel boardwalk will maintain its structural integrity and aesthetic appeal for many years, reducing the need for frequent repairs or replacement.
Low Maintenance:
Galvanised steel requires minimal maintenance compared to concrete. It does not require sealing or coating to protect against corrosion. Routine cleaning and occasional inspections are typically sufficient to keep a galvanised steel boardwalk in good condition. This translates to lower ongoing maintenance costs and less disruption to the surrounding environment.
Aesthetics and Design Flexibility:
Our galvanised steel boardwalk systems offer a sleek, modern, and visually appealing appearance for any existing or new site. The smooth surface of galvanised steel can enhance the surrounding environment, creating an attractive and inviting pedestrian pathway.
Additionally, galvanised steel is highly versatile in terms of design options. It can be customised to accommodate various widths, curves, and gradients to fit the specific requirements and topography of the site, we can also add our balustrade systems to increase safety levels even further.
Our modular system can be connected to stair modules, viewing platforms and even a bridge so that nearly any type of terrain can be traversed easily.
Environmental Considerations:
Galvanised steel is an environmentally friendly material choice. It is fully recyclable, which aligns with sustainable construction practices and reduces the environmental impact of the project. Additionally, the modular nature of a galvanised steel boardwalk allows for easy disassembly and reinstallation, making it a viable option for sensitive or ecologically significant areas where minimal disruption is desired.
Installation Efficiency:
Compared to concrete footpaths or timber decking, the installation of a modular stainless steel boardwalk system can be quicker and more efficient. Prefabricated components can be manufactured off-site, allowing for faster assembly and reduced on-site construction time. This can result in cost savings and minimised disturbance to the local community during the construction phase.
Accessibility and Safety:
Our modular boardwalks are designed to meet accessibility standards, ensuring safe and convenient access for pedestrians, including those with mobility challenges. The smooth surface of galvanised steel reduces the risk of slips and falls, especially in wet or icy conditions, making it a safer option for pedestrians.
Unique design elements of our modular boardwalk system
Stainless steel structural material
It may have been possible to use timber or other materials to construct this staircase but using galvanised steel will ensure it has a long lifespan beyond 100 years.
Galvanised steel will withstand the elements which for this site is a mixture of ground moisture from run off as well as some flooding in the marsh/swamp areas close to the ponds.
100% custom designed for the existing conditions
Rather than using pre-fabricated systems our Modular Boardwalk System is 100% custom designed to suit the specific existing conditions of the site. It means there is relatively little change to the landscape & the new structure fits the site rather than the other way around.
Our system helps to protect the environment while also being easy to install on site and in this example it had to be made to sit low to the ground.
Modular construction
Our system is manufactured in our factory in NSW and then transported to the site ready to be installed. The precision engineering and metal fabrication means that everything is ready to be installed on the site without making further changes or adjusment.
This reduces installation time, labour costs & maximises efficiency but also means it can be used nearly anywhere.
Expandable boardwalk design
This project was focussed on building the new pathways. In the future if the developer built another site nearby the two systems could be connected.
New raised boardwalks can be constructed to follow existing tracks, change direction or gradients to suit the location.
Modular boardwalk to span waterways
We can design or adapt our Modular Boardwalk System to be used as a bridge to span creeks, small rivers or other water courses.
Outdoor boardwalk installations for high density living sites
ENCAT regularly works with civil works contractors, local or state government departments or national parks services to design, manufacture and install civil use structures to suit any type of application or existing site. We have been doing this since 1989
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