Gold Coast Airport Topped with an Abundance of Plywood

The expansion of the Gold Coast Airport terminal represents a significant infrastructure upgrade, doubling the building’s footprint to accommodate growing passenger demand across the Gold Coast and Northern NSW regions.

With more than 30,000 square metres of additional floor area, including a new departure lounge, aerobridges, baggage handling facilities and border control areas, the project demanded materials capable of delivering durability, acoustic performance and construction efficiency at scale.

STRUCTAply Square Edge was specified as a key roofing substrate solution, supporting both performance and program delivery.

The Design Challenge

Constructing a three-level airport terminal presented multiple constraints:

• Tight construction timelines
• Large uninterrupted roof spans
• Acoustic performance requirements
• Safety and exclusion zone management
• Global supply chain pressures

The roofing system required a robust, stable plywood solution capable of supporting acoustic treatments while enabling safe and efficient installation processes.

The Porta Solution

A double layer of STRUCTAply Square Edge, totalling 25mm and installed across approximately 21,000 square metres, was used over the entire roof area to meet acoustic performance requirements.

This build-up allowed roof works to progress safely, creating a stable working platform and reducing the need for extensive scissor lift and exclusion zones. Once installed, roofing sheets were fixed directly over the plywood substrate, improving workflow efficiency.

STRUCTAply Square Edge delivered:

• Structural strength and durability
• Dimensional stability across large roof areas
• Acoustic support performance
• Improved on-site safety and access
• Installation efficiency on a major Tier 1 project

The method proved so effective it has since been adopted on additional large-scale projects.

Sustainability, Australian Manufacturing & Supply Reliability

STRUCTAply Square Edge is manufactured at Porta using sustainably grown Australian plantation pine.

Building during a global pandemic added significant logistical pressure to the project. Like many construction materials at the time, plywood was in short supply globally. However, because STRUCTAply Square Edge is locally manufactured in Australia, product could be delivered directly to site in large volumes, including 13 semi-trailer loads, ensuring continuity of construction.

This reliable domestic supply chain reduced delays and provided confidence to the project team during a period of global disruption.

By sourcing plantation-grown pine and manufacturing locally, Porta supports responsible forestry practices, regional employment and dependable product availability for major infrastructure projects.

Plantation-grown timber is a renewable building material that stores carbon for the life of the structure when used in long-term applications, contributing to reduced embodied carbon outcomes.

The Outcome

The completed terminal expansion strengthens the Gold Coast’s position as a major gateway for domestic and international travel.

The result is:

• A high-performance roofing substrate across 21,000m²
• Improved acoustic outcomes
• Enhanced construction safety and workflow efficiency
• Sustainably grown Australian plantation pine
• Manufactured in Australia at Porta

This project demonstrates how STRUCTAply Square Edge performs at infrastructure scale, delivering reliability, efficiency and structural integrity for Australia’s most demanding builds.