Like NEXTDC’s Sydney SY5 data centre, M3 provides secure, high-performance colocation services supported by extensive power, cooling and connectivity infrastructure. The multi-stage development is designed to support the growing demand for reliable and resilient digital infrastructure.

Project Details
Client: NEXTDC
Builder: Kapitol Group
Architect: HDR
Location: West Footscray, Melbourne
Capacity: 225 MW
Project Value: $1.5 Billion

Unison’s Ongoing Involvement

Unison Joints has supplied specialist expansion joint systems across Stages 1, 2 and 3, with work now continuing on Stages 4, 5 and 6.

To date, Unison has supplied 1,100 metres of specialist expansion joint systems, including:

• Waterproof expansion joint seals
• Fire-rated strips
• Extra-heavy-duty seismic cover plates
• Roof expansion joint seals
• Wall and façade seals

The scale and complexity of M3 require expansion joint systems capable of accommodating movement while maintaining critical fire protection, waterproofing and structural performance.

With three further stages currently underway, Unison is proud to continue supporting the development of one of Melbourne’s major data centre projects.

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For the 2026 Cranbourne Park car park project, Unison Joints manufactured and supplied 660 metres of waterproof expansion joint seals.

The waterproof seal supplied was Aquo P, a purpose-designed expansion joint water seal suitable for car parks, waterproof decks and other concrete structures where movement and water ingress need to be managed.

Why Waterproofing Expansion Joints Matters

Expansion joints allow sections of a concrete structure to accommodate movement caused by temperature changes, shrinkage, structural movement and other factors.

A failed or deteriorated joint can allow water to penetrate into the structure, potentially contributing to deterioration of surrounding concrete and reinforcement.

Aquo P is designed as a waterproof expansion joint seal, incorporating UV inhibitors and high movement capability. Its welding technology also allows the seal to be formed at junctions and upturns, helping create a continuous waterproofing solution.

With Cranbourne Park accommodating close to 1,700 vehicles and serving millions of visitors each year, maintaining the integrity of its car park infrastructure is an important part of ongoing facility management.

The project showcases the application of a purpose-designed waterproof expansion joint seal in a busy commercial environment, providing a solution engineered for movement while helping protect the underlying structure from water ingress.

The Cranbourne Park project is another example of the importance of selecting the right expansion joint system for demanding car park environments.

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Rather than simply supplying a standard product, our engineers assess the specific requirements of each project and recommend a system designed for the application.

Our engineers consider key factors including:

• Structural and seismic movement
• Fire-rating requirements
• Waterproofing
• Traffic and loading
• DDA accessibility and slip resistance
• Floor, wall and ceiling applications
• Architectural requirements

Having our engineers in-house means faster decisions, direct technical support and greater control — without relying on external engineering consultants or third-party manufacturers.

With engineering and manufacturing under one roof, we can develop practical, buildable solutions for complex applications.

Our team has designed systems and supported major projects across hospitals, airports, stadiums, shopping centres, carparks and transport infrastructure, delivering specialist expansion joint systems for demanding environments.

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Unison Joints expansion joints are engineered to protect car park structures by accommodating movement, absorbing stresses, and maintaining surface integrity.

Why Car Parks Need Premium Expansion Joints

Car parks differ from standard floor surfaces because they experience:

✔ Heavy wheel loads from cars, trucks, and service vehicles
✔ High-frequency traffic in all directions
✔ Exposure to rain, UV, oil, and chemicals
✔ Large surface areas with temperature variances

These conditions demand joints that don’t just fill gaps—but actively protect the structure. Built to absorb movement and resist load transfer, these joints provide: Excellent weather resistance for outdoor car parks Superior flexibility for temperature and structural movement High load capacity for vehicles and occasional heavy equipment Custom sizing for exact application Easy installation Seamless integration with concrete surfaces Optional sealants and profiles help Prevent Leaking to lower decks

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Expansion joint systems are designed to accommodate movement.
Yet, failures still occur — and more often than not, the issue isn’t the product itself.

Understanding why expansion joints fail is critical for architects, engineers, and contractors who want long-term performance and compliance.

Movement Is Underestimated

Buildings are constantly moving — expanding, contracting, creeping, settling, and swaying. When an expansion joint system is not designed to handle actual site movement:

• Seals can tear
• Cover plates may buckle
• Concrete edges can crack

Accurate movement calculation is essential to avoid premature failure.

Waterproofing Is Not Properly Integrated

Water ingress is one of the most common causes of building damage. If waterproofing membranes and expansion joints are not coordinated:

• Leaks develop
• Corrosion begins
• Internal finishes deteriorate

A fully integrated waterproofing and joint system is essential for long-term durability.

Fire Rating Is Inadequate

Expansion joints create openings in fire-rated structures. If the fire-rated joint system:

• Does not match the slab’s fire rating, or
• Cannot accommodate full movement under fire conditions

…it compromises both compliance and safety.

The Wrong System Is Specified

Not all expansion joint systems are interchangeable. Different environments require different solutions:

• Car parks demand heavy-duty, trafficable systems
• Hospitals require hygienic, antimicrobial seals
• Podium decks need waterproof and UV-resistant systems
• Seismic joints must accommodate large, multidirectional movement

Specifying the wrong system leads to early failure

Poor Installation Practices

Even the best-designed expansion joint system will fail if installed incorrectly. Common installation issues include:

• Uneven joint gaps
• Over-tightened fixings
• Compressed or damaged fire barriers

Quality installation is just as important as design and product selection.

The Bottom Line

Expansion joints are critical building systems — not finishing details.

Successful performance depends on early coordination between:

• Structural design
• Waterproofing systems
• Fire compliance
• Architectural finishes

When treated as an afterthought, failures are inevitable. When prioritised early, expansion joint systems protect both the building — and your reputation — for decades.

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In 2025 – 2026 Australia saw a significant increase in demand for fire-rated expansion joint and barrier systems, with Unison Joints leading the way in supplying custom, site-specific solutions directly to projects nationwide.

This surge was driven by several key factors:

Hospital Upgrades and Healthcare Infrastructure Projects

Modern hospitals are complex, high-risk environments with strict fire safety requirements and critical infrastructure. Across Australia, many hospitals underwent redevelopment or expansion, creating strong demand for custom fire-rated and seismic joint systems.

Unison Joints delivered fully certified, Australian-made solutions, protecting both patients and assets while meeting stringent compliance standards.

Replacement of Inferior Imported Systems

Many older projects had imported expansion joint systems that failed to meet Australian standards or long-term performance expectations. These systems often caused:

• Leaks and water damage
• Fire compliance failures
• Premature wear and costly maintenance

Developers and architects increasingly turned to Unison Joints to replace underperforming imported products with engineered, certified, and durable Australian-made solutions — ensuring long-term reliability and safety.

Large-Scale Construction Activity

Major infrastructure projects across commercial, transport, and public sectors required robust expansion joint systems capable of handling complex building movements.

Unison Joints’ ability to manufacture and supply site-specific solutions directly allowed projects to meet tight deadlines and avoid performance issues associated with generic or imported products.

Stricter Fire Compliance Regulations

Tighter Australian fire and building codes in 2025 meant that cutting corners was no longer an option. Architects, engineers, and developers demanded certified, tested, and compliant expansion joint systems to ensure the safety of people, property, and assets

Increased Focus on Safety and Long-Term Performance

Building owners and consultants placed a premium on durability, compliance, and long-term reliability. By choosing Unison Joints, they secured custom-engineered expansion joint systems that deliver decades of performance without compromise.

The Bottom Line

The record demand for fire-rated expansion joints and barrier systems in 2025 was driven by:

• Hospital upgrades and healthcare infrastructure projects
• Replacement of underperforming imported systems
• Large-scale construction activity
• Stricter fire compliance regulations
• Increased focus on safety and long-term performance

By manufacturing and supplying directly for over 25 years Unison Joints provided precision-engineered, Australian-made fire and seismic solutions, backed by decades of in-house engineering expertise — delivering compliance, reliability, and peace of mind for every project.

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Partnering with JHG (John Holland Group) and Peddle Thorpe Architects, our team worked hand-in-hand to refine seismic coverplate systems for floors, internal walls, ceilings, and roofs. The goal was simple but critical: deliver expansion joint solutions that are seamless, fire-safe, water-resistant, and engineered to handle seismic movement.

Our collaborative approach meant every design decision was discussed, tested, and tailored to the hospital’s unique needs. Products supplied included:

• PyroTX I and PyroTX B seismic fireseals for maximum fire protection
• Unison Aquo H Hypalon glands and adhesives to secure water and movement sealing
• SiR seismic roof expansion joint covers, specifically designed for roof movement

Installation was executed flawlessly thanks to our trusted partners: Master Floors Group handled floor expansion joints, fireseals, and waterseals, while Wadsworth Contracting installed internal wall and ceiling systems.

This project wasn’t just about supplying products—it was about collaborating across disciplines to ensure the building performs safely, looks seamless, and meets the highest standards. At Unison, we see ourselves as part of the wider team, working together to solve challenges and create buildings that stand the test of time.

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The iconic Zayed Tennis Centre in Abu Dhabi is currently undergoing refurbishment, and we’re proud to be part of this important project. A key focus has been ensuring that all seating plates within the stadium are watertight and safe for pedestrian traffic—a critical factor for both the comfort and safety of visitors.

To achieve this, 900 linear metres of our Aquo-P expansion joint seal with Flextread topper have been installed vertically and horizontally by Repcrete UAE, the project’s expert installation contractors. This high-performance system provides a watertight barrier, a smooth, pedestrian-friendly surface, and slip-resistant protection thanks to the Flextread topper. Its flexibility allows the joints to accommodate structural movement while maintaining a long-lasting seal.

Working alongside Repcrete UAE, this project highlights our commitment to delivering reliable, innovative expansion joint solutions that keep stadiums and public spaces safe, durable, and ready for heavy use.

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1. Quality You Can Rely On: Australian manufacturing is held to some of the strictest standards in the world. Local production means tighter quality control, superior craftsmanship, and products that are built to perform and built to last.

2. Supporting Local Industry: Every purchase helps sustain Australian jobs, skills, and suppliers. By choosing local, you’re investing directly in the future of our communities and keeping specialist expertise right here at home.

3. Faster Lead Times & Reliable Supply: With manufacturing based in Australia, products can be delivered quickly and without the risks of overseas shipping delays. Local control also means greater flexibility when you need a custom or time-sensitive solution.

4. Designed for Australian Conditions No one understands the demands of our climate, regulations, and building standards better than local manufacturers. Products designed and tested in Australia are purpose-built for our environment.

5. Proven Compliance: Australian-made products are manufactured to meet national standards, codes, and regulations. This gives builders, architects, and certifiers peace of mind that projects will pass inspections and stand the test of time.

6. Accountability & Service: When you buy Australian-owned and made, you’re dealing directly with the manufacturer. That means responsive support, technical expertise, and a partner who stands behind every product.

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