The team from BVN Architecture and Jasmax consulted with Architectural Metalformers to create the architects’ vision of a conical, volcano-shaped roof. Looking directly over the viaduct itself, the Smart Tray Custom feature roof was a challenge to conventional tray roof design and installation.

To achieve the free-flowing lines associated with a natural volcanic shape, the designers opted for faceted roofing sheets for the corners, as well as for the concave and convex surfaces of the kidney-shaped northern aspect. This gives the illusion of soft curved corners. The company’s initial concerns about working on a 60° roof pitch proved accurate and extreme care had to be taken while working on these tricky surfaces.

Initially the team from Architectural Metalformers had planned to work from CAD drawings but minor “as built” variations resulted in the team resorting to tape measures, string lines and a notepad. Good old trigonometry functions were essential to come up with a quick, efficient and accurate system for transferring the details back to the factory for production into the Smart Tray sheets, each with its own unique sequenced number relating back to its exact spot on the roof.

The result is a dramatic unique roof that adds extra interest to the already vibrant Auckland waterfront, and now is a landmark in its own right.