The new Western Sydney International Airport is a state-of-the-art piece of infrastructure currently in the final stages of construction, and due to open in late 2026. Designed to maximise the passenger experience, the airport will offer incredible views through the floor-to-ceiling windows and skylights and natural ventilation.

To achieve this, careful planning and construction of the roof was critical for achieving high level acoustic compliance. Knauf Insulation products were selected as they have demonstrated acoustic, thermal and fire safety performance requirements. Knauf Insulation was also able to deliver prompt samples for testing, flexibility in product delivery, and proactive technical advice and support.

What was the challenge?

The Western Sydney International Airport design has been labelled a ‘once-in-a-generation project’ due to its unique structure. The design incorporates floor-to-ceiling windows, displaying the stunning Blue Mountains backdrop and offering an abundance of natural lighting. The terminal design additionally features a single-ridge metal roof in an aerofoil profile reminiscent of an aircraft wing. As a result, roofing insulation that passed stringent testing was required in order to achieve acoustic and thermal performance for the project’s entire envelope.

Non-combustibility and high thermal performance were also key criteria to ensure safety and maximum comfort for the 10 million passengers expected to pass through the airport each year once in operation.

What was the solution?

The project’s principal contractor, Multiplex, selected roofing specialists Red 8 Roofing to complete the roofing scope of works for the terminal building. After a rigorous selection process, Knauf Insulation was selected by Red 8 Roofing to supply glasswool insulation solutions. Red 8 Roofing’s Project Manager, Hunter Key, explained that not only did the range of specialised products meet compliance, but Knauf Insulation made the entire process simple, from compliance testing to logistics.

Knauf glasswool insulation

Due to its unique and modern design, the terminal and piers (east and west) required an acoustic rating of Rw55. Knauf Insulation produced a custom roll product based on the existing roofing blanket, which was specified following acoustic absorption testing that showed excellent acoustic performance. Given the insulation is visible on the semi-exposed soffit, a Black Glass Veil (BGV) facing was added for aesthetics.

To ensure compliance, a high-density, multi-layered system was implemented on the roof, incorporating a combination of 11kg/m³ and 35kg/m³ rolls. Additionally, a 14kg/m³ soffit batt was applied to the internal roof lining, enhancing both the thermal and acoustic performance of the entire roofing system.

Knauf Insulation products are tested to be non-combustible in accordance with AS 1530.1. Due to the semi-exposed soffit design and the implementation of BGV, additional fire testing was undertaken to ensure compliance.

Knauf glasswool insulation

Knauf Insulation’s glasswool roofing insulation is produced with ECOSE® technology, a plant-based binder, with no added formaldehyde, acrylics, dyes or colours. ECOSE® technology also allows the insulation to be compressed at a higher rate, meaning more product per package and minimised logistics requirements without compromising performance.

Learn how we worked with Red 8 Roofing and Rooflogic to meet the strict acoustic, thermal and fire performance required for the new Western Sydney International Airport.

Why Knauf Insulation?

Knauf Insulation’s products exceeded requirements across the project’s key performance criteria – thermal, acoustic, and fire safety performance. As a result, the airport is able to deliver a safe, comfortable passenger experience complete with stunning views and plenty of natural lighting.

With construction of the project taking place in stages, product availability was another key consideration in the decision-making process. Knauf Insulation’s ability to fast-track manufacturing of custom products and meet last-minute scheduling changes made it a reliable choice. Compression packaging additionally cut down on logistics and warehousing requirements and simplified installation.

Sustainability was another important aspect that had to be considered throughout the project. Through the inclusion of ECOSE® technology, Knauf Insulation’s glasswool products are Declare Red List free – meaning they are free from any raw materials found on the Red List. All products are also GreenTag Level A Certified and made from up to 80% Australian recycled glass – attributes that allowed Red 8 Roofing to meet environmental sustainability reporting requirements.

Architecture & Design Team

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Knauf Insulation

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