Duratec recently completed the first stage of fuel infrastructure works for the new Western Sydney Airport. The successful delivery of this project is testament to the company’s capabilities in the energy sector.
Sydney’s new airport
Upon completion in late 2026, the Western Sydney International (Nancy-Bird Walton) Airport (WSA) will be a full-service airport catering for domestic and international passengers, as well as freight services. Multiplex is delivering the main terminal and apron, as well as facilities to accommodate up to 10 million passengers per year.
The construction giant is also undertaking design-and-construct services for all structures within the terminal precinct, including a plaza and connections to the Metro rail station, bus station, taxi ranks and car parks. Roads, footpaths and ancillary buildings are also incorporated in the scope.
Duratec delivers first stage of airport’s fuel infrastructure
In early 2022, Multiplex engaged Duratec to undertake the aviation fuel hydrant main package of the WSA construction project. Works began on site in April last year and have recently been completed following the successful supply, installation and pre-commissioning of the pipeline and associated infrastructure.
Located between the aviation fuel farm boundary and the terminal apron, the fuel hydrant main pipeline measures 10.2 kilometres in length and forms a single-line loop from the fuel farm pump station, reticulating around the runway and returning to the pump station.
Delivery of works
Following are the works delivered by Duratec:
- Approximately 80,000 cubic metres of detailed earthworks, i.e. trenching and backfill
- 10.2 kilometres of DN450 API 5L PSL2 welded pipework for the aviation fuel ring main
- 78 apron hydrant points
- 18 low-point drains
- 18 high-point vents
- 9 sub-surface concrete valve chambers with class-G multi-part gatic covers and motorised control valves
- Supporting electrical infrastructure, including around 60 kilometres of buried conduits, 64 class-G electrical pits and 120 kilometres of installed power, control and communications cabling
Highlights and innovations
In delivering WSA’s initial fuel infrastructure, Duratec demonstrated creative thinking and the application of innovative solutions to achieve positive outcomes. Highlights included:
Accelerated delivery program
The COVID-19 pandemic meant there were supply chain issues and procurement delays. Duratec implemented an accelerated delivery program to overcome the delays, which resulted in all stages of works meeting the required completion dates and ensuring the overall construction of the airport remained on track.
Phased array ultrasonic testing
The team used a phased array ultrasonic testing regime – an advanced, non-destructive inspection technique that provides increased flaw characterisation and high repeatability for ongoing monitoring during pipeline service. Other advantages of phased arrays include improved portability, convenience, inspection speed and safety.
Value-engineering
Thanks to its in-house technical division, Duratec was able to share its construction knowledge and expert engineering experience to support the client during detailed design phases, ensuring smooth delivery.
Duratec’s engagement for this prestigious project represents the company’s careful and strategic expansion into the energy sector. By leveraging the skills, experience and capabilities developed from works undertaken on various Defence fuel transformation projects, Duratec is committed to delivering infrastructure that is fit-for-purpose and meets industry operational standards.
