Asset Renewal and Replacement Program
We have been engaged as a Construction Partner collaborating with WaterNSW to deliver services under their five-year Asset Renewal and Replacement Program (ARRP). The ARRP contract kicked off in 2021 with the works under the program varying in size and complexity across a large geographical footprint in NSW. The scope has included civil, structural, mechanical, and electrical minor capital works and rehabilitation.
The services we have been providing under the ARRP include:
- Concept design.
- Estimating.
- Detailed design.
- Early tender and contractor involvement.
- Annual Integrated Works Program.
- Construction.
- Maintenance and facilities management of all assets, including water and wastewater treatment plants, network pipelines, pump stations, reservoirs, and facilities such as data centres, offices, and depots.
Warragamba Radial Gate Control Measures
Warragamba Dam includes four radial gates and a central drum gate that are critical to flood operations and dam safety. We were engaged to deliver renewal works on the radial gates. The scope included replacing high park brake callipers, refurbishing associated hydraulic systems, upgrading the hydraulic power unit, and replacing gate drive motors and brakes. Electrical modifications were also implemented, including anti-condensation heater upgrades and the conversion of the battery backup system to a modern 24-volt configuration. The completed works have strengthened operational reliability and maintainability while enhancing overall dam safety performance.
Shoalhaven Control Gate Renewals
We were engaged to deliver renewal works on the Shoalhaven Control Gates. The Shoalhaven Scheme Stage One supplies water and supports pumped storage hydroelectric generation. The scheme uses fixed wheel gates operated by hydraulic hoists and closed by gravity. We renewed the control regulating gate and associated control systems and upgraded the high voltage power supply, including construction, commissioning, and testing. Now complete, the project enhances operational reliability, safety, and efficiency, ensuring the continued performance of the hydroelectric and water supply assets.
Warragamba Pipeline Corridor Restoration
We delivered civil construction and upgrades along the Warragamba Pipeline corridor to improve the stability of batters and embankments, as well as drainage and access roads for the remediation of ongoing risks and extension of the design life, ensuring the protection of Sydney’s water supply lines from Warragamba Dam to Prospect Reservoir.
Warragamba Deep Water Pump Station (DWPS) Flood Remediation Project
The Deep Water Pump Station transfers Sydney’s raw water from Warragamba Dam to Prospect Reservoir. Following major floods in 2021 and 2022, we reinstated the facility to its original condition. The scope included repairing and replacing damaged equipment with full testing and commissioning.
Balranald Weir WHS Upgrade
Our teams were engaged to replace a steel access platform and deliver associated civil works to improve flood resilience, access and safety.
Warragamba Pipeline Valves and Controls Upgrade Project
We completed the remaining works on the two pipelines from Warragamba Dam to Prospect Reservoir, varying in size from 3m to 2.1m in diameter. The scope included replacing or refurbishing 23 major valves, upgrading power and control systems, replacing access structures, installing CCTV at major cross connections, and delivering a reliable pressure monitoring and breakage detection system. The project required four key shutdowns, with critical planning and coordination to return the system safely to service. Delivered with WaterNSW and Sydney Water, the works improved reliability, safety and overall service performance.
Greater Sydney Road Renewals Project
WaterNSW has a large number of assets throughout NSW that require access via safe and well-maintained roads. Due to their poor condition, the access roads for Cordeaux Dam and Avon Dam require upgrades, and we have been engaged to design and construct the remediation for these sites in accordance with the WaterNSW Drawings, Technical Notes on Drawings, Sydney Catchment Authority Road Management Manual rev 10.7.5, RMS Design and Construction Specifications, Australian Standards, and the Austroads Manual.
Electrical Renewals at Gogeldrie Weir and Copeton Dam
We were awarded Electrical Renewals projects at Gogeldrie Weir and Copeton Dam. Works at Gogeldrie Weir have been completed, while delivery at Copeton Dam is currently underway. These upgrades are renewing critical electrical assets, reducing operational risk, improving return to service times, and enhancing technician safety while addressing workplace hazards.
Improved project delivery through a standardised approach
A standardised approach to all ARRP projects has been developed collaboratively with WaterNSW and other stakeholders. This approach addresses the challenges of integrating decades-old infrastructure and equipment while meeting operational requirements. Projects begin with an early contractor involvement phase focused on constructability, innovation opportunities, and value for money before progressing to design and construction. Workshops and working groups consider each site’s conditions and stakeholder requirements. A three-step process of identifying challenges and needs, defining methodology, and optimising delivery has refined the approach, minimised plant disruptions, reduced program schedules, and lowered construction costs.
Long term benefits
The works under the ARRP have been divided into two categories: Maintaining Capability and Regulatory Compliance. The Maintaining Capability works include Renewal and Replacement, Water Monitoring, and Catchment Protection programs, while the Regulatory Compliance works include Dam Safety, Weirs and Gates, and Fishway programs. These works aim to extend asset life, ensure compliance, improve WHS, and benefit water supply.
Mitigating program challenges through collaboration and open communication
With WaterNSW overseeing assets statewide, the ARRP’s geographical challenges have been effectively mitigated through a collaborative culture and open communication. Early contractor involvement has been key to ensuring project scope and outcomes are clearly defined and understood from the outset, significantly reducing construction risk. This approach not only streamlines project delivery but also ensures alignment among all stakeholders, promoting efficiency and successful outcomes.
Delivering innovation and value
As the program evolved, a culture developed where program partners are empowered to openly challenge and provide input for the best project outcomes. Early contractor involvement, including engagement with end users, stakeholders, operations, designers, and project teams, has helped improve project scoping from the outset. This approach has considered constructability and overall project cost, ultimately aiming to offer price certainty and ensure aligned outcomes by fostering a clear understanding of scopes, objectives, and construction costs.