Sydney International Airport T1 – Sydney Airport & Qantas

Outcomes

The Client

About the Client

Sydney Airport is Australia’s busiest international gateway, facilitating millions of passengers annually and operating highly complex infrastructure systems that support aviation security, baggage handling, and passenger comfort. Qantas, Australia’s flagship airline, operates premium lounge facilities within Terminal 1, requiring high-performance environments aligned with international standards.

Project Significance

The project was delivered within the Departures zone of Terminal 1, a live and operational environment with no tolerance for service disruption. Delivered in partnership with SHAPE Australia, the works formed part of the broader “Project Sunrise” development, requiring precise coordination to maintain operational continuity while enabling major structural and architectural upgrades.

What we achieved with our Customer

The project encompassed four distinct operational zones across Sydney International Airport Terminal 1, including the Qantas Lounge, critical riser infrastructure, Mezzanine tenancy, and Gate 10 departures level.

SYD Tenancy (Warm Shell)

• Delivery of a new warm shell tenancy on the Mezzanine level within Sydney International Airport Terminal 1.
• Installation of a dedicated new Air Handling Unit (AHU) system to support future tenant operational requirements and occupant comfort standards. Provision of core mechanical infrastructure to create a flexible foundation for future fit-out works.
• Coordinated installation activities within a live airport environment while maintaining compliance with strict airport operational and safety protocols. Careful integration of the AHU system within a constrained mezzanine environment to align with broader Terminal 1 development objectives.
• Executed works with minimal disruption to surrounding airport operations and adjacent construction activities.

Critical Riser Relocation

AE Smith undertook the relocation of large-diameter chilled water and heating hot water risers that service critical airport infrastructure, including baggage handling systems and security screening equipment. This enabled the successful relocation of mission-critical services with zero disruption to airport operations, passenger comfort, or security systems.

• Key isolation points were established to minimise downtime and maintain system functionality throughout the transition.
• Surgical Riser Relocation: Moving large-diameter main risers in a live environment required meticulous planning. We engineered a staged switchover methodology, ensuring the airport’s “lifeblood” services were maintained during peak operational hours.

Gate 10 Departures Level

At Gate 10, the project required close coordination between mechanical and structural trades to facilitate significant architectural and steelwork upgrades.

• Existing ductwork and grilles were strategically removed to allow for the installation of new structural slabs and steel beams within tightly controlled construction windows.
• AE Smith conducted detailed re-measurement and coordination activities to ensure the precise reinstallation of mechanical systems within the revised building geometry.
• Agile Re-Engineering: Following the installation of new steel beams at Gate 10, our team performed a comprehensive re-measurement and coordination exercise. This ensured that the new ductwork and grilles were perfectly integrated into the modified structural layout.

Qantas Lounge (Cold Shell)

Within the Qantas Lounge zone, AE Smith transitioned the tenancy to a cold shell environment while simultaneously upgrading critical life-safety infrastructure.

• All works were completed within restricted after-hours access windows and in accordance with stringent aviation compliance standards.
• Across all project zones, the coordinated delivery methodology established a high-quality, compliant foundation for future fit-out and operational development.
• Life Safety Integration: In the Qantas Lounge zone, the team transitioned the space to a cold shell while simultaneously upgrading the essential smoke exhaust systems and MSSB, ensuring the site remained compliant with strict aviation fire-safety protocols throughout construction.