SYDNEY GATEWAY STAGE 1 & 3

Sydney Gateway Stage 1 & 3

Client: John Holland Seymour Whyte (JHSW)
Scope: CCTV Inspection & Reporting, Drain Relining, Robotic Cutting
Location: Mascot, NSW
Completion: 2023–2024

Scope:

Stage 1: International Terminal and Qantas Drive Connection and Stage 3: Direct connection to Sydney Airport from WestConnex

  • Drain cleaning and repairs
  • UV Lining
  • Sectional Repairs
  • On a TfNSW Site
  • Drainage pipe inspections and photography/videography for dilapidation survey
  • Confined Space Entry
  • Waste disposal
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PROJECT OVERVIEW

The Sydney Gateway Project is a critical infrastructure upgrade designed to improve connections to Sydney Airport, Port Botany, and the surrounding road network. DrainTech Solutions was engaged by John Holland Seymour Whyte to undertake specialised pipeline rehabilitation works during Stage 1 and Stage 3 of the project. Our scope included CCTV inspection and reporting, drain relining, and robotic cutting across multiple drainage assets within complex urban and operational environments.

OBJECTIVES

Our primary objectives were to:

  1. Assess asset condition through NATA-accredited CCTV inspections and WinCan/WSA-compliant reporting.
  2. Rehabilitate damaged pipelines using high-quality structural relining solutions with a 100-year design life.
  3. Remove obstructions such as concrete, debris, and intrusions using advanced robotic cutting systems to restore asset capacity and performance.
  4. Ensure minimal disruption to critical transport and airport operations by executing works in accordance with tight traffic and tidal windows.
METHODOLOGY

Stage 1 – Qantas Drive Drainage Works

  • Conducted CCTV condition assessments to confirm defect locations and scope.
  • Installed multiple sectional repairs to cracked and damaged pipes, using Saertex UV-cured liners for rapid installation and minimal downtime.
  • Employed roto-cutters for precision removal of intrusions and obstructions prior to lining.
  • Coordinated night shift works to align with traffic control and airport operational requirements, ensuring minimal impact on stakeholders.

Stage 3 – Stormwater and Tidal Area Works

  • Undertook confined space entry (CSE) works with BA rescue and airline systems in tidal-influenced pits.
  • Deployed Jet-Vac recycler units for high-efficiency cleaning prior to inspection and relining.
  • Managed H₂S gas hazards with continuous atmospheric monitoring, implementing strict safety hold points when gas levels exceeded safe thresholds.
  • Coordinated with JHSW to align work with low tide windows, optimising access and safety.
CHALLENGES & SOLUTIONS

Challenge

Solution

Tidal influences limiting work time in pits

Programmed works around precise tide charts, commencing operations 2 hours before low tide.

Hazardous gas levels (H₂S peaks exceeding 50ppm)

Implemented continuous gas monitoring, staged ventilation, and enforced immediate evacuation protocols until safe re-entry.

Complex urban worksite with traffic and airport access constraints

Conducted works predominantly on night shifts and coordinated with traffic control setups to avoid operational disruption.

Presence of obstructions such as sandbags deep within pipelines

Used confined space entry with rescue standby and Jet-Vac units to safely remove blockages.

 

OUTCOMES & KEY STATISTICS

Outcomes

  • Completed comprehensive CCTV reporting in compliance with WSA 05 requirements.
  • Delivered structural rehabilitation of multiple stormwater assets using UV-cured liners, extending asset life by 100 years.
  • Successfully executed robotic cutting to restore full pipe capacity prior to relining.
  • Maintained zero lost-time injuries (LTIs) across the project duration.
  • Delivered works on time and within agreed budget, despite challenging environmental and operational conditions.

Key Statistics

  • Assets inspected: Over 3 km of drainage pipelines
  • Relining installed: Multiple repairs ranging from 825mm to 1500mm diameter
  • Robotic cutting: Completed on multiple lines for removal of hard obstructions
  • Shifts worked: Combination of day and night operations, with up to 8 consecutive night shifts during peak program delivery.
CONCLUSION

The Sydney Gateway Stage 1 & 3 works demonstrated DrainTech Solutions’ capability to deliver complex drainage rehabilitation in high-risk, time-critical environments. Through a combination of technical expertise, specialised equipment, and close collaboration with JHSW,                  we successfully delivered safe, compliant, and durable solutions that will support Sydney’s transport infrastructure for decades to come.