Western Sydney Airport Terminal and Speciality Services package (Aprons Subcontract)
About the project
BMD was responsible for the full design, supply, installation, and certification of the apron infrastructure spanning the interface between the terminal building and the taxiway, with Beca providing engineering design services. This included coordination with multiple contractors across the broader precinct and the delivery of complex works for a highly regulated airside environment.
The scope comprised the construction of a 1,150 metre long by 120 metre wide concrete apron pavement, providing aircraft parking positions for refuelling, loading and unloading. The apron seamlessly integrates with the terminal and runway systems, with key features including high-specification concrete pavements, stormwater infrastructure, airfield lighting, utilities containment and precision line marking.
Project scope
Construction of over 145,000 m² of concrete pavement and 149,000 m² of sealed pavement, using materials produced on site
Installation of 25,000 m³ of structural fill, 30,000 m³ of cement-treated base and 60,000 m³ of concrete via on-site batching and pugmill
63 kilometres of sawcut and sealed joints, 76,000 dowels and 530 tonnes of steel reinforcement for long-term durability
2.5 kilometres of reinforced concrete drainage pipes as well as stormwater pits and oil interceptor tanks
Full pavement subsoil drainage network with integrated flame trap pits
30 kilometres of underground conduits for electrical and communication services
Fire and potable water mains
Over 9,000 metres of concrete backfilled trenches and 230 utility pits
Installation of high mast floodlights and apron line marking
Design, fit-out and certification of apron infrastructure and furniture
Integration of apron systems with surrounding terminal and taxiway interfaces
Outcomes
Delivered a durable, fit-for-purpose apron pavement using reduced materials, recycled water, and a low embodied carbon concrete mix developed in collaboration with design partner Beca and supplier Holcim. The mix contributed to the overall WSI project target sustainability objectives whilst meeting technical requirements for the concrete pavement.
Achieved a 5 Star Green Star (Best Practice) rating under Design and As Built v1.3: 4 Stars, and a minimum of 65 points for an "Excellent" rating under the Infrastructure Sustainability Council’s IS v1.2 framework
Partnered with a specialist airport design consultant, applied proven methodologies and established on site production facilities to manage technical complexities and ensure compliance.
Developed and implemented an innovative concrete post-paver reinforcement placement method – used by BMD for the first time – significantly improving safety, cost efficiency, production speed, and quality by enabling continuous paver use and reducing manual handling.
Industry awards
CCF NSW Earth Awards finalist 2025, project value category $75 million to $150 million
Engineers Australia Excellence Awards 2025, Project of the Year finalist 2025