Greta 1 Water Pumping Station

Project Description

Client:  Wyndham Ridge Estate (Iris Capital)
Location:  Greta, NSW
Date: 2017

Greta 1 Water Pumping Station (WWPS) is a ‘pit style’ water pressure boosting pump station in Hunter Water’s area of operation, designed by GCA in conjunction with our broad service offering for the Wyndham Ridge Estate development.

Read more about GCA’s involvement with Wyndham Ridge Estate here.

The water pumping station design included three multi-stage KSB water pumps operating in a duty-assist-standby configuration and on variable speed drives. The use of three pumps enables only one pump to operate during low and typical flow conditions with a second pump assisting during very high demand periods. The third pump is present on standby in the rare occasion that one of the other pumps stops operating unexpectedly.

Key activities

  • Catchment modelling for a variety of scenarios to reflect significant expected changes in supply pressures to the pumping station over time due to developments elsewhere in the water network
  • Carefully considered pump selection and operational control to cover the wide range of flow and boosting requirements
  • Civil, hydraulic, and structural design for Hunter Water approval
  • Coordination of electrical switchboard design to Hunter Water standards
  • Preparation of engineering drawings, reports, cost estimates, and technical specification

Beresfield 22 Wastewater Pumping Station

Project Description

Client:  Hunter Land Holdings
Location:  Beresfield, NSW
Contractor:  Patroy Enterprises
Date: 2017 – 2018

Beresfield 22 Wastewater Pumping Station (WWPS) is a submersible-type wastewater pumping station in Hunter Water’s area of operation.

Key statistics include:

  • Concrete wet well of nominal diameter (DN)  2700mm
  • Approximately 530m of DN140mm Polyethylene (PE) sewer rising (pressure) main
  • Two 15kW submersible pumps operating on a variable speed drive

Variable speed drives were selected to control the pump motors, allowing Hunter Water to adjust the pump flow rate to reflect changes in catchment wastewater loading conditions over time. This approach ensures energy usage is no greater than necessary.

Key activities

  • Catchment analysis to determine initial stage and ultimate wastewater loadings
  • Hydraulic calculations for pump station pipework to ensure operational efficiency
  • Civil, hydraulic, and structural design for Hunter Water approval
  • Sewer rising (pressure) main design including water hammer computer simulation
  • Coordination of electrical switchboard design to Hunter Water standards
  • Preparation of engineering drawings, reports, cost estimates, and technical specification

Billy’s Lookout

Project Description

Client:  McCloy Group
Location:  Teralba (Lake Macquarie), NSW
Date: 2011 – 2018

The Billy’s Lookout development is uniquely located at high elevations at the northern end of Lake Macquarie. The site area is approximately 70 hectares with an ultimate development yield of 485 residential lots.

GCA's Involvement

  • Preparation of a revised stormwater management strategy including flow and water quality modelling
  • Water and sewer servicing strategies including water network pressure modelling, for Hunter Water approval
  • Civil engineering design of roads, stormwater drainage, and ancillary infrastructure
  • Split level (“grade separated”) entry road design to better reflect natural slope on the land whilst also creating the opportunity for entry landscaping features
  • Major stormwater culvert crossing design
  • Stormwater quality treatment and detention basin design
  • Water supply and gravity sewerage design (Hunter Water Major Works)
  • Water and sewerage rail line crossing design

Freeway Business Parks

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Project Description

Client:  Hunter Land (www.hunterland.com.au)
Location:  Off Weakleys Drive, Beresfield
Date: 1999 – Current

Freeway Business Park is one of the premier business parks in the Newcastle / Hunter Region. It is located at the start of the M1 Motorway at Beresfield with strategic road transport linkages heading toward Sydney, Newcastle, the Hunter Valley, and the North Coast of NSW. It has strong industry clusters in Transport, Engineering and Construction Services. The site is formed by the Central, South and North precincts.

GCA’s involvement in this major development stretches back to our company inception. During GCA’s project tenure the Northern and Southern Precincts successfully passed through various development phases including land use rezoning, Development Approval from the NSW State Government as a “State Significant Development”, and public infrastructure Construction Approvals (roads, drainage, and utilities) for each development stage.

Our building design, civil engineering and structural engineering design teams have also been involved in most of the building developments on each lot within the Southern and Northern Precincts.

A key element in the success of this project was the ability of GCA to develop a stormwater strategy that did not involve the need for stormwater detention facilities, thus maximising the development yield.

GCA's Involvement

Over the many years that GCA has been involved with this project we have provided a wide range of services including:

  • Preparation of development layouts and marketing plans
  • Engineering consultancy and advisory to assist with obtaining government and authority approvals
  • Stormwater Management Strategies including stormwater modelling (flow rates and water quality).
  • Civil engineering design of roads, stormwater drainage, and ancillary infrastructure.
  • Design of road widening / lane duplication for 1km segment of Weakleys Drive for the frontage of the Northern Precinct including dual-lane roundabout to create site access via Canavan Drive and secondary site access via Bowden Way. The works were subject to approval from the NSW Roads and Maritime Services (NSW RMS).
  • Design of lead-in road (Yangan Drive) to the Southern Precinct including coordinating with a bridge constructor.
  • Investigation and documentation of a water supply servicing strategy for the northern precinct including water network modelling.
  • Design of local water and sewerage utility services including Hunter Water approvals.
  • Design of wastewater pumping station and pumped sewer main including Hunter Water approval.
  • Ongoing design of many buildings on lots within the estates (building design, civil engineering, structural engineering).

Regional Trunk Watermain Relocations, Boolaroo

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Project Description

Client:  Pasminco Cockle Creek Smelter Pty Ltd
Authority:  Hunter Water Corporation
Contractor:  Patroy Enterprises
Location:  Main Road, Boolaroo (Lake Macquarie), NSW
Date: 2012
Value: $1M

Through 2011 – 2013 a new intersection was designed and constructed at the intersection of TC Frith Avenue and Main Road, Boolaroo.

The intersection and ancillary roadworks impacted several major utility services including three regionally significant trunk watermains. Two of the mains service the western side of Hunter Water’s operation area and form part of the backup water service plan for the Central Coast.

The watermains were relocated and replaced in the vicinity of the roadworks to ensure ongoing successful operation to Hunter Water’s water supply network.

GCA's Involvement

GCA were responsible for investigations, concept and detailed engineering designs and specifications for replacement / relocation of:

  • A total of 180m of 500mm Cast Iron watermains (original construction around year 1956)
  • 170m of 300mm Cast Iron watermain (originally constructed in year 1933)

Throughout the design process we focused keenly on anticipating the construction method and developing design details and specifications that would result in minimal shutdowns for the existing watermains.

The shutdown time and risk to Hunter Water’s supply base was ultimately minimised through development of:

  • Specialised connection details
  • Early works components that could be completed initially and left in-place for concrete to cure without additional forces whilst the watermains remained in service
  • A variety of materials (Polyethylene, Mild Steel, Ductile Iron) with consideration to the high operating pressures and with consideration to the individual construction considerations in each part of the project site
  • Specifying special pipe trench details and structural protection measures where warranted.

Our relationship with Hunter Water staff was also key to the success of the project. Through this we were able to meet with Hunter Water to discuss network operation issues and the anticipated network shutdown procedure and issues that would need to be addressed.

The project was successfully constructed without any impacts on Hunter Water’s customer base.

Williamtown Wastewater Transfer Scheme

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Project Description

Client:  Hunter Land, on behalf of Hunter Water Corporation & Various Stakeholders
Principal Contractor:  Bolte Civil
Location:  Williamtown, Tomago, Raymond Terrace (NSW)
Date: 2010 – 2014
Value: $20M

GCA were engaged as specialist project managers, responsible for delivery of the investigation, design, and construction of the Williamtown Wastewater Transfer Scheme (WWTS). Key stakeholders included Hunter Water Corporation, Hunter Land (property developer), and Newcastle Airport Limited.

The Williamtown WWTS comprised a new regionally significant municipal sewerage transfer scheme that will receive sewage from existing and future major developments and pump it through to Hunter Water’s Wastewater Treatment Works at Raymond Terrace.

The scheme involved:

  • Two new regional wastewater pumping stations with cast-on site pump wells and supplementary concrete storage structures.
  • 4km of new trunk sewerage pipelines in a variety of materials and installation conditions.
  • Over 40 pipeline valves, drainage structures, and air release structures.
  • Major pipeline crossings including under roads controlled by the NSW Roads and Maritime Services and under environmentally sensitive areas.
  • Extensive Dewatering and Acid Groundwater Management and Treatment
  • Extensive Acid Sulphate Soil Management and treatment
  • Extensive Community and Key Stakeholder Management Consultation

The scheme will initially support the Newcastle Airport, Williamtown RAAF Base extension, Williamtown Aerospace Centre, and the Northbank Enterprise Hub at Tomago, incorporating the Westrac facility. The system was designed and constructed with the vision to support major regional growth in the Williamtown and Tomago areas for many years to come.

GCA's Involvement

As project managers, GCA’s core role was to procure all project elements with the key aim of delivering value for money for all stakeholders. We worked very closely with Hunter Water representatives to ensure

Our key tasks included:

  • Preparation of the brief for design consultants
  • Assessment of consultant tenders
  • Engagement of the design consultant
  • Management of the route options assessment, concept design and detail design
  • Liaison with Hunter Water Corporation’s operations, environment, asset management and property sections
  • Agency and stakeholder consultation including :
    NSW Office of Water
    NSW Department of Environment and Climate Change
    NSW National Parks
    NSW Roads and Traffic Authority Energy Australia
  • Preparation of construction tender and contract documentation
  • Assessment of construction tenders
  • Engagement of the successful Contractor
  • Contract management (Superintendency) throughout Construction phase
  • Resolving requests for information and resolving site issues during construction particularly in very challenging parts of the project site
  • Attaining final completion certificate from Hunter Water Corporation
  • Ongoing management of budget, timeline, and quality throughout the project
  • Ongoing regular status reporting to Hunter Water Corporation

Wyndham Ridge Estate

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Project Description

Client:  Wyndham Ridge Estate Pty Ltd (Iris Capital)
Principal Contractor:  KCE Pty Ltd
Location:  Greta, NSW
Date: 2014 – current

Wyndham Ridge Estate is a boutique 350-lot development positioned at the edge of the township of Greta, close to the new township of Huntlee, near to the Hunter Valley Vineyards and approximately 30 mins to Newcastle on the Hunter Expressway.

Key to obtaining Client satisfaction on this project was GCA’s ability to complete the designs and obtain approvals for the first two stages of the development (including major lead-in roads and services) within an incredibly compressed timeframe of only 14 weeks from initial engagement to being construction-ready.

GCA's Involvement

GCA’s tasks on this project included:

  • Involvement in early work on stormwater and flooding for the rezoning phase for the site.
  • Civil engineering design for an early “bulk earthworks” package for the entire development site.
  • Civil engineering design of roads, stormwater drainage, and ancillary infrastructure for all stages of the development.
  • Civil and structural engineering design for lot benching and retaining walls
  • Civil engineering design for upgrades to existing local roads and augmenting an existing intersection on the New England Highway (a NSW RMS controlled road).
  • Detailed water network modelling.
  • Design of duplicate lead-in watermains and a gravity sewer pipeline including special details for attaching the pipes on the side of two new road bridges
  • Design for a new water booster pumping station (Hunter Water approval)
  • Design of a new sewage pumping station (Hunter Water approval)
  • Design, inspection and certification of local water and sewerage reticulation under Hunter Water’s new Developer Works infrastructure delivery process.