The Belmont Desalination Plant is designed to provide a reliable, rainfall-independent water supply for the Lower Hunter region, producing up to 30 million litres per day. The project features extensive steel marine works, including the fabrication and installation of multiple steel structures such as intake and brine pipelines, platforms, and support frameworks.
The marine scope required careful coordination of structural, environmental, and logistical elements. Steel components were engineered to withstand harsh coastal conditions, including corrosion, tidal forces, and wave action. Fabrication followed strict quality controls, with protective coatings applied for durability in the marine environment. Installation involved both land- and marine-based methods, with key structures positioned offshore using specialised lifting and barge equipment. All works were carried out in compliance with environmental regulations and protection measures.
CaSE provided drafting and engineering for the temporary works design from tender through to detailed design for the offshore marine caissons and associated works. The scope included lifting and rigging arrangements, staging drawings, constructability reviews, TBM breakthrough assessments, stability analysis against wave loading, and the design of cutting shoes, guide rollers, and guide piles.
Additional deliverables covered subsea template and access platform design, wharf structural / geotechnical assessments, jacking systems, dredge control structures, dredgeability assessments, and lifting solutions for major components.
Delivery required meticulous planning, temporary works design, and interface management to safely coordinate heavy lifts, staged demolition, and the commissioning of new structures within live operational environments. The multidisciplinary scope encompassed offshore intake and brine pipelines, advanced reverse osmosis treatment systems, and associated infrastructure, ensuring a sustainable water supply for the community.
In parallel, works also involved upgrading the single-track rail line near Mascot into a double-track corridor to improve freight capacity into Port Botany. The 3 km upgrade traversed heavily constrained corridors, including major intersections, arterial roads, and Sydney Airport access routes.
Construction works included the removal and replacement of two existing bridges with longer-span, post-tensioned concrete bridges - each installed within critical weekend shutdowns to minimise disruption to road and rail operations.
Additionally, a third bridge over Southern Cross Drive was duplicated, requiring complex temporary truss falsework to support formwork and facilitate construction of the new post-tensioned structure. CaSE ensured all temporary works met structural, geotechnical, and marine environment requirements, supporting safe, efficient installation of the intake structure 1km offshore.
