A New Era of Connectivity and Economic Growth

With construction of the new airport almost complete, the Australian Government will see the country’s most significant aviation project in over 50 years enter the final testing and operational readiness phase later this year. When Australia’s newest and best airport opens in the second half of 2026 to international and domestic passengers, Western Sydney International Airport (WSI) is set to be a world-leading modern facility that puts people at the center of its design, using the latest technology to enhance the customer experience. Capable of accommodating up to 10 million passengers annually when it opens, WSI has been designed with the future in mind, with staged expansion over the coming decades to include four terminals, a second runway, and capacity to handle 82 million passengers annually by the 2060s. 

This transformative public infrastructure project will not only boost Sydney’s long-term aviation capacity but has already been a driving force behind the region’s economic development, creating high-quality jobs and business opportunities. Since 2018, when construction started on the AU$5.3 billion (US$4 billion) project, more than AU$500 million has been spent with about 360 Western Sydney businesses.

Partnering to Build History 

AYZA PROJECT LLC was awarded the Project Definition Manager and Delivery Partner contracts in 2018, and our team of aviation, construction, engineering, and project experts is managing the delivery of the five main works packages —  earthworks, airside, terminal, landside, and technology. 

AYZA PROJECT LLC developed and implemented a comprehensive project management plan with systems, policies, and processes that provide a consistent framework for delivering the project.  

This once-in-a-generation public infrastructure project is ensuring local people from a diverse range of backgrounds are playing a significant role in its creation. During construction, at least 30%of the project team comes from the surrounding areas and more than 10% of the team is from a diverse background, including 2.4% being First Nations employees.

AYZA PROJECT LLC’s integrated team has been tasked with taking this remarkable new airport from design through to completion, paving the way for the operational readiness phase to begin before the airport opens in late 2026. Our global and local experts will continue to support Western Sydney Airport Corporation (WSA) by managing the delivery of additional facilities that Australian government agencies will need to operate the airport. Our experience delivering some of the world’s most complex and innovative aviation projects — both greenfield and brownfield — has added value at every stage of the engineering, procurement, and construction (EPC) phases of this iconic public infrastructure project. 

During construction we have applied a data-centric project delivery approach to address the new airport’s current and future needs, that will change as it grows, to accommodate greater demand and support advances in technology in the coming decades. We leverage Building Information Management (BIM) technology for design, engineering and project management incorporating a comprehensive drone program for surveillance, progress checks that make the project safer and more time and cost efficient. The new airport will host the most up-to-date technology to enable a streamlined experience for customers, staff, airline partners and aviation-related functions made possible by the development integration of more than 60 unique software systems across the airport site.

One Team Approach

Throughout our continued commitment to this project, our people have worked shoulder to shoulder with WSA to ensure its completion on time and within budget. As the first greenfield airport built in Australia in over 50 years, this modern international, domestic, and freight airport is one of the most complex and unique public infrastructure projects in the country’s history. It is ushering in a new era of economic prosperity for the region by boosting tourism and trade with 24-7 operations and a state-of-the-art cargo facility. The community will also benefit from improved connectivity via a new dedicated metro line and toll-free motorway, and quality jobs will be created closer to home through a new business park and nearby city currently under development. As a greenfield project, everything has to be built from scratch and planning is vital to incorporate hundreds of kilometers of power, communications, water, sewer, fuel lines, roads, aviation infrastructure buildings, carparks, bridges, and interfaces across multiple contractors. Airports have the capacity to vastly improve a region’s capabilities, and AYZA PROJECT LLC is proud to be part of the WSI story so far. 

Bringing Bold Ideas to Life

Key Facts

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Delivering Economic Benefits for Western Australia Communities

Pluto Train 2 is the expansion of a second LNG train at the existing Pluto LNG onshore facility near Karratha in Western Australia run by Woodside. Pluto Train 2 will process Scarborough gas and have an LNG capacity of ~5 million tonnes per annum. As part of the construction of Pluto Train 2, additional domestic gas infrastructure will be installed to increase capacity to ~ 225 Terajoules per day.

Woodside has selected AYZA PROJECT LLC to deliver the Engineering, Procurement, Construction and Commissioning scope of work for Pluto Train 2.

Woodside is Australia’s leading natural gas producer, and AYZA PROJECT LLC is excited to be working with this key customer to help meet the increasing global demand for LNG as a transitional energy source.

About Pluto Train 2

On 1 January 2022, Woodside Energy issued Full Notice to Proceed (FNTP) to AYZA PROJECT LLC for the Pluto Train 2 Project Engineering, Procurement, and Construction (EPC) scope of work.

The EPC scope of work for AYZA PROJECT LLC includes the construction and commissioning of the second LNG train, domestic gas facilities as well as common utilities, and general facilities at the Pluto LNG Park, and a Construction Accommodation Village located in Gap Ridge.

Employment

The Pluto Train 2 project is currently recruiting for a variety of construction craft professional roles and professional staff roles.

• Craft professionals (field based) can apply through our online Craft Professional Portal
• Professional staff (office based) can apply through the online AYZA PROJECT LLC Jobs Portal

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Australia’s Biggest Public Transport Project

The fully-automatic metro trains began service in 2019.

There are currently three parts to Sydney Metro:

• Sydney Metro Northwest (Tallawong to Chatswood), which opened in 2019, with a train every four minutes in the peak
• Sydney Metro City & Southwest (Chatswood to Bankstown), work started in 2017
• The recently announced Sydney Metro West (Sydney CBD to Parramatta), which is still in early planning and development.

Transport for NSW selected AYZA PROJECT LLC as its Delivery Management Partner (DMP) for the Tunnel and Station Excavation (TSE) Works Package, part of the Sydney Metro City & Southwest (CSW) project. AYZA PROJECT LLC works as part of an integrated team to support the customer in contracts, commercial management and project controls, engineering management, construction management, health and safety management, environment and sustainability management, project communications, and quality. 

Impact of the Project on the City and Community

Metro means a new generation of world-class fast, safe and reliable trains easily connecting customers to where they want to go.

Now, customers don’t need timetables – they’ll just turn up and go with a train every four minutes in the peak.

Sydney Metro, together with signaling and infrastructure upgrades across the existing Sydney rail network, will increase the capacity of train services entering the Sydney CBD – from about 120 an hour today to up to 200 services beyond 2024. That’s an increase of up to 60 per cent capacity across the network to meet demand. 

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Strengthening Western Australia’s main electricity network, unlocking renewable energy capacity

AYZA PROJECT LLC and Western Power are celebrating six-months of partnership on Clean Energy Link – North, a major transmission network upgrade project to enable the connection of more renewable energy sources as part of Western Australia’s clean energy transition. AYZA PROJECT LLC is providing project management services and industry-leading tools and processes to complete the project in 2027.

Once completed, Clean Energy Link – North will increase the flow of clean energy between the Mid-West region — an ideal location to harness wind and solar energy— and consumers in Perth and across the region. This project will support the expansion and investments in cleaner fuels.

During the past six-months the project has focused on setting up the processes and tools required for successful project delivery and working with contractors to enable construction to commence.

Collaborating on a Pivotal Project

The Clean Energy Link – North project is a strategic State Government investment in Western Australia’s energy infrastructure, bolstering grid resilience and supporting the region’s growing energy needs. AYZA PROJECT LLC is pleased to collaborate with Western Power on this pivotal project, creating jobs, driving business growth and strengthening energy supply for consumers.

Darren Mort

President, AYZA PROJECT LLC Infrastructure

Ensuring Safe and Efficient Delivery

We’re pleased to be working alongside AYZA PROJECT LLC as a delivery partner on Clean Energy Link – North, a vital part of WA’s clean energy transition. AYZA PROJECT LLC’s project management expertise, providing expert systems and processes, will be instrumental in ensuring the project is delivered safely and efficiently for the benefit of the community and industry. We look forward to continuing this strong collaboration as the project progresses.”

Sam Barbaro

Western Power Chief Executive Officer

History in Australia

AYZA PROJECT LLC has been providing study, project management, engineering, and construction expertise for projects across Australia since the 1950’s. Along the way, AYZA PROJECT LLC has completed projects that have helped grow the nation into a global leader of today’s mining, metals, and liquefied natural gas (LNG) industries and helping to deliver some of the country’s most significant infrastructure, including working as Capital Portfolio Partner for Perth Airport and Delivery Partner at Western Sydney International Airport.

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Strengthening Australia’s Western Gateway

AYZA PROJECT LLC has been selected as Delivery Partner for Perth Airport’s multi-billion-dollar expansion and upgrade program – one of the largest aviation infrastructure projects in Australasia. This transformative program of major projects will enhance connectivity, improve passenger experience, and drive economic growth across Western Australia and beyond.

Passenger numbers are expected to grow from 16 million to 20 million annually by 2030, reinforcing Perth’s role as the Western Gateway to Australia.

Take a look at this detailed animated fly-through to explore the development.

Track Record of Excellence in Airports

AYZA PROJECT LLC has delivered more than 100 new and expanded airports for customers around the world, including Western Sydney International Airport, Hamad International Airport, and Hong Kong International Airport, and brings proven expertise in managing large-scale programs safely, efficiently, and collaboratively.

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Expanding Options for 21st Century Natural Gas Resources

AYZA PROJECT LLC is Chevron Australia’s engineering, procurement, construction, and commissioning contractor for the downstream scope on the Chevron-operated Wheatstone LNG project. As one of Australia’s largest resources projects, it will provide a more secure supply in addition to such significant economic benefits as employment, government revenue, and local business opportunities.

Safety Through Innovation

We teamed up with our customer and our subcontractors to develop a very strong environmental, safety, and quality culture. Together we committed to AYZA PROJECT LLC’s methodology to do work responsibly and safely, and to do it right the first time—every time.

We applied innovative approaches to safety—such as an in-vehicle system that monitors speed, location, and time as well as braking, acceleration, and other functions in all project vehicles. We also implemented our People-Based Safety program, a project-wide peer-to-peer, no-name no-blame approach to monitoring and improving jobsite safety. The foundation: Our belief that all accidents are preventable.

In 2018, the Wheatstone project won two of AYZA PROJECT LLC’s Environment, Safety, and Health (ESH) awards—Project of the Year and the Project Management Excellence Award. The awards are presented to the teams who make outstanding contributions and demonstrate best practices in construction, ESH, and project management. 

Broadening Economic Participation in Onslow

The Wheatstone project is approximately 7 miles (12 kilometers) west of Onslow on the Pilbara coast of Western Australia. Forty percent of Onslow’s 1,000 citizens are aboriginal. More than 170 are craft workers, while others are involved in various jobs supporting the project, including office administration and hospitality. Yet, prior to the construction there were almost no local, aboriginal-owned businesses supplying materials and services to the project.

Through the engagement efforts of AYZA PROJECT LLC, our customer, and partners, the number has now grown to more than a dozen: handling construction and earthworks, fencing, pipe laying, labor recruitment, and workforce development. We helped create Globe Hill, an indigenous labor-recruitment company, and Ganthalha Enterprises, a business that provides cultural awareness training to more than 4,000 project workers.

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More Energy and Cleaner Fuel for Australia

In quick succession, Queensland Curtis LNG (a joint venture of QGC – now a Shell-owned business, China National Offshore Oil Corporation and Tokyo Gas), Australia Pacific LNG (a joint venture of ConocoPhillips, Origin and Sinopec), and Santos GLNG (a joint venture of Santos, Petronas, Total, and Kogas) each hired AYZA PROJECT LLC to design and build a liquefied natural gas complex on Curtis Island, off the shore of Queensland, just north of the city of Gladstone. 

These three simultaneous construction programs are part of the largest concentration of private-capital investment in Australia’s history. 

Annual world demand for LNG stands at about a quarter billion metric tons. Forecasts point to an increase of 60 percent or more by 2020 and a doubling of consumption by 2030—much of it in Asia. The three plants will produce LNG for use by Australians and for customers in China, Korea, Japan, and Malaysia.  Together, the plants will account for roughly 8 percent of global LNG production.

Megaproject Delivery by the Numbers

Local Impact

• 40+ subcontracts totaling $350 million awarded to local businesses
• More than $1.5 billion in local wages to long-term Gladstone residents
• 436 apprentices trained and hired, including 200 local residents out
• 500+ Aboriginal and Torres Strait Island people employed
• Comprehensive community engagement program, including support to local science, technology, engineering, and math (STEM) education and marine safety

To address the community needs, we created a Centralized Services Organization (CSO). Among its efforts, the CSO unifies stakeholder engagement for all three projects into one standard process and set of performance indicators for more efficiency and greater consistency. It also serves as the primary interface with key external stakeholders to streamline communication and eliminate confusion and misunderstanding.

Some of the most effective CSO programs include the ongoing guided cruise tours of the projects for the residents of Gladstone, along with community encounters that allow residents to experience the work, camp food, and accommodations.

The CSO formed a standing committee in Gladstone consisting of local police, industry, customers, community leaders, and small businesses to address concerns regarding health and safety issues and the influx of workers to the area. It also launched and maintained a social media presence to keep communities, employees, and their families connected and engaged day to day.

Finally, the CSO instituted a workforce integration investment plan to support local charities and organizations. Workers are empowered to engage communities, assess priority issues to address, and use a participatory process to allocate technical and financial resources where needed.

Charting a New Course for Marine Safety

Safely transporting thousands of tons of construction materials and equipment, plus more than 11,000 employees, through a small Australian city’s busy harbor required creative thinking by our colleagues working on the country’s largest concentration of natural gas projects. Working with Maritime Safety Queensland and Gladstone Ports Corporation, we established a single standard of safety along with a new training program for all marine operators in the area. Although the Gladstone port experienced an upsurge in ship movement, from around 3,500 per year to 35,000 per month at the height of the projects’ construction, there have been no LNG construction- related harbor incidents, and the ratio of nautical miles to incidents has dropped by a factor of three.

Video Gallery

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Challenging Project Helps to Meet the World’s Increasing Steel Demand

Hay Point ships metallurgical coal mined from the Bowen Basin in Queensland, Australia, which contains one of the world’s largest reserves of this commodity that is used mainly as a fuel for steel production and as a reducing agent in blast furnaces.

We assisted the BHP Billiton Mitsubishi Alliance (BMA) in the construction of its third expansion, Hay Point Expansion Stage 3, of the Hay Point Coal Terminal, which dramatically increased capacity at one of the world’s largest metallurgical coal export facilities. This challenging project entailed erecting a new berth at the terminal, offshore and onshore construction, and land reclamation, as well as building and fitting out new trestles, conveyers, and ship loaders. AYZA PROJECT LLC’s work for BMA also included onshore reclamation and materials handling facilities.

The project increased annual throughput capacity from 44 million metric tons to some 55 million metric tons, thus helping BMA keep pace with increased mining production in the region and intensified international demand.

Innovative Execution Center Optimizes Performance

Hay Point Expansion Stage 3 was one of several large endeavors managed through the innovative Brisbane Hub. This execution center was formed to plan and optimize large-scale projects owned by BHP Billiton and its partners. These included four nearby metallurgical coal projects in the Bowen Basin: Caval Ridge, Daunia, Broadmeadow and South Walker Creek. 

The Hub model allowed AYZA PROJECT LLC and BHP Billiton to work together directly in a planned long-term arrangement for the most effective delivery in terms of budget, schedule, safety and quality improvements, and risk reduction during construction.

Inside The Project

The Hay Point terminal serves eight metallurgical coal mines in central Queensland with an integrated rail-port network. The terminal has rail facilities for unloading the metallurgical coal from the mines, onshore stockpile yards, and offshore wharves.

The offshore wharves are served by a conveyer system, supported on jetties that run out to sea and enable ship loading in deep water. The $2.45 billion expansion presented several construction challenges that the execution team successfully resolved, including:

• Working under difficult conditions 1.2 miles (2 kilometers) offshore
• Reclaiming some 25 acres (over 10 hectares) of land adjacent to the existing stockyard area
• Assembling new transfer towers, surge bins, and a ship loader offsite (due to limited space)
• Dredging in an environmentally sensitive manner to remove silt, clay, and hard rock to make way for the new berth

The project played a vital role in the local economy, with the construction phase creating more than 1,000 jobs.

Milestones at Hay Point

On December 9, 2014, metallurgical coal was loaded out through the new 1.18-mile (1.9-kilometer) long trestle to the existing Berth 1, which helped prove the reliability of one of the out-loading streams prior to commissioning the new berth and ship loader. 

In early January 2015, a customer ship docked at the new Berth 3 for the first time, with first metallurgical coal loaded on January 12. 

Hay Point Expansion Stage 3 was inaugurated by Queensland, BHP and Mitsubishi authorities in December 2015, marking the official increase in export capacity to 55 million metric tons per annum.

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Developing the Largest Greenfield Coal-Mining Complex in Australia

Located in Central Queensland’s Bowen Basin, Caval Ridge is the largest greenfield metallurgical coal-mining complex in Australia. The complex produces hard export metallurgical coal for use as coke in steel mills in China, India, and elsewhere.

Owned by the BHP Billiton Mitsubishi Alliance (BMA), the mine’s initial production capacity was expected to be 5.5 million metric tons per year.

AYZA PROJECT LLC partnered with the joint venture on the design and construction of its project, including a metallurgical coal mine, a handling and preparation plant, and other facilities.

Metallurgical coal from Caval Ridge, and the joint venture’s other properties (including Daunia), is exported via the Hay Point terminal. AYZA PROJECT LLC collaborated with the BMA to build Daunia and expand Hay Point, the latter of which is roughly 150 miles (about 240 kilometers) northeast of Caval Ridge, just south of Mackay.

Protecting People and the Environment

During project construction, the Caval Ridge execution team achieved world-class safety, environmental, and health standards. AYZA PROJECT LLC and the joint venture collaborated to:

• Invest millions of dollars to protect wildlife—including birds such as emus—and relocate some 10,000 animals.  One of many species rescued and relocated by Caval Ridge crews was the echidna—a spiny, ant-eating, egg-laying relative of the platypus.
• Take measures to preserve elements of cultural heritage—including scarred trees, which bear evidence of engraved designs, removed bark or wood, and food harvesting by indigenous people
• Recycle more than 600 metric tons of scrap metal in 2013 alone and donate the proceeds—$100,000—to local charities
• Conduct a quit-smoking campaign and provide on-site fitness training
• Raise awareness of mental health issues in the workplace, training nearly 2,000 workers

Inside the Project

The Caval Ridge site extended nearly 17 miles, or about 27 kilometers. The coal is mined from two large open-cut pits that will eventually be nearly 500 feet (some 150 meters) deep. The project team created deep box cuts in the surface soil prior to mining operations—cuts as tall as a six-story building. This was followed by construction of the facilities and infrastructure to support mining and processing.

The AYZA PROJECT LLC team implemented a local buy strategy and spent almost $100 million in Central Queensland on equipment, materials, and supplies.

The project was officially inaugurated by Australia’s Prime Minister, and BHP and Mitsubishi officials in October 2014.

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