With the majority of construction now complete, Western Sydney International (Nancy-Bird Walton) Airport is on track to commence operations in late-2026.
Building Australia’s first international greenfield airport in more than fifty years is no small feat. Infrastructure sat down with Western Sydney International (WSI) CEO, Simon Hickey, for an update on this monumental project and the impact its already having on the region.
“This is one of the biggest and most complex infrastructure projects being undertaken in Australia,” Mr Hickey said.
“And construction is now more than 80 per cent complete, with major works to conclude in the first half of next year.”
Over the course of the multi-year program, there have been numerous disruptions, including COVID19 shutdowns, bushfires that came up to the fence line and drainage systems overtaken by floods. With the help of its delivery partner, Bechtel, WSI has been able to progress safely, with the project remaining on time to open in late 2026.
Multiplex, CPB ACCIONA Joint Venture, AeroWest Joint Venture, and DXC Technology are the four major works contractors engaged for the project.
“A key challenge for us was integrating those packages, which has gone really well,” Mr Hickey said.
“We’ve kept open lines of communication across all the contractors and worked to ensure we understand who’s responsible for what.
“Having four major works contractors also created that competitive tension and best-in-class across the site, which has helped maintain our momentum.”
Overhead
In July, the completion of the airport’s terminal roof — more than 25m off the ground at its highest point — marked a major milestone for the project. As one of the largest roofing contracts in Australia, the project needed to be handled with care and precision.
“The roof consists of ten layers, including a structural liner and top roof sheet made from BlueScope COLORBOND® steel coils, produced in Port Kembla and painted in Western Sydney,” Mr Hickey said.
“This material was then passed through custom roll-forming machines on site, creating roof sheets up to 75m long.
“Joined together, they are the largest of their kind ever produced and craned onto a roof in Australia.”
40km of Australian-made steel purlins and more than 3,500 tonnes of steelwork used to support the terminal roof were primarily fabricated between Adelaide, Whyalla, Tamworth and Orange.
As a custom design, the project created an opportunity for upskilling. Even experienced roofers participated in weeks of specialised training to master the installation.
Lead roof contractor, Red 8, provided the labour force required for the project, including ten apprentices. Approximately two-thirds of their team came from Western Sydney.
A further 30 engineers, architects and specialist consultants were involved in developing and monitoring the design and construction.
“It’s a good example of where we used the best of Western Sydney, the best of technology, in order to deliver something unique,” Mr Hickey said.
Green slate
“Building a new greenfield airport means that we’re ready for the challenges of tomorrow as well as today,” Mr Hickey said.
“This means building in efficiency and effectiveness throughout the airport. Sustainability begins well before the first shovel hits the ground.”
WSI’s roof structure is a prime example of this approach. At the main entry to the terminal is an expansive veranda space, supported by eight 15m-tall concrete columns. These columns, reinforced with internal hollow steel sections, cleverly conceal downpipes that collect rainfall for the almost two hectares of roofing. This rainfall can then be recycled for use in airport operations like bathroom facilities, irrigation and cooling towers.
Sustainability and effective water management has also been a focus throughout the construction process. Around 98 per cent of the water used for WSI’s earthworks packages was recycled water captured on site. Approximately 5.5 million tons of recycled crust sandstone from the Sydney Metro and WestConnex projects was repurposed for the base layer of the 3.7km airport runway. WSI has also committed to planting more than 2,500 trees and grasses from the Cumberland plains into its 117 hectares of land designated as Environmental Conservation Zones, with the help of the local community, schools and Rotary clubs.
As a brand new airport, WSI can incorporate the latest innovations in aviation from the ground up, taking inspiration from Australia and overseas.
“We looked at some of the best airports around the world and cherry picked what we thought were the best parts of those,” Mr Hickey said.
WSI will be the second airport in Australia to have a digital aerodrome instead of a traditional control tower, following Canberra.
“We’re also implementing a CATIIIB landing system,” Mr Hickey said.
“Currently the only other airport in Australia with a CATIIIB system is Melbourne Airport. With CATIIIB, aircraft can land and take off in fog and all weather conditions.
“As we move forward, sustainable aviation fuel (SAF) is a key initiative of the aviation sector, and we will be capable of delivering SAF to aircraft from day one of operations.” WSI’s airfield is also designed for efficiency with rapid exit taxiways, which will see average taxi times of around five minutes, helping airlines save fuel.
Seamless journey
Another recent trend in aviation is making it easier, faster and less stressful for passengers going through airports. From advanced tote-based baggage systems to smart aero bridges that adjust automatically to the height of the aircraft, WSI has put a strong focus on creating a hassle-free travel experience.
“Moving through an airport is an inherently stressful ordeal,” Mr Hickey said.
“Finding ways to achieve the best efficiency, effectiveness and ease of use for our passengers moving through the airport was a top priority.”
WSI’s international and domestic terminals are integrated under one roof, creating faster connection times for travellers. The terminal design incorporates an abundance of natural light, which plays a significant role in reducing passenger stress. Swing gates have been implemented throughout the terminal to enhance efficiency and productivity during different travel peak times across international and domestic services. Multiple self-service options are designed to cater to the growing number of passengers who prefer to check in online.
But a smooth travel experience relies on much more than what happens inside the terminal.
“It’s really important when you’re an airport, that you have connectivity, not just in terms of flights or airlines,” Mr Hickey said.
“We’ll be the first airport in Australia to have a metro from day one. There’s also the new toll-free motorway, the M12, which connects to the M7, helping bring people to and from the airport in a seamless way.”
These crucial transport links, being delivered by the New South Wales Government, will not only improve connectivity but also support job growth in the region.
Mr Hickey said these were examples of how the airport has been a positive catalyst for these investments and changes in and around the community.
Local connections
Western Sydney is home to about two and half million people, making it the third largest catchment for an airport in Australia. By the early 2030s, that number is expected to rise to approximately three million.
“We’re really proud to be here in Western Sydney,” Mr Hickey said.
“We’ve spent about $500 million with Western Sydney businesses to date and have worked with businesses small and large to bring the airport to life.”
Take, for example, the self-service check-in and bag drop hardware. This was produced by Micron Manufacturing in Blacktown, employing about 30 locals to manufacture the kiosks. Steel used for fencing and concrete reinforcements on the airside package was sourced from Horsley Park, Windsor and Victoria. The aluminium panels, a defining feature of the terminal ceiling, were manufactured in Moorebank. Work on the terminal ceiling, which resembles the Blue Mountains, is now being finalised, as WSI readies itself for opening in 2026.
“There’s about 30 other structures that we’re putting together across the rest of the site, so there’s plenty more milestones ahead,” Mr Hickey said.
Safe landing
Safety has remained a top priority throughout the construction of Western Sydney International, underscored by a strong safety performance across the 2024 financial year.
“I think one of the reasons we’ve remained on time and productive is our relentless focus on safety, and that’s a key differentiator of this project,” Mr Hickey said.
“We had a year-end Total Recordable Injury Frequency Rate of 2.6, which is well below industry benchmarks.
“As for proactive safety activities, more than 13,500 safety lead indicator activities were undertaken across all of the airport’s development packages over the course of FY24.”
This included 10,600 workplace monitoring activities, 2,316 workforce engagement activities and 587 safety leadership walks.
“An ongoing emphasis on visible leadership, cultural alignment, and active engagement with our main contractors will be essential moving forward to ensure a safe working environment for everyone involved in this project.”
Once major construction wraps up next year, WSI will move into a lengthy testing and commissioning phase across the entire project.
“We’ll stress test the entire airport, making sure that all systems are working together, so that we’re ready to go when we open in 2026.”
