The Magazine | Australian National Construction Review | Rouse Hill Bus Depot
DSD Sets a New Benchmark for Public Transport Infrastructure in
Western Sydney
Developer / Client : ComfortDelGro Corporation Australia
Main Construction Company : DSD
Architect : PNB Architecture
Structural Engineer : Steelcorp
Redefining construction excellence with future-ready, sustainable design
Spanning an impressive 41,500m², the project stands as a shining example of what’s possible when innovation, execution excellence, and environmental responsibility come together under one visionary team.
Led by co-founders Misael Canas, Marcos Pescara, Michael Doueihi and Shannon Darcy, DSD has once again proven its capability to deliver complex, large-scale projects to the highest standard setting a benchmark that the industry can look to as the new standard in construction delivery.
Engineering for the Future – Today
The Rouse Hill Bus Depot isn’t just built for now, it’s engineered for what’s next. With more than 2km of underground conduit installed to support future electric vehicles (EVs), and a workshop designed to accommodate the maintenance of zero-emission buses, including hydrogen-powered models,
the facility has been designed to seamlessly adapt to the evolving needs of Sydney’s public transport network.
This commitment to sustainability and long-term planning was recognised with a prestigious 5-star NABERS rating – an impressive achievement that cements the depot as an environmental and sustainability leader in public infrastructure.
“We’re not just building for today, we’re building for what’s next,” said Shannon. “Our goal was to create a facility that not only meets current demand but evolves with it.”
A Benchmark in Sustainability, Innovation, and Safety
The Rouse Hill Bus Depot sets a new benchmark in innovation, sustainability, and construction excellence. From design through to delivery, the facility has been developed with an unwavering focus on reducing environmental impact while increasing operational efficiency.
At the core of this cutting-edge facility is a purpose-built 23,000m² bus footprint. While the depot was originally designed and constructed to accommodate 198 diesel buses, a decision was made to future-proof the site for electric buses by installing 2km of underground conduits.
Supporting this is a fully equipped workshop tailored for heavy vehicle maintenance, advanced refuelling stations, in-ground hydraulic systems engineered for long-term durability, bus washing facilities, and a state-of-the-art, fully compliant Heavy Rigid RMS-spec mechanical workshop.
Further enhancing the depot’s credentials is the integration of robust fire protection measures, including fire-rated glazing imported from Germany, sprinkler systems, along with fuel tank plinths and durable pavement construction all designed to ensure a safe and resilient working environment.
A key part of the project’s success was the exceptional safety record and execution efficiency achieved throughout all three stages of construction. DSD’s meticulous approach and attention to detail ensured the project not only met, but exceeded, stringent industry benchmarks.
Built with Purpose, Delivered with Precision
Executing a project of this magnitude required deep coordination, technical mastery, and an unrelenting focus on quality. By self-performing critical works, DSD maintained control over every aspect of delivery from civil works to structural integration ensuring timelines and outcomes were met with confidence.
The team also took proactive steps to protect and preserve the local environment, implementing erosion and sediment control strategies, smart stormwater harvesting and filtration systems, and initiatives aimed at maintaining local biodiversity. These sustainability measures aligned with best-practice environmental standards and were executed with precision and care.
“From the modern, high-tech workshop and specialist equipment to the expansive 23,000m2 bus parking area, this facility was purpose-built by DSD to the highest standards—with safety as a priority, long-term durability, and minimal future maintenance requirements in mind,” Shannon added.
Collaboration at the Core
The success of the Rouse Hill Bus Depot was made possible through strong collaboration with key stakeholders including transport planners, engineers, sustainability consultants, and local authorities. This alignment ensured that the depot wasn’t just fit for purpose but also set up to support the transition to greener mobility and enhanced public transport efficiency across Western Sydney.
Through a shared vision and coordinated execution, the team brought together a wealth of expertise to deliver a facility that reflects the future of public transport – quality, sustainability, operational excellence, and long-term value.
A Lasting Legacy for the Community
This depot is more than just a construction milestone, it’s a symbol of future-forward thinking, community support, and industry-leading execution. It represents the type of infrastructure that makes a lasting, positive impact on the regions it serves.
“This depot reflects everything we stand for: quality, resilience, and a passion to take on innovative and complex projects,” said Shannon. “We’re proud to deliver infrastructure that will serve Sydney well into the future.”
With this flagship facility now complete, DSD continues to raise the bar, shaping the future of transport infrastructure across Australia with confidence, integrity, and vision.
For more information contact DSD Group, Suite 308, 10 Century Circuit, Norwest NSW 2153, phone 02 9616 2990, email info@dsdgroup.com.au, website
www.dsdgroup.com.au
Strong, Stylish and Functional; Blinds Made for Busy Commercial Environments
Case StudiesBlindman (NSW) Pty Ltd, a leading provider of internal and external window furnishings and security doors, played an essential role in the Rouse Hill Bus Depot project.
With over 35 years of experience, the company brought its extensive knowledge in blinds, curtains, shutters, awnings, and security solutions to enhance the functionality and aesthetics of the depot’s facilities.
Blindman was responsible for the installation of blinds and accessories on windows and doors throughout the depot, ensuring privacy, light control, and energy efficiency for various internal spaces. Given the nature of the facility, it was crucial that the window treatments met durability and operational requirements.
“We understand that high-traffic commercial spaces like the Rouse Hill Bus Depot require window furnishings that are not just visually appealing but also robust and long-lasting,” said Blindman General Manager, David Wilcox. “Our team worked closely with the project managers to select the best materials and designs suited for this high-use environment.”
A team of five specialists from Blindman handled the installation, ensuring timely and seamless integration of blinds across the facility.
“Attention to detail is key in projects like this,” David explained. “Every window and door needed the right type of blind for its function, whether for glare reduction in office areas or increased privacy in amenities.”
Blindman’s reputation for excellence extends beyond the Rouse Hill Bus Depot, with ongoing work in aged care facilities, schools, hotels and hospitals.
“We take pride in providing high-quality home and commercial improvement products that enhance both aesthetics and functionality,” David said.
With a commitment to precision, durability, and customer satisfaction, Blindman continues to be a trusted name in window furnishings and security solutions across New South Wales.
For more information contact Blindman (NSW) Pty Ltd, phone 1300 225 465, email sales@blindman.com.au website www.blindman.com.au
Seamlessly Welding Quality and Innovation Together
Case StudiesModern Welding Group delivers expert metal fabrication, combining craftsmanship and technology for durable, high-quality structures.
Modern Welding Group has long been a leader in high-quality metal fabrication. Their expertise was on full display at Rouse Hill Bus Depot project, where their experienced fabrication team played a pivotal role in delivering custom architectural and structural metalwork—including balustrades, office handrails, glazing balustrades, louvres, and awnings—with exceptional precision and innovative craftsmanship.
According to Jack Xu, Contract Administrator and Architect at Modern Welding Group, the project required a combination of traditional craftsmanship and cutting-edge technology. “We were able to utilise all the main forms of welding—TIG, Stick, and MIG. For on-site installations, we relied on TIG welding, while our in-house fabrication was completed using MIG welding and Stick welding to ensure a seamless finish,” Jack explained.
One of the most technically demanding aspects of the project was the curved balustrade at the front of the site and the primary façade louvres. “These elements imposed a minor challenge,” Jack noted,
“but we overcame them by drawing from our extensive industry experience and leveraging newer technologies such as drones, point clouds, and advanced CAD software.”
Modern Welding Group sources materials from long-standing Australian suppliers with a proven track record in environmental sustainability. “We use galvanised and stainless steels, which are not only durable but also sourced responsibly to ensure long-term efficiency,” Jack emphasised.
“The experience we’ve gained from overcoming technical difficulties and collaborating with other trades will help us expand our team of professionals and tackle even more exciting projects in the future,” Jack said.
With their commitment to precision craftsmanship, Modern Welding Group continues to deliver work that not only meets the highest expectations for structural integrity and aesthetic excellence, but is also fully compliant with key industry standards including AS 1170.1, AS 1288:2021, AS/NZS 2208:1996, AS/NZS 1170.2:2002, and BCA Part B, Clause D2.16.
For more information contact Modern Welding Group, 48 Gould Street, Strathfield South NSW 2163, phone 02 9642 1161, email info@modernwelding.com.au, website www.modernwelding.com.au
Arrow Hawke Delivers World-First Innovations at Rouse Hill Bus Depot
Case StudiesArrow Hawke delivered efficient, sustainable workshop solutions for Rouse Hill Bus Depot with innovative prefabrication expertise.
Arrow Hawke Industries brought its expertise in custom workshop design, prefabrication, and installation to the Rouse Hill Bus Depot project, delivering a highly functional, future-ready facility tailored for both current diesel and future ZEB (Zero Emission Bus) fleets.
With over 30 years of experience in manufacturing prefabricated truck and bus pits and automated wash systems, Managing Director Varuna Krishnaratna led the delivery of a fully integrated solution.
“We designed and installed an 18-metre suspended ceiling service pit—the first in the world with a 140-tonne rollover capacity,” said Varuna. “The pit includes safety and operational features that significantly improve workshop efficiency.”
Arrow Hawke developed a dual-fleet workshop layout to meet the needs of both vehicle types, ensuring long-term viability. A compressed air and oil reticulation system was installed, along with advanced servicing tools including a roller brake tester, suspension and alignment tester, and a trade waste system with interlocks to prevent oil discharge into sewers.
A standout innovation was the integration of a 15,000-litre oil store within the pit, eliminating the need for a separate warehouse and cutting construction costs. On-pit oil dispensing and waste oil capture systems also enhanced productivity, enabling a full bus service in under 70 minutes—a 22% improvement.
Environmental performance was another focus. Arrow Hawke installed an automatic bus wash system capable of washing 15 buses per hour using just 1,050 litres of water—compared to 150 litres for one car. The water recycling system reuses 93% of water and has become a model for future CDC depot upgrades.
“We used zero-VOC paints and built all components offsite to reduce waste, streamline deployment, and ensure precision,” Varuna added.
Arrow Hawke also introduced a proprietary jacking system, making them the only company globally offering this innovative solution. From pioneering workshop design to sustainability leadership, Arrow Hawke Industries is building the bus depots of tomorrow—today.
For more information contact Arrow Hawke Industries, Unit 2, 1 Widemere Road, Wetherill Park NSW 2164, phone 0497 797 701, email varuna@arrowhawke.com.au, website www.arrowhawke.com.au
SAP Group Australia Painting the Town Green; Eco-Friendly Coatings at Rouse Hill
Case StudiesSAP Group Australia completed durable, eco-friendly protective coatings at Rouse Hill Bus Depot using advanced techniques.
SAP Group Australia has successfully completed extensive protective coatings and painting works at the Rouse Hill Bus Depot, ensuring long-term durability and sustainability of the facility. The project, which involved a combination of internal and external painting, exposed surface treatments, and specialised protective coatings, is a testament to SAP Group’s expertise in large-scale infrastructure projects.
SAP Group Australia prioritised environmentally responsible solutions for the Rouse Hill Bus Depot, incorporating low-VOC (Volatile Organic Compound) coatings to align with green building standards.
“We are committed to using environmentally friendly materials and techniques that not only enhance infrastructure longevity but also reduce long-term maintenance costs and environmental impact,” said Managing Director Daniel Zrinski, who emphasised the company’s focus on sustainable solutions.
The team applied high-performance coatings such as Taubmans All Weather Low Sheen for exterior surfaces and Taubmans Professional Low Sheen for internal walls, ensuring resistance to harsh weather conditions, wear, and pollution.
In The project scope included protecting critical infrastructure elements, such as exposed services, wet areas, and high-traffic zones, with corrosion-resistant coatings.
SAP Group’s expertise in rope access techniques minimised the need for heavy machinery. “By implementing innovative access solutions, including rope access where possible, we were able to enhance efficiency, minimise resource waste, and maintain the highest standards of workmanship,” Daniel explained.
With a 10-year product guarantee from PPG Architectural Coatings and SAP Group’s 5-year workmanship guarantee, the coatings will significantly extend the lifespan of the depot’s structures, ensuring a cost-effective maintenance plan for years to come.
The successful execution of this project underscores SAP Group’s expertise in sustainable infrastructure maintenance, setting a benchmark for future transport developments.
For more information contact SAP Group Australia, phone 1800 72 72 22, email info@sapgroup.com.au, website
www.specialisedaccesspainting.com.au
Shielding Workers. Protecting the Future
Case StudiesEcoshield enhances workplace safety with custom welding screens, noise control, and sustainable industrial solutions.
Ecoshield, a leader in industrial environment control solutions, played a key role in enhancing safety, efficiency, and sustainability at the Rouse Hill Bus Depot. As part of this major infrastructure project, Ecoshield was responsible for the design, manufacture, and installation of a custom welding screen, ensuring a safer and more controlled workspace within the depot’s state-of-the-art workshop.
“Our goal with this project was to create an environment that prioritises both worker safety and long-term sustainability,” said Myles Glass, Founder and Director of Ecoshield. “By implementing high-quality protective solutions, we help reduce operational hazards while contributing to the depot’s overall efficiency.”
Ecoshield specialises in industrial noise control, protective screens, and environment-enhancing solutions designed to minimise workplace risks. The custom welding screen at Rouse Hill Bus Depot was engineered using low-emission materials and durable, high-performance coatings, ensuring long-term resilience with minimal maintenance.
“Sustainability is at the core of everything we do,” Myles explained. “By using eco-friendly materials, we not only improve the lifespan of our solutions but also help infrastructure projects like this reduce their environmental impact.”
As public transport moves towards a greener future, projects like the Rouse Hill Bus Depot require durable and sustainable solutions that reduce lifecycle costs and minimise resource consumption.
“The lessons learned here can be applied to future transport infrastructure developments,” Myles said. “By integrating sustainable materials and precision-engineered solutions, we’re helping build transport facilities that are safer, more efficient, and environmentally responsible.”
Ecoshield’s work at Rouse Hill Bus Depot underscores its commitment to innovation, safety, and sustainability, setting a new benchmark for eco-friendly infrastructure solutions in the transport sector.
For more information contact Ecoshield Industrial Environment Controls, 3/44 Jones Street, Harlaxton QLD 4352, phone 0473 129 877, email info@ecoshields.com.au, website www.ecoshields.com.au
Sealing the Future
Case StudiesNoviion Engineering ensured Rouse Hill Bus Depot’s durability with expert façade, waterproofing, and remedial solutions.
Noviion Engineering, a leader in façade, waterproofing, and remedial engineering, played a key role in the Rouse Hill Bus Depot, ensuring façade integrity and long-term durability.
As specialists in façade engineering and waterproofing, Noviion provided consultation to address the depot’s unique architectural and environmental challenges.
“Weatherproofing a structure like this is not a one-size-fits-all approach. Given the complexities of the design, we had to employ highly specific detailing to ensure longevity and protection against harsh weather conditions,” George Dahrie, Principal Engineer at Noviion Engineering, explained. “Ensuring proper thermal breaks was essential to prevent condensation and heat loss, particularly in a facility that houses critical transport infrastructure,”
With a strong portfolio that includes projects like Concord High School and the Air Trunk Data Centre, Noviion Engineering continues to set the benchmark for innovative façade and waterproofing solutions in Australia’s construction industry.
For more information, contact Noviion Engineering, phone 02 9635 9789, website www.noviion.com.au
From One Truck to Industry Leader: Road and Rail Excavations Marks its 10th Anniversary
Case StudiesCelebrating its 10th anniversary, Road and Rail Excavations has grown from a single-truck operation in 2015 to a leading provider of utility and civil services across Sydney and greater New South Wales.
Founded by Adrian Ruane, the company has built a reputation for expertise in electrical infrastructure, water and wastewater systems, civil works, and traffic management. With a decade of achievements, Road and Rail continues to embrace innovation and deliver high-quality, sustainable solutions for major infrastructure projects.
“When I started in 2015, it was just me, a truck, and a 5-tonne excavator. Ten years later, I’m proud of what we’ve become, and it’s thanks to the dedication of our amazing team,” reflected Adrian.
This commitment to excellence, integrity, and client satisfaction has fueled the company’s growth, making it a trusted partner in the construction industry.
One of the company’s recent milestones includes the acquisition of Ultegra, a leading infrastructure firm specialising in substations, overhead lines, and asset maintenance. This expansion has allowed Road and Rail to scale operations and broaden its service offerings, further strengthening its position as an industry leader.
Road and Rail Excavations played a crucial role in the successful delivery of the Rouse Hill Bus Depot, a key infrastructure project supporting Sydney’s public transport network. As the Level 1 Accredited Service Provider (ASP), the company was responsible for the design and installation of High Voltage (HV) electrical mains and a substation, which was later handed over to Endeavour Energy.
Additionally, Road and Rail was engaged to install 106 electric vehicle (EV) charging stations, ensuring the depot is equipped to support a future fleet of sustainable, zero-emission buses. This project underscores the company’s expertise in complex electrical infrastructure and commitment to facilitating environmentally responsible transport solutions.
The tight project timeline posed one of the most significant challenges, requiring meticulous planning, coordination, and execution.
Working closely with DSD Group, Road and Rail Excavations ensured daily communication and streamlined processes to meet deadlines without compromising quality. The team also navigated the complexities of working within confined spaces and alongside multiple contractors, showcasing their adaptability and problem-solving capabilities.
“As a leading provider of utility installations, we take immense pride in delivering exceptional service. We’ve built our reputation on reliability, safety, and efficiency, and this project was no exception,” explained Shane Coleman, General Manager.
Road and Rail’s ability to collaborate seamlessly and execute high-precision work ensured that the electrical infrastructure and EV charging stations were completed on time and to the highest standards.
Safety and sustainability remain at the heart of Road and Rail Excavations’ operations. The company consistently implements strict safety protocols, regular site inspections, and ongoing workforce training to maintain industry-leading standards. Moreover, their focus on sustainable infrastructure aligns with Australia’s transition to a greener future.
With ten years of industry leadership, Road and Rail Excavations is poised for continued growth and expansion. The company remains dedicated to adopting the latest technologies, refining best practices, and exceeding client expectations.
Their portfolio includes significant projects such as the Warringah Freeway Upgrade, 132kV Feeder Installation, and M6 Stage 1 Zone A Sewer Project, further cementing their status as a premier civil and utility contractor.
Looking back on the company’s achievements, Adrian Ruane remains focused on the future. “Celebrating ten years is a proud milestone, but it’s only the beginning. We’re committed to driving innovation and delivering the highest standards in utility and infrastructure solutions for years to come.”
For more information contact Road and Rail Excavations, phone 0414 594 063, email tenders@roadandrailexcavations.com.au, website www.roadandrailexcavations.com.au
Smarter Engineering for a Sustainable Future
Case StudiesDeboke Engineering delivered sustainable, high-performance infrastructure at Rouse Hill Bus Depot, enhancing efficiency and resilience.
The Rouse Hill Bus Depot is more than just a transport hub—it’s a benchmark in sustainable infrastructure, designed to enhance operational efficiency while minimising environmental impact.
A key player in this transformation was Deboke Engineering Consultants, a Sydney-based multidisciplinary firm specialising in civil, structural, stormwater, and remedial engineering.
Led by Directors Andrew Arida, Charbel Felfleh, and Joseph Dagher, Deboke’s expertise was instrumental in ensuring that the depot’s engineering solutions met sustainability targets while enhancing long-term durability and efficiency.
“The Rouse Hill Bus Depot was designed with sustainability at its core, integrating advanced stormwater management and rainwater harvesting for bus washing,” explains Arida and Dagher. “The project also incorporated Water Sensitive Urban Design (WSUD) principles, ensuring that stormwater quality and reuse were prioritised to minimise environmental impact and enhance operational efficiency.”
From the outset, Deboke’s role was critical in designing systems that balanced sustainability with the depot’s high-traffic demands. Given the site’s large-scale hardstand areas and continuous vehicular movement,
the team implemented a range of stormwater treatment and erosion control strategies.
A collaboration with Ocean Protect resulted in a custom-engineered stormwater filtration system that captures and treats pollutants such as Total Suspended Solids (TSS), Total Nitrogen (TN), Total Phosphorus (TP), and Gross Pollutants (GP) before releasing water into public infrastructure and natural waterways.
“Given the nature of the site, it was critical to address contaminants entering the stormwater system,” explains Arida and Dagher. “This system ensures that clean water exits the site, aligning with WSUD strategies to enhance environmental sustainability.”
In addition to water management, Deboke Engineering Consultants focused on using low-maintenance, highly durable materials to reduce the environmental impact across the depot’s lifecycle. “Additionally, sustainable construction methods, such as prefabrication where feasible, helped minimise waste and construction time,” says Felfleh.
This combination of smart material choices, efficient engineering solutions, and sustainability-driven construction methodologies positioned the depot as an example of environmentally responsible transport infrastructure.
A key focus of the project was minimising carbon emissions and ensuring the depot’s long-term resilience. Deboke achieved this through a rainwater tank reuse system, reducing reliance on external water sources.
“Coupled with the rainwater tank reuse system, this creates a highly efficient mechanism for controlling water quality in new developments, while simultaneously reducing operational costs and environmental impact,” Arida and Dagher notes.
Beyond the depot’s immediate needs, Deboke also integrated future-proofing measures to ensure that the site could adapt to changing transport technologies and evolving sustainability standards. This included designing the stormwater and civil infrastructure to accommodate future electrification of the bus fleet, which will further reduce emissions over time.
The Rouse Hill Bus Depot is just one of many complex engineering projects Deboke Engineering Consultants is currently undertaking. Their portfolio reflects a deep commitment to sustainability, innovation, and problem-solving, with ongoing projects including:
With a strong reputation for delivering complex infrastructure solutions, Deboke Engineering Consultants continues to push the boundaries of sustainable engineering. Their expertise in stormwater management, structural innovation, and sustainable construction makes them a valuable partner in future-proofing Australia’s transport and infrastructure landscape.
“Sustainability is no longer just an option—it’s a necessity,” says Felfleh. “At Deboke, we are committed to engineering solutions that not only meet today’s standards but also anticipate the challenges of tomorrow.”
For more information contact Deboke Engineering Consultants, 17 William Street, Ryde NSW 2112, phone 02 9188 0688, website www.deboke.com.au
Rouse Hill Bus Depot
March 2025In a landmark achievement for Western Sydney’s transport infrastructure, DSD has delivered one of the most advanced and future-ready public transport depots ever constructed in the region, the Rouse Hill Bus Depot.