Benmax delivered mechanical systems for Newcastle Airport’s expansion, enhancing sustainability and efficiency through precision HVAC integration.
Benmax
The Newcastle Airport Terminal Expansion represents a major step in transforming the Hunter Region’s aviation gateway into a modern, sustainable transport hub.
As part of Construction Control’s delivery team, Benmax was responsible for the mechanical services scope, managing detailed design coordination, prefabrication, installation, and commissioning to ensure seamless integration across all building systems. The company’s work supported a smooth delivery process while enhancing comfort, sustainability, and operational resilience within the new terminal.
The scope included:
- Three chilled-water secondary pumps,
- Three heating-water secondary pumps,
- One air-cooled chiller,
- Two air-cooled multifunction heat pumps,
- Air-handling units servicing terminal zones,
- 50+ VAV terminals for localised climate control,
- Daikin VRF and standalone systems to support the communications and border-force areas.
Working with Johnson Controls, the team also delivered a new Building Management and Control System integrating energy sub-metering, CO²-based demand ventilation, and future interfacing capability with
flight-information systems.
Delivering high-performance HVAC systems within a live, operational airport required precise planning and close collaboration. Leveraging its experience in complex mechanical services delivery, Benmax adopted an integrated approach, combining design co-ordination, prefabrication, and commissioning, to minimise disruption, manage programme risk, and achieve building performance targets from day one.
“This project demanded meticulous sequencing, and extensive after-hours work to minimise disruption,” explained Matt Browne, Construction Manager – Newcastle.
The Benmax team coordinated closely with Construction Control and airport operations to schedule shutdowns, adhere to aviation-security protocols and maintain airside access controls. Passenger comfort, safety and continuity of services were prioritised throughout construction and commissioning.
A key driver of the mechanical design was the project’s sustainability target. The expansion aims to achieve a 5 Star Green Star “As Built” rating, shaping every major system decision.
“The target of achieving a 5 Star Green Star rating was central to every stage of design and delivery,” Matt said. The installed systems utilise low-GWP refrigerants (R1234ze and R454B), high-efficiency EC fan air-handling units, and variable-speed drives across pumps and fans to reduce energy use. Ventilation rates were engineered to provide 50% more outdoor air than required by AS 1668.2 to enhance passenger comfort and indoor
air quality.
To ensure ongoing operational performance, Benmax implemented comprehensive metering, commissioning, and building-tuning protocols. Airtightness testing, clean-air compliance to ASHRAE 62.1 and AIRAH hygiene standards, and staged performance verification were all documented to Green Star certification standards. The result is a flexible, efficient system built for long-term resilience.
One of the project’s defining innovations was the simultaneous heating and cooling system configuration. “We developed a high-efficiency mechanical solution using air-cooled four-pipe multifunction heat pumps in tandem with a low-GWP screw chiller,” Matt said. This arrangement enables heat rejected from one part of the terminal to be reused in another, significantly improving thermal efficiency and reducing electrical load. Combined with finely tuned BMCS control strategies, the system balances comfort, performance, and energy outcomes across varied terminal zones.
Coordination was critical to success. Benmax collaborated with Construction Control, multiple specialist trades, and airport management within a tightly governed interface framework designed to maintain passenger flow and operational continuity. Clear communication ensured every stage of work aligned with safety requirements and live terminal constraints.
Looking back on the project, Matt reflects on both its technical achievement and its regional significance. “We’re most proud of delivering a high-performance system that has helped transform Newcastle Airport into a modern, sustainable gateway for the Hunter Region. The project represents not just an engineering achievement, but a demonstration of how regional capability can deliver infrastructure to metropolitan standards.”
With the expansion now complete, the mechanical systems operate quietly behind the scenes — supporting comfort, efficiency, sustainability and the passenger experience.
For Benmax, the project stands as a high value reference point in delivering cutting edge HVAC infrastructure for aviation environments across Australia and beyond.
For more information contact Benmax, 33 Hincksman Street, Queanbeyan NSW 2620, phone 02 6122 3800, email administration@benmax.com.au, website www.benmax.com.au
