Eastern Sydney Shopping Centre Major Plant Upgrade
Project Overview
Brown & Moodie was engaged to deliver a comprehensive chiller and cooling tower plant upgrade at one of Sydney’s premier shopping centres.
The project involved replacing several hundred metres of large-bore riser pipework where a dilapidation assessment had identified wall-thickness deterioration and potential risk.
The complexity of the works successfully included hot tapping, high-pressure large-bore pipe freezing, major plant shutdowns and all executed within a live retail and commercial environment over the busiest trading periods of the year.
Client/ Builder: Beaver Williams
Sector: Retail Centre
Location: Eastern Sydney, NSW
Project Duration: 3 months
Scope: Chiller and cooling tower upgrade, including replacement of degrading riser pipework and associated plant systems
The Objective
The project’s objective was to upgrade the central plant while maintaining continuous operation of the shopping centre and adjoining office tower.
Key goals included:
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Improve system performance and reliability
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Minimise operational disruption during peak trading periods
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Deliver a high-quality installation within a strict timeframe
Challenges
This project presented significant access, scheduling, and operational challenges:
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Extremely tight program and restricted workspace
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Difficult access through low-clearance car parks and loading zones
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Live retail and office environments requiring careful coordination to avoid disruption
All works were undertaken while the centre remained fully operational, demanding precise staging, safety management, and after-hours scheduling.
Solutions and approach
Given the constraints of space, timing, and building occupancy, Brown & Moodie implemented a highly coordinated and flexible project delivery approach.
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Extended working hours: Crews operated from early mornings through to late evenings and night shifts to maintain program progress within the limited timeframe.
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Collaborative coordination: Close communication was maintained with the client, builder, security, and suppliers to manage deliveries, shutdowns, and site access.
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Staged integration: Connections to existing systems were completed during weekends using a combination of pipe freezing, hot tapping, and system drain-downs.
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Offsite fabrication and QA: Detailed sequencing and quality control of pipework fabricated in our workshops ensured safety and consistency throughout installation and commissioning.
Results and Impact
With more than 1,000 metres of large-bore steel pipework delivered through a low-clearance car park and a single goods lift, this project demanded meticulous planning and execution.
Despite the constraints, Brown & Moodie successfully completed the upgrade on time and within budget, ensuring uninterrupted operation of all building services throughout construction.
Technologies used
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Combination of roll-grooved, flanged, and fully welded connections for pipework, valves, and plant equipment.
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Scope included demolition, rigging, pipe freezing, hot tapping, TIG welding, and brazing activities.
