Delivering complex construction in a live airport environment

SHAPE delivered the expansion and refurbishment of Sydney Airport’s T1 Pier B East Bussing Terminal within a live, high security environment, maintaining public access and daily terminal operations throughout construction.

Appointed by Sydney Airport Corporation under a Design and Construct model, SHAPE combined fitout, refurbishment and new construction to improve passenger movement, operational efficiency and the overall travel experience. Spanning the Departures, Arrivals and Ramp Levels, the redevelopment expanded the building footprint and improved connections through a new glazed lift tower, escalators, stairs and two feature voids. A standout achievement was the installation of a 3,000 kg OTIS glass lift, the largest-duty glass lift installed by OTIS in Australasia. A new boarding gate, refurbished gate lounges and bathrooms, and upgraded finishes and joinery completed the passenger-facing improvements.

Behind these spaces, SHAPE delivered structural strengthening, new roof structures, façade works and expanded plantrooms. Services diversions and plant relocations were coordinated alongside extensive integration of mechanical, electrical, fire, security, communications and passenger information systems.

Keeping the terminal operational required detailed staging and close coordination with Sydney Airport. Works were programmed around peak passenger periods and restricted overnight working windows, supported by operational readiness checklists at the start and end of every shift. Sound-rated and low-height hoardings, ramps, bird cages, tunnels and bollards helped manage construction activity while maintaining safe movement around the works. The team also resolved over 150 site conditions through proactive planning, contract administration and ongoing stakeholder collaboration, maintaining daily terminal operations as the project progressed.

The completed redevelopment provides better connections, refreshed amenities and more functional passenger spaces. It demonstrates SHAPE’s ability to deliver technically complex construction within a secure, operating environment while keeping the needs of passengers and the airport central to delivery.