Holsworthy Barracks Critical Water Infrastructure Upgrade

Scope

Upgrade of critical water mains infrastructure servicing at Holsworthy Barracks, including:

Valve Infrastructure

• Supply and installation of 2 x DN375 sluice valves and 1 x DN225 sluice valve
• Installation of 3 x DN225 risers with surface-level valve covers
• Integration of SS316 stainless steel flanges, Gibault connections, bolts, nuts, and washers

Custom Junction Works

• Fabrication and installation of a custom PE100 4-way junction with DN450 outlet
• Precision engineering to meet exact specifications and operational requirements
• Quality control and testing of fabricated components

Civil Works

• Complete trenching, bedding, compaction, backfill, and reinstatement
• Excavation management in confined and complex underground environments
• Site restoration to Defence standards

Plant & Equipment

• Supply and use of heavy plant, including 22.5t and 5.5t excavator, positrack, and a 4t tipper
• Specialized equipment deployment for precision water infrastructure works
• Coordinated logistics and equipment management

Challenges & Context

The works were carried out under a time-critical weekend shutdown window to minimise operational disruption. During execution, upstream valves failed to seal, resulting in high water flow into the excavation. Our crew safely completed the installation of two DN375 valves under pressure—while managing continuous dewatering and confined excavation access. Additional complexities included:

• Relocation of a Telstra pit
• Coordination of fabrication lead times within a 3-week window

Critical Operational Constraints

• Time-Critical Weekend Shutdown: Limited window to complete works without disrupting base operations
• Upstream Valve Failure: Unexpected high water flow into excavation requiring immediate adaptation
• Under-Pressure Installation: Safe completion of DN375 valve installation while managing water flow
• Continuous Dewatering: Managing water ingress throughout the installation process
• Confined Access: Working within restricted excavation spaces with safety protocols

Technical Complexities

• Telstra Pit Relocation: Coordination and safe relocation of telecommunications infrastructure
• Fabrication Lead Times: Managing custom PE100 junction fabrication within 3-week delivery window
• Precision Installation: Exact alignment and installation of custom 4-way junction components
• Quality Control: Ensuring all connections and installations met Defence infrastructure standards

Risk Management

• Real-time adaptation to unexpected water flow conditions
• Safety protocols for under-pressure valve installation
• Continuous monitoring and dewatering operations
• Coordination with Defence operations and security protocols

Outcome

Despite significant technical challenges, the project was completed 14 hours ahead of schedule, preventing disruption to water services at the facility.

Project Achievements

• Ahead of Schedule Delivery: Completed 14 hours ahead of planned timeline
• Zero Service Disruption: Maintained critical water services throughout installation
• Technical Excellence: Successfully managed under-pressure valve installation
• Safety Performance: Zero incidents despite challenging working conditions
• Quality Delivery: All installations met or exceeded Defence infrastructure standards

Technical Success

• Successful installation of all valve infrastructure under challenging conditions
• Custom PE100 4-way junction fabricated and installed to exact specifications
• Complete site restoration and reinstatement to Defence standards
• Effective coordination of heavy plant and equipment deployment

Operational Benefits

• Enhanced water infrastructure reliability and capacity
• Improved valve control and system isolation capabilities
• Reduced future maintenance requirements
• Strengthened critical infrastructure resilience

Demonstration of Expertise

This project highlighted Odina Industries' ability to adapt to unexpected technical challenges while maintaining safety, quality, and schedule performance. The successful under-pressure valve installation demonstrated advanced technical capabilities and commitment to operational continuity within Defence environments.