Costin Roe Consulting produced a civil engineering report and water cycle management strategy, including TUFLOW 2D hydrodynamic flood modelling and assessment, to support an application for industrial development within the newly-defined Aerotropolis zone which surrounds the new Western Sydney Airport.

When the NSW Government confirmed Badgerys Creek as the location for Sydney’s much-needed additional airport, it was announced that residents and workers in Western Sydney will benefit from easy access to strong local and international connections and a “24-hour economy” conveniently centred around the new airport facility.

Continuing industrial development within Western Sydney Aerotropolis zone

Strategic planning for greenfield land in close proximity to the new airport, within the zone now defined as the Western Sydney Aerotropolis, is intended to unlock opportunities to deliver new jobs and homes supported by key infrastructure whilst conserving and improving environmentally-sensitive areas and wildlife habitats. The government’s vision for the Airpotropolis includes contributing towards the creation of 200,000 new jobs for Western Sydney and a new “high-skill jobs hub” across aerospace and defence, manufacturing, healthcare, freight and logistics, agribusiness, education, and research industries.

One challenge presented in the practical delivery of facilities and infrastructure needed to realise the Aerotropolis vision is that portions of land available for development within the zone have been classified as flood-affected. However, expert civil engineering practices in accordance with sustainable water management and environmental conservation guidelines can often mitigate the risk of flooding to allow for industrial development and improve the management and quality of water in a broad area surrounding the actual development site. Such improvements have been demonstrated in some areas now deemed to be within the Aerotropolis zone which had been developed for industrial and residential purposes under previous localised guidelines.

The Western Sydney Aerotropolis LUIIP (Land Use and Infrastructure Implementation Plan), released in September 2018, sets out the statutory pathway to be used for development applications within the Aerotropolis zone. There are also individual plans for the nine newly-defined Aerotropolis precincts which are:

Kemps Creek Warehouse, Logistics and Industrial Facilities Hub - Locality Plan

The site as indicated on the Kemps Creek locality plan.

  • Aerotropolis Core
  • Northern Gateway
  • South Creek
  • North Luddenham
  • Rossmore
  • Mamre Road
  • Kemps Creek
  • Badgerys Creek
  • Agriculture and Agribusiness Precinct

Costin Roe Consulting delivered 2D hydrodynamic (TUFLOW) modelling and assessment authored by Mark Wilson, B Eng (Civil) B Surv ME CPEng, Director of Costin Roe, the submission of which contributed to rezoning and development approval for an industrial complex on a flood-affected 43.85 hectare site at 585-649 Mamre Road, Orchard Hills, in the former Mamre West Precinct, for Altis Property Partners (developer) via Hansen Yuncken (project manager), in 2016. The firm is recognised for its expertise in hydrodynamic modelling and sustainable water management practices, being Highly Commended for ‘Excellence in Integrated Stormwater Design‘ in 2017.

Kemps Creek Warehouse and Logistics Hub development application process

By 2018, when Frasers Property and Altis Property Partners (the joint venture or JV) prepared to proceed with an application for the development of the Kemps Creek Warehouse and Logistics Hub at 657-769 Mamre Road, Orchard Hills, the site had become included within the Kemps Creek precinct under the Western Sydney Aerotropolis LUIIP. Some guidelines, references, and benchmarks would differ from previous successful development applications for nearby sites. Costin Roe Consulting was commissioned by the venture partners to prepare a Civil Engineering Report & Water Cycle Management Strategy (WCMS) to support the necessary State Significant Development (SSD) Application to the Department of Planning and Environment (DP&E), encompassing a formal request for the Secretary’s Environmental Assessment Requirements (SEARs) prepared by town planning consultants, Willowtree Partners. The proposed development would first involve earthworks and infrastructure development across the entire site, carried out in two stages, followed by the construction of warehouse facilities.

Mark Wilson, BEng(Civil) BSurv ME CPEng, Director of Costin Roe Consulting, author of the Civil Engineering Report & WCMS for the 585-649 Mamre Road development proposal.

The Civil Engineering Report & Water Cycle Management Strategy authored by Mark Wilson, assisted by Costin Roe’s TUFLOW modelling specialist engineer, Mitchell Cross, provided an assessment of the civil engineering characteristics of the development site and technical considerations of earthworks and geotechnical aspects; roads and access; and the WCMS. The WCMS addressed key water cycle management aspects including the stormwater quantity and quality, water supply and re-use, flooding, and erosion and sediment control. Consistent with environmental priorities in contemporary NSW industrial development, the overall environmental considerations relevant to the proposed development were defined in the Willowtree report as including soil and water, noise, air quality, flora and fauna; waste, Aboriginal and historical heritage, traffic and transport, visual amenity and design, infrastructure and services, and socio/economic impacts. The development is intended to contribute to employment opportunities in Western Sydney through an environmentally-sensitive, ‘Six Star’ rated estate and state-of-the-art warehouse and logistics facilities featuring the latest technology.

Validating suitability of 112-hectare site for industrial development

The total site proposed by the JV for development comprises 112 hectares with 1.1km direct frontage to Mamre Road. Predominantly clear of vegetation from historic pastoral use, free of both contamination issues and critical flora/fauna habitat, the site is relatively flat with a <1% slope producing a 4-metre cross-fall from the higher side, along Mamre Road, down towards the western boundary of South Creek and the portion of land identified as flood-affected.

An example of TUFLOW 2D hydrodynamic flood modelling for the report by Costin Roe Consulting.

In accordance with the requirements of Penrith City Council and the NSW Floodplain Development Manual, and referencing the Updated South Creek Flood Study¹, the flood assessment by Costin Roe Consulting confirmed that the floor levels of the proposed buildings near South Creek would be set at 1% AEP² flood level plus 500mm freeboard. Costin Roe used MUSIC (the Model for Urban Stormwater Improvement Conceptualisation) for stormwater quality modelling to simulate the performance of proposed stormwater management systems and ensure pollutant retention requirements would be met.

The Civil Engineering Report & Water Cycle Management Strategy by Costin Roe Consulting, including the Overflow Land Reports 1-3, formed part of the 2019 package of reports, plans, and other documents submitted for consideration and decision-making by authorities, and exhibited to the public on the NSW Planning Portal as the Kemps Creek Warehouse, Logistics and Industrial Facilities Hub, a major project for NSW. Approval will facilitate the development of a warehouse, logistics and industrial facilities hub including the construction and operation of nine warehouses comprising 163,671m2 of floor space, 754 parking spaces, and a 33-lot Torrens Title subdivision.


¹ Updated South Creek Flood Study (rp6033rg_crt150128-Updated South Creek Flood Study (FINAL – Volume 1)
² AEP stands for the Annual Exceedance Probability – the likelihood of occurrence of a flood of a given size or larger occurring in any one year






APEC Haus - Costin Roe Consulting Engineers

Costin Roe Consulting successfully designed the lifting beam for the raising of continuous 60 to 70 metre-long Kingspan insulated roof panels at APEC Haus, the US$37 million Leaders’ Conference Centre being constructed at Port Moresby, Papua New Guinea, in preparation for the APEC Summit to be held in November 2018.


Architectural illustration of the completed APEC Haus project [image: Jim Fitzpatrick Architects].

APEC Haus has been cited in PNG news media by the PNG prime minister, Peter O’Neill, as set to be “converted into a world-class museum” after the leaders’ meeting. “Many of our artifacts, thousands of years old and held in museums (elsewhere), we want to bring back here,” Mr O’Neill was reported as saying.

The PNG-focused employment website ‘People Connexion’ ranked APEC Haus as the second of “6 building projects set to change Port Moresby” in their APEC 2018 update.

Conrad Gargett was successful at tender for the documentation of APEC Haus Leaders’ Conference Centre, Papua New Guinea, designed by Jim Fitzpatrick Architects (Concept Design and Project Design Director).

The Conrad Gargett website describes the APEC Haus project:

Built on reclaimed land near Ela Beach in Port Moresby’s central business district, APEC Haus is an iconic design resembling a Lakatoi Sail. 

The interior design will also create a unique Papua New Guinea experience using a contemporary palette inspired by traditional materials of the region, shell, clay, timber and metal, to identify different functional spaces within the building.

It is envisaged that the purpose built convention centre will generate revenue after APEC, by hosting a gallery in addition to an upstairs function and conference space.

APEC Haus - Costin Roe Consulting Engineers

APEC Haus lifting beam designed by Costin Roe Consulting [image: Kingspan Insulated Panels Pty Ltd).

APEC Haus - Costin Roe Consulting Engineers

APEC Haus lifting beam designed by Costin Roe Consulting [image: Kingspan Insulated Panels Pty Ltd).

APEC Haus - Costin Roe Consulting Engineers

APEC Haus lifting beam designed by Costin Roe Consulting [image: Kingspan Insulated Panels Pty Ltd).

Costin Roe Consulting has congratulated Lipman Pty Ltd on winning a prestigious 2016 MBA Excellence award for the Veolia Woodlawn MBT facility construction at Tarago, NSW.

The award for site safety on a commercial project with a construction value of more than $50M is one of several sought-after industry credits recently received by Lipman, the firm also winning 2016 awards for works at 580 George Street, Sydney, Trinity Grammar School Aquatic Centre, and ARV Lober Square Redevelopment Stage 2 (housing) in the annual Master Builders Association (“MBA”) honours list.

Lipman receives MBA award for Veolia Woodlawn

Lipman cadet pictured with award

On behalf of Lipman, project engineer Mitchell Jeffries thanked all partners and participants involved in the Woodlawn Project following the MBA awards presentation event at the Star Casino, Sydney, on Saturday 5 November 2016, attributing the award to the “Daily Pre-Start & Zoning Procedures… incorporated on the project to assess and control high-risk activity.”

Costin Roe Consulting successfully completed the civil and structural engineering requirements for the Veolia Woodlawn MBT facility project on appointment by Lipman.

“It’s an honour for our firm to have been involved in the extraordinary environmental achievement represented by the Veolia Woodlawn MBT facility, and to work with Lipman for their uncompromising commitment to both quality of construction and site safety throughout construction,” said Grant Roe, managing director of Costin Roe Consulting, in response to the announcement of Lipman’s win for Woodlawn.

Comments on the project by MBA Awards judges were published on the MBA website as follows:

“This project was on a grand scale – 90,000m2 of site area – to use the Woodlawn Mine Site as a waste disposal facility. This required the property to be rehabilitated for agricultural use – no mean feat. The precision and orchestrated coordination of day-to-day operations judged was second to none, with the inclusion of elements such as 24m lengths of pipe installed within a 2mm tolerance, structural beams installed at 25m above ground level within 2mm +- tolerance, each welded joint x-rayed and certified. Integral to the cohesive manner in which the trades undertook their high-risk activities was the ability, where possible, to have trades working on their own designated multi work zones, mitigating the hazard of overlapping high-risk work activities when moving or installing infrastructure elements of a grand scale. A project where precision and wisely calculated decisions by the site team made quality the natural catalyst for excellent safety procedures on site to follow.”


Costin Roe Consulting devised the civil engineering strategy to support a proposal by DEXUS to continue industrial development in a former quarry. The report authored by Costin Roe director, Mark Wilson B Eng (Civil) B Surv ME CPEng, would assist to facilitate completion of the original master plan for the site.

Greystanes Estate is a 156-hectare area within the SEL (Southern Employment Lands) precinct of western Sydney, positioned between the cities of Parramatta to the east, Blacktown to the north, Penrith to the west, and Liverpool to the south. The majority of the eastern portion of the SEL has been developed into a high-quality industrial and business park, valued by corporate occupants and employees for its proximity to public transport, cycleways, and the M4, M5, and M7 motorways – the Sydney CBD only 33 minutes’ drive away. Greystanes Estate has been publicly renamed “Quarry at Greystanes” since the first stages of development were completed.

About DEXUS and Greystanes Estate

Quarry Greystanes location map

Map showing Quarry site in relation to major cities of western Sydney.

DEXUS is one of the largest listed owners and managers of industrial properties in Australia. Known for working in partnership with their customers, and construction specialists, DEXUS’ mission is to deliver industry-benchmark property solutions tailored to the specific needs of manufacturing, logistics, and warehousing organisations. Existing DEXUS developments within Greystanes Estate include a distribution centre of 20,000 m² with associated office spaces of 1000 m² and 500 m², completed in 2012.

The 2016 proposal by DEXUS would represent the final parcel of land in the industrial precinct of the Estate to be developed – an area of 25.6-hectares on the western side referred to as “Lot 18” in documentation and called “Quarry West”. As the final stages (5 and 6) of the approved concept plan for the entire site, development approval for Lot 18 would bring to completion the rehabilitation and re-purposing of the large open-pit quarry which Greystanes Estate once was. The quarry had provided crushed rock and blue metal for road and building construction across Sydney.

Costin Roe Consulting appointed to provide civil engineering services

Quarry Greystanes live webcam

Watch live webcam of the Quarry industrial centre at Greystanes.

Costin Roe Consulting has been involved with previous developments at Greystanes Estate including industrial complexes for Solaris Paper and Symbion Health, and was commissioned by DEXUS to report on the civil engineering and storm-water management aspects associated with the proposed subdivision and development of Lot 18. Approval to proceed would eventually culminate in the construction of several large-scale industrial buildings and depend on successful completion of numerous subdivision and infrastructure requirements. Classified as a “major project” for approval with NSW Department Of Planning and Environment (DoPE), Lot 18 also needed to meet the engineering and planning requirements of both Holroyd City Council and Blacktown City Council, within the context of the approved Masterplan Strategy for the Greystanes SEL, the expansive area of Lot 18 straddling the two council jurisdictions.

Mark Wilson, Director, Costin Roe Consulting

Mark Wilson, B Eng (Civil) B Surv ME CPEng, Director, Costin Roe Consulting

“As civil engineers engaged in support for the development application, our objectives were to create a development site which respected the proposed architectural layout, responded to the topography and site constraints, and provided an appropriate and economical stormwater management system,” said Mark Wilson. “The development would need to incorporate best practice in water-sensitive urban design, consistent with the water quality requirements of both councils.”

The report and engineering design by Costin Roe Consulting would refer to earlier studies and reports made in relation to the whole Greystanes Estate site by engineering firms including PSM, PB, and GHD; the Landcom publication Managing Urban Stormwater, Soils and Construction (1998) – The Blue Book; the Institution of Engineers, Australia publication Australian Rainfall and Runoff (1988 Edition), Volumes 1 and 2 (AR&R), and the NSW Department of Environment and Conservation document Managing Urban Stormwater: Harvesting and Reuse.

Unique site history presenting uncommon challenges


View of earthworks underway at DEXUS development site, Greystanes.

Located on the eastern edge of Prospect Hill, extensive quarrying for approximately 100 years had left Lot 18 with an irregular, crater-like topography. Historically, as part of quarrying operations, several areas of the site had been filled in an uncontrolled manner using a variety of materials at depths of up to 32m. The western boundary of the development area is formed by the walls of the former quarry and these walls extend some 40-50m above the proposed developed site levels. One section of walling had partially collapsed due to a landslip that occurred decades ago.

From 2001, however, there had been controlled filling of the site at certain intervals, and of the four areas subjected to uncontrolled filling during the site’s long operational history, three areas were previously determined as suitable for industrial loading without additional working.

Effective, economical civil engineering strategies

Mark Wilson determined that an additional 500,000-600,000m³ of fill would be required to bring the land to proposed levels through earthworks to be undertaken by CWJ Civil on behalf of Boral Pty Ltd, operators of the former quarry now helping to facilitate easier development by DEXUS, with roughly half of this requirement able to be met through the redistribution of suitable fill available on-site.

Symbion Health

Symbion Health facility developed by DEXUS at Quarry Greystanes, civil and structural engineering by Costin Roe Consulting.

The objectives with the earthworks were to allow the construction of the large flat building pads required for industrial use, with building levels above the 1 in 100-year (“Q100”) average recurring interval (“ARI”) flood level; facilitate site access to the proposed development site from nearby Reconciliation Road and the proposed internal road network; drain the stormwater from the development site, and facilitate the eventual industrial land-use applications. The steep embankments formed by the former quarry walls on the western side of the site would be stabilised, and the subsided section also remediated.

It was advised that the conditions of the site would need to be taken into account with building design. Pad footings would be suitable for foundations on controlled fill or rock, limited to a maximum safe bearing value, and piering would only be required to support buildings with high loads or tolerances over areas of uncontrolled fill. Comprehensive recommendations were also made by Costin Roe, in conjunction with the geotechnical consultants PSM, for the construction of slabs and pavements, site management requirements, erosion and sediment control, road widths and alignments, road pavement construction, and pedestrian facilities.

Emphasis on water conservation and water quality

DEXUS development Quarry Greystanes 2012

Solaris Paper facility developed by DEXUS at Quarry Greystanes, civil and structural engineering by Costin Roe Consulting.

Prior to preparation for development by DEXUS the site had no formal stormwater management or drainage. The design needed to incorporate the principles of Water Sensitive Urban Design (“WSUD”) to target the pollutants present in the stormwater so as to minimise the adverse impact these pollutants could have on the receiving waters, such as Prospect Creek. Collected roof water is generally free of pollutants, but a bio-retention system would be needed to address the gross pollutants, sediments, nutrients and hydrocarbons that are typically present in stormwater runoffs from car parks, roadways, and paved areas. Rainwater harvesting would provide for re-use as part of future individual building development applications and minimise the site’s future reliance on potable water supplies for purposes like flushing toilets and irrigating landscaped areas.

Regarding flood management, often an issue with industrial building development in some low-lying areas of Sydney, the development lots of the future Lot 18 subdivision would not be subjected to localised flash flooding, nor would the overall estate be affected by any larger regional flooding issues. Buildings would need to be set at a level 500mm above the Q100 ARI water level. Assessment by Costin Roe Consulting confirmed that the overall perimeter drain design completed by GHD in the early planning stages would be able to contain the Q100 ARI storm flow. The perimeter drains were re-documented by Costin Roe and constructed as part of the Boral earthworks exercise once approval for the subdivision and preparation of the site for development was achieved. DEXUS has successfully constructed several facilities in the northern and western sectors of Greystanes Estate, Costin Roe Consulting being involved in either or both the civil and structural engineering.

Quarry West panorama view

Quarry Greystanes - west aerial view

Mamre Flood Report

Commissioned by Altis Property Partners (developer), via Hansen Yuncken (project manager), Costin Roe Consulting undertook an overland flow (flood) assessment of 193 hectares of land in Orchard Hills, Sydney. The assessment was required to accompany an application for rezoning to facilitate the development of new industrial facilities on a 43.85-hectare subdivision.

2D TUFLOW hydrodynamic modelling by Costin Roe Consulting assisted in gaining the go-ahead for the proposed development – unlocking formerly unusable land to create business and employment opportunities, and improving the management of overland flow for the site and other land in the vicinity.

The assessment prepared by Mark Wilson, B Eng (Civil) B Surv ME CPEng, Associate Director (Civil Engineering) of Costin Roe Consulting, first involved building two-dimensional TUFLOW hydrodynamic modelling for peer review by Worley Parsons, the engineers of a flood study of the area by Penrith City Council. Assisting Mark Wilson with the detailed programming and configuration of the TUFLOW modelling was Mitchell Cross, one of Costin Roe Consulting’s team of flood modelling engineers with TUFLOW modelling engine expertise.

To achieve peer-reviewed validation, Costin Roe Consulting’s TUFLOW modelling was used by Mark Wilson to simulate the occurrence of a range of probable flooding scenarios on the area – in its undeveloped state – to show the accuracy of the firm’s two-dimensional modelling performance against the accepted numerical data.

2D flood modelling for report by Costin Roe Consulting

2D model of the 1% annual exceedance probability (1% AEP) flood levels in the Mamre West Precinct (before construction of the proposed development) as built by Costin Roe Consulting using TUFLOW hydrodynamic modelling technology.

Next, Mark Wilson used the validated TUFLOW modelling-build to calculate and illustrate the differences in flood levels, velocity, and general hydraulics for the same range of probable flooding scenarios following construction of the proposed development, which would happen in two stages.

Finally, the two-part assessment Overland Flow Report Stage 1 and Stage 2 by Costin Roe Consulting successfully informed the NSW Department of Planning & Environment, Penrith City Council, development partners, and various stakeholders on the mitigation and management of land overflow at the site during and after construction of each stage of the project.

As a result of the scenarios produced by the 2D TUFLOW modelling in the Costin Roe Consulting assessment, it was demonstrated that a large percentage of this flood-affected land could be developed, and was suitable for rezoning, which would allow the Altis-proposed industrial development to proceed.

Costin Roe Consulting’s mastery of the TUFLOW modelling engine, and expertise in producing two-dimensional simulations of floodwater behaviour pre/post-development, enabled everyone – including the broader community following exposure of the proposal – to more easily appreciate the benefits offered by the development proposed by Altis, and more favourably consider the statutory changes needed to allow civil works and construction to begin.

Area formerly categorised as ‘high hazard’ due to overland flow

The site proposed by Altis for the development of major new warehousing and logistics facilities was the 43.85 hectare subdivision of a larger parcel of land zoned ‘Rural Residential’. For the proposed development to be given the go-ahead, the State Environmental Planning Policy (Western Sydney Employment Area) 2009 would need to be amended, and the land rezoned ‘General Industrial’.

Located at 585-649 Mamre Road, Orchard Hills, the site lay within what is known as the Mamre West Precinct. The site was identified by Penrith City Council in the report known as the South Creek Flood Study (Worley Parsons) on the Mamre West Precinct as being affected by overland flow associated with adjacent South Creek.

During overland flow events as detailed in the South Creek Flood Study, floodwater on the undeveloped site would be shallow and of low velocity except for the north-west corner, where slow-moving water could potentially reach 1.1m in depth. This area had been categorised by Penrith City Council as a ‘high hazard’ zone.

With a residential area to the north of the proposed development, and Erskine Park Employment Area on the eastern side, Altis and its project partners would be compelled to show conclusively that the civil works planned to make the 43.85-hectare site viable for development would not increase the risk or hazard of inundation for properties neighbouring or upstream/downstream of the development when completed and the overland flow from South Creek re-occurred.

Development would provide new access road and formal drainage system

Mark Wilson, Associate Director (Civil Engineering), Costin Roe Consulting

Mark Wilson, BEng(Civil) BSurv ME CPEng, Associate Director of Costin Roe Consulting, took the lead role in the flood-modelling assessment for the proposed Altis development at Orchard Hills.

Costin Roe Consulting’s easy-to-understand TUFLOW modelling successfully demonstrated how the Altis development would ultimately mitigate and improve the management of overland flow on the site and surrounding area. This would be achieved via engineered land-filling and the building of infrastructure, including a formal drainage system, where none had existed before.

A new access road would be constructed as part of the development project and handed over to the City upon completion. Previously unusable land in a district with prime accessibility to greater Sydney would be made serviceable. More jobs would be located in the far western suburbs of Sydney, handy to residential population centres where the types of land suitable for new industrial developments are in short supply.

Rigorous examinations and consultations involving two levels of government

However, with the Department of Planning & Environment (NSW) the consent authority for zoning amendments under the State Environmental Planning Policy (Western Sydney Employment Area) 2009, and Penrith City Council as a key authority to be consulted due to Section C3.5 of Penrith City Council Development Control Plan 2014 and its guidelines for flood-liable lands, the development proposal had to satisfy rigorous examinations and consultative processes involving these authorities. This is where the external scrutiny of the Costin Roe Consulting 2D TUFLOW modelling-build by Worley Parsons helped meet the high standards of diligence applied by the two levels of government.

Positive feedback throughout the modelling process

“The Mamre Road flood assessment for Altis and Hansen Yuncken involved a high level of consultation with Penrith Council, NSW Department of Planning, and peer review by Worley Parsons. We received positive feedback throughout the modelling process,” said Mark Wilson of the Overland Flow Report Stage 1 and Stage 2 by Costin Roe Consulting. “We will be completing more 2D flood assessments of this nature in future.”



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