As Transport for NSW moves toward an all-electric bus fleet, depots across the state are being upgraded to support large-scale charging infrastructure.
Busways is a major private bus operator working in partnership with Transport for NSW to deliver public transport services across metropolitan and regional New South Wales. Operating under long-term service contracts, Busways manages depots and fleets that form a critical part of the state’s bus network, including facilities now being upgraded to support electric operations.
At Busways’ Penrith depot, that transition required a significant piece of structural work to be delivered within a live operational environment, to a schedule aligned with the opening of Western Sydney International (Nancy-Bird Walton) Airport.
NEPEAN Engineering was engaged to deliver the end-to-end structural solution for the steel gantry that supports overhead charging infrastructure above the buses. The work was critical to ensuring electric buses would be operational in time to service the new airport.
The challenge: Delivering electrification without disrupting operations
Penrith is one of the first bus depots to become fully electric under Transport for NSW’s requirement for Sydney’s bus fleet to transition away from diesel. Unlike a greenfield project, the electrification upgrade needed to be delivered while the depot remained fully operational.
NEPEAN Engineering was recommended to the project team by an engineer from Northrop who had prior experience working with the company, and was familiar with its capability to deliver complex structural solutions within constrained, operational environments.
“There was no option to pause operations while the work was delivered,” says Anthony McGlynn, Project Manager at NEPEAN Engineering. “We needed to design and install the structure in a way that allowed the depot to function as normal throughout the program.”
Around 130 buses depart the depot each day, leaving little margin for disruption. To maintain continuity of service, the total depot electrification program is being delivered over approximately two years, staged across two main phases to allow works to proceed while daily operations continue.
From detailing to delivery
NEPEAN Engineering was responsible for the full delivery of the structural steel gantry supporting the overhead charging system. This included completing the shop drawings, managing fabrication, blasting and painting, and coordinating transport and installation.
The final structure comprised a 60-metre long single-span gantry weighing approximately 40 tonnes. Fabrication was completed in sections and delivered to site across three loads, each around 4.7 metres wide. The longest section, measuring 22.5 metres, required specialist transport planning and coordination to safely access the depot.
As the design progressed, several changes were required to accommodate the charging infrastructure. NEPEAN Engineering managed these changes through the detailing process and provided expert advice on the most effective and economical methodology for fixing and attaching the charging componentry to the structure.
This ensured the final design remained practical to fabricate, transport and install within the physical and operational constraints of the site.
“Working in close collaboration with the customer and the engineer, across detailing, fabrication, trial fitting and installation, meant we could manage design changes quickly and keep the project moving,” Anthony says. “That integrated approach was critical in delivering a solution that worked both on paper and on site.”
Installation works were carefully sequenced to align with depot operations. By coordinating transport, lifting and installation activities around daily bus movements, the gantry was installed safely and efficiently while fleet operations continued.
No room for delay
The depot upgrade forms part of the broader transport network supporting the opening of Western Sydney International (Nancy-Bird Walton) Airport, which is scheduled to commence operations in 2026. Free bus services will operate at regular intervals between the airport and key centres including Penrith, Liverpool and Campbelltown, requiring electric buses to be operational from day one.
“The delivery timeline was fixed, and there was no flexibility around when the infrastructure needed to be ready,” Anthony says. “Our focus was on removing risk from the program and ensuring the gantry was delivered and installed with confidence against that deadline.”
By completing the structural gantry and enabling the installation of overhead charging infrastructure, NEPEAN Engineering helped ensure Busways’ Penrith depot was prepared to support electric bus services aligned with the airport’s opening and the expansion of zero-emission transport across Western Sydney.
With the gantry in place, Busways now has the structural infrastructure required to charge electric buses and support the transition of its fleet from diesel to electric.
Customer feedback highlighted the strength of the contractor experience, including clear coordination through a single point of contact, reliable delivery to schedule, and a consistent, solutions-focused approach throughout the project.
NEPEAN Engineering anticipates working with the customer on future depot modification projects across the greater Sydney area, as more facilities are upgraded to support electric bus operations.
