Case Study
Department of Transport & Main Roads Chiller Upgrade
Here's a showcase of past work completed by SABE Services Group
Client: Department of Transport & Main Roads
Sector: Government
Duration: 2 weeks
SABE Services Group recently completed a major HVAC infrastructure upgrade for the Department of Transport and Main Roads (DTMR) in Loganholme. Delivered by our experienced projects team, the works involved the replacement and upgrade of a 330kW chiller, along with associated pipework modifications and electrical upgrades to support the new system.
The Department of Transport and Main Roads is a key Queensland Government agency responsible for delivering safe, efficient, and sustainable transport infrastructure and services across the state. Managing an extensive network of roads, public transport systems, and customer service centres, DTMR plays a vital role in connecting communities, supporting economic growth, and improving everyday mobility for Queensland. Maintaining dependable building services across its facilities is essential to ensuring staff can continue delivering these critical services to the public.
The project was carefully planned and executed to minimise disruption to building operations while ensuring a seamless transition to the upgraded plant. As a result, the facility now benefits from a more reliable and efficient air conditioning system designed to support occupant comfort and long-term performance.
Challenge
The existing chiller had exceeded its expected service life and was operating on only one circuit following a partial failure, significantly reducing its performance and reliability. With the system nearing total failure, SABE Services Group was engaged to source and deliver a suitable replacement chiller as a matter of urgency, despite industry lead times of up to 20 weeks for comparable equipment.
During the initial site assessment, our electrical technicians identified that the existing mains power cabling was undersized and unsuitable for the new chiller installation, requiring a full upgrade to meet current load demands and compliance requirements. Further complexity was created by the location of the Main Switchboard (MSB) in the basement, with existing mains cabling routed underground through conduit to the external chiller compound.
Just days before the scheduled replacement works were due to commence, the ageing chiller suffered a complete failure, escalating the urgency of the project and increasing the importance of delivering a rapid, well-coordinated solution to restore cooling to the facility.
Solution
SABE Services Group responded quickly to the critical failure by identifying a suitable 330kW R32 chiller that was readily available in stock, avoiding extended lead times while still meeting the building’s specific cooling demands and the site’s limited electrical capacity. The selected unit incorporated an integrated hydronic module and expansion tank, allowing the team to simultaneously replace the ageing pump infrastructure and improve overall system efficiency and reliability. To further manage electrical constraints and protect the system during startup, a soft starter was installed to reduce inrush current.
Our in-house electrical team delivered a comprehensive upgrade of the site’s power infrastructure, installing new mains cabling on elevated cable trays within the basement car park to meet current standards and the requirements of the new plant. Following the removal of redundant cabling from the existing underground conduit, new cabling was installed and prepared for seamless connection to the chiller.
Throughout the project, SABE Services Group also provided a temporary cooling solution to maintain comfortable working conditions within the building, allowing occupants to continue normal operations while the upgrade works were completed.
Results
Following the successful completion and commissioning of the project, the new chiller was fully operational and seamlessly integrated with the existing pipework system, complete with new insulation and protective cladding.
The upgraded plant now provides reliable, energy-efficient cooling throughout the facility, significantly improving system performance and reducing the risk of future breakdowns.
With modern equipment in place and supporting infrastructure upgraded, the Department of Transport & Main Roads can now benefit from a dependable air conditioning solution that enhances occupant comfort, supports day-to-day operations, and delivers long-term value for the site.
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