Delivering switchboards for a major healthcare precinct

The NSW Government’s $835 million John Hunter Health and Innovation Precinct (JHHIP) — an expansion and redevelopment of the existing John Hunter Hospital in Newcastle — is one of the state’s most significant healthcare infrastructure projects.

According to the government, the expanded facility will deliver a 60% increase in intensive care unit (ICU) capacity and almost 50% more theatres to the already busy hospital. Home to a major emergency department and critical acute services, the precinct demands exceptional electrical infrastructure — delivering reliability, safety and long-term performance.

Australian company Star Group was the lead electrical contractor, responsible for sourcing switchboards capable of supporting continuous hospital operations while also meeting strict compliance, delivery and budget requirements across the multi-year project. The company, which has more than 60 years of experience across complex electrical installations, opted for local switchboard manufacturer Fuji SMBE Macquarie.

“We chose to source all switchboards for the JHHIP project from Fuji SMBE Macquarie because we consider them a tier-one board builder that can deliver high-quality product at scale, within tight timeframes,” said Robbie Peel, Project Manager – Construction at Star Group.

All switchboards supplied by Fuji SMBE Macquarie were manufactured and assembled in Australia and designed and verified in accordance with AS/NZS 61439. In total, the project included approximately 14 large low-voltage main switchboards and more than 130 miscellaneous distribution boards installed throughout the eight-level facility.

“AS/NZS 61439 mandates rigorous design verification to ensure safety, reliability and performance,” Peel explained. “For a major government healthcare project of this importance, compliance with the standard was essential.”

The primary equipment supplied was a commercial low-voltage main switchboard (LV MSB), used for the distribution, control and protection of electrical power throughout the facility. The switchboards supply downstream distribution boards and final subcircuits while supporting safe operation, coordinated protection and maintainability within a high-fault-level environment.

Designed specifically for healthcare applications, these switchboards incorporated formed construction, fully type-tested switchgear, short-circuit withstand ratings suited to site conditions, and clear circuit identification to support safe installation, commissioning and ongoing maintenance. These features help minimise downtime and ensure operational continuity in critical clinical environments.

Beyond technical compliance, Peel praised Fuji SMBE Macquarie’s responsiveness during the project.

“We’ve worked with Fuji SMBE Macquarie on demanding projects in the past, and what sets them apart is their willingness to support us throughout the project,” he said.

“They were always available to respond to technical queries, provide additional information or supply components when requirements changed.”

Critical flexibility

For a project of this scale and duration, flexibility was a necessity. Fuji SMBE Macquarie supplied modular switchboards that allowed Star Electrical to accommodate evolving clinical and operational needs without disruption to the overall program.

“The project started around four years ago and is now nearing completion,” Peel said. “Over a timeframe like that, requirements are developed. The modular construction made it straightforward to implement changes as the client’s needs developed.”

Customisations delivered by Fuji SMBE Macquarie included bespoke compartment layouts and dimensions, integration of metering and monitoring equipment, site-specific ingress protection ratings, interface provisions for building management systems, and allowances for future load growth. It was important for all custom features to be implemented without compromising compliance with relevant Australian and New Zealand standards.

“Hospitals have very specific operational requirements, both now and into the future,” Peel said. “Having switchboards that are adaptable, while still meeting stringent safety and compliance obligations, was essential for this project.”

Australian manufacture: a key benefit

Local manufacture played a prime role in meeting project and whole-of-life objectives. The fact that Fuji SMBE Macquarie manufactures and assembles its switchboards in Australia means there can be more consistent quality control, reduced supply-chain risk, and long-term access to technical support and spare parts.

In addition to manufacturing and supply, Fuji SMBE Macquarie provided technical assistance during installation and commissioning, comprehensive as-built documentation, and test reports to support compliance, maintenance and future modifications.

Image caption: Fuji SMBE Macquarie supplied hundreds of switchboards with customised functions to Star Electrical, the lead contractor for the John Hunter Health and Innovation Precinct. Image: Supplied