Most of the intensive care unit and rooms in three wards at a major Hunter hospital were shut at the weekend for "deep cleaning" of mould that could harm patients.
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The Calvary Mater Newcastle had to transfer two stable patients from the ICU to wards for "clinical cleaning in ICU", an email to staff at 8pm on Friday said.
Staff said about five patients in total were transferred out of ICU.
The hospital also closed two wards in January due to mould in the air-conditioning ducts and maggots falling from vents onto patients.
This included the closure of a haematology day ward - also known as ward 5D - with cancer patients moved to another ward.
As the mould crisis at the hospital deepened, the Minns government said on Sunday that "critical cladding remediation works" would begin at the hospital "as soon as practicable".
Staff say the cladding will stop water leaking into the hospital, but that the mould is "being caused by the air-conditioning system and humidity".
They highlighted that temporary measures being used to manage and reduce the risk of the mould continue to fail.
"We are angry, shocked and deeply disillusioned with those in positions of authority," one staff member said.
"Staff are experiencing escalating psychological distress, burnout, moral injury and fear of speaking out."
An email sent to Mater staff at 8pm on Friday said "air quality testing results provided to hospital management today indicate slightly elevated levels of Aspergillus fumigatus".
This mould had been found in "the intensive care unit (ICU) and in a total of three rooms in Ward 4A, 4B, 4C".
"The results are not at a level considered dangerous to healthy individuals," the email said.
"Specific patient groups including those immuno-compromised, with severe respiratory disease and ICU patients can be vulnerable."
The email said a company called Medirest conducted "deep cleaning of the entire ICU, including clinical and non-clinical spaces and affected rooms in Wards 4A, 4B and 4C".
A hospital staffer said an "anaesthetic bay for a theatre came back positive for mould in 4A".
"4B is surgery. 4C is general medical. This is the first time they've tested all areas for mould.
"Rooms were cleaned by cleaning staff who were required to stay back at short notice with little warning. They felt pressured."
A Hunter New England Health spokesperson said "deep cleaning of impacted areas in clinical and non-clinical spaces is complete".
"Follow-up cleaning is being conducted. We will continue routine air testing for the duration of mould remediation works that are underway and being carried out by the facilities manager, Novacare.
"These works will take several months to complete and require replacement of mechanical systems and ductwork."
NSW Health Minister Ryan Park said improvement works to "the heating ventilation and air-conditioning system started on January 14".
The hospital's email to staff said management had "requested a full inspection of the HEPA filtration in each of the six ICU rooms".
Additionally, "hospital grade air purifiers" had been distributed "across all affected areas".
A hospital staffer said the air purifiers should be more widespread through the hospital.
"The mould is absolutely everywhere through the whole air-conditioning system."
Hunter New England Health said an inspection would be done of "the individual HEPA filtration systems" that supply affected areas.
"Additional portable HEPA filters are being deployed," the spokesperson said.
Mater management informed ICU staff of the mould issue about 5pm on Friday. By Sunday morning, after cleaning, patients had returned to the ICU.
A hospital staffer said the mould crisis was taking a toll on staff.
"The constant sudden disruptions are unsettling and exhausting. Staff just want to come to work, feel safe and do their jobs properly.
"Unfortunately, the situation at the Mater continues to unravel daily.
"The Mater now feels less like a cancer hospital and more like an episode of Stranger Things. Staff are on constant high alert, bracing for what may come next."
"Passive words of reassurance are no longer acceptable. It is incomprehensible that this situation has been allowed to continue for so long," a staff member said.
"Who is taking responsibility, and when will this be fixed? Patients continue to be exposed to potentially serious and preventable risks."
The mould has been linked in research to pneumonia.
A recently released Bureau of Health Information study found the Calvary Mater had "higher than expected mortality" for pneumonia, despite a statewide decrease.
The Mater is a public hospital run by a private company called Novacare, which is responsible for the buildings' maintenance and cleaning.
Honeywell is responsible for the hospital's maintenance and one of four companies that makes up Novacare.
Honeywell said last month that its scope of work did not include "rectifying structural defects or mechanical design, including cladding issues and facade leaks".

