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Hornsdale Wind Farm

The Hornsdale Wind Farm is located approximately 200km North of Adelaide, South Australia. CATCON was contracted to perform Balance of Plant civil works Hornsdale Windfarm on Stages 1, 2 & 3. Works included; design & construction of wind turbine foundations, crane hardstands, laydown areas, roads, foundation interface grouting, fencing, substation benches & Operation and Maintenance Facility for the 309Mw Wind Farm project.

Works were performed over a two and half year period with CATCON undertaking the Principal Contractor Role over all 3 stages. Some key challenges included Environmental and Cultural Heritage restrictions and the fast tracking of Stage 3 meant a tight time from award to construction. CATCON completed CBoP works ahead of program while maintaining a positive relationship with all stakeholders and the local community.

Main equipment used throughout the project included; D9 dozers, 25-40tn Dump trucks, 5tn-36tn excavators, 140h & 14H graders, WA380 loaders, pad foot rollers, smooth drum rollers, 825C Compactor, concrete pumps, Primary and Secondary crushing plants, telehandlers, 50tn-200tn cranes and drill rigs.

Facts & Figures:
Construction of 99 Wind turbine foundation bases for Siemens 3.3Mw wind turbines
Construction of 99 Crane hardstands and associated laydown area’s
Construction of 85 km of roads
67 tns high strength grout used
Onsite crushing & Placement of 280,000tns of pavement material
Placement of 38,000m3 of concrete
Placement of 4,400tn reinforcing
Construction of 19,800 individual foundation bolts in group sets of 200
Construction & Installation of 99 foundation bolt assemblies
110,000tns of foundation excavations







Internal Roadworks

WTG Base Earthworks

WTG Base Reinforcing

Steel Reinforcing

Concrete Pour to WTG Base

Complete Pour

Completed Turbines and Internal Roads

Sunrise at Hornsdale