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
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