Rozelle Interchange

The McElligotts team had the pleasure of providing the protective coating for four additional bridge girders and the outriggers that will form part of the pedestrian land bridge that is currently being constructed for the Rozelle Interchange.

The Rozelle Interchange will consist of an underground motorway interchange between Sydney’s M4 and M5 and is a part of the larger WestConnex project. Overall, WestConnex is Australia’s biggest road project and is being overseen by John Holland and CPB Contractors. Once completed, these tunnels will provide a vital missing link between Sydney’s inner-west suburbs.

While the majority of the Rozelle Interchange project is taking place underground, a new 10-hectare public park space is also being built on top – which includes the construction of a new mixed pedestrian and cyclist land bridge.

The steel girders for this bridge have been fabricated by McElligotts long-term partner Haywards in Tasmania. The protective coating was undertaken by our Tasmania team, applied using airless spray in a workshop using products from Dulux Protective Coatings. The first coat was Zincanode 402, designed to protect steel for harsh corrosive environments, followed by Duremax GPE to the structure’s irregular areas such as its welds and edges. Next came a coating of Duremax GPE MIO to provide enhanced barrier protection to the girder’s surface. Finally, a topcoat of Weathermax HBR MIO was applied to provide lasting protection for all the parts.

McElligotts would like to express its gratitude to everyone on the team who worked on this special project as well as all our partners involved. The first two girders were delivered in November, while the other two will be ready in the new year.

Rozella Interchange Project

Farley Wastewater Treatment Works

The team at McElligotts have recently completed remedial work at the Farley Wastewater Treatment Works. This project was part of the larger upgrades occurring at the Treatment Works between 2020-2022 by Hunter Water, aimed to increase the capacity of the facility to meet the demands of the local population growth up until 2032.

The Farley Wastewater Treatment Works is located to the south-west of Maitland in the Hunter Region of New South Wales. The Plant currently treats up to 7.2 megalitres of effluent per day and can handle wastewater for over 50,000 people in Maitland and its surrounding regions. A $70 million upgrade to the facility has been taking place since 2020 that will result in an increased capacity and improved water quality at the Treatment Works.

McElligotts was contracted by John Holland to provide protective coating services to the large concrete chemical bunds at the facility. This process has involved our team abrasive blasting away the surface laitance from the chemical bunds before applying the coating system. Now that the chemical bunds have been fully coated, they will provide continual protection against chemicals containers and drums for years to come.

It was a pleasure having the opportunity to work on this project – as the McElligotts team acknowledge the small part they have played in helping the people of Maitland have continual access to clean drinking and non-drinking water. We would like to thank Hunter Water and John Holland for choosing McElligotts to work on the Farley Wastewater Treatment Works.

Tumut Penstock Snowy Hydro

The team at McElligotts recently had the pleasure of working on several penstocks located in Tumut 1 Power Station – a part of the Snowy Mountains Hydro Scheme in New South Wales. This job saw our team removing hazardous lead based paint and corrosion from the external penstocks 3 & 4 – each 2.5 metres in diameter.

We had to carry out our work during a power outage at the station, meaning we only had a short window of time in which to complete the task. We began by erecting scaffolds around the penstocks for access, as well as setting up a frame for encapsulation, air monitoring and waste management. Once the encapsulation was installed, we used a Hepa filter dust extraction unit to manage any lead dust particles that may escape during the abrasive blasting process. This was done to protect our workers and the power station’s crew.

With the abrasive blasting complete and the penstocks’ exteriors returned to their original surface, we used a vacuum unit to thoroughly remove any lead waste that was left over. Our final task was then to apply a primer, intermediate and final protective coating of paint per the Snowy Hydro paint specifications.

We would like to thank Snowy Hydro Limited for giving us the opportunity to work on this important project. On average, the Snowy Hydro power stations produce 4,500 gigawatt hours of renewable energy each year. Maintaining the penstocks is an essential step in ensuring that Snowy Hydro can continue operating at full capacity and provide power for the one million homes and businesses that they service.

Before:

Tumut Penstock Snowy Hydro Snowy Hydro Tumut Penstock Tumut Penstock

After:

Penstock Snowy Hydro

Snowy Hydro

Central Coast Stadium Lighting Towers

In 2020, the team at McElligotts were engaged to work on a project involving Lighting Towers 1 & 2 at Central Coast Stadium in Gosford. The stadium was built in 2000 and includes 4 slanting lighting towers that allow for matches to be played, viewed, and broadcasted at night. Our job was to clean away any corrosion and apply a high build epoxy and polyurethane finish to the entire steel structures of 2 of these towers.

Our work began in June 2020 by erecting scaffolding with work platforms around the towers before encapsulating them with containment sheeting. After that, our team used high pressure water to wash the lighting tower’s steelwork and abrasive blasted any isolated corroded areas. We then spot prime prepared those corroded areas with an epoxy zinc rich primer. This first stage of the project ended with us hand abrading the steelwork of all existing sound paint coating.

The next step was applying a Surface Tolerant 2-pack high build epoxy to the steel structure of both lighting towers. This was followed by applying a 2-pack high build polyurethane finish coat to ensure the towers will continue looking fresh over a long period of time. All that was left was our team dismantling the containment setting, work platform, and scaffolding, and by October 2020, Central Coast Stadium had Lighting Towers 1 & 2 looking as good as new.

We would like to thank our hardworking team for showing their skills, expertise, and experience in completing this project to the high standard that we always strive for at McElligotts. We hope that the people of Gosford and the Central Coast region can now enjoy watching and playing sports under the glow of their freshly cleaned and painted lighting towers.

Ryde Bridge

In February 2017, McElligotts was contracted by Duratc on behalf of Maritime Services to complete the rehab and painting of the Ryde Bridge, a steel bridge structure with two truss spans, a central lift span and approach spans.

The Ryde Bridge is located just west of the Sydney CBD and connects Ryde in North Sydney to Rhodes in Sydney’s West, spanning the Parramatta River. Constructed in 1935, this bridge replaced the need for ferries to carry supplies between these two points, creating a new convenience for road traffic, bikes and pedestrians. In addition, Ryde Bridge has significant significant local history being the only lift span bridge on Sydney Harbour since these types of bridges are no longer designed and built. Since its construction, Ryde Bridge has proved an important transport route for outer suburbs to access inner Sydney via car.

As part of the rehabilitation, McElligotts had to perform strengthening repairs on the entire bridge which included:

  • 11, 000 sqm of riveted steel truss
  • Establishment of scaffolding and level A containment
  • Safe working areas and maritime vessel management
  • Abrasive blasting
  • Safe removal of the lead-based coating bridge below deck
  • Application of the new protective 3 coat system

Ryde Bridge Repairs

Snowy Hydro

An international engineering marvel both today and at the time it was devised, the Snowy Mountains scheme, or Snowy Hydro, is a network of sixteen dams, seven power stations and 225km of pipelines and aqueducts in Southern New South Wales. The sheer scale of the project required 25 years of continual construction and connected new Australians with regional communities in the process. The project provides over 30% of the renewable power on the Eastern Australian electricity grid, which runs from Rockhampton to Melbourne, Adelaide and Tasmania.

Even today, talking about the Snowy Mountains scheme both conjures up memories for older Australians and inspires younger, technically minded Aussies. Such is the reverence for the scheme in Australian culture, that a Snowy Hydro 2.0 is in the works to deliver more renewable energy across the Eastern Australian grid. It’s a project that is cemented in Australian history as one of our defining moments, and as one of our first renewable energy projects, it’s helped ease the impact on our beautiful environment.

Over two decades ago, McElligotts had the pleasure of working on this iconic piece of Australian infrastructure. On what was the largest project we’d ever undertaken at the time, we applied specialised protective lining to 1.5km of 3m steel pipes. As both the stakes for failure and the quality demanded from the client were extremely high, we imported cutting-edge robot spraying technology from the United States to assist with the job. It allowed us to complete the massive undertaking in less than 12 weeks, with some of the most uniform paint depths we’d ever seen at the time.

This was one of the first times such technology was used in Australia and marked a turning point in McElligott’s history. Since that time, we’ve continued to invest in new technologies to provide efficient, durable and consistent results for larger infrastructure and construction projects.

Snowy Mountains System

In addition to honing our own capabilities and providing enhanced protection to vital piping in the Snowy Hydro scheme, we had the opportunity to employ over 60 locals in the process. The Snowy Hydro scheme is a vital part of the local economy and we were beyond pleased to work with locals and hone the skills of our existing workers.

Check out company director John McElligott discuss the Snowy Hydro project  in more detail below, and if you have any questions or would like to discuss an upcoming project with McElligotts then please get in touch.

 

Kangaroo Valley Pipeline Relining

From April to September 2013, McElligotts was contracted to work on the Kangaroo Valley pipeline by the Sydney Catchment Authority. It was a large job involving a complete strip and relining of a 1.8Km long, 2.6m wide pipeline.

The pipeline had only two access points, which definitely brought some hurdles throughout the project. Our initial work was to remove the old vinyl ester coating from the steel before abrasive blasting with our robotic blaster system. All waste from the old coating had to be safely removed from the pipeline using a commercial vacuum system. Once the required profile was created, we relined the piping with a solvent-less epoxy lining with robotic spraying equipment. Learn more about our specialised coating application services.