Completed in 2020, this 604-bed facility provides accommodation for Woodside Energy's fly in/fly out workers. The village also includes a swimming pool, sports courts, gym, kitchen/diner and a central administration hub.

Our WA team provided specification and application support throughout the design and build. There were different specifications for various elements of the build, including structural steel (both covered and exposed), and external steel doors and doorframes.

"We worked closely with the project team to ensure each substrate received adequate protection, taking into account the specific environment it would be exposed to," explains Joel Bock, Dulux Protective Coatings' State Sales Manager.

Protecting structural steel inside and out

The structural steel received a three-coat specification. For extra protection, spot priming was also completed on the interior rafters and exterior exposed beams.

• First coat shop applied: Dulux® Durezinc™ i90 was applied at 75-microns (µm)
• Spot primer repairs onsite: Dulux® Zincanode® 402 at 75-microns (µm)
• Second coat: Dulux® Durebild® STE MIO at 100-microns (µm)
• Topcoat: Dulux® Weathermax® HBR at 75-microns (µm)

A dual-location application process was used for the structural steel, with the priming coats applied in a Perth workshop. This ensured the steel was well protected for its journey north.

On site, an intermediate coat of Durebild STE MIO was followed by a topcoat of Weathermax HBR. Dulux Northwest Territory Manager Kevin Johnston explains: "Durebild STE provides excellent barrier protection for steelwork. The addition of micaceous iron oxide (MIO) is ideal in high UV environments."

Steel doors and doorframes

The external doors and doorframes received a different specification.

• First coat: Dulux® Luxaprime® ZP at 75-microns (µm)
• Second coat: Dulux® Aquanamel® Gloss at 19-microns (µm)
• Topcoat: Dulux® Aquanamel® Gloss at 10-microns (µm)

"Luxaprime ZP is a high build anti-corrosive primer. With both zinc phosphate and micaceous iron oxide pigments, it combines excellent protection with single pack convenience," Kevin says.

Application support

Kevin was on site in Karratha to assist with the brush and roller application. With the applicator using Dulux Protective Coatings for the first time, Kevin explained the Inspection Test Plan (ITP) and the importance of achieving the correct DFT for full product performance. He also worked behind the scenes to ensure a timely supply of stock for this large-scale project.

"The clients were extremely pleased with the results," Kevin says. "They found great value in the custom specification and on-site support.”