Scale and Operational Design
Spanning a total of 93,000 square metres, the facility is a multi‑storey, temperature‑controlled distribution centre designed to support chilled and fresh food operations. Warehousing is spread across two floors to maximise efficiency. The site also includes integrated truck wash and refueling facilities to support high‑volume logistics movements.
The overall design prioritises operational reliability, efficient material flow, and temperature consistency at scale.
Location and Logistics Advantage
The centre is located within Charter Hall’s Light Horse Logistics Hub in Sydney’s western corridor, positioned at the junction of the M4 and M7 motorways. This location provides direct access to major freight routes and improves delivery timeframes across New South Wales. The site’s positioning supports faster turnaround for transport operators and ensures consistent delivery of chilled products to stores.
Construction Progress and Scale
Construction commenced in late 2024 and has advanced at pace, with more than 1,000,000 work hours recorded to date. The project spans a 31,818 m² fresh distribution centre and a 24,560 m² chilled distribution facility, highlighting the significant scale of the development.
Protective Coatings Scope
Action Alliance were responsible for the application of protective coatings to structural steel, encompassing both offsite fabrication and onsite installation works. Two protective coating systems were specified for the project, with coatings applied either in the fabrication yard or onsite, depending on steel origin, handling, and installation requirements.
The coating specifications were developed by Dulux® Protective Coatings specialists Roger Tobler, Jack Jaber, and Darren Brewer, ensuring long‑term durability, corrosion protection, and compliance with fire performance requirements.
The Link Bridge was painted at Action Alliance’s Victorian workshop, where all components were fully abrasive blasted and coated during fabrication. Unlike other project steel, Link Bridge components received a four-coat system offsite, prior to delivery to site.
The full system applied comprised of:
• 1st coat: Dulux® Durepon® EZP epoxy primer at 75-microns DFT, is an inhibitive epoxy primer formulated with anti‑corrosive pigments to deliver effective corrosion protection.
• 2nd coat: Dulux® FIRETEX® FX6010 @ required FRL thickness requirements.
• 3rd coat and Topcoat: Dulux® Weathermax® HBR a high‑build polyurethane topcoat, applied at 75-microns DFT each, delivering long‑term weathering performance and colour retention.
On‑Site Steel and Fire Protection
Steel columns fabricated overseas arrived onsite pre‑blasted and primed, while locally fabricated Link Bridge components painted onsite at Action Alliance’s yard.
Onsite works focused on fire protection and completion of the protective coating system, including the spray application of approximately 3,000 litres of FIRETEX® FX6010 to achieve the required fire resistance level (FRL) thicknesses.
Weather exposure and durability requirements were addressed through the application of two coats of Weathermax® HBR in N35 Light Grey, each applied at 75-microns DFT, forming the final protective topcoat layers. These were applied by brush and roller where required to achieve the specified film build.
Columns exceeding 20 metres in height required specialised spray equipment and tailored application methods. On‑site samples were prepared to verify adhesion performance over the existing primer system
“FIRETEX® FX6010 delivered fast drying times, consistent film build, and reliable performance in cold temperature conditions. Its successful application on this project represents Action Alliance’s first major intumescent coatings deployment using FIRETEX® FX6010 in New South Wales, setting a new benchmark for future fire protection works,” explains Jack.
Image courtesy of Action Alliance.
