Reducing energy consumption by 37% and eliminating 137 tonnes of annual CO₂ emissions through ceramic thermal insulation at a remote Pilbara mining facility.

Project Details

Industry

Mining & Resources

Location

Pilbara, Western Australia

Facility

Mess / dining & commercial kitchen

Use Cases

Energy efficiency, asset protection, waterproofing, worker safety

Project Dates

Application 11–13 Dec 2024; post-application performance observed from 5–15 Dec 2024 and beyond

Product Credential

Thermoshield — Australian-made, true ceramic insulation coating (a genuine insulator, not a reflective paint)

Project Environment & Overview

Hope Downs 4 is a remote mining operation in the Pilbara where metal roof temperatures routinely exceed 60°C. The mess facility's commercial kitchen generated intense internal heat, forcing the HVAC system to run at full capacity throughout daylight hours. Powerhouse applied Thermoshield ceramic insulation coating over three days with zero disruption to site operations.

Impact Snapshot

37%

Reduction in energy consumption on monitored boards

18°C

Drop in maximum roof surface temperature

137t

CO₂-e avoided per year (≈ 2,264 trees)

558kW

Daily energy use reduction across monitored circuits

The Challenge

In the Pilbara's extreme climate, the mess and commercial kitchen at Hope Downs faced a compound heat problem:

Brutal Ambient and Solar Load: Metal roof temperatures routinely exceeded 60°C, driving heat into the roof assembly and dining areas during peak service.

High Internal Gains: Ovens, fryers, and dishwashers continuously radiated heat into the space, forcing the heating, ventilation, and air-conditioning (HVAC) system to work harder through the hottest part of the day.

Exposed Ductwork: Roof-mounted or externally routed ducts absorb radiant heat, elevating supply-air temperatures and creating condensation/mould risk on cold sections. An insulation-first fix was required to cut heat soak – the gradual absorption and re-radiation of heat through the building – and stabilise the air path.

Water Ingress and Corrosion: Wind-driven rain and capillary action at sheet laps, penetrations, and degraded sealants were causing leaks during summer storms. This repeated wetting accelerated corrosion at fasteners and joints, threatening structural integrity, electrical safety, and food-service hygiene due to risk of mould. Thermal cycling – the repeated process of materials being heated and cooled – widened gaps, compounding ingress and rust.

Energy and Emissions: Cooling demand spiked daily and peaked constantly during daylight hours, increasing consumption and Scope 1 emissions.

Operational Reality: The facility required a fast, non-disruptive intervention with no shutdowns, a robust warranty, and proven performance under cyclonic rain, dust, and high-UV conditions.

The team specifically needed an insulation-first solution, something that would impede heat flow through the building envelope, not just reflect sunlight, and simultaneously improve waterproofing and worker safety.

Industrial building roof with HVAC units in a remote, arid landscape
Aerial view of a white metal roof on a large industrial building with HVAC vents and ductwork, located in remote Australia.

The Solution

To tackle the sustained daylight-hour peaking on the cooling plant, Powerhouse applied Thermoshield ceramic thermal insulation coating to the mess roof, paired with minor roof repairs and targeted waterproofing. The solution was engineered to flatten consistent peaks by cutting roof and plenum heat soak so the HVAC could cycle rather than run flat-out.

This approach combined:

Australian-made Thermoshield ceramic thermal insulation coating (a true insulator, rather than a reflective paint) to reduce heat flux into the building envelop, flatten sustained daytime peaks, and restore compressor cycling.

Waterproofing and rust conversion at vulnerable junctions (laps, fasteners, penetrations, gutters), backed by a 10-year warranty.

Surface temperature reduction and thermal shock control – post-application roof maximum fell from 62.8°C to 44.8°C (-18°C), smoothing day-night swings and reducing thermal expansion/contraction that loosens fixings and accelerates corrosion.

Installation was completed over three days (11-13 Dec 2024), with no disruption to site operations, and was sequenced to avoid breakfast and dinner service peaks.

Ceramic Thermal Insulation
Rust Converter
10 Year Warranty

The Outcome (Overview)

37% reduction in energy consumption measured on monitored distribution boards.

558kW drop in daily energy use across the monitored circuits.

Maximum roof surface temperature reduced 18°C from 62.8°C to 44.8°C.

137t CO2-every year avoided (monitored scope) – equal to approximately 2,264 trees.

Immediate post-install storm test passed with no leaks or water ingress.

Safer access for maintenance – hot-surface burn risk substantially reduced.

Aerial view of a mining camp with accommodation blocks, large industrial buildings, sports courts, and red earth terrain in Pilbara, Western Australia
Aerial view of a remote mining camp with rows of accommodation buildings, recreational facilities, and industrial structures in the Pilbara region, Western Australia.

What Changed

Insulation Cuts Heat Flow, Lowers HVAC Load

Within days of application, the insulated roof assembly showed a sharp drop in surface temperatures and heat flux. By impeding conductive and radiative heat transfer through the metal sheet, compressor runtime and fan energy use were cut materially. Lower roof and plenum temperatures also reduced heat soak into exposed ductwork, improving supply-air stability and further lowering compressor cycling.

Waterproof, Durable, and Safer to Work On

The waterproofing program targeted the primary leak paths – laps, fasteners, penetrations, and gutters – eliminating known ingress points and converting active rust. After significant storms in December, the mess reported no leaks. By isolating metal from oxygen and moisture, corrosion progression was arrested, extending service life and reducing unplanned repairs. Lower peak surface temperatures also minimise thermal expansion and contraction cycles, protecting fixings and sheeting. The cooler surface further removes burn hazards for technicians.

Operational Continuity

The coating and repairs were scheduled around site activities, avoiding shutdowns. All work was completed on live assets with standard controls and access.

Ceramic Insulation vs Reflective Paint

What's The Difference?

Ceramic coatings act as insulation (low thermal conductivity plus thickness) to impede heat flow year-round. Most reflective paints mainly rely on high solar reflectance; they can cut summer sun gain but contribute little thermal resistance and may increase winter heating demand in cold climates.

How Ceramic Insulation Wins

  • Mechanism: Low-conductivity ceramic matrix and film thickness reduces conduction and radiant transfer through metal skins; reflective paints primarily reduce absorption on sunny days and add negligible R-value.


  • Year-Round Performance: Ceramic reduces summer heat gain and winter heat loss; reflective paints can be counter-productive in cold/cloudy seasons where more solar gain is desirable.


  • Peak Vs. Base Load: Ceramic flattens sustained daytime peaks and reduces evening run-on (less stored heat to purge). Reflective paints mostly trim midday peaks when sun is highest.


  • Ducts and Cold Surfaces: Ceramic lowers heat soak into exposed ductwork and reduces condensation risk on cold sections. Reflective paints have minimal impact on these paths.


  • Resilience and Maintenance: Ceramic systems are thicker, can bridge micro-cracks, and are less sensitive to soiling for performance. Reflective paint is rendered largely ineffective as soon as it's dirty or dusty, so it's a short term solution for heat and requires frequent cleaning to maintain reflectance.


  • Waterproofing Synergy: Our system integrates waterproofing and rust conversion, addressing ingress and corrosion alongside thermal performance.


  • Fuel and Emissions: By lowering both daytime peaks and after-hours run-on, ceramic insulation delivers more consistent diesel/gas fuel (Scopel) reductions on self-generation sites.


For cold-climate clients – that is, those in southern or high-altitude areas with colder winters or frequent overcast weather – ceramic insulation helps retain indoor heat and mitigate condensation; a purely reflective coating can increase heating energy in winter. Ceramic insulation is therefore the safer, all-season choice across mixed climates.

Whether planning new infrastructure or optimising existing operations, we're here to help you navigate what's next.

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Acknowledgement of Country

Powerhouse acknowledges the Traditional Owners of the lands on which we live and work, and pay our respects to Elders past and present.




Through our work and partnerships, we are committed to supporting First Nations communities to lead and benefit from the energy transition, creating lasting economic and social outcomes.

© All Rights Reserved.

Whether planning new infrastructure or optimising existing operations, we're here to help you navigate what's next.

Email

Acknowledgement of Country

Powerhouse acknowledges the Traditional Owners of the lands on which we live and work, and pay our respects to Elders past and present.




Through our work and partnerships, we are committed to supporting First Nations communities to lead and benefit from the energy transition, creating lasting economic and social outcomes.

© All Rights Reserved.

Whether planning new infrastructure or optimising existing operations, we're here to help you navigate what's next.

Email

Acknowledgement of Country

Powerhouse acknowledges the Traditional Owners of the lands on which we live and work, and pay our respects to Elders past and present.




Through our work and partnerships, we are committed to supporting First Nations communities to lead and benefit from the energy transition, creating lasting economic and social outcomes.

© All Rights Reserved.