
Delivering 12 EV charging stations across 27 remote Western Australian sites as principal contractor, compressing seven-month timelines to two days per site.
Project Details
Industry
Government Infrastructure / Energy
Location
Regional and Rural Western Australia
Facility
Public EV charging stations across Horizon Power network
Use Cases
Remote infrastructure delivery, principal contracting, in-house multi-trade capability
Project Dates
August 2023 – May 2025
Product Credential
Remote concrete solution - pre-casting methodology to manage concrete needs in remote locations
Project Environment & Overview
Western Australia's EV charging highway spans 7,000km from Mundrabilla to Kununurra, with 110 charging points across 49 locations. Horizon Power struggled to find contractors capable of delivering the full scope at remote sites. Powerhouse was engaged as principal contractor across 12 stations, delivering every trade element in-house — from electrical and concrete to welding and logistics.
Impact Snapshot
12
EV charging stations delivered as principal contractor
27
Horizon Power sites across regional WA
2 Days
Per site once methodology established (down from ~7 months)
100%
Scope delivered in-house (no subcontractors)
The Challenge
WA is now home to one of the world's longest connected electric vehicle (EV) charging highways – a 7,000km route stretching from Mundrabilla in the south to Kununurra in the north, with 110 charging points across 49 locations.
Building electric highways and expanding public charging infrastructure was deemed critical by government stakeholders in encouraging wider EV adoption in the community. Delivering this infrastructure, however, was complex for the companies responsible – Horizon Power and Synergy. Each charging station presented two distinct challenges:
Remote Site Locations: Scattered across some of WA's most isolated terrain, contractor mobilisation was difficult, expensive, and logistically demanding. Reliable connectivity was also non-negotiable – commissioning each station required live communication with engineers, meaning unreliable technology wasn't an option.
Complex Scope: Building each station required a combination of technical skills – electrical works, concrete footings, trenching, rigging, and welding – that are rarely found together within one organisation. For most, that meant subcontracting small, fragmented parcels of work: difficult to coordinate, difficult to price, and unappealing to take on. As a result, Horizon Power struggled to secure contractors willing and able to deliver the full scope, and timelines at some sites blew out significantly.




The Solution
To tackle the sustained daylight-hour peaking on the cooling plant, Powerhouse Renewables Group applied Thermoshield ceramic thermal insulation coating to the mess roof, paired with minor roof repairs and targeted waterproofing. The solution was engineered to flatten constant peaks by cutting roof and plenum heat soak so the HVAC could cycle rather than run flat-out.
The approach combined:
Australian-made Thermoshield ceramic thermal insulation coating (true insulator — not a reflective paint) to reduce heat flux into the building envelope, flatten sustained daytime peaks, and restore compressor cycling
Waterproofing & rust conversion at vulnerable junctions (laps, fasteners, penetrations, gutters), backed by a 10-year warranty
Surface temperature reduction & thermal-shock control: Post-application roof max fell from 62.8°C → 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 lunch and dinner service peaks.
In-House Multi-Trade Delivery
Pre-Cast Footing Methodology
Starlink-Enabled Commissioning
The Outcome (Overview)
12 EV charging stations delivered across 27 Horizon Power sites as principal contractor.
Delivery timeframes reduced from approximately seven months to as little as two days per site once methodology was established.
Pre-cast footing methodology developed and proven in the field.
All projects delivered on time and on budget.
Full scope delivered in-house: electrical, concrete, trenching, rigging, welding, and logistics.
Ongoing Operations and Maintenance (O&M) contract secured with Horizon Power.



What Changed
This program of work marked a turning point for Powerhouse. It was the first time the business stepped into the role of principal contractor on a project of this complexity and multi-disciplinary scope – and we delivered. We refined the methodology with each successive site, and what began as a two week process was ultimately compressed to two to four days per site without compromising quality.
The result was a demonstrated, repeatable capability for remote infrastructure delivery that few competitors can match. Powerhouse is now the contractor of choice for Horizon Power's ongoing maintenance of the network, with an O&M contract that reflects the trust built through consistent, high-quality delivery.
More broadly, this project showed what is possible when a contractor combines genuine in-house capability with a willingness to problem-solve in the field. The pre-cast footing system, the Starlink-enabled commissioning process, and the end-to-end logistics model are now core parts of how Powerhouse approaches remote infrastructure and partnering with clients operating in similarly complex delivery environments.