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.

Construction of concrete foundations for renewable energy systems in remote Australian industrial site with tools and machinery.
Powerhouse Renewables Group installation in remote Australian outback with vehicles and equipment
White Tesla charging at an electric vehicle fast charger in remote Western Australia.
Powerhouse Renewables Group electric vehicle charging station in remote Australia at night

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.

Powerhouse Renewables Group team members pose next to electric vehicle fast chargers in Western Australia.
WA EV Network fast charger in remote Western Australia at sunset
Aerial view of a remote industrial facility in the Australian outback with solar panels and dirt roads, representing Powerhouse Renewables Group's solutions for demanding environments.

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.

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.