Energy

We create custom-engineered precast components for large-scale energy projects, supporting complex infrastructure with precision and consistency.

Introduction

Wheatstone LNG Plant

Permacast expertly delivered the Wheatstone Gas Project, managing a highly complex and ambitious scope that required precision engineering, rigorous quality control, and innovative precast solutions. The project showcased our ability to produce a diverse range of specialised precast components, including culvert trench units, perlite-lined trench units, perlite wall panels, fire-rated wall panels, and robust firewall columns. Our approach demonstrated exceptional attention to detail, adaptability, and reliability, ensuring the highest standards were met across all aspects of manufacturing and delivery.

Project Overview

Permacast delivered highly complex precast elements for the Wheatstone Gas Project, including bespoke and expertly-engineered trench units, wall panels and columns.

Client

Laing O’Rourke

Location

Onslow

Duration

2015

Industry

Energy

Project Specifications

  • 975 Culvert Trench Units (average weight 20 tonnes)
  • 113 Perlite Lined Trench Units
  • 760 Perlite Wall Panels (average weight 170 kilograms)
  • 703 Fire Wall Panels (average weight 4 tonnes)
  • 254 Firewall Columns (average weight 14 tonnes)

Project Details

  • Each precast culvert unit was uniquely designed to precisely match the finished floor level (FFL) gradients and falls, ensuring perfect site integration.
  • Advanced 3D modelling was employed to guarantee constructability and manufacturing accuracy for every unit.
  • Originally intended as an in-situ solution, the project was adapted for precast components without compromising design integrity.
  • Products were manufactured to exacting standards, with stringent quality controls and comprehensive reporting throughout the process.
  • Detailed joint designs ensured watertight connections, eliminating leaks at in-situ interfaces.
  • Capacity to store up to 700 culverts enabled efficient just-in-time delivery, optimizing site logistics.
  • Utilised high-specification S50 low-heat concrete to achieve overnight strengths of 20 megapascals.
  • Maintained a consistent production rate with daily casting of six culverts, meeting tight project timelines.

Introduction

Gorgon LNG Plant

Permacast is manufacturing the reinforcement cages and precast elements for three new drill centres (DC-D, DC-E, and DC-F) at one of the largest LNG projects in the world, the Gorgon LNG Plant. Set to deliver 11,300 tonnes of precast foundations, along with pits, duct banks, U-Drains, transformer bunds and more – the scope of work has involved careful planning and specialised handling to meet the project’s demanding protocols.

Project Overview

Permacast is manufacturing and delivering the reinforcement cages and precast elements for three new drill centres on Barrow Island for the Gorgon LNG Plant.

Client

Ertech

Location

Barrow Islands

Duration

Current (commenced in 2024)

Industry

Energy

Project Specifications

When the project is complete, Permacast will have:

  • 748 precast foundations, weighing a total of 11,300 tonnes
  • 78 precast pits, weighing a total of 1,015 tonnes
  • 141 Duct Banks, weighing a total of 791 tonnes
  • 84 U-drains, weighing a total of 438 tonnes
  • 5 Transformer Bunds , weighing a total of 308 tonnes
  • 718 units of miscellaneous precast items, weighing a total of 710 tonnes

Project Details

When the project is complete, Permacast will have:

  • Delivered high-volume, heavy precast elements whilst maintaining strict quality standards.
  • Collaborated closely with client to achieve design and schedule demands.
  • Coordinated complex logistics and safe handling and transport of high-tonnage precast materials.