Duratec has completed a major concrete remediation and steel upgrade project at Newport Power Station in Victoria. As a result, the works will contribute to the continued safe and reliable operation of one of Australia’s critical energy assets.
Delivered for EnergyAustralia, the project required Duratec to design and install a new mezzanine floor system within a live operating power station. To achieve this, the team applied detailed planning, engineering oversight and disciplined sequencing. Consequently, the facility remained fully operational for the duration of the works.
Supporting a critical Victorian energy asset
Located on the west bank of the Yarra River, Newport Power Station is a gas‑fired intermediate‑load facility capable of generating up to 510 megawatts of electricity. Importantly, the station plays a key role in meeting periods of high electricity demand across Victoria, making asset reliability and safety essential.
Duratec was awarded the project in November 2024 under a design‑and‑construct contract. The team completed the works and de‑mobilised in April 2026.
Scope of remediation and upgrade works
Duratec’s scope focused on the replacement and remediation of approximately 50 square metres of flooring infrastructure. This included removing the existing concrete slab and installing new structural steel supports.
Specifically, the works involved:
- Installing a new structural steel support system, including framing and bracing
- Installing a Fibre‑Reinforced Plastic (FRP) grated flooring system to provide a durable, non‑conductive surface for an operational electrical environment
- Delivering targeted concrete remediation works adjacent to the new floor system
- Applying fireproofing to new steelwork in designated areas to meet safety performance requirements
In total, Duratec installed seven tonnes of structural steel, used around 1,500 litres of concrete repair product, and applied approximately 1.2 tonnes of fireproofing coating. Notably, the coating system — Chartek 1709 — required specialist training, which Duratec personnel successfully completed and were certified to apply.
Engineering solutions in a live operating environment
However, access constraints presented a significant challenge. In response, Duratec engineered bespoke access and scaffolding systems suited to the live environment. One temporary scaffold supported up to three tonnes of live plant, including a 500‑kilogram separation tank. This approach allowed crews to safely remediate the concrete floor beneath critical operational equipment.
Project delivery insight
Ehsan Negahban, Project Manager at Duratec, said the project highlighted the importance of collaboration and adaptability.
“This project demonstrates the importance of collaboration and adaptive delivery in complex operating environments, particularly when working within an active power station,” he said.
“By combining detailed design, disciplined sequencing and close collaboration with the client, we delivered the works safely while supporting the ongoing operation of this critical energy asset.”
