The Project

In 2024, BHP completed the Nelson Point Wind Fence — part of its $300 million Pilbara Air Quality Program. Built in three sections on the western side of BHP’s Finucane Island port, the 31-metre-high fence uses structurally supported mesh panels to reduce wind speeds, which in turn minimises dust lift-off from iron ore stockpiles.

At over two kilometres long and ranging in height from 24 to 31 metres, this colossal structure is the first of its kind in Australia. Because the Pilbara is cyclone-prone, the wind fence is rated to withstand extreme wind speeds, with mesh curtains that automatically release under cyclonic conditions. During Tropical Cyclone Zelia, the fence’s design features performed exactly as intended.

The Challenge

The steel structure of the BHP Wind Fence comprises 169 main columns fabricated from steel pipe up to 31 metres long. Hundreds of large-diameter steel tubes are used for bracing and support, connecting the columns, carrying the mesh panels, and providing diagonal reinforcement to prevent movement or tilting.

The fence is divided into three sections: Fence A (816 m), Fence B (358 m), and Fence C (828 m). Fences A and B are located at Finucane Island, while Fence C is at Nelson Point. In total, the three wind fences contain more than 3,000 tonnes of structural steelwork. Because the structure is located close to the ocean, corrosion protection is critical. The marine environment exposes the steel to salt, which accelerates corrosion by attracting and retaining moisture. This creates a conductive layer that speeds up the electrochemical reactions responsible for rust formation.

The Solution

Ferro-Clean applied more than 36,000 litres of protective coatings to approximately 3,000 tonnes of structural steelwork for the project. The 169 main columns were coated at Ferro-Clean’s Office Road facility in Kwinana. To paint items 31m long and weighing over 18T, the Kwinana facility’s large blast rooms and more than 10,000 m² of painting space were essential in enabling smooth workflow and consistent throughput. Bracing and support steel were processed at the Maddington facility, allowing a large volume of steel to be completed to the deadline.

Ferro-Clean expanded into the Kwinana site in 2022 to increase capacity and free up room at its other facilities for specialised works such as platework coatings, ceramic tiling, and rubber lining. Major upgrades were completed at Office Road, including a second large blast room, installation of one of the largest blast machines ever built in Australia, and full concrete flooring – all of which substantially improved production capability and coating quality.