Warragamba Pipeline Coating Remediation

Doolee were awarded the second stage of the Warragamba Pipeline Recoating which involved the abrasive blasting and coating of over 900 meters of pipeline. This included the application of an inorganic zinc primer followed by the application of 3 coats of oleo‑resinous aluminium topcoat. The project was unique in its complexity as all coating works were performed on a live pipeline, ensuring there were no disruptions to its operations during peak summer months. Our work on the Warragamba pipeline is a key part of our broader commitment to infrastructure asset management for critical water utilities across Australia.

To ensure optimal conditions for the coating application, our team deployed multiple dehumidifiers to reduce the high dew point temperatures experienced during summer. Additionally, the project required the erection of scaffolding and the installation of shrink‑wrap encapsulation to provide a controlled environment for surface preparation and coating. These measures were crucial in minimised contamination and ensuring longevity of the applied coating system.

Challenges

• Summer conditions presented challenges due to high dew point temperatures. Our team used multiple dehumidifiers to create suitable working conditions, ensuring that the coating system cured without complications.
• Operating on a live pipeline.

Highlights

• The entire scope of work was completed without any interruptions to WNSW’s operations or Sydney’s water supply.
• Successful application of a thin film of inorganic zinc primer, achieving a smooth finish free of mud cracking.
• A dedicated crew of eight competent blasters and four skilled applicators, supplemented by trade assistants, was mobilised to ensure smooth workflow and timely delivery.
• Installation of shrink-wrap encapsulation over scaffolding provided a controlled environment which was crucial for achieving high-quality surface preparation and coating application. The encapsulation also was essential to protect the surrounding environment, residents and workers from dust and hazardous fumes.