When it comes to renewable infrastructure, strength isn’t just in the steel – it’s in the partnerships that bring projects to life.
Steel is integral to the energy transition. From wind turbines and solar farms to large-scale storage projects, it provides the strength and reliability required for this infrastructure. Much like steel forms the structural foundation of energy infrastructure, strong partnerships form the foundations that make their delivery possible.
This was the case at the Limondale BESS (battery energy storage system), which was enabled by a partnership between Calibre Steel and Solidity.
The landmark project aims to support New South Wales’ grid by soaking up excess renewable energy and storing it until it’s needed most. As the first successful project in the state’s inaugural Long Duration Storage Long-Term Energy Service Agreements, it represents a step forward in the NSW energy transition.
Comprising 144 lithium-ion batteries, the BESS can store up to 400 megawatt-hours (MWh) of clean energy. But before any of them could be installed, the site needed a strong foundation: 864 helical piles, each engineered to withstand a range of structural stresses.
Solidity, which was engaged to lead the design, fabrication and installation of the piles, turned to Calibre Steel to supply the all-important steel plate and ensure it met its structural requirements – and the partnership played into the project’s success from day one.
Solidity Managing Director, Brodie Houghton, said the company places a strong emphasis on local partnerships that align with its values of quality, reliability and supporting Australian manufacturing.
“Calibre Steel stood out as a trusted supplier with proven capability to deliver high-grade Australian steel within the tight timeframes the project demanded,” he said.
Calibre Steel Customer Relationship Manager, Maddie Dharmapala, said once the partnership was locked in, the first step was engaging with Solidity to understand the project’s drivers, pain points and engineering requirements.
“Having that early engagement and scope clarity helped us understand where our steel plate fit in the broader deliverables of the project,” she said. “It allowed us to align with Solidity’s strategic priorities, and become a solutions partner, rather than just a supplier.”
Houghton agreed that this was a critical first step.
“The clear communication and shared commitment to delivery was the key to the project’s success,” he said.
Let’s get technical
To support the heavy weight of the battery units, the helical pile foundation was designed to meet strict structural and geotechnical requirements.
Each battery required six helical piles, engineered to withstand the compression, tension, and lateral forces they would be subject to upon the project’s completion.
The piles were fabricated with 139.7mm shaft diameters. The lengths and helix configurations were determined through geotechnical analysis, with Solidity ensuring the piles had maximum load-bearing capacity while also remaining efficient to install.
Produced at Solidity’s in-house manufacturing facility in Victoria, the piles and pile caps utilised high-quality steel supplied by Calibre Steel. The company provided TRU-SPEC steel and grade 350 steel plate in thickness of 12mm, 16mm and 20mm.
Solidity’s decision to use TRU-SPEC steel was driven by the company’s commitment to using Australian-made steel.
“For a project like Limondale BESS, which is at the forefront of Australia’s energy transition, it was essential that the foundations were as local as the ambition,” Houghton said.
Importantly, Houghton said, using Australian-made steel also ensures compliance with project standards, traceability of materials, and alignment with government and client expectations around sustainability and economic contribution.
As a tier one distributor of Australian steel, Calibre Steel worked closely with TRU-SPEC steel manufacturer BlueScope to supply the steel.
With only 60 days to complete the project, Solidity and Calibre Steel worked side-by-side to ensure the deadline was met.
Solidity streamlined its manufacturing and installation workflows, running a just-in-time fabrication model that made use of reliable supply.
“Calibre Steel was instrumental in this,” Houghton said. “The team understood our timeline constraints and delivered ahead of schedule, allowing us to keep momentum on site and meet critical milestones without delay.”
Dharmapala said Calibre Steel provides “a personalised service”.
“In addition to myself, there was also a head estimator and a transport and operations manager working in line for the project,” she said.
Dharmapala believes Calibre Steel’s internal resources are the company’s secret weapon to meeting deadlines and overcoming project challenges.
“We all work together and prioritise,” she said. “Whether it’s expediting logistics, updating grade requirements or accommodating engineering challenges, we worked very closely with the Solidity team to ensure the project maintained momentum.”
Houghton shared a similar sentiment.
Once production was complete, Solidity utilised its own freightliner and semi-trucks to transport the piles to the project site, covering a distance of 450km without any transportation delays.
On-site, Solidity powered ahead to complete the installation with high precision and efficiency, installing 45–50 piles per day. With the help of Calibre Steel, Solidity delivered the foundation works on time, within budget and with zero safety incidents throughout the installation process.
“From the outset, Calibre Steel was responsive, solutions-focused and proactive in keeping production and logistics aligned with our schedule,” Houghton said. “Their flexibility and professionalism helped us navigate supply challenges without compromising on quality.”
Enduring impact
With its strength and versatility, steel will continue to play a pivotal role in the energy transition.
Calibre Steel’s work with Solidity to deliver the Limondale BESS highlights this importance, demonstrating the significance of strong partnerships in the delivery of critical energy infrastructure and supporting sovereign capability.
With renewable projects growing in scale and complexity, the demand for high-quality, reliable steel is only going to increase. “It’s never been more important to work with a trusted supplier, like Calibre Steel,” Dharmapala said. “You need to partner with a company that has the capabilities to work in the renewable energy space.
“At Calibre Steel, we do so much more than just delivering steel. Our team takes the time to understand your project timelines, project objectives and technical requirements, ensuring reliable support and high-performance outcomes.
“From quality steel plate to dependable service throughout the project lifecycle, we’re here to help you succeed.”
For more information, visit calibresteel.com.au and solidity.com.au
