Client
Western Power
Location
39 Fairway, Crawley WA
Project Value
$70,000
Completed
March 2026
The situation
Western Power needed structural roof and ceiling remediation at their Crawley substation, a live electrical facility that couldn’t be taken offline. The deteriorated roof framing and ceiling structure required full replacement, with roofing elements reinstated and the ceiling upgraded to meet fire rating requirements, all while preserving existing services and finishes.
Works included fibreglass scaffolding, demolition of the existing plasterboard ceiling and insulation, careful removal and stacking of existing roof tiles for reuse, replacement of battens and rafters, reinstatement of gutters and downpipes, three layers of fire-rated plasterboard, and a painted finish to match the existing ceiling.
The challenge
Working inside a live substation is not a standard construction environment. The electrical hazards required arc-rated PPE, insulated tools only, strict minimum approach distances, and constant communication with the Permit Holder.
The fibreglass scaffold requirement added another layer of complexity. Unlike standard aluminium systems, fibreglass scaffold is supplied in fixed kits and must be erected strictly to manufacturer specifications. It can’t be repositioned freely, each configuration had to be pinned around permanent electrical equipment. When it became clear during the plasterboard installation that the existing scaffold wasn’t sufficient to work safely, additional scaffold was sourced. That cost approximately one week.
Our Process
01
Secure
All inductions and training completed before mobilisation. Plywood protection installed around live busbars. Arc-rated PPE, insulated tools, designated access routes, and minimum approach distances observed throughout. Constant communication with the Permit Holder.
02
Deliver
Materials planned and staged carefully to work within the substation’s access constraints. Scaffold configurations designed around permanent electrical equipment to maintain safe working clearances at all times.
03
Work
Full structural remediation — new LVL rafters and wall plates, roof tile reinstatement, gutters and downpipes, three layers of fire-rated plasterboard with staggered joints, painted to match. Existing roof tiles reused where possible.
04
Clean
Site maintained to substation standards throughout. Scaffold and temporary facilities removed on completion.
05
Handover
Project delivered with only one minor variation, site inductions not identified by the client, valued at $192.50. Substation remained operational throughout.
The result
Zero safety incidents
High-consequence electrical environment managed without incident. All safety protocols followed throughout.
Minimal variations
One variation for $192.50. Thorough scope understanding meant no surprises on cost.
Substation kept live
Western Power’s facility remained operational throughout. No disruption to energy supply.