Global Power Generation Australia (GPGA)’s 97MW Hawkesdale Wind Farm stands tall on lands of the Eastern Maar people, approximately 30km north-west of Warrnambool in Victoria.
Harnessing the plentiful wind resources in Victoria, Hawkesdale Wind Farm produces clean energy while helping the state achieve its ambitious renewable energy targets and creating new economic opportunities for the local community.
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Efficiency through innovation
GPGA tasked the highly skilled team at BMD with the job of delivering the balance of plant at Hawkesdale Wind Farm, with Vestas supplying and installing the turbines and Consolidated Power Projects carrying out electrical works.
BMD’s scope of work included the design and construction of 19km of access roads, 23 hardstands, and 23 circular wind turbine generator (WTG) foundations, along with a high-strength pavement capable of supporting 250kPa of bearing pressure. This ensured the durability and stability required for heavy construction equipment, wind turbine components, and ongoing maintenance activities.
The project also involved the design, supply, installation, testing, and commissioning of electrical networks, including 40km of electrical reticulation, earthing, and fibre cabling. Additionally, BMD was responsible for the design and construction of the 33kV substation, as well as the operation and maintenance buildings.
BMD Constructions general manager VIC/SA/TAS Ivan Fratric said the build came with a number of site-specific challenges.
“Challenges such as achieving the required 250kPa compaction for Vestas’ crane on wet ground were resolved through cost-effective innovation,” he explained.
“Instead of purchasing expensive engineered materials, the team maximised available resources by identifying and compacting onsite material to meet specifications. This approach delivered cost savings for GPGA and reduced material transport and procurement time.”
Further efficiency measures included strategic scheduling adjustments, developed in collaboration with GPGA and Vestas.
“Instead of following the initial plan to build the road first, BMD adapted the construction sequence by excavating and preparing the turbine foundations first,” Fratric said.
“This approach allowed Vestas to work in reverse order on the collector groups. With multiple collector groups involved, this adjustment minimised exclusion zone disruptions, enabling seamless crane access for turbine installation. By demonstrating flexibility and proactive co-ordination with both GPGA and Vestas, BMD accelerated project delivery, improved site logistics, and maximised efficiency—ultimately achieving cost savings and a streamlined construction process.”
Safety and sustainability
A fall protection system for wind farm foundation pedestals was customised for the project and was the first safety device of its kind to be used in this application.
“This system was specifically designed to protect workers from the risk of falling into the anchor cage void during steel fixing and concrete placement operations,” Fratric explained.
“This innovative solution significantly enhances safety when working at height, and was recognised for its ingenuity by being shortlisted in the 2023 WorkSafe Awards under the OHS Leadership/Achievements category.”
BMD also installed three SolarSheds—an innovative off-grid power solution that transformed traditional site setup and accelerated construction timelines.
This enabled construction to commence six weeks earlier while the main site facilities were still being established. Once the main site compound was fully mobilised, two of the three SolarShed containers were relocated further into the site as a satellite compound for workers.
By storing solar energy during the day for 24/7 operation, the SolarSheds eliminated noise pollution from conventional diesel generators, reduced reliance on fossil fuels, and improved overall site sustainability.
Grid connection
BMD facilitated seamless co-ordination between a variety of contractors, ensuring efficient execution of tower installation, electrical works, and transmission line scope.
The BMD team delivered the design and construction of a 33kV substation alongside high-quality operation and maintenance buildings, ensuring durability, functionality, and compliance with industry standards.
The project team worked closely with Consolidated Power Projects to facilitate electrical scope delivery and interfaced with AusNet for transmission line integration.
“BMD, working closely with Consolidated Power Projects, successfully designed, supplied, installed, tested, and commissioned essential electrical infrastructure, ensuring seamless integration and long-term reliability,” Fratric said.
“This included the delivery of 40km of electrical reticulation, earthing systems, and fibre optic cabling, forming the backbone of the wind farm’s power distribution network. The electrical reticulation system connects each turbine to the collector substation. Functioning like a large-scale power board, the collector substation efficiently channels electricity from multiple turbines, regulating and directing the power flow to the transmission line.”
Throughout installation and commissioning, BMD ensured optimal network performance, compliance with industry standards, and a robust, future-ready electrical system.
A job well done
BMD’s transparent and timely communication with GPGA allowed for informed decision-making, ensuring the project progressed with minimal impact on time and costs.
Highlighting this strong working relationship, GPGA managing director Pedro Serrano said, “One of the key strengths of BMD lies in their collaborative, open, and honest approach on site. Their willingness to engage with all stakeholders, including our team and other contractors, has fostered a positive and productive work environment. BMD’s dedication to safety has been exemplary, ensuring an outstanding safety record throughout the project’s execution. Their commitment to maintaining the highest quality standards has also been evident in all aspects of their work.”
Project specs
Hawkesdale Wind farm spans approximately 2,280ha of land primarily used for grazing sheep and cattle. The project comprises of 23 turbines and is expected to generate 333,000MWh of carbon-free energy annually—enough to power the equivalent of an estimated 67,000 Australian homes each year.
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Local focus
Impressively, 100% of the materials used on the project were sourced locally from Holcim Quarry in Tarrone and WA Molan & Sons Quarry in Woorndoo. By incorporating locally sourced materials, BMD reduced transportation costs and environmental impact. This approach also supported surrounding communities by boosting regional businesses and sustaining local employment opportunities.
Beyond operational considerations, the project raised over $30,000 for the Western District Health Service, more than $10,000 for the Royal Children’s Hospital (Head Shave), over $8,000 for Movember, and collected 353kg of food for Foodshare, thanks to the close collaboration between BMD and GPGA. As part of the BMD Community Grant Program, the Russell’s Creek Cricket Club women’s team, and Hawkesdale Macarthur Football and Netball club also received funds.
These efforts underscored the project’s commitment to leaving a lasting positive impact beyond construction, strengthening community relationships, and making a tangible difference in the lives of those who call this region home.
