Coates powers BMD’s Port to Renewable Energy Zone site offices with hybrid energy solutions

Find out how Coates is supporting BMD in delivering renewable energy infrastructure with off-grid power solutions that reduce emissions and cut costs

Coates is supporting BMD with off-grid hybrid power solutions at two key worksites for the Port to Renewable Energy Zone project, an upgrade to the state road network enabling safe transport of oversized and over mass equipment from the Port of Newcastle to the Central-West Orana Renewable Energy Zone in New South Wales.

The hybrid systems are delivering reliable energy to power temporary site offices and storage areas – one of the most energy-intensive parts of any worksite – at Mayfield in Newcastle and at Dunedoo, 100km northeast of Dubbo. Each system includes a 90kWh Battery Energy Storage System (BESS), 45kVA inverter, 40kVA generator and an external fuel tank, powering approximately 250m² of site offices and lunchrooms.

Coates Power & HVAC engineers estimate each hybrid setup could save BMD over $20,000 in operating costs and significantly reduce CO₂ emissions by up to 86 tonnes over the 12-month project duration. Battery storage alone can deliver substantial benefits, depending on site usage and load requirements. In this case, Coates has achieved strong sustainability outcomes simply by integrating a BESS, which has significantly reduced generator run hours.

“BMD is committed to managing climate change risks and limiting our emissions by exploring carbon emissions reduction opportunities through our entire value chain. Working with Coates to embed best practice technologies, like hybrid systems, aligns with our strategy for decarbonisation and improving environmental performance across our operations,” says John Vida, BMD Constructions General Manager NSW/ACT.

“We prioritise environmental protection across our operations by reducing carbon emissions, enhancing waste management through circular economy principles and actively protecting biodiversity in the areas where we work. Without access to grid power, even in the middle of Newcastle, we needed a more sustainable alternative to diesel to power our site compound. Coates’ hybrid power systems have provided us with a more efficient alternative and are helping us to reduce operating costs, while reliably supporting the 24/7 energy needs of our site compounds.”

According to Kurt Edwards, Power & HVAC Manager at Coates, delivering hybrid power solutions takes more than just equipment – it requires technical expertise.

“Hybrid setups require specialist design, installation, coordination with the electrical design of the portable buildings, commissioning and ongoing monitoring to perform reliably, which is why Coates’ in-house expertise is key,” says Kurt. “We worked closely with BMD to deliver a tailored solution that meets both their operational needs and sustainability goals.”

Alongside portable buildings and hybrid power systems, Coates is providing BMD with a range of hire equipment, including ablution blocks and sewerage tanks, 2-tonne tipper trucks, 18-tonne rollers, concrete and Armorzone MASH TL2 plastic barriers, Variable Message Sign (VMS) boards, temporary fencing and storage containers.

BMD was awarded the contract to deliver the first stage of works of the Port to Renewable Energy Zone project in April 2025. This includes new turning lanes, pavement widening, drainage adjustments, relocation of utilities and other safety improvements at 19 locations spanning 300 kilometres from the Port of Newcastle to Elong Elong near Dubbo.

The upgrades will support the safe and efficient transport of large and heavy components, such as wind turbine blades up to 100 metres long and synchronous condensers up to 6.2 metres wide, while also benefiting all road users by reducing delays, easing travel through intersections and improving road safety.

Works are currently underway and are expected to be completed by mid-2026.

Australia’s renewable energy sector is expanding rapidly, with a record $4.9 billion invested in large-scale energy storage and 2.8 GW of new capacity added in 2023, according to the 2024 Clean Energy Australia Report. 

As demand for renewable generation, storage and transmission infrastructure grows, Coates is providing other leading construction companies with the equipment, services and support they need to build essential infrastructure, including projects in NSW, Victoria and Queensland.

“With many renewable infrastructure projects located in regional areas, the scale of our fleet and the reach of our branch network mean we can mobilise quickly to provide a wide range of equipment and site services,” says Kurt. “We’re proud to support customers like BMD who are upgrading transport routes to enable Australia’s transition to renewable energy.”