Kurnell Caltex Refinery Removal – Industrial Demolition Services
    Botany Bay, NSW
    Kurnell Caltex Refinery Removal – Industrial Demolition Services

    Project overview

    Caltex Kurnell refinery site shut down after 58 years of operation, requiring the removal of infrastructure. The site was then converted into a fuel import terminal. The project covered approximately 100 hectares of demolition work zones.

    Industrial Demolition Services (IDS) completed much of the early works for the Kurnell refinery conversion project. The works were competitively tendered, and IDS was awarded the PDU and CLOR Tank Farms. Both projects were completed ahead of schedule with no Medical Treatment Injuries or Lost Time Incidents. IDS was then awarded the remaining demolition works on the Kurnell refinery site.

    Scope of work

    The Caltex Kurnell Refinery demolition and removal requirements included:

    • refinery process units and associated infrastructure
    • tanks and associated infrastructure
    • pipeways – above and underground pipelines
    • redundant buildings and services

    Specialist services required:  Decommissioning  |  Hazardous Waste  |  Industrial

    Unique challenges

    IDS used the services of around two dozen experienced demolition labourers and plant operators for this project. The site crews, under the guidance of our dedicated site supervisors and his team, operated a fleet of six excavators over two demolition zones.

    The site had plant ranging in size up to 120 tonnes, with specialist rotating shear attachments, in addition to materials handlers and other machines using grabs, hammers and other demolition attachments.


    IDS undertook more than 30 controlled collapses on site, all of which were completed successfully and, more importantly, safely. By weight, the largest of these was a 700 tonne Re-generator Unit, sitting on nine columns at a height of 55 meters. The tallest controlled collapse was a 65 meter furnace stack, which weighed in at 200 tonnes.
    While the demolition of process units was being undertaken, Industrial Demolition Services also undertook the removal of approximately 50 tanks and 180km of pipes.


    IDS processed approximately 50,000 tonnes of scrap steel and over 100,000 tonnes of concrete.


    Stage One: March – May 2019
    Stage Two: August – November 2019