A coastal transformer station in Indonesia faced corrosion, unauthorized access, and high maintenance costs due to its aging chain-link fence. A zinc‑steel perimeter fence with heavy-duty galvanized posts, duplex corrosion-resistant coating, and integrated earthing was specified and installed. Post-upgrade, the station experienced zero intrusions, a 60% reduction in maintenance cost, and a 15% insurance premium decrease. The system combines modular steel panels, coastal-grade finishes, and compliance with ISO, ASCE, and IEEE standards for long-term security and durability.
Upgrading Fence Security for a Coastal Transformer Station with Zinc‑Steel Perimeter System
On the southern coast of Indonesia, a regional utility operator faced chronic issues at one of its isolated transformer stations: the perimeter fence, installed 12 years earlier, had corrosion patches, repeated breach incidents by unauthorized vehicles and goats, and high maintenance interventions every monsoon season. The operations manager reported: “Each year we budgeted USD 45,000 just for fence repairs, cleaning, and intrusion response. Our risk exposure was growing and our insurance renewal came with sharper premiums.”
1. Project background & key issues
The station supported three 10 MVA pad‑mounted transformers delivering power to a coastal community and offshore facilities. The original fence was a standard chain‑link with galvanized coating, topped with single strand barbed wire. Major failures included:
Severe corrosion on posts and wires from salt air and spray, reducing expected life significantly.
Unauthorized vehicular access: two incidents of small pickup trucks forcing through gates during night shift maintenance hours.
Inadequate earthing and bonding of the fence system, raising potential touch‑voltage concerns during fault events.
2. Specification & engineering design
The specification included:
Panels: Steel sheet mesh panels (2.0 mm thickness) zinc‑plated to 275 g/m² per side, with welded mesh infill 8 mm wire.
Posts: Heavy‑duty steel tube Ø 89 mm, hot‑dip galvanised, embedded 900 mm in concrete. Referenced ASTM F2611-08.
Finish: Duplex system – galvanising plus polyester powder coat RAL 7012 for coastal durability.
Earthing: Bonded to station grid as per IEEE Std 80‑2000.
Standards: ISO 9001, ASCE structural design, ASA acoustic standards.
3. Installation
Manufactured in ISO-certified facility. Modules of 2.5 m width × 2.8 m height preassembled. Footings poured, posts earthed, panels installed during shutdown window.
4. Results
Zero intrusion post-installation.
Maintenance dropped 60% (USD 45,000 → USD 18,000/year).
Insurance premium reduced by 15%.
Independent corrosion testing: less than 0.5 mm zinc loss in 12 months.
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