The completion of The Star Gold Coast’s second hotel and apartments tower is more than a construction milestone, it’s a showcase of what precision engineering and specialist coating expertise can deliver at scale. At 65 storeys, the tower demanded materials and methodologies capable of performing in one of Australia’s harshest coastal environments. Usher Group rose to that challenge, deploying a high-performance, four-coat protective coating system that sets a benchmark for structural steel protection in Queensland.
The Project and the Challenge
Structural steel in coastal high-rise construction faces a uniquely demanding set of conditions. Salt-laden air accelerates corrosion, intense UV exposure degrades surface coatings, and fire safety requirements for tall buildings demand rigorous, independently verified protection. For The Star Gold Coast’s signature V-shaped structural steel components, there was no room for compromise.
Usher Group was engaged to design, fabricate, and apply a coating solution that would address all three challenges simultaneously — corrosion resistance, passive fire protection, and long-term durability — within the construction schedule of one of Queensland’s most high-profile developments.
The Solution: A Tailored Dulux® Protective Coatings Four-Coat System
Working in close collaboration with Dulux® Protective Coatings, Usher Group’s James Booth developed a four-coat system specifically tailored to the performance requirements of the project. Each coat was selected for a distinct and critical function:
1st Coat — Dulux® Zincanode® 402 @ 75µm DFT: A two-pack epoxy zinc-rich primer applied to abrasive blast-cleaned steel, delivering robust cathodic corrosion protection as the first line of defence against the coastal environment.
2nd Coat — Dulux® FIRETEX® FX6010: An intumescent coating providing up to 120 minutes of certified fire protection. Fast-drying and suitable for both interior and exterior applications, it can be applied directly to blast-cleaned or primed steel.
3rd Coat & Topcoat — Dulux® Weathermax® HBR @ 75µm DFT each: A high-build polyurethane topcoat delivering UV stability, graffiti resistance, and long-term gloss and colour retention — engineered to perform in harsh marine environments and extreme UV exposure.
“This four-coat system was the ideal choice for The Star Gold Coast’s iconic V components because each layer delivers a critical function — corrosion resistance, fire protection, and long-term durability. Together, it guarantees structural integrity in one of Australia’s most demanding coastal environments.” — James Booth, Usher Group
Why This System Works
The strength of this approach lies in the integration of each coating layer into a unified, performance-driven system. Rather than treating corrosion resistance and fire protection as separate briefs, the four-coat solution addresses both within a single cohesive specification — reducing inter-coat compatibility risks and delivering a fully certified outcome that meets the stringent requirements of modern high-rise construction.
Usher Group’s Expertise in Protective Coatings
Usher Group’s work on The Star Gold Coast Tower 2 reflects the breadth of capability that defines the business. From identifying the right coating specification through to fabrication and on-site application, the team managed every stage with the technical depth and project management discipline that complex commercial builds demand.
Work with Usher Group
If your next project requires high-performance structural steel protection — whether passive fire protection, anti-corrosion systems, or specialist coating applications — Usher Group has the expertise to deliver. Contact our team to discuss your project requirements.
