The Silo D Project at the Melbourne Cement Facility represents a significant advancement in modern cement storage infrastructure, distinguished by its unprecedented scale, structural complexity, and engineering sophistication. The facility enhances Victoria’s cement logistics capability and establishes a regional benchmark for large-scale industrial infrastructure delivered to contemporary engineering standards.
Commissioned in late 2023, Silo D is recognised as the world’s largest multi-compartment cement silo, providing a total storage capacity of approximately 45,000 tonnes. The asset plays a critical role in meeting Victoria’s high-volume cement demand while strengthening export capability through its strategic integration with the Port of Melbourne logistics network.
We were responsible for the delivery of the complex civil and structural works associated with the project, drawing on its extensive experience in heavy industrial construction, large-scale reinforced concrete structures, and technically demanding foundation systems. The project required disciplined engineering execution, precise construction tolerances, and coordinated management of multiple structural, mechanical, and electrical interfaces.
Structurally, the silo adopts a multi-cellular configuration comprising two rows of six outer cells and a single inner cell arrangement. The structure incorporates a substantial reinforced concrete roof enclosure integrated with complex structural steel frameworks supporting mechanical handling systems and electrical services. Our implemented rigorous dimensional control and quality assurance processes to ensure alignment, load transfer, and long-term structural performance consistent with design intent and relevant Australian Standards.
A highly specialised foundation system was constructed to support the significant vertical and operational loads imposed by the silo. The foundation consists of a 2.6-metre-thick reinforced concrete ring beam with an external diameter of 38.5 metres, founded on 155 continuous flight auger (CFA) piles arranged in an annular configuration. This system was designed to provide global stability, minimise differential settlement, and distribute loads efficiently across variable subsurface conditions.
Comprehensive geotechnical and structural assessment was undertaken through three-dimensional finite element modelling using PLAXIS 3D software. The analysis evaluated soil–structure interaction, pile group behaviour, global and differential settlement, and load-sharing mechanisms within the foundation system. These studies informed an optimised, high-integrity foundation solution, which delivered with strict adherence to design parameters, inspection and test plans, and verification requirements.
Operationally, the silo is equipped with an advanced IBAU discharge system, offering significantly reduced energy consumption and maintenance demands when compared to conventional discharge arrangements. The facility achieves high throughput performance, with self-unloading vessels capable of feeding cement into the storage cells at rates of up to 1,200 tonnes per hour, complemented by four truck loading lanes, each capable of 300 tonnes per hour.
The discharge and handling system exceeded its design objective of achieving 99 per cent emptying efficiency, optimising storage turnover, reducing material residue, and enhancing overall operational reliability. We coordinated closely with mechanical and electrical contractors to ensure precise integration of structural and process systems, enabling reliable performance from commissioning.
Throughout the project lifecycle, we maintained a strong focus on safety engineering, constructability, and interface management. High-risk activities, including mass concrete placement, working at height, heavy lifting, and plant–personnel interaction, were managed through layered risk controls and continuous on-site supervision.
The successful delivery of Silo D demonstrates our capability to execute technically complex, large-scale industrial infrastructure through disciplined engineering practices, robust quality management systems, and an experienced construction workforce. The project stands as a reference asset illustrating the firm’s ability to translate advanced engineering design into durable, high-performance built outcomes.
