The Cockburn Cement Limited’s (CCL) Upgrade Project involved the expansion of the cement operations at Kwinana, WA. The expansion project scope included: a bulk materials conveyor linking the Kwinana Bulk Terminal (KBT) facility to a new 110,000t clinker storage shed, incorporating an automated reclaim system, to eliminate road transport and minimise clinker handling using mobile equipment; a slag feed system that will handle granulated blast furnace slag and additives such as gypsum and limestone; a ball mill circuit with the installation of two new cement mills capable of grinding slag and clinker; and a new 21,000t finished product storage, truck loading and weighbridge infrastructure for storage and despatch.

Commencing the package in January 2022, Melchor utilised in-house earthworks, electrical and instrumentation, and structural concrete capabilities. The works comprised of detailed excavation (18,000 cubic meters), backfilling (27,000 cubic meters), and construction of all major concrete structures including formwork (18,500 square meters), reinforcement (1,500 tonne) and concrete (11,500 cubic meters). A highlight of the project was the execution of a complex ball mill structure.

Improvements to construction methodology within the Cement Silos enabled Melchor to reach early completion.