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Munster Legacy Plant
Client: MACS Australia / ADBRI
Location: Kwinana, WA
Duration: August 2021 – December 2021
Structure Overview
Constructed in the latter part of the 20th century, three kiln stacks, varying in height from 62m to 84m, made from refractory bricks and cement with asbestos lining, were in need of demolition at Cockburn Cement, in addition to four, 26m tall concrete slurry tanks.
Scope of Works
Mainline was engaged by MACS Australia to complete the demolition works at Cockburn Cement.
The demolition scope encompassed:
- Kiln Stack 2 -62m in height
- Kiln Stack 3 – 64m in height
- Kiln Stack 4 – 84m in height
- Other associated ancillary structures, which included ducts, walkways, etc, down to the existing ground level
- Four slurry tanks (26m in height) and associated infrastructure
Equipment Deployed
- 275t Crawler Crane
- 49t Excavator with extension arm, HB4700 hammer and grab
- 36t Excavator with extension arm, concrete muncher, shear, hammer & grab
- 25t Excavator with extension arm, shear & grab
- Purpose built concrete pulveriser
- 150t mobile crane
- 80ft Boom Lift
- 125ft Boom Lift
Operational Challenges & Solutions
The Munster site’s wet process kilns were decommissioned from 2008 to 2014, resulting in an ageing legacy plant with no repurposing potential and gradual deterioration.
The legacy plant, located near the expanded infrastructure and live plant was positioned within 90m to a rail corridor and less than 400m from residents. This posed challenges. Given the physical constraints and community environmental concerns, a controlled top-down demolition technique was chosen.
Demolition occurred in two stages. Initially, three stacks underwent top-down demolition using a crane-lifted pulveriser attachment, aided by an excavator with a HD camera system. The pulveriser circled the stacks, reducing their height to 15m, allowing the excavator to complete the demolition. In the second stage, slurry bottles and related structures were removed using mechanical and felling methods due to space limitations.
Asbestos, both friable and non-friable, was safely removed prior to and during demolition.
The entire project, conducted from August to December 2021, saw Mainline process and recycle over 400T of steel, relocating an additional 4,000T of concrete and brick to an onsite fill facility.
Project Highlights
- Shortlisted for 2022 World Demolition Award
- Greater than 98% of materials were recycled or repurposed
- Zero impact on environment
- Completed on time with no HSE incidences