Boral Cement Geelong
Truck Wheel Wash Bay and Unloading Ramp

Boral Cement suspended clinker manufacturing at the Waurn Ponds site in Victoria, Australia, with the intention to operate as a cement milling facility using imported clinker to the site. In preparation for the clinker import to the site, Boral Cement began works to upgrade their current facility including the detailed design and construction of a new Wheel Wash Bay and Truck Unloading Station.

Berne Fleming Civil was engaged to undertake the detailed design and construction of a wheel wash bay to accommodate the 30,000 Tonne shipments which would arrive approximate every 20 days providing an annual import tonnage of 550,000 Tonne. The wheel wash bay was designed to accommodate a target average rate of 300 trucks per day (i.e. 1000 hours of unloading and transport) which would eliminate and prevent road contamination. The wheel wash station was required to prevent the drag of loose material onto the public road network adjacent to the Waurn Ponds site from the clinker delivery trucks.

Works included the detailed design and construction of a wheel wash drive through concrete bath (accommodating approximate 282, 30 Tonne trucks per day), including side walls, spray nozzles, overflow pipes, steel track assembly, foundations for 22,700 litre water storage tanks, open sediment pits containing a 6.5m³ of water volume and a cattle grid catchment arrangement installed to capture expected dragged water from trucks wheels leaving the wheel wash bath.

The Truck Unloading Station (TUS) around the existing cooler pit was constructed alongside the wheel wash bay and included the construction of footings, including piers, pile caps, plinths and hold-down bolts, concrete truck access ramp and infill slab profiles and miscellaneous civil works including bollards and replacement of pit covers.