The expansion of the Cockburn Cement plant in Kwinana aims to reduce CO2 emissions by 20% through the installation of cutting-edge cement production technologies. This modernisation effort will not only enhance environmental sustainability but also ensure a continuous and reliable supply of high-quality cement products to the Western Australian market, thanks to the introduction of two new 100 tonne per hour (tph) ball mill grinding circuits.

The modernisation of the Kwinana plant will also eliminate the need for heavy vehicles on local roads by enabling the direct receipt and storage of bulk raw materials via a new raw materials feed conveyor system and a fully enclosed 110,000-ton storage shed from the Fremantle Port Authority's Kwinana Bulk Terminal.

SIMPEC, a subsidiary of WestStar, has been contracted by Cockburn Cement to provide structural, mechanical, piping, electrical, and instrumentation (SMPE&I) support services for the modernisation project. The scope includes new grinding circuits and a raw material storage and reclamation system designed to produce various cement products for the local market. The construction features two 100 tph grinding units, a 110,000-tonne raw material storage facility, and a recovery system, along with six new 3,200-tonne finished product silos equipped for truck loading.

Sarens played a crucial role in this project by performing heavy lifting operations for the installation of two large filtration units and two highly engineered covers for the ball mill building. These efforts are part of a broader upgrade that is expected to save approximately $19 million in the first year by reducing energy, maintenance, and transport costs.

The crane options were limited due to the available ground bearing capacity at site. By using the LR1350 without SL we were able to keep the GBP <210kPa and relocate the crane fast as to install both roof sections in a single day. Maximum wind speed for these lifts was 9m/s, which meant that the team had to keep a close eye on a suitable weather window. 

The LR1350-1/LN crane, with a lifting capacity of 350-tonnes, was used to lift the 35.1-tonne filters. For the rigging, Sarens utilised an S17 Spreader beam and two specially designed lifting beams. The filtration units are vital for managing the environmental impacts of the cement process and required meticulous coordination, involving up to 29 lifting points for safe installation.

Sarens also successfully installed two roof sections in a single day, each weighing over 20 tonnes. Currently, 12 cranes of various sizes and configurations continue to support ongoing tasks at the plant.

The expansion will create a state-of-the-art facility, consolidating Adbri's Munster and Kwinana cement production plants into one location serving Western Australia. Once operational in 2024, cement production will transition from Munster to Kwinana, while lime manufacturing will remain at Munster. This new facility will bolster the region's cement supply with its advanced capabilities.