A Benchmark in Engineering Excellence
Ingenia is proud to showcase the award-winning RMS Silo Project, a testament to our expertise in steel construction and innovative engineering solutions. Recognised at the 2024 SA Australian Steel Institute (ASI) Steel Excellence Awards, this project highlights the power of collaboration and the versatility of Australian-made steel in delivering exceptional outcomes.
Project Overview
Awarded to McMahon Services as the head-contractor who engaged Ingenia as the lead designer, the RMS Silo Project involved the design, supply, fabrication, assembly, and commissioning of a 1,000-tonne raw meal silo. The scope extended to include infeed and discharge equipment, ancillary systems, and associated steelworks. Ingenia, as the project’s design partner, was responsible for delivering a fully coordinated design that optimised material usage, enhanced constructability and safety, and improved long-term maintenance for the end user.
Design Innovation and Engineering Excellence
At the core of this project was an emphasis on design optimisation and constructability. Ingenia’s multidisciplinary team advanced the project from Front-End Engineering Design (FEED) to detailed design, ensuring compliance with industry standards, including AS1170, AS4100, AS3600, AS3774, and EN1991-4.
Key innovations included:
- 30% reduction in material mass: Achieved through optimisation of strake and plate thicknesses.
- Non-standard 5-column design: Using 500 WC 440 high-strength steel, balancing structural strength with accessibility for maintenance.
- Lifting and assembly at ground level: Prefabricated segments were lifted in two pieces, reducing the need for work at height and improving site safety.
- Ring beam structures and load cell supports: Integral to structural optimisation, enhancing long-term efficiency and ease of maintenance.
Cutting-Edge Technology and Construction Efficiency
Ingenia’s use of Virtual Reality (VR) technology during internal design reviews set a new approach for the industry of a project this size. This innovative approach helped identify and resolve potential issues early, ensuring a seamless transition from design to construction. By visualising the design in a virtual environment, internal stakeholders were able to foresee challenges and optimise solutions before they became costly or time-consuming onsite.
During the construction phase:
- BIM and CBFEM methods were used for heavy connection design, ensuring precision and structural integrity.
- Transportable silo segments were fabricated and coated locally, reducing onsite construction time and costs.
- Load cells rated to 600T were innovatively mounted for easy replacement, ensuring long-term operational efficiency.
Coatings, adhering to ISO 12944-1, were selected for their durability, offering 20 years to first maintenance, further contributing to the project’s sustainability.
Environmental Sustainability and Local Impact
The 1000-tonne Raw Meal Silo Project is a shining example of sustainable engineering. Ingenia prioritised the use of Australian-made steel, aligning with the ASI Steel Sustainability Australia scheme. By utilising high-strength materials, the project reduced overall material usage while maintaining structural integrity, supporting both environmental and economic sustainability.
Additionally, the majority of the project’s work was carried out locally, strengthening regional industries and minimising the carbon footprint associated with transportation.
Buildability and Collaboration
Ingenia’s success relied on strong partnerships with McMahon Services, Adelaide Brighton Cement, and local fabricators, including Port Adelaide Construction, Macweld Industries, and SES Industrial Services. A combination of meticulous planning and effective documentation ensured the project’s buildability.
Key collaborative efforts included:
- Safety in Design reviews, enabling stakeholder input at critical stages.
- Construction staging workshops with fabrication teams and crane suppliers, ensuring safe and efficient assembly.
- Streamlined transport logistics, ensured by local fabricators, enhancing both transport and onsite assembly.
Why This Project Matters
The RMS Silo Project exemplifies the potential of steel construction projects in industrial applications. It sets a benchmark for future projects in terms of innovation, safety, and sustainability, reinforcing Ingenia’s leadership in structural engineering and collaborative construction.
Learn More
Discover more about how Ingenia leverages Australian-made steel and engineering expertise to deliver award-winning projects. Contact us today for your next industrial project.
