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The 11,000m2 Mondiale Container Facility developed by the Dexus asset group and constructed by SARICH Building, located in Jandakot, WA is one of the earliest adopters of the Sigma Slab® solution developed and patented by Bekaert® and CCL® with the collaboration of Aleemax in Australia and placed by S&C Concrete Services.
This project is a revolutionary application of the SigmaSlab® system when furnishing an external container hardstand slab, specifically constructed to undergo consistent high point loads, continuous heavy vehicle activity, and harsh ecological conditions. This scheme depicts peak excellence within concrete through the integrated utilisation of Bekaert’s ultra-high-performance Dramix® steel fibres, as well as CCL®’s encapsulated post-tensioning system—with the potential to fully eliminate any requirement for traditional reinforcement and joints.
With a pavement footprint measurement reaching 190m, SigmaSlab® attains improved crack control, substantially lower upkeep requirement, and enhanced structural resilience. A bespoke SFRC mixture was fashioned for fulfilling site-specific needs, whilst the build phase incorporated concrete maturity sensors, pour overseeing, and a robust concrete quality assurance plan.
Via integrating advanced concrete mixes, performance-oriented design methods, and accurate execution, this project depicts how future slab technology can increase both utility and durability, reduce construction timeframes, increased construction safety, and reduced carbon footprint. While inherently future-proof and capable of adapting to endless functionality change improving the asset value, it aligns organically with the institute’s ambition of cultivating excellence within concrete through ingenuity, resilience and innovative usage.
Dexus
Mondiale Container Facility
20/07/25
Jandakot, WA
This SigmaSlab® external container hardstand project demonstrates advancement in concrete technology through the revolutionary combination of Dramix® ultra-high-performance steel fibres alongside CCL®’s encapsulated post-tensioned system, eliminating the need for rebar and joints.
The concrete, supplied by BGC Concrete and mix design reviewed by Aleemax, was a high-quality 40 MPa mix with no cement replacement. Designed for optimized durability, it exemplifies the performance and reliability of well-executed, conventional concrete at its purest form.
Durability was a primary design outcome. By tailoring CCL®’s PT system stressing process to suit the mix design in real world conditions using ConXedge® concrete maturity system for stressing locations and times, the system significantly improved crack resistance and fatigue performance, extending the service life of the slab with minimal maintenance. This result was achieved without reliance on alkali-activated binders or SCMs; instead, the improvement exists in the clever application of Dramix®’s high performance and high aspect ratio fibre, supported by real-time quality assurance and maturity monitoring for timely and specific stressing locations by Aleemax during the pour process.
The project greatly exceeded its structural and operational performance stipulations through provision of a smooth slab exhibiting improved durability, reduced material consumption, and streamlined construction. This work contributes to a growing knowledge base of performance-based concrete systems and represents a step forward in practical, field-proven concrete innovation—directly aligned with the future of resilient, sustainable, and high-performance slabs for industrial use.
The SigmaSlab® external container hardstand project depicts an outstanding engineering response by Bekaert® and CCL® to a strict industrial environment, where robustness, load-bearing capacity, and durability are critical. The slab was specifically designed to withstand 160ton concentrated loads, 150ton axle load reach stacker transit, and severe ecological factors—situations typical of container placement and handling operations.
The elimination of typical reinforcement and saw-cut joints inside a seamless slab arrangement denotes a noticeable step in slab design methodology. The engineered combination of Bekaert Dramix® steel fibres as well as CCL®’s encapsulated post-tensioning system has enabled the construction of panel lengths exceeding 190 metres on similar jobs, reducing long-term maintenance associated with joint deterioration, spalling, and water ingress.
To improve early shrinkage crack control, bespoke tie joints were designed and supplied by The Construction Sore. This solution streamlined the formwork process and facilitated timely stressing of the PT component to engage the compressive forces and maximize crack control.
The design featured a bespoke SFRC combination, in conjunction with crack-width regulation stipulations, referencing EN 1992-1-1 and FIB Model Code 2010. This allowed the project team to quantify and control serviceability limits while accommodating sub-base friction, shrinkage, thermal curling, and real-world loading effects. This design was peer-reviewed and certified by Peritas engineers to ensure that all detailing and specifications were carefully tailored to the exposure classification for external hardstand conditions, including concrete strength class and curing protocols designed to maintain performance over time.
This Sarich Building construction displayed a heightened calibre of concrete construction practice, incorporating innovating techniques and technologies to accomplish a superior industrial hardstand slab that is both durable and future-proof.
The use of Dramix® steel fibres and CCL® PT systems eliminated conventional rebar, improving site safety and efficiency. This simplified solution enabled a faster setup, smaller labour forces on site, and more efficient concrete placement over large panel areas while eliminating the need for pumping. A bespoke tie joint was supplied by The Construction Store that streamlined the formwork process.
During construction, all concrete pours were overseen under a rigid QA system managed by Aleemax, including:
Finishing techniques were to meet higher flatness and durability standards than typically required for container stacking and vehicle turning zones. Thanks to bespoke placing techniques and laser screed efficiency, concrete supply exceeded 140m3/h to accommodate for the large 2,200m2 pours (exceeding 75m in length). These were placed and finished by S&C Concrete with attention to surface uniformity, quality finishing and curing.
This project provides valuable learnings. It also establishes a new standard for effective, safe, and performance-based concrete construction within heavy-duty industrial environments.
While mainly structural and performance-driven, the Dexus development external container hardstand project depicts how revolutionary concrete technology can contribute to a clean, functional, and aesthetic element alongside a positive ecological outcome in a demanding industrial setting.
The removal of all saw-cut joints delivers a seamless, monolithic plane that enhances both the visual uniformity along with the serviceability of the hardstand. The result is a seamless surface free of deterioration, typically associated with standard jointed configurations. This elevates the esthetical appearance in addition to the safety of the facility, especially in logistics environments where strict equipment operation coupled with surface reliability are necessary.
From within an ecological perspective, the SigmaSlab® system renders quite a few sustainability improvements. By substituting traditional reinforcement with ultra-high-performance steel fibres and streamlining material volumes via post-tensioning, the slab required substantially less steel and concrete, directly reducing embodied carbon. The system’s large longevity and minimal maintenance means fewer resources are consumed as time progresses, strengthening both ecological and financial sustainability.
Furthermore, the removal of saw cuts and typical joints reduces risks of water ingress and deterioration, fortifying ecological resilience and prolonging the functional lifespan of the slab via minimal rectification.
The SigmaSlab® external container hardstand project constitutes an outstanding step forward in sustainable and resilient concrete construction. Engineered to extend durability, and minimal maintenance, all of which reduce environmental impact across the slab’s entire lifecycle.
Through reducing slab thickness and eliminating rebar and joints, compared to the RC slab solution, SigmaSlab® managed to reduce the quantity of steel needed by 78% and concrete by 27%, directly lowering the embodied carbon by 1,400ton of CO2 eq. To reach the same reduction in carbon emission, this would be equivalent to replacing approximately 15,000m3 of traditional concrete with a green concrete mix.
The system’s construction substantially lowers maintenance demands, preventing against water ingress, edge deterioration, and joint spalling—all common failure points within traditional slab designs.
SigmaSlab® further improves sustainability regarding construction logistics. With reduced steel quantity, there’s minimised cranage, smaller deliveries, and optimised material handling—translating to a minimal site footprint, diminished transport energy consumption, and lessened emissions, consistent with circular economy principles.
The SigmaSlab® offers adaptability, ensuring it can accommodate future operational changes without the need for costly structural modification or early replacement.
