The Mainfreight logistics facility at Roe Highway Logistics Park required a heavy-duty concrete pavement capable of supporting extreme loading conditions while maintaining long-term durability and operational efficiency. 

The project involved the construction of a 7,200 m² high-performance industrial slab designed to accommodate five-high stacked shipping containers and the movement of large container handling forklifts. These loading conditions required a structural solution that exceeded the performance of conventional jointed concrete pavements. 

To achieve this, the project team implemented the SIGMA Slab® system, combining Bekaert®’s high-performance Dramix® steel fibres with a CCL post-tensioning system, delivering a robust and efficient slab with no conventional joints. 

The SIGMA Slab® system integrates steel fibre reinforcement and post-tensioning to control cracking, improve load distribution, and significantly increase slab performance. 

For the Mainfreight facility, this approach allowed the slab to:

• Support heavy container stacking up to five units high 
• Handle high wheel loads from container handling equipment 
• Operate with no traditional joints, improving operational performance 
• Deliver enhanced durability and reduced maintenance requirements 

Sustainability & Material Efficiency 

A key outcome of the SIGMA Slab® design was the significant reduction in construction materials when compared to a traditional plain concrete pavement. 

The project delivered: 

• ~950 m³ reduction in concrete volume 

• Up to 70% reduction in conventional steel reinforcement 

• Lower embodied carbon through reduced material consumption 

• Faster construction with fewer installation stages 

• Reduced long-term maintenance due to joint elimination 

These efficiencies contribute directly to lower environmental impact and improved sustainability outcomes for the project. 

Project Outcome 

The completed 7,200 m² SIGMA Slab® provides Mainfreight with a high-performance logistics pavement capable of supporting demanding container storage and heavy vehicle operations. 

By integrating advanced fibre technology and post-tensioned design, the slab delivers a durable, joint-free surface optimised for modern logistics operations while achieving significant material savings and sustainability benefits.