Case Study

The Mondiale facility required a high-performance concrete hardstand capable of supporting extreme operational demands, including:

• 5-high stacked containers
• Heavy container handler traffic
• Continuous high-load movements
• 10,500m2 of operational pavement

With efficiency in construction, durability, and long-term asset performance critical, the project required a slab system that could minimise joints, accelerate construction, and reduce lifecycle maintenance exposure.

The project adopted the SigmaSlab® system — an integrated design methodology combining:

• Dramix steel fibres high-performance steel fibre reinforcement
• CCL post-tensioning technology

This hybrid approach combines distributed fibre reinforcement with active post-tensioning to deliver enhanced crack control, improved load distribution, and significant joint reduction compared to conventional reinforced slab construction.

Key Outcomes

Joint Minimisation
Only two joints were required across the entire 10,500m2 hardstand.

Design Efficiency
The synergy between fibres and post-tensioning enabled an optimised slab design.

Construction Speed
Large panel pours were achieved, reducing reinforcement installation time and improving placement efficiency.

Reduced Lifecycle Maintenance
Fewer joints and improved crack control translate into lower repair frequency, improved surface performance, and enhanced operational uptime in a high-demand logistics environment.

Sustainability & Environmental Performance

The SigmaSlab® solution contributes to improved environmental outcomes through:

• Material Optimisation
• Reduced Embodied Carbon Potential
• Extended Service Life
• EPD Transparency

Project Result

The SigmaSlab® system delivered a durable, high-capacity container hardstand engineered for structural performance, construction efficiency, and long-term sustainability.

From design concept through to delivery, SigmaSlab® provided measurable construction efficiencies, reduced maintenance exposure, and whole-of-life value beyond conventional slab systems

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.