Everleigh AFL Clubhouse
- Civil
- Structural
“We are proud to design and deliver a second flour mill in partnership with BESIX Watpac and we look forward to the impact this project will have on the Ballarat region’s economy through the creation of construction and ongoing operational jobs."
Jamie Shelton, Principal, Structural Engineer, Northrop Consulting Engineers
Partnership
Northrop has partnered with BESIX Watpac since 2012 on more than 10 different projects. Our shared experience covers sports centres, industrial, residential and retail projects, and the Allied Pinnacle flour mill in Tennyson, Brisbane. The specialist experience gained and the project success at Tennyson lent BESIX Watpac to appoint Northrop for the structural component of the Ballarat flour mill project for George Weston Foods (GWF).
Project
GWF’s North Melbourne Mill is nearing the end of its remarkable 100+-year life. With the surrounding environment putting extra pressure on its operations, this presented GWF with an exciting opportunity to reimagine and modernise operations in a new location, by sourcing a greenfield site in Ballarat. The new site had great potential, where they could develop a concept for a state–of–the art seven-storey, 7,079sqm flour mill with mill design specialist Bühler.
The goals and challenges for the complex included ensuring direct supplier access for loading and unloading grain, making sure the structural design worked in concert with Bühler’s intricate mill mechanics, fortifying the building against vermin, and a facility that is free of dust, clean, and easy to maintain, which enabled access to replace large components of the milling plant. In addition, careful design of the concrete structure was required to support the specialist milling plant and to accommodate multiple and complex floor penetrations, and significant attention was given to mitigate the vibration from the milling equipment
Delivery
The Northrop team undertook a collaborative approach with all stakeholders to understand the structural requirements of the mill process and plant as well as developing a cost-effective steel structure. This would ensure smooth and efficient access to the building.
With such specific requirements needed from the milling equipment’s interaction with the structural design, we ensured a close working relationship was maintained with Bühler and BESIX Watpac, meeting multiple times a week to integrate our structure with their plant equipment. We vermin-proofed the building by using solid precast walls to incorporate unique construction joints, ensuring they could not enter the building or occupy wall cavities and providing a clean and easy to maintain solution. The structure was detailed to mitigate ledges and other flat surfaces where flour dust could collect, and vermin could travel. Each floor penetration and vibration challenge were assessed and solved with a first principals’ approach. The client appreciated our tailored methodology to design the best outcome for each given situation.
Impact
Throughout the concept and schematic design period, Northrop provided structural options that were tested by GWF and BESIX Watpac to find the most cost-effective solution. Our team championed the use of low-carbon materials, including the use of low-energy steel and cement replacement. We also designed the structure so that it can be fitted with solar panels and rainwater re-use to enhance the project’s sustainability credentials. When it goes into operation, which is planned for the end of 2026, the new flour mill will offer state-of-the-art jobs in Regional Victoria and create a lasting legacy for generations to come.
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