Horseley Logistics Park (CMCs), NSW

Sector: Industrial Logistics Infrastructure
Solution: Controlled Modulus Columns (CMC) rigid inclusions

Project Overview

From a former quarry to premium warehouses… that’s the transformation currently underway at Horsley Park in Western Sydney! 🏭

Menard delivered the ground improvement works for Stage 2 & 3 of ESR Horseley Logistics Park in partnership with Texco Construction, to support the construction of a 58,000 m2 warehouse development on the site of a former quarry.

The Challenge

Working over reclaimed quarry ground presents a unique set of geotechnical challenges associated with highly variable fill, long-term creep that can be expressed in differential settlement of the slabs and the high-level pad footings. That’s where Controlled Modulus Columns (CMCs) solution comes into play.

The Menard Solution

By installing CMCs across the warehouse footprint, we’re creating a composite ground system that reduces total settlement and control differential settlement beneath the slab-on-ground (1/400) and pad footings, with a low-vibration method alternative to cost conventional deep foundations and a great example of how CMCs can unlock development potential on brownfield and post-extraction sites.

A big thank to Texco, and the end client ESR for the ongoing collaboration. Projects like this are a reminder that with the right ground improvement solution, yesterday’s quarries can become tomorrow’s supply-chain for NSW.

Value for builders, developers & consultants

• Reduced settlement risk by improving composite ground stiffness beneath the pavement.
• Improved long-term performance for heavy-duty hardstand construction over variable ground, ensuring continuous logistics activities.
• Design support before, during and after installing the CMCs.
• Menard worked alongside the project team including the end client, head contractor/builder, and consultant to integrate the ground improvement design with pavement requirements and construction staging

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