DAV04 Warehouse – Brisbane Airport

The DAV04 Warehouse development at Brisbane Airport required advanced ground engineering to support a high-load retaining wall. The site, comprised of challenging clay deposits, demanded a solution that could reliably provide necessary bearing capacity while mitigating settlement risks.

We implemented a Mass Soil Mixing (MSM) solution, constructing custom-engineered soil-mixed blocks beneath the retaining wall footing. By designing variable block geometries that extended to the founding level, we optimized the structural support precisely where required.

Our methodology involved injecting ready-mix grout directly into the clay matrix. To ensure technical precision, GPS-integrated mixing rigs were programmed with site-specific design drawings. The grout was then thoroughly blended with the in-situ soil to create homogeneous, structural-grade blocks.

Maintaining the specific water-cement ratio for the readymix grout was a primary challenge during transit. We resolved this through an on-site "marination" process, where water was adjusted and mixed into the ground just prior to soil blending. Homogeneity and strength targets were verified through extensive CPT testing.

MSM provided a superior, cost-effective alternative to traditional piling, which would have necessitated the construction of an expensive working platform. By utilizing variable geometry for the MSM blocks, we optimized the total material volume, providing the client with a high-performance foundation that minimized waste and project delivery time.