The Application of 3D Finite Element Method in the Design of Large Piled Foundation System – Case Study: Melbourne Cement Facility

This paper provides an overview of the foundation design and analysis process carried out for the Melbourne Cement Facility silo located in Port Melbourne, Victoria, Australia. The proposed silo is a cylindrical multi-compartment cement storage facility supported on a 2.6m thick concrete ring beam with an external diameter of 38.5m. The ring beam is supported by a piled foundation system comprising 155 CFA piles in an annular pile layout. The site is underlain by Quaternary Sediments of Yarra Delta which are further underlain by Werribee Formation. This paper describes a detailed soil-structure interaction analysis performed using the finite element program PLAXIS 3D, which was used to assess the foundation performance with particular attention to global and differential settlement of the pile group. The study evaluated the complex load sharing between the piles and the ring beam, and the differences in load mobilisation between piles within the group. The results of this study highlight the capability of 3D FEM analysis for obtaining an optimised foundation design solution and understanding and addressing various technical challenges associated with silo foundation systems of this type.