Golden Bay Cement, established in the 1870s and operating at its Portland, Northland site since 1917, is New Zealand’s largest cement producer, manufacturing over 850,000 tonnes annually. Five concrete silos built in the 1960s had developed significant deterioration, prompting the need for detailed investigation and long‑term remediation. Freyssinet NZ was engaged to undertake comprehensive concrete condition assessments across all silos and to design and implement a full remediation and strengthening solution for Silos 2, 3, and 4. Each silo stands 33 metres high, 7.7 metres in diameter, with 230 mm thick concrete walls. Following the successful completion of Silo 2, the same methodology was applied to Silos 3 and 4 to restore structural integrity and extend operational life.

  • Customer/Owner:
    Golden Bay Cement
  • Engineer
    Freyssinet AU/Beca
  • Works period
    July 2017 - September 2018

Freyssinet Scope

  • Removed existing silo coatings using ultra‑high‑pressure water blasting
  • Cut out deteriorated concrete and corroded reinforcement
  • Reinstated reinforcement and applied dry‑spray shotcrete for structural repair
  • Installed weather‑resistant protective coating systems
  • Strengthened silos using Freyssinet 1×15 post‑tensioning anchorage systems
  • Maintained full silo operation throughout works to avoid production disruption

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