A Borg company

Autoclaved Aerated Concrete Manufacturing Facility

Project Completion Date: 2019

Project Highlights

  • 450 tonnes of fabricated steel constructed and 6,300 m3 of concrete poured
  • 4KM of electrical and 6KM of gas & water installation
  • 130,000 tonnes of virgin excavated natural material
  • Pits and hoppers for bulk material delivery, mixing towers and services plumbing supplied.


Location: Somersby, NSW
Industry: Manufacturing

CSR began production of Hebel in Australia 30 years ago and remains the only local manufacturer of Autoclaved Aerated Concrete in Australia and New Zealand.

With a growing demand for new residential estates, retirement facilities, terraced housing and commercial developments, CSR Hebel needed to increase its capacity to service the needs of the construction market which now regards Autoclaved Aerated Concrete (ACC) as a mainstream building product, providing customised solutions for walls and floors.

Planning for Hebel's new state-of-the-art facility began in 2017, with the focus remaining on the local economy and minimising the carbon footprint.
Autoclaved Aerated Concrete Manufacturing Facility
Project #28

The Challenge

Crossmuller was tasked with designing and constructing a new facility that would enable Hebel to double its current capacity in response to the growing market demand for its products.

Features of the new facility had to ensure a strong focus on minimising the carbon footprint, such as zero wastewater through efficient recycling and preserving a protected species of flora by allocating a portion of the land as a conservation zone.

The project included a scope of design and construction of the building, including bulk earthworks and steel fabrication. Electrical works included building infrastructure and control system wiring to support the mechanical supply of belt conveyors for bulk material, transport devices for the process such as pre-assembled sets of reinforcing mesh.

The Solution

The new-state-of-the-art facility borrows the best technology from around the world and combines it with decades of local knowledge and expertise to showcase the best in AAC automation, customisation and environmental waste management.

This new facility has allowed Hebel to double its current capacity and continue to service the growing demand of the Australian construction market for innovative, quality building products.

Crossmuller's capacity allows for building, fixing or troubleshoot any issues along with supplying services and products from an Australian Made and Owned company. The team at Crossmuller hold an expert understanding of how facilities should integrate, specialising in all elements of design and construction, electrical, automation and manufacturing.
Project #28