The Malt House District Silos have been a significant landmark to generations of Melbournians. Originally developed as brewing and malting sites in the 1850s and 60s, malting still takes place there today. The complex consists of malt houses, stores, silos, offices and – not to forget – the treasured Nylex sign and clock. MANN was contracted to remove seven full silos, each approximately 45 m (147 ft) high, and surrounding buildings. They created a world-first demolition methodology, leveraging sophisticated demolition robots, custom-made working platforms and anti-shock shelf angle brackets. This unprecedented sequence played a pivotal role in addressing the concerns raised about environmental and commercial constraints. Due to the close proximity to the main freeway, surrounding bridges, underpasses and road weight restrictions, it was geographically impossible to float in plant with the capability to reach the required heights. MANN had to develop a demolition sequence that would ensure the remaining heritage silos and the iconic Nylex Clock were not damaged. Consideration was given to the levels of vibration that would be generated and the structural integrity of the remaining silos once the work was completed. • The demolition methodology developed required absolute precision and ongoing problem-solving to ensure that the end goal was never compromised. • Installed 24-hour vibration monitoring and involved Heritage Victoria in real-time notifications. • Devised a unique methodology using demolition robots and custom-made platforms instead of traditional long-reach excavators. • Used encapsulated scaffolding to prevent wind and rain interference, allowing continuous operation. • Selected demolition robots with internal water suppression systems to minimise dust. • Engaged third-party engineering reviews and non-destructive testing for safety assurance. • A unique and robust safety and rescue plan was created through collaboration between MANN and Melbourne’s Fire Brigade. • Coordinated rubble removal to avoid delays in demolition progression. • The Leap Frog concept was adopted, where three custom-made working platforms were manufactured to house demolition robots. These exclusive platform designs were engineered to serve as both platforms and crane Man Boxes, allowing seamless movement and access to any silo. • Completed on time and within budget. • Achieved a 99% recycling rate, including collection and cleaning of 95,000 heritage bricks for future use. • Zero safety incidents recorded among site teams and subcontractors. • Innovative demolition techniques set a new industry standard. • With an endorsement from the state’s safety governing body, SafeWork, our design is a registered new Man Box concept. Safety being the most important focus for MANN, our Leap Frog methodology enabled all the robot works to take place while keeping the operator at a safe distance working from perimeter scaffold, topping out at 45m above ground level, the site team were able to have a clear line of site from perimeter scaffold, while also exerting the maximum productivity. In the World Demolition Awards, the project won the 2021 Urban Demolition under US$10 million award. The Malt District
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