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Abstract This paper proposes an approach to generate realistic particle shapes considering the major plane of orientation of particles in discrete element modelling (DEM). The particle generation framework includes capturing high-quality scanning electron microscope (SEM) images, followed by image processing and generation of clumps using a commonly used multi-sphere (MS) approach in particle flow code (PFC3D). A set of experimental direct shear tests (DST) and subsequent DEM simulations were performed by incorporating realistic particle shapes. The simulation results show a good agreement with those obtained in the laboratory. In addition, the normal stress showed a significant effect on the structural anisotropy of the granular materials.