concrete VOLUME 57 ISSUE 2
readinG concrete can contribute to your skills maintenance
Designs for a National Earthquake Museum VUW ARCHITECTURE STUDENTS PROPOSE MEMORIAL STRUCTURE
The Benefits of Concrete Roads NEW RESEARCH SHOWS RIGID PAVEMENTS TO BE 25% CHEAPER
Maori Concrete Motifs WHITIREIA CAMPUS REDEVELOPMENT COMBINES SHAPE, texture AND COLOUR
THE MAGAZINE OF THE CEMENT AND CONCRETE ASSOCIATION OF NEW ZEALAND
UPFRONT
concrete
Prime Minister John Key recently announced Saturday 20 September as the date of the general election.
Editor/Advertising:
MAGAZINE Adam Leach
Almost immediately political parties began positioning themselves in relation to key issues through various ‘policy’ announcements.
+64 4 915 0383
Of particular interest, or should that be concern, to the concrete industry is the Labour party’s Forestry and Wood Products Economic Upgrade policy package.
Subscriptions:
adam@ccanz.org.nz
Announced mid-March by David Cunliffe at the ForestWood conference in Wellington, the policy package is part of Labour’s plan to transition New Zealand to a “modern, high value economy.”
Angelique Van Schaik +64 4 499 8820 admin@ccanz.org.nz concrete is published quarterly by CCANZ (Cement & Concrete
However, the material specific nature of the policies is so overt that if implemented they would create an inappropriate commercial advantage for one construction material over another.
Association of New Zealand)
The Pro-Wood Government Procurement Strategy component is particularly alarming. It stipulates that “all government-funded project proposals for new buildings up to four storeys high shall require a build-in-wood option at the initial concept / request-for-proposals stage (with indicative sketches and price estimates).”
PO Box 448
Sound familiar? It is the same flawed policy floated, but shelved, by the Ministry of Agriculture and Forestry several years ago, one which CCANZ vocally opposed. Now, as then, it is completely inappropriate to mandate that decision makers in the construction process must consider wood as a structural option. Such preferential treatment of one industry over another would set a disappointing precedent.
Level 6, 142 Featherston St Wellington NEW ZEALAND Tel: +64 4 499 8820 Fax: +64 4 499 7760. Email: admin@ccanz.org.nz Website: www.ccanz.org.nz
Government should not be picking winners when it comes to the selection of construction materials, which should stand or fall on their own technical, cost, aesthetic and sustainability credentials.
ISSN: 1174-8540
Building environment rating tools, such as the Green Star rating tool, have gained traction over recent years, and offer a far more objective assessment of the benefits of construction materials.
ISSN: 1179-9374 (online)
To suggest that timber is a more sustainable option and as such should be the preferred material for government buildings is too simplistic. I do not dispute that wood has sustainable properties, or that forestry is important to New Zealand’s Kyoto obligations. However, this does not outweigh or negate the sustainability of other construction materials such as concrete.
Disclaimer: The views expressed in concrete are not necessarily those of the Cement & Concrete Association of New Zealand. While the information contained in the magazine is printed in good faith, its contents are not intended to replace the services of professional consultants on particular projects. The Association accepts no legal responsibility of any kind for the correctness of the contents of this magazine, including advertisements.
In addition, the policy does a huge dis-service to the hardworking men and women in the cement and concrete industries. Favouring a single construction material during the design phase of a government building could seriously impact on their livelihoods and jobs. My sentiments are shared by the steel industry. Metals NZ believe the policy undermines the technical expertise of structural engineers, architects and quantity surveyors, who are the best people to evaluate the most suitable building materials based on the desired product performance and commercial outcomes for a particular project.
© Copyright 2014 CCANZ (Cement & Concrete Association of New Zealand)
On his blog, ACT leader Jamie Whyte refers to Labour’s policies as “forced consumption”, and believes they are “not merely a path to national economic decline. They appeal to immoral and anti-social urges: vote for me and I will prey on others for your benefit.” In a withering attack, Economic Development Minister Steven Joyce called the policy “classic 70s ‘government knows best’ interventionism,” and asked the question “what next, supplementary minimum prices for wood?” In short, this policy does not create a level playing field for the use of construction materials in government buildings. In fact, materials other than wood will be considerably disadvantaged by this policy. The wide-reaching implications of this policy are extremely concerning and it should in no circumstances be adopted. Rob Gaimster CCANZ, CEO
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Cover photo: National Earthquake Museum, Wellington. Design by Megat Othman, 3rd year architecture student at VUW.
NEWS
NEWS BASE ISOLATION 201 As part of the Concrete Futures project CCANZ, along with the New Zealand Concrete Society, held the Base Isolation 201 seminar series in Auckland, Wellington and Christchurch during December 2013.
Dr Alistair Russell (CCANZ Manager – Structural Performance & Engineering Systems) and Professor Ian Buckle
Ian Buckle, a Foundation Professor at the University of Nevada in Reno, was the principal speaker, with Barry Davidson, a wellknown New Zealand based structural engineering researcher and practitioner, co-presenting. As with the Base Isolation 101 seminar series held in March 2013, at which Ronald Mayes, Simpson Gumpertz & Heger’s base isolation project engineer, spoke alongside Ian Buckle, the 201 series sought to reacquaint New Zealand designers with what base isolation has to offer, and how to go about getting it. Specifically, attendees gained a more advanced understanding of base isolation than given in the introductory series, and left being able to determine with confidence the properties of a base isolation system to meet required levels of seismic performance, and design/specify corresponding isolation hardware.
NEW BUILDING AND CONSTRUCTION ENGINEERING STANDARD NZS 3917:2013 Conditions of Contract for Building and Civil Engineering - Fixed Term has been published. NZS 3917 is the final in a suite of three standards which includes NZS 3910:2013 and NZS 3916:2013. A review took place in 2011 of key areas of NZS 3910:2003 Conditions of Contract for Building and Civil Engineering. It was the first revision in 10 years of the form of contract most commonly used for building and civil engineering construction contracts in New Zealand. During the review, a decision was made by the committee that it should be published as three tailored standards:
Strengthening existing brick and masonry buildings against earthquake loads Many older brick and masonry buildings now must be structurally upgraded or face an early retirement at the hands of the demolition contractors. Other buildings, such as those damaged by earthquakes need to be strengthened as part of their reinstatement to safe habitable buildings. The SEISMOLOCK GRC Plaster is formulated to provide a strong bond to the surface of a masonry wall while the embedded layers of fibreglass mesh provide the tensile strength to resist in-plane shear loads and face loads on brick and masonry walls.
• NZS 3910 Conditions of Contract for Building and Civil Engineering Construction • NZS 3916 Conditions of Contract for Building and Civil Engineering – Design and Construct • NZS 3917 Conditions of Contract for Building and Civil Engineering – Fixed Term
www.reseneconstruction.co.nz 0800 50 70 40
These three standards supersede NZS 3910:2003. For more information visit the Standards New Zealand website www.standards.co.nz
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NEWS
MBIE VIDEOS ABOUT REPAIRS TO EARTHQUAKE-DAMAGED HOUSES After an earthquake floor structures may have been twisted, wrenched or tilted. The Ministry of Business Innovation and Employment (MBIE) has produced three videos to help repair, re-level or restore floor structures ‘right first time’. • Packing house piles • Lifting a wall plate • Jacking up a foundation These resources are part of MBIE’s continuing support of the residential rebuild in Canterbury, which has included guidance, workshops and builders’ booklets. Specifically, these videos show one practical approach to the work, and support the guidance document - Repairing and Rebuilding Houses Affected by the Canterbury Earthquakes. Visit the MBIE website to watch the videos www.dbh.govt.nz/guidance-information
NEW ZEALAND HOUSING AND CONSTRUCTION QUARTERLY (NZHCQ) The New Zealand Housing and Construction Quarterly (NZHCQ) analyses sector trends in the building, construction and housing sectors. The NZHCQ report brings together information from Statistics New Zealand, Quotable Value, and the Ministry of Business Innovation and Employment (MBIE) to provide a comprehensive picture of the sector for the quarter. Visit the MBIE website to download the report - www.dbh.govt.nz/ nz-housing-and-construction-quarterly
Building a Better New Zealand 2014 Conference Scheduled for 3-5 September in Auckland, the Building a Better NZ conference will bring together a wide range of industry stakeholders including researchers, leaders, policy makers, innovators, designers and manufacturers to focus on research findings and case studies of best practice. Aligned strongly with the New Zealand Building Research Strategy the conference will unite local and international speakers to share their knowledge and insights on innovative, high performance and low impact approaches to developing, maintaining and retrofitting the built environment. Spanning policy, planning and design, through to construction, maintenance, refurbishment, reuse or deconstruction, the focus of the conference will be the future of New Zealand’s built environment and how to transform the building sector to deliver on the needs of future New Zealand. Visit the conference website for more details www.buildingabetternewzealand.co.nz
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NEWS
PCA LAUNCHES POTHOLE CAMPAIGN To capitalize on the media attention potholes across North America are currently receiving the Portland Cement Association (PCA) has launched an outreach campaign to get the word out about the need for more infrastructure investment and the need for more durable paving materials: concrete. The campaign is anchored in a section of PCA’s web site called www.OneBigPothole.com The name stems from an NPR (National Public radio) interview with outgoing US Secretary of Transportation Ray LaHood covering the challenges involved in gaining approval for transportation funding. LaHood suggested that Americans would be okay with increased funding for repairs because they already know that “America is one big pothole right now.” In addition to background materials and news feeds about potholes, the site features an interactive map showing social media mentions of potholes. The campaign kicked off in March 2014 with media interviews of PCA President and CEO Gregory M. Scott, who shared how cities can reduce road maintenance costs by building streets and roads with durable concrete.
W E N
Scott was interviewed by national and regional radio and television stations, as he stressed that a concrete road has a useful life that is twice as long as an asphalt road, 30 years compared to 15 for asphalt. Citing MIT (Massachusetts Institute of Technology) CSHub research, Scott noted that the life-time maintenance costs are four times less for a concrete road when compared to an asphalt road.
Aquapel infused lightweight concrete flooring super hydrophobic, with steel mesh reinforcing waterproof when cut easy handling, cost effective all weather installation
www.reseneconstruction.co.nz 0800 50 70 40
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Concrete Roads
The Affordable Option CCANZ recently commissioned economic consultants Infometrics to investigate the high-level case for building concrete roads. It was found that in a baseline scenario comparing the economics of asphalt and concrete roads, concrete came in around 25% less expensive. INFRASTRUCTURE INVESTMENT On many occasions CCANZ has taken the opportunity to highlight the range of economic, environmental and safety benefits offered by rigid concrete pavements. As the Government continues to invest heavily in roading these benefits become more compelling. Sustainable infrastructure development, particularly a modern roading network, is crucial to the country’s ability to secure economic growth. The Government is spending around $12.2 billion in state highways over the next 10 years, including making further progress on the Roads of National Significance. The emergence of the Public-Private Partnership (PPP) model, used to realise Wiri prison and the soon to begin Transmission Gully, is seen as a way to use private sector innovation and funding sources, as well as increase certainty of project delivery by re-assigning risk. The current environment is ideally suited for decision makers to embrace innovative and long-lasting roading building techniques that, as demonstrated by the Infometric’s analysis, offer significant cost savings. ECONOMIC EVIDENCE The Infometrics report - The Case for Concrete Roads - indicates that over a 30-year life span concrete roads can yield significant
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cost savings compared to those built using alternative materials. The adoption of concrete roads has the potential to cut hundreds of millions of dollars from the cost of major New Zealand roading projects. The report’s findings took into account historical price trends for the outputs of the Petroleum Products and Non Metallic Mineral Manufacturing (NMMP) industries as proxies for the price trends in bitumen and concrete respectively. Likely future price paths were also examined, with the oil price in US dollars and the US$/ NZ$ exchange rate informing bitumen price forecasts. The cost of carbon emissions was also considered. The price volatility of bitumen compared with concrete was found to be a key factor in why roads constructed using concrete offer cost advantages. The price of concrete is generally stable, while bitumen, closely tied to global oil prices and the US/NZ exchange rate, tends to be unpredictable. The likely future material prices trends look to further enhance the case for concrete roads. Petroleum Products prices have risen 180% since 1994 and will probably continue to increase annually at 5.8%. This is compared to a rise of just 44% in NMMP prices over the same period, with a projected annual increase of 2%. To a large extent the Petroleum Products’ price premium reflects
The Case for
Concrete Roads
for Cement and Concrete Association of New Zealand
A BACKGROUNDER
Prepared by Infometrics Ltd May 2013
the costs associated with an uncertain overseas supply market. In contrast, the low annual price increase of 2% associated with concrete construction is due to the stable nature of domestic sources. Overall the difference in CO2 emissions associated with concrete and asphalt roads was not deemed to be significant over a 30year horizon. This finding took into account evidence that rigid concrete roads generate less tyre rolling resistance, implying less fuel use, especially by trucks. They may also require less lighting at night due to greater reflectivity. The report also considered the impact of escalation clauses for the price of bitumen or oil in roading contracts. Such clauses inherently favour asphalt solutions proposed during tendering, and can potentially be seen as type of subsidy for one construction material over another. SCENARIO TESTING The report concludes by testing a set of scenarios involving different discount rates and expected service lives for an historic SH20 Mt Roskill project. Two different pavement options were
considered - Structural Asphaltic Pavement and Continuously Reinforced Concrete Pavement (with exposed aggregate finish). In the baseline scenario with a discount rate of 8% and a 30 year service life the concrete option emerged 25.1% cheaper than the asphalt option. Lowering the discount rate by one percentage point raises the cost difference to 26.7%. THE COMPLETE PACKAGE Combined with a host of other advantages, including but not limited to, tailored skid resistance, enhanced driver comfort as well as reduced maintenance and associated traffic disruption, the economic argument presented by Infometrics demonstrates that concrete roads are the ‘complete package’. With the Christchurch Motorways project, described as the most ambitious ever seen in the South Island’s largest city, gaining momentum, what better time than now to discuss how to deliver the best roading solutions available. Feel free to contact CCANZ (admin@ccanz.org.nz) if you would like to discuss the Association’s work in the area of concrete roads.
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CCANZ APARTMENT
DESIGN SEMINAR background
Presenters
Good apartment design is one of the biggest challenges currently facing architects in New Zealand as our population undergoes a demographic transformation.
Ralf Kessel (reg. EU architect) Cement & Concrete Association New Zealand (CCANZ)
Add to this rising property prices - particularly in Auckland and Christchurch - the scarcity of land for development, and the relatively slow rate of residential construction, and it is inevitable that apartments will become a long-term housing solution.
Author of the CCANZ Apartment Design Guide.
However, New Zealand is still relatively inexperienced in terms of apartment design and we need to be aware that there are many design requirements to achieving quality results.
Designer of many residential multi-unit buildings including the Piermont / Monument Apartments in Wellington.
Seminar Outcome
TONY KOIA (Auckland Seminar) (reg. NZIA architect) Koia Architects
The seminar will highlight the most important challenges for architects in apartment design, and provide insight into the work of New Zealand practices with a proven record in successful apartment design.
Allan Wright (Wellington Seminar) (reg. ANZIA architect) Architecture +
Designer of many outstanding residential multi-unit buildings in Auckland and Queenstown. WELLINGTON SEMINAR
Presentations CCANZ architect (EU) Ralf Kessel will use the CCANZ Apartment Design Guide (download from www.ccanz.org.nz) to recommend suitable space dimensions, address parking issues, discuss urban design and explore how to deliver enhanced fire safety, sound proofing and durability in apartment buildings. At the Wellington seminar ANZIA registered architect Allan Wright will use case studies to demonstrate how real-life design challenges were overcome to create well-functioning and attractive apartment buildings. NZIA registered architect Tony Koia will do the same at the Auckland seminar. NZIA CPD Event (15 points)
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Wednesday 21st May, 3.00pm - 4.30pm School of Architecture, LT 1 Victoria University of Wellington (VUW) 139 Vivian Street, WELLINGTON AUCKLAND SEMINAR Friday 6th June, 3.00pm - 4.30pm Conference Centre, LT 423-342 University of Auckland 22 Symonds Street, AUCKLAND Registration Email: admin@ccanz.org.nz Phone: 04 499 8820 Cost: Free Date for Christchurch seminar to be announced.
Image: Diederick Van Heyningen
CCANZ UPDATES WEATHERTIGHT CONCRETE
CONSTRUCTION CODE OF PRACTICE Cited by the NZ Building Code as Acceptable Solution 3 for Clause E2 External Moisture
(E2/AS3), the Code of Practice for Weathertight Concrete and Concrete Masonry Construction covers the weathertightness of the building envelope for concrete slabs on the ground, concrete walls and associated methods of insulation, concrete flat roofs and decks, and concrete to timber construction junctions. To aid planners and builders the Code of Practice follows the same format as existing weathertightness solutions but offers larger detail drawings. CCANZ developed the Code of Practice in partnership with building and construction industry representatives, and its acceptance into the NZ Building Code followed wider consultation.
in the area of weathertight concrete and concrete masonry design and construction.” “It will allow builders, designers and their clients to choose from a wider range of building materials, and in turn enable the weathertight advantages of concrete and concrete masonry systems to enhance New Zealand’s building stock.”
CCANZ Chief Executive Rob Gaimster is delighted with the updated Code of Practice and believes it will offer ongoing benefits to builders and home owners.
This latest version includes a new section on wall weathertightness systems for masonry veneer that has been extracted from NZS 4229:2013 Concrete Masonry Buildings Not Requiring Specific Engineering Design.
“The development of this document and its inclusion as an Acceptable Solution in the New Zealand Building Code will continue to help alleviate uncertainty amongst consent authorities
As of Friday 14 February 2014 the Code of Practice was cited as E2/AS3. Visit the CCANZ website to download a copy www.ccanz.org.nz
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in-situ concrete homes offering strength, style & comfort Renowned for building some of New Zealand’s finest concrete homes, Ross Bannan of auckland based Bannan Construction recently took time out to chat with Concrete magazine about his passion for in-situ construction and quality formwork systems, as well as the importance of good communication and professional development. THE EARLY YEARS Ross started out in New Zealand’s residential construction industry in a similar fashion to many others. After completing his apprenticeship with a large commercial company in 1989 he transitioned into traditional timber frame residential construction.
methodologies using in-situ forms grew to the point where I was confident enough to build complicated cast in-situ concrete homes for customers.” WHY (IN-SITU) CONCRETE?
Influenced however, by the building technologies he had seen overseas and wanting to give his work a stronger sense of permanence, Ross began to utilise precast concrete.
The durability and weathertight advantages of concrete, combined with its plastic properties and design flexibility are what attract Ross to the material.
“I started to wonder why I was building imitation (plastered) concrete homes rather than the genuine article,” says Ross. “I researched how to best employ precast concrete panels to build detailed and bespoke residential homes, and received some invaluable advice from Paul Cane of Formstress and Andrew Sinclair of Wilco Precast.”
“I am a firm believer in building homes that withstand the test of time and reduce as much maintenance as possible,” says Ross. “The typical timber frame home just seems so flimsy, and is becoming increasingly problematic to construct with the extra building envelope requirements and cavity systems. Weathertight issues are always present.”
“My early precast concrete houses were successful and very satisfying, but I was receiving more and more enquiries from customers wanting in-situ elements within the precast concrete frame,” says Ross.
“Cast in-situ construction offers greater peace of mind against the elements, and can be just as affordable as any other building type. From a design perspective there are an endless range of shapes and forms, restricted only by the imagination of the qualified and experienced design/build team and the customer.”
“With further research, along with attendance at international seminars and some local knowledge gained through CCANZ and various individuals, my understanding of efficient construction 10 concrete
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“My motivations for choosing in-situ concrete are very similar to those of my customers. The low maintenance properties of
concrete, along with the scope for architectural flair, are important factors. The desire to be different, to stand out from the mass of timber framed houses, is also an attraction. Concrete offers both permanence and prestige for home owners.” THE IMPORTANCE OF FORMWORK AND MIX DESIGN Always striving for quality outcomes, Ross recently purchased his own GHI metal framed ‘Tritech’ formwork material from Germany, and along with Aden Bolton, set-up Formwork Solutions to make available (for hire or purchase) the range of GHI products. “The correct formwork makes the difference between good concrete work and great concrete work,” says Ross. “You have to have faith in the form when you and your team are pouring and vibrating the mix through the shuttered forms.” “Tolerances are generally minimal, so any movement whatsoever can be disastrous. The use of the strong forms allows for externally mounted vibrators that negate the need for plunge vibrators that can potentially damage the form-liner.” “It is also critical to obtain the correct mix design for the concrete. In this regard, Kevin Mischewski and Stevenson Concrete have been fantastic partners from the start, working very closely with me to develop the correct mix design for each specific requirement,” adds Ross. “It is vital to have the support of your local ready mixed concrete supplier and for them to understand exactly what you are doing.” “I am very excited about the GHI ‘Circumflex’ formwork panels we recently brought to New Zealand, which can be reduced to a radius of 1000mm. On my current project in Remuera I am making extensive use of them as there are many challenging curves as well as a huge helical staircase. They have literally saved me thousands of dollars by not having to build multiple specific radius shutters. In fact, these are the only curable shuttering products currently in New Zealand from what I understand.” COMMUNICATION AND EDUCATION / TRAINING Ross prides himself on maintaining clear communication channels with both the customer and architect from the outset. He believes
www.bannanconstruction.co.nz
p 09 849 8287
this is key to ensuring the most efficient and effective construction methodologies are selected to bring the design to life, and above all, help keep the customer happy. “One of Bannan Construction’s many points of difference is that I’m on-site and accessible 99 percent of the time. Customers are a lot more informed now than in the past. They have canvassed options, and want to discuss the various pros and cons.” “I like to be involved early on in the design process as this allows me to talk over the best construction approach for each individual application,” says Ross. “There are many construction details to iron out early in the project, which directly affect the way the home is designed and which can have a dramatic impact on the budget.” “At times I do feel that practical in-situ concrete knowledge amongst specifiers in New Zealanders is limited, and that there is a perception that residential concrete construction is too expensive. That is not to say there isn’t a desire amongst specifiers to push the boundaries using in-situ concrete, but a more hands-on appreciation of the appropriate methodology would lead to more efficient and less expensive solutions.” “For instance, rigid wall insulation may come at an additional cost, but this is more than made up for by the reduction in construction time, plus you have an assurance that it won’t bend during the pour. Similarly, terminating walls at the window can be achieved effectively without the need for capping or compromising weathertightness.” “So that is why I place a premium on my own professional development, by attending conferences and seminars, as well as actively networking with concrete professionals in New Zealand and overseas. I enjoy sharing my knowledge and experience, and have acted as a consultant on other projects, as well as assisted CCANZ with its weathertight concrete code of practice.” “At the end of the day, if New Zealand is constructing a better, more resilient residential building stock by utilising the properties of in-situ concrete, then I am happy.” The following project is an example of Bannan Construction’s work.
www.formworksolutions.co.nz
m 027 495 2407
f 09 849 8284
e rmbannan@xtra.co.nz
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B A N N A N C O N S TR U C TI O N C A S E S T U D y - W E S T M E R E H O U S E
WESTMERE HOUSE THE HOUSE IS A JOURNEY FROM STREET TO WATER, WITH A NARROW POND BY THE ENTRANCE WALKWAY CONTINUING THROUGH THE HOUSE, ON TO THE POOL, AND LEADING TO THE OPEN SEA BEYOND.
project principals Architect Consultant Contractor Concrete
Ponting Fitzgerald Architects George Downey Bannan Construction Stevenson Concrete
This 900m2 home, which backs onto the upper Waitemata harbour, is in effect a large scale piece of sculpture. Massive in-situ concrete walls stand as monoliths, with the house weaving around them. The main body of the house includes the well-proportioned double height living room with its cave-like media room behind. The living room is framed by a wall 12m long and 5m high which includes the fireplace and runs through to the outside deck where it holds the barbecue and an outside fireplace. This wall is punctured with openings and manipulated with various shapes to bring some subtle curves to its massive form. This house is a complex exercise in layering of spaces from the street to the sea. The exposed decorative rough sawn timber finish provides texture without being harsh. The oak floors are warm and the cedar ceilings reassuring without being oppressive. The use of in-situ concrete throughout has led to a low maintenance home that retains its warmth through the colder months and repels the heat during the summer months.
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CONCRETE CONSTRUCTION COURSE CCANZ has developed a Concrete Construction Course designed for those responsible for supervising the receipt and placement of fresh concrete on-site - typically this would be the site foreman (or equivalent) and the formwork carpenter. Building apprentices would also find the course invaluable. The aim of the course is to promote quality concrete construction. Built around NZS 3109 Concrete Construction, the curriculum for the 2-day classroom based course will meet both industry needs and the relevant NZQA standards. The course is comprised of the following 5 modules: 1. Introduction to Concrete
a. Cement manufacture
b. Ready mixed concrete production
c. Constituent materials
d. Applications 2. Properties of Fresh and Hardened Concrete
4. Formwork
a. Requirements of formwork
b. Formwork materials, systems and design
c. Falsework d. Construction 5. Site Practice
a. Handling & placing
b. Compaction, finishing & curing
c. Hot & cold weather concreting
d. Control of surface finishes & cracks
The popular CCANZ publication The New Zealand Guide to Concrete Construction is an ideal resource to accompany the course. It can be downloaded in chapters from the CCANZ website – www.ccanz.org.nz/documents.aspx The course will be rolled-out during July in Auckland, with Wellington and Christchurch dates to be announced.
a. Relevant Standards
The registration fee is $1,100+GST.
b. Fresh & hard concrete tests
To register your interest in the Auckland, Wellington or Christchurch course contact CCANZ on (04) 499 8820 or email admin@ccanz.org.nz
3. Reinforcement
a. Reinforcement types
b. Manufacture
c. Handling & installation
Queries about the course content can be directed to Alistair Russell (Manager – Structural Performance & Engineering Systems) on (04) 915 0384 or email alistair@ccanz.org.nz
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concrete 13
CARVED CONCRETE AT W LOCATED IN THE GO-AHEAD CITY OF PORIRUA,
CAMPUS COMMUNITY
NORTH OF WELLINGTON, WHITIREIA POLYTECHNIC
With a total footprint of around 3817m2, the $16.5m Building 1 houses the Faculty of Health, administration, classrooms and conference facilities – including laboratories and simulation suites that provide state-of-the-art training facilities to around 1000 nursing and paramedic students. The project progressed throughout 2012-2013 under the direction of CGM + Foster Architects Ltd, GAZE Commercial (Interior Design) and Maycroft Construction.
IS UNDERGOING A STAGED RE-DEVELOPMENT TO BUILD A COMMUNITY FOCUSED FACILITY. THE RECENTLY COMPLETED BUILDING PROGRAMME 1 IS A STRIKING ADDITION TO THE CAMPUS BUILT AROUND THE POETIC USE OF CONCRETE.
The aim of this redevelopment was to build a community focused campus - one that is fully interconnected. Flexible ‘learning spaces’ and ‘learning streets’ have been included throughout the building to form a holistic education facility that creates a “campus community” and integrates with the wider community. This sense of union and collaboration between elements extends to the use of construction materials. Concrete and glass work
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WHITIREIA POLYTECHNIC together to create a sense of permeability, an open and light filled environment which completely engages with the learning experience. Similarly, concrete and steel work harmoniously together. The new structure sits on a fully insulated concrete foundation, the first floor and supporting structures are also concrete, while the upper levels and roof structures are in steel. DECORATIVE PRECAST Concrete itself, used extensively in (decorative) precast panels and columns, also acts as a conduit, bringing together the internal and external environments, as well as the past with the present. This connection is achieved primarily through the intricate Maori patterns that adorn the building facades and corridors. The carved concrete surfaces, conceived by Whitireia Whakairo tutor James Molnar, have their roots steeped in Maori tradition, but with a modern twist made possible through new technologies.
Conveying historical, environmental, cultural and urban narratives unique to Whitireia and its surroundings, the highly detailed carvings are underpinned by the concept of Korowai - the cloak of knowledge - that wraps the new building. The prominent triangles are a direct reference to the prehistoric connection to Whitireia maunga (mountain); mapped up from the landscape that they represent around the Porirua inlet. The process of creating the decorative panels and columns involved firstly sketching the design, which was then captured digitally, converted into a vector file, and given depth and texture to become a three dimensional object. This formed the basis of a real time negative mould (formliner) that was created by Christchurch based CNC Routing Ltd. The moulds were then sent to Emmetts Civil Construction Ltd of Whanganui who prepared the precast concrete panels and columns, which after some hands-on finishing where ready to erect on-site. volume 57 issue 2
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Concrete itself, used extensively in (decorative) precast panels and columns, also acts as a conduit, bringing together the internal and external environments, as well as the past with the present.
As which the patterns, the colours selected to highlight parts of the concrete also have traditional significance, For instance, the conspicuous triangles use a red colour matched to the blood of a shark used in Maori paintings. SUSTAINABLE FEATURES Building 1 also boasts a range of sustainable construction features. From a design perspective the fully accessible and flexible layout allows teaching / learning environments to be customised as required. Natural light and ventilation were utilised wherever possible, as were low VOC materials. The latest in sustainable systems are also present throughout, with solar hot water heating and grey water recycling, as well as underfloor heating in the floating concrete slab, and very high levels of insulation, such as R5.8 in the ceiling. Building longevity has been ensured through the selection of durable construction materials, as well as leaving the services and structural elements exposed to allow for future reconfiguration. Now in the post occupancy evaluation period feedback indicates the sustainable and artistic moves throughout the design, linked intrinsically to the use of concrete, have created a successful building for the end users, one which will draw the Whitireia and wider Porirua community together.
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Whitireia Polytechnic Building Programme 1 Client Architect Interior Design Contractor Precast Concrete
Whitireia Polytechnic CGM + Foster Architects GAZE Commercial Maycroft Construction Emmetts Civil Construction
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David Barnard
(Image courtesy of Fletcher Trust Archive) Sandy Cormack
Bob Park
Len McSaveney
NEW ZEALAND’S
CONCRETE TRAILBLAZERS AS OUTLINED IN THE PREVIOUS ISSUE OF CONCRETE MAGAZINE, 2014 IS THE YEAR THE NEW ZEALAND CONCRETE SOCIETY (NZCS) CELEBRATES ITS 50TH ANNIVERSARY. THROUGHOUT ITS EXISTENCE THE SOCIETY HAS BENEFITTED FROM AND HELPED FOSTER THE VISION, INTELLECT, WISDOM AND DETERMINATION OF A GROUP OF INDIVIDUALS WORTHY OF THE TITLE – TRAILBLAZERS. These individuals have made a significant contribution to the concrete industry and wider building and construction sector, as well as to the infrastructure of a New Zealand emerging as a modern and forward thinking nation during the second half of the 20th century. Outlined below is a small selection of these trailblazers, who along with Bob Norman, Nigel Priestley, Bob Irwin, Lyall Holmes and several others will be acknowledged in a commemorative publication detailing the history, accomplishments and influence of the NZ Concrete Society. SANDY CORMACK Perhaps no other individual is more synonymous with the concrete industry in New Zealand than Sandy Cormack.
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Wellington born, Sandy was an engineer who became chief executive of Certified Concrete Ltd from its establishment in 1938 until retiring in 1971. He moved to Auckland in 1940 where he remained based until he passed away in June 1985, aged 79. Sandy was the person who introduced and developed ready mixed concrete to this part of the world, and was deeply committed to pioneering advances in precast / prestressed concrete. He also involved himself in numerous research projects and the formation of the various industry associations that still operate today. Sandy had a principal role in setting-up the NZ Portland Cement Association (NZPCA) in 1948, and served on the board until 1978. Through his work in introducing quality control to concrete production he also served on many Standards committees.
Sandy was instrumental in establishing the NZ Ready Mixed Concrete Association (NZRMCA), and its plant classification scheme. He was involved with the establishment of the Prestressed Concrete Institute (later to become the Concrete Society), and was its first president. When the NZ Concrete Research Association was founded in 1972, he was chairman of its technical advisory committee and served on its board until 1985. However, many believe Sandy’s greatest achievement was his influence almost 75 years ago in the creation of the first ready mixed concrete plant in Australasia at Grant Road, Wellington. It was that project which launched New Zealand into high-tech concrete, and it was from there that the formidable drive and talents of Sandy Cormack were to provide huge leadership and service. PROFESSOR ROBERT (BOB) PARK Renowned in New Zealand and internationally, Professor Bob Park was key in the creation of the seismic design method called capacity design, an important innovation with regard to reinforced concrete structures and a notable development in the history of earthquake resistance. Born in Fiji, Bob came to New Zealand in 1951 and studied civil engineering at Canterbury University, where in 1956 he joined the academic staff. Then after 6 years overseas, during which time he completed his PhD at the University of Bristol, Bob returned to the University in 1965 where he spent the next 35-years. Over the course of his career Bob won multiple awards for technical papers, contributed to numerous technical committees, and received honours from an array of professional bodies. President of the NZ Concrete Society from 1975-76, Bob spent 28-years on Council. In 1995 he was awarded an OBE in the Queen’s Birthday Honours. Highly respected as one of the most knowledgeable people within the field of concrete and earthquake resistance research, as well as an inspirational teacher, Bob passed away in November 2004.
DAVID BARNARD David started his career in the United Kingdom in 1952 developing engineering experience in local government, contracting and consultancy before coming to New Zealand in 1974. Described as a “single-minded advocate for concrete” David spent close to 25-years at CCANZ, including in its previous guises of the NZ Portland Cement Association and the NZ Concrete Research Association. David was the NZ Concrete Society president from 1987-88. Refer to any technical publication or Standard on concrete or concrete masonry produced since the mid-1970s and chances are David either wrote it or was a significant contributor. Tireless in his efforts to implement relevant research and deliver practical training David has prided himself on developing strong relationships across the construction sector and imparting independent advice. Examples of David’s achievements include the introduction of daytime training for concrete construction workers, the development of the Certificate in Concrete Technology and Construction correspondence course, and an emphasis on durability research that led to a specific chapter on the subject in NZS 3101 Concrete Structures Standard. Although David retired from his role at CCANZ in 1999 he remains busy as a consultant. LEN McSAVENEY NZ Concrete Society president from 1988-89, active within fib, and a staunch supporter of student research, the term “Innovator” is often used to describe Len McSaveney. In fact, a March 2002 issue of Concrete used the parlance of the day - “Change Insurgent” to describe Len’s role as a promoter of new ideas and technology. Graduating from Canterbury University in 1964 Len went to work for what is now Holmes Consulting Group. After a time travelling Len moved back to New Zealand in 1974 to work for R.T. Scott Limited, a company later bought by Stresscrete, and in turn by the Fletcher organisation. Len’s long association with Fletchers included roles at Firth Industries and Golden Bay Cement. Lightweight aggregate in Wellington’s Westpac Stadium, the thousands of concrete power poles across the middle of the North Island, and the uptake of self-compacting concrete all owe a debt to Len’s willingness to embrace change.
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nat i onal ea rt h q uake museum
DESIGN PROPOSALS
NATIONAL EARTHQUAKE MUSEUM
CCANZ Architect (EU) Ralf Kessel was recently asked to help review the design proposals submitted by architecture students at Victoria University of Wellington’s School of Architecture. Under the direction of Andrew Charleson (Associate Professor – Architecture) the 3rd year students were faced with a brief to conceive a National Earthquake Museum on a prominent Wellington waterfront site. Using concrete as the primary construction material the museum was to offer a range of functional spaces, while at the same time symbolising the immense power of seismic events to shape landscapes and lives in New Zealand. The following pages showcase a small selection of the many outstanding designs presented by the students.
Jonathan Molloy This design uses a range of experiential perspectives to illustrate how seismic events impact people in different ways. Governing factors include proximity to the quake, degree of personal loss as well as the environment in which the event is experienced. The museum consists of three exhibition spaces based on three perspective experiences - the observer, the victim and the memorial. Each space is connected by a circulation area that re-orientates users, enhancing their understanding of each experience.
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Tayler Matthews The architectural concept of this Earthquake Museum design seeks to portray the immense force and inevitable collision of the Australasian and Pacific tectonic plates beneath New Zealand. The curving roof emphasizes this opposing movement, as does the interior layout which flows towards the central meeting / memorial point. Exhibition spaces help develop a journey between the symbolic built forms, as do the bridges, which also create fluid light patterns that imply shift.
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nat i onal ea rt h q uake museum
Brett Nicholas (RIGHT)
Megat Othman (BELOW) Focussed on giving architectural expression to the concepts of earthquake, monumental and museum, this stark and jagged structure appears torn upwards from the surrounding land. Combining something sudden and violent that causes great destruction and upheaval (earthquake) with a desire to store and exhibit important objects (museum) on a grand scale (monumental), this design captures and conveys the brutal impact of seismic events in a manner that compels and haunts.
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Visitors to this contemporary Earthquake Museum follow an upward and gently spiralling path that encourages interaction with the exhibits and facilities. The sense of journey within the tightly packed building leads towards the central memorial, which is nestled within the protective cover of the main structure. Also making use of a rising helix configuration the central memorial offers a quiet and reflective shape in which to commemorate those whose life have been affected by earthquakes.
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CCANZ STRUCTURAL ENGINEER ALISTAIR RUSSELL CONSIDERS A SERIES OF QUESTIONS AROUND STEEL REinFORCING AND ITS BEHAVIOUR DURING an earthquake
WHAT HAPPENS TO REINFORCEMENT IN A CONCRETE BUILDING DURING AN EARTHQUAKE? Reinforced concrete buildings inherently rely on the ductile characteristics of steel reinforcing to ensure a predictable and non-brittle response when subjected to loads. This is especially important for earthquake loading and where capacity design is utilised. Steel reinforcement generally is designed to behave elastically during service loading, and to yield at ultimate loads. When the yield strain (corresponding to the yield stress) is exceeded, irrecoverable plastic deformation occurs, whereas the elastic portion of strain is recoverable. As deformation increases following yielding, the strain in the bar will increase but the stress remains constant, and this is known as the yield plateau. As the strain in steel reinforcing increases beyond the yield plateau, strain hardening occurs and the remaining strain capacity becomes less. Following deformation of a steel reinforcing bar, such as during an earthquake, testing can be performed to determine the amount of strain hardening which has occurred in the bar, and in Christchurch this is being correlated to determine the accumulated plastic strain, and thus the percentage of peak strain capacity remaining. When peak strain is reached, the bar will rupture. As earthquake shaking tends to impose cyclic loads and deformations on structures, the phenomenon of strain hardening should more correctly be referred to as “low-cycle fatigue”. Insurers are becoming concerned about a trend to cite strain hardening as a reason for demolition of damaged reinforced concrete buildings in Christchurch. WHAT ARE THE DIFFERENT TYPES OF REINFORCEMENT USED IN NEW ZEALAND? The types of reinforcing steel that can be used in New Zealand are governed by a joint Australian/New Zealand Standard, AS/NZS 4671:2001. This Standard outlines a number of types of reinforcing steel, of which two are most commonly used in New Zealand. These are Grade 300E and Grade 500E and the primary difference between the two types is the yield strength of the steel. Grade 300E reinforcement has a nominal yield strength of 300 MPa and Grade 500E reinforcement has a nominal yield strength of 500 MPa. Moreover, the strength of Grade 500E reinforcement can be achieved in two distinct processes: Microalloying or the Quenched and In-Line
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Tempered (QT) method. Engineers must be aware of significant limitations on the use of QT reinforcement, which because of its non-homogeneous cross-section, may not be cut, rebent, welded or threaded.
Grade 300E
Grade 500E
Figure 1: Bar marks identifying Grade 300E and Grade 500E reinforcement
martensite – high strength, hard
pearlite – low strength, ductile
Figure 2: Cross section of a Q+T reinforcing bar
WHAT ABOUT HISTORIC REINFORCEMENT? Although only two grades of reinforcement are used in New Zealand today, other types of reinforcement have been used in earlier times. While knowledge of these reinforcement types is irrelevant to the designer of new structures, it is vital that engineers understand older reinforcement types when assessing the performance of existing buildings. Some of the more prevalent previous reinforcement types are described below. Grade 275 Before 1989 New Zealand reinforcement was graded according to the “minimum” yield stress, rather than the lower characteristic yield stress as is used now. The steel used in Grade 300E reinforcement has a minimum yield strength of approximately 275 MPa, so before 1989 this reinforcement was referred to as Grade 275.
Grade 430 Grade 430 reinforcement was the predecessor to Grade 500E. It was a high ductility micro alloy steel with a lower characteristic yield strength of 430 MPa. Grade 430 was withdrawn from New Zealand early in the 2000s to allow alignment of New Zealand and Australian reinforcing steel Standards. Grade 380 Grade 380 was a high strength, low ductility reinforcing steel used in New Zealand until ~1989. It has much poorer properties than later high strength reinforcement types. Non-metric Before metrification of reinforcement occurred in 1973 New Zealand used a variety of reinforcement to British and US Standards. Most common amongst these are Grade 40 and Grade 60 bars. These have minimum yield strengths of 40 ksi and 60 ksi respectively, corresponding to metric values of 275 MPa and 414 MPa. WHAT IS HARDNESS TESTING OF REINFORCEMENT AND WHAT DOES IT MEAN? Measuring the surface hardness of a steel reinforcing bar which has undergone strain hardening, and comparing that value with an equivalently determined hardness value of a bar which has not undergone strain hardening, provided that appropriate boundary conditions are maintained, may be used to provide an estimation of the residual strain of that bar. It is important that the limitations of the test method used are identified and understood. There is considerable complexity involved in correlating the surface hardness with the reinforcement deterioration due to cyclic loading, and correspondingly, with the expected future performance of the overall building. This is particularly important considering the different types of reinforcement available currently and historically in New Zealand, and why an understanding of the reinforcement characteristics and manufacturing process is valuable. WHAT CAN BE DONE ABOUT BUILDINGS WHICH HAVE BEEN SUBJECTED TO LOW-CYCLE FATIGUE? In theory, where some concentrated cracking has occurred, as long as that crack can be opened up, and filled with good quality, high strength epoxy, then any subsequent cracks should be initiated elsewhere, in a non-strain hardened region of the bar.
of lower strength than other areas, and can be because of a minor random imperfection. At locations of significant imperfections (defects), such as the result of spot welding or notching, highly concentrated deformations can occur leading to bar rupture or fracture. This highlights the importance of understanding the characteristics of reinforcement bars, and the limitations on handling and installation. Depending on the extent of damage, parts of the building may have to be replaced or retrofitted. The view could be taken that where any strain hardening has taken place, that portion of the building – usually a beam adjacent to a column – needs to be replaced so that it is in the same condition as when it was first constructed, as it may be considered that any strain hardening represents a reduction in total pre-existing capacity. If there are enough of these regions in the frame that need replacing, the cost to do this work may tip over so that it becomes less economical to repair than to fully replace the building. WHAT DOES THIS MEAN FOR CONCRETE BUILDINGS IN THE FUTURE? The design and construction of “traditional” Concrete Moment Resisting Frame (CMRF) structures will come under greater scrutiny, and this may create opportunities to further the use of new (or less widely used) technologies, which employ damage resistant design philosophies. Largely as a result of the Christchurch earthquakes, seismic design philosophies in New Zealand are tending towards limiting nonstructural damage as much as possible, instead of focussing on just designing for life-safety. The requirements to limit building damage, non-structural damage and building downtime are increasingly being given greater weighting in new structural design, particularly as a result of the cost of repairing and rebuilding many structures in Christchurch. The New Zealand concrete industry has been at the forefront of such new damage resistant design concepts, with the development of both Base Isolation and PRESSS technologies originating from this country, as well as other emerging technologies, such as non-tearing joints in concrete moment resisting frames. Based on its generally high mass and high stiffness, concrete as a material is naturally well suited to such design methods.
Strain hardening correlates with some increase in strength, and any further yielding will occur where the strength is the least (or lower). Initial yielding of a reinforcement bar is likely to occur at a location
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CCANZ Library Listed below is a small selection of recently acquired material by the CCANZ library. email library@ccanz.org.nz TO BORROW. CONCRETE MIX DESIGN, QUALITY CONTROL AND SPECIFICATION BY KEN W. DAY, JAMES ALDRED & BARRY HUDSON
APARTMENT DESIGN GUIDE
Thoroughly revised and updated this fourth edition addresses current industry practices that provide inadequate durability and fail to eliminate problems with underperforming new concrete and defective testing. Many specifications now require additional criteria in an attempt to improve durability or other properties. This book discusses the trend towards adding performance requirements to existing prescriptive specifications. It also explores the matter of prescription versus performance specification and especially the specification of non-strength-related performance such as durability. CURING CONCRETE BY PETER C. TAYLOR Curing concrete is often low on the list of priorities, particularly when budgets and timelines are under pressure. Yet the increasing demands being placed on concrete mixtures also mean that they are less forgiving than in the past. Therefore, any activity that will help improve hydration and performance, while reducing the risk of cracking, is becoming more important. Curing Concrete explains exactly why curing is so important and shows how to best do it. The author also gives numerous examples of how curing has affected concrete performance in real-world situations. These include examples from hot and cold climates. Written for construction professionals who want to ensure the quality and longevity of their concrete structures, this book demonstrates that curing is well worth the effort and cost.
Library Quiz To go in the draw to win a copy of Curing Concrete by Peter C. Taylor answer the following simple question: According to Infometrics research approximately how much cheaper are concrete roads compared to asphalt alternatives?
The CCANZ Apartment Design Guide sets out key considerations, and provides recommendations on size, daylight and interior climate requirements, along with effective soundproofing and fire protection. Email admin@ccanz.org.nz to request your FREE copy of the Apartment Design Guide
Email your answer to library@ccanz.org.nz. Entries close Friday 30 May 2014. Congratulations to David McKay of Trengrove Architects Ltd, who correctly answered the Vol 57 Iss 1 Library Quiz to receive a copy of Tadao Ando: Houses by Philip Jodidio.
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www.ccanz.org.nz
News from the Associations CONTACTS New Zealand Ready Mixed Concrete Association Ph (04) 499 0041 Fax (04) 499 7760 Executive Officer: Adam Leach President: Jeff Burgess www.nzrmca.org.nz New Zealand Concrete Masonry Association Ph (04) 499 8820 Fax (04) 499 7760 Executive Officer: David Barnard President: Mario Fontinha www.nzcma.org.nz Precast NZ Inc. Ph (09) 638 9416 Fax (09) 638 9407 Executive Director: Rod Fulford President: Paul Cane www.precastnz.org.nz New Zealand Concrete Society Ph (09) 536 5410 Fax (09) 536 5442 Email: concrete@bluepacificevents.com Secretary/Manager: Allan Bluett President: Carl Ashby www.concretesociety.org.nz New Zealand Master Concrete Placers Association Ph (07) 575 3214 Fax (07) 575 3618 Email: office@mcpa.org.nz www.mcpa.org.nz
NEW ZEALAND CONCRETE SOCIETY (NZCS) CELEBRATION PUBLICATION TO MARK 50 YEARS The NZ Concrete Society will celebrate its 50th birthday by producing an anniversary publication, an oral history video and an audio visual timeline scroll. The theme of the Concrete Industry Conference 2014, to be held at Wairakei Resort, will be looking back at the past 50 years, plus the website and logo will be revamped, there will be a seminar series and articles will be published throughout the year. Gavin Cormack, son of the Society’s founder, Sandy Cormack, is chairing a steering committee which is sourcing and managing material for the commemorative publication, video and A/V timeline.
Gavin Cormack
Gavin says the 100-page book will tell the stories, in words and photographs, of the Society and concrete’s role in New Zealand over the last five decades. It will open by placing the Society into the context of the 1960s and discuss the post-WWII environment that led to its formation, the impact of trade unions and other issues of the time like draconian foreign exchange laws and state control of major construction projects. Among the industry’s trailblazers who will be celebrated are Bob Norman (second President 1966); Morley Sutherland (President 1970-71); J.B.S. (Hans) Huizing; Rob Irwin; and Bob Park.
Jason Ingham
The book will feature significant structures built in the last half century including the original Newmarket Viaduct (first in-situ cantilever bridge), the Mangaweka Railway Viaduct (first base isolated bridge), the Ngauranga Interchange in Wellington (first push bridge); the Sky Tower (tallest structure); and Victoria University’s Alan MacDiarmid building (first multi-storey PRESSS building). “Fallibility is part of the pioneering ethic, and there’s much value in exploring failures, lessons learned and the implications for future projects.” A look to the future will discuss shifting boundaries and the fact there’s always room for improvement in the way concrete is engineered and used. “Christchurch’s rebuild presents an opportunity to develop new specifications and uses for concrete. The next decade could be, as Gerry Brownlee has intimated, the Society’s finest hour.” Jason Ingham, the NZCS Immediate Past President, is chairing conference organising committee. Already, three keynote speakers have been secured: Professor Hugo Corres Peiretti, Professor Ken Hover and Gavin Cormack. NZCS Secretary Allan Bluett says the conference partners, CCANZ, Precast NZ and NZRMCA, have agreed the conference theme will be to look back at the last 50 years. For nostalgic reasons Concrete Industry Conference 2014 will be held in Wairakei Resort, the venue for the first NZCS conference held in August 1965.
Wairakei Resort, Taupo 9–11 October
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