Concrete Magazine - Volume 62. Issue 03

INAUGURAL CONCRETE INDUSTRY AWARDS SET NEW BENCHMARK IN EXCELLENCE

HOLCIM NZ LAUNCHES LOW-CARBON INITIATIVES AND A NEW BRAND IDENTITY

UPFRONT concrete MAGAZINE

A RESILIENT, LOW CARBON, CONCRETE WAY FORWARD

In the wake of Cyclone Gabrielle there has been a lot of comment around the urgent need to plan and build resilient infrastructure, whether that be flood mitigation, electricity supply or roading networks.

While there are many questions to be answered, there is no doubt that concrete will be a key part of the eventual answers, more so as industry pledges to reduce its carbon footprint as set out it the soon to be released Aotearoa New Zealand Concrete and Cement Industry - Roadmap to Net-Zero Concrete 2050.

RESILIENT CONCRETE INFRASTRUCTURE

Concrete’s overarching properties based around durability make it an asset in both mitigating and adapting to climate change. It forms part of wind farms, hydroelectric schemes and geothermal plants.

Concrete can also improve the resilience of buildings and communities through improved stormwater management, flood defences and many other forms of critical infrastructure, such as our state highways and local roads.

Recent weather events have demonstrated that New Zealand requires a durable, long-term solution to mounting infrastructure woes. As part of a multi-pronged approach, the government must give serious consideration to building concrete roads.

During the first part of 2023, the condition of the country’s roads took up a lot of column inches and airtime minutes, as a plague of potholes saw frustration grow.

Prime Minister Chris Hipkins has indicated that one approach moving forward will be to relocate stretches of vulnerable roads to more stable ground. While re-routing roads makes sense, we must also ensure that the materials it is built with are also resilient.

The level of maintenance work required to our asphalt road network is enormous. A situation that would have only been made more challenging by the closure of the Marsden Point oil refinery and subsequent questions around the bitumen supply chain. The inherent durability of concrete roads would lessen this burden, a priority as the impact of climate change will make extreme weather events more frequent.

Vague concerns around access to buried services, skid resistance, surface noise and seismic resilience of concrete roads can all be accounted for through appropriate design, as demonstrated overseas.

The economics of concrete roads has been proven time and time again, with Infometrics having shown that in a preferred scenario concrete is around 30 percent less expensive than its asphalt counterpart.

The final tick in the plus column is for the sustainability credentials of concrete (including low carbon attributes) and industry commitment to decarbonise.

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ISSN: 1174-8540

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Disclaimer: The views expressed in concrete are not necessarily those of the Concrete NZ. 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.

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Cover image: Pacifica Tower, Auckland. David Calder-Flynn.

These are clearly articulated in the Aotearoa New Zealand Concrete and Cement IndustryRoadmap to Net-Zero Concrete 2050, set for publication mid-2023.

LOW CARBON CONCRETE INFRASTRUCTURE

By describing an achievable pathway to producing net-zero concrete by 2050, the decarbonisation roadmap sets out a positive vision for how the New Zealand cement and concrete industry can play a major role in building a sustainable future. Industry has already made progress in reducing greenhouse gas emissions. An updated independent review of our efforts shows that the industry has reduced emissions from concrete production by 11 percent between 2005 and 2020, despite production increasing by 11 percent during that same period.

This roadmap includes the levers (e.g., rapid uptake of supplementary cementitious materials such as fly ash and ground granulated blast furnace slag to replace cement) and milestones needed to achieve net-zero carbon concrete by mid-century.

It covers both ready mixed concrete and concrete products, and also involves the major participants

in the concrete value chain, including cement manufacturers, concrete producers and designers of buildings and infrastructure.

Developed with support from sustainability firm thinkstep-anz and engagement with Concrete NZ’s member groups, the roadmap is also informed by, and aligned with, international work, such as the Global Cement & Concrete Association’s (GCCA) 2050 Cement and Concrete Industry Roadmap for Net Zero Concrete.

Building on past and current initiatives, the concrete industry will look to remain successful in reducing its emissions by leveraging further R&D, investment and commitment from researchers, government and all stakeholders throughout the value chain.

With its mid-year publication, our roadmap to 2050 net-zero will further strengthen the case for concrete roads to be part of plans to (re)build more sustainable infrastructure.

Ngā mihi, Rob Gaimster Concrete NZ Chief Executive

For

maximum protection of concrete in severe sewage conditions

2. HYDROGEN SULPHIDE PROTECTION

1. KILLS MICROBES

6. SULPHATE RESISTANCE

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WEATHERTIGHT CONCRETE CODE OF PRACTICE UPDATED

CONCRETE NZ HAS PUBLISHED A REVISED 2022 VERSION OF THE CP01 CODE OF PRACTICE FOR WEATHERTIGHT CONCRETE AND CONCRETE MASONRY CONSTRUCTION TO HELP ESTABLISH NEW STANDARD PRACTICES.

Concrete NZ chief executive Rob Gaimster notes that the update of the 2014 version was prompted by a need to improve the thermal performance of residential concrete buildings and account for new construction systems.

Insulation shown in the Code’s details has been enhanced and thermal images of the details themselves included - enabling a better understanding of the risk of condensation at the internal surface areas and junctions.

“It has been eight years since the CP 01 Code of Practice for Weathertight Concrete and Concrete Masonry Construction was last updated,” Rob says.

“The majority of the edits have been revisions of the detailed drawings to allow for improved thermal performance.

“The addition of acceptable surface temperature factors will help architects and designers determine a detail’s climate zone suitability, while new Appendix A describes the methodology that was used to develop the detail and provides further thermal performance information.”

The Code’s updated details also reflect new weathertightness systems that have become more prevalent in New Zealand over the past decade, such as double glazing and thicker thermal insulation.

Sustainable Engineering Ltd director and contributor to the 2014 and 2022 versions

Jason Quinn believes the update demonstrates admirable leadership from Concrete NZ, establishing new standard practices in advance of New Zealand Building Code minima.

“An important new focus in the CP01:2022 is thermal performance, and we calculated the thermal bridging and surface temperature factors (mould index) for the various details,” Jason says.

“These calculations help architects and designers to understand the risk of mould growth and underpin comprehensive changes to the detailed drawings of this document.

“When we build better, everybody benefits.”

The updated Code has been prepared for use by practitioners with the appropriate qualifications, experience and professional judgement as a way to demonstrate compliance with the Building Code Clause E2 External Moisture.

Practitioners using this Code should ensure design solutions meet all the performance requirements of the New Zealand Building Code.

The 2022 version should be assessed as an alternative solution. The current 2014 version remains the cited version in Acceptable Solution E2/AS3 and should be assessed as an acceptable solution for New Zealand Building Code Clause E2 External Moisture.

The new CP01:2022 - Code of Practice for Weathertight Concrete and Concrete Masonry Construction can be downloaded for free from the website: www.concretenz.org.nz

Point Chevalier HousePonting Fitzgerald Architects

HOLCIM NZ LAUNCHES LOWCARBON INITIATIVES AND A NEW BRAND IDENTITY AT AUCKLAND EVENT

HOLCIM NEW ZEALAND (HOLCIM) HAS OFFICIALLY OPENED A NEW LOW-CARBON CEMENT REPLACEMENT FACILITY AT THE PORTS OF AUCKLAND, WHICH CAN REDUCE EMBODIED CARBON FROM CONSTRUCTION OF THE BUILT ENVIRONMENT. AT A PREVIEW EVENT IN LATE APRIL, INDUSTRY LEADERS ENJOYED A TOUR OF THE INNOVATIVE FACILITY AND WERE INTRODUCED TO THE NEW BRAND IDENTITY.

Holcim also unveiled the ECOPlanet and ENVIROCore lower carbon products, backed by green credentials. ECOPlanet can reduce embodied carbon by more than 30 percent compared to General Purpose (NZ) Cement. At the forefront of green building solutions, Holcim is committed to playing an essential role to accelerate New Zealand’s transition to a net zero future.

George Agriogiannis, Chief Executive Officer of Holcim Australia & New Zealand says: “Today marks a milestone for our company in our transformation to become the global leader in innovative and sustainable solutions. Our world is changing in many ways, with population growth, urbanisation and the climate challenge. We are determined to play our part to accelerate low-carbon and circular construction in Aotearoa New Zealand, to build a net zero future by 2050. Our new identity sends a signal that we are committed to building progress for people and the planet, enabled by lower carbon products and solutions such as ECOPlanet and operation of a new cement replacement facility.”

Kevin Larcombe, Executive General Manager, Holcim New Zealand says: “Cement is a key ingredient in the most commonly used building material in the world. Each year over 1.5 million tonnes of traditional cement is used in Aotearoa

New Zealand, generating 1.3 million tonnes of CO2. With the government committed to net zero by 2050, the team at Holcim wants to play an enabling role. For us, building progress means lowcarbon cement products for homes, buildings and infrastructure. It means providing advice, tools and resources to help customers specify projects with confidence. Decarbonising construction is essential to building a future that works for people and the planet.”

With its new identity launch Holcim is reinforcing its focus on providing the industry’s broadest range of low-carbon building materials. Becoming a net zero company in 2050, Holcim puts sustainability at the core of its strategy and drives the circular economy, as a leader in recycling. It is making its business smarter in a data-driven and agile way while fostering open innovation.

Dave Barker, Master of Ceremonies, Holcim New Zealand.

George Agriogiannis, Chief Executive Officer of Holcim Australia & New Zealand.

Hon Rachel Brooking, Associate Minister for the Environment.

Rob Gaimster, Concrete NZ Chief Executive, was amongst the dignitaries.

Desley Simpson, Deputy Mayor of Auckland.

Kevin Larcombe, Executive General Manager Holcim New Zealand.

FLETCHER BUILDING OPENS

FIRST-OF-ITS-KIND CONCRETE INNOVATION LAB

FLETCHER BUILDING’S CONCRETE DIVISION (CONSISTING OF FIRTH, GOLDEN BAY, AND WINSTONE AGGREGATES) HAS STEPPED UP ITS COMMITMENT TO DEVELOPING INNOVATIVE AND INCREASINGLY SUSTAINABLE CONCRETE SOLUTIONS, WITH THE OPENING OF NEW ZEALAND’S FIRST COMMERCIAL CONCRETE INNOVATION LAB, IN CHRISTCHURCH.

The Concrete Innovation Lab has been established to fast track the development of new concrete products and solutions with a particular focus on innovating to decarbonise concrete. The aim being to support customers as their building needs and specifications change in response to the need to build for climate change.

Concrete is a complex material with intricate chemistry involved in every batch. While most concrete labs are designed to assure product quality, what sets the Fletcher Concrete’s Innovation Lab apart is that it is purely dedicated to product innovation.

Dene Cook, Divisional Technical Manager, and all things Concrete mastermind, explains “Concrete is an amazing building material and one that has stood the test of time due to its strength and durability. Yet we know the concrete products we use today are very unlikely to be the ones we are using in 10-20 years’ time. Building for climate change is a huge imperative for generations to come and this requires us to invest in getting the solutions right today.”

“As an industry we have committed to decarbonising concrete, with the Global Cement & Concrete Association (GCCA), detailing a roadmap to net zero by 2050. Fletcher Building is excited by this challenge and the work we will do in the Concrete Innovation Lab will turn this from a paper commitment to a reality.”

“Concrete is a high-volume product meaning that even incremental changes can create significant sustainability benefits at scale. Last year, we launched EcoSure Cement, which is significantly lower in embodied carbon than most cements around the world and certainly the lowest in the New Zealand market. We operate in a very competitive industry and for every step forward we take, others are likely to follow. This can only be seen as a good thing when dealing with the global challenge of climate change.”

Nick Traber, Fletcher Building’s Chief Executive, Concrete agrees: “Prioritising concrete innovation is crucial if we are going to succeed in decarbonising the built environment. We acknowledge that as an industry leader, we have a responsibility to lead the way in innovating for a more sustainable future.”

Trevor Sawyer, Dene Cook, Steve Schulte and David Mortimer at the opening of Fletcher Building’s commercial concrete innovation lab.

“We are fortunate to have both the resources and people expertise to focus on improving the performance of this critical building material. Moreover, our Concrete Innovation Lab provides an environment for our team to be bold and creative so we can bring new products to the market quicker than ever before. In short, it represents an exciting opportunity to solve real-world challenges and improve the world around us.”

Fletcher Building pledged its commitment to reducing carbon emissions in 2019 when it became the first building and construction firm in Australasia to set a verified Science-Based Target (SBT) for carbon reduction, committing to reduce its emissions by 30% by 2030. In 2022 it added a strategic goal to be net zero by 2050. Fletcher Building’s carbon emissions are externally audited and publicly available within its Annual Report.

Concrete is the second most used material in the world. First used by the ancient Romans it has stood the test of time as a durable and resilient construction material. Each batch of concrete is unique, and is scientifically tested to ensure its strength, durability and is 100% fit for the purpose it has been created for.

It is the science of concrete that creates the art. The Fletcher Concrete Innovation Lab is dedicated to enabling our team of concrete engineers, technologists and industry specialists to develop innovative and increasingly sustainable concrete solutions which will meet the demands of building for climate change.

Dene Cook, Fletcher Building Divisional Technical Manager, welcomes guests.

NEW FROM MAX® – THE RB441T TWINTIER™ REBAR TYING TOOL – NOW

WITH 5.0AH BATTERIES

THIS NEW GENERATION MAX® REBAR-TIER THE RB441T TWINTIER™ WAS INTRODUCED WITH 3 NEW DESIGN FEATURES TO PROVIDE THE GREATEST EFFICIENCY AND HIGHEST LEVEL OF SAFETY REINFORCING IRONWORKERS HAVE EVER EXPERIENCED.

The TwinTier’s “dual wire feeding mechanism” increases tying speed by reducing the time needed to twist and feed the wire, consequently reducing the cost, and shortening the time required for construction. The tool’s dual-wire wrap ensures each tie is reinforced for maximum hold.

The TwinTier’s “wire pull back mechanism” firmly pulls the tie wire in to adjust the tie to the rebar’s size to maximize the strength of the tie. When forming a tie the tool makes a loop with the wire and then pulls the wire to tightly secure and lock the rebar in place.

The TwinTier’s “wire bending mechanism” feeds a precise amount of wire to match the thickness of the rebar being tied and cut down on the use of unnecessary wire. This bending mechanism consistently feeds, pulls back, twists and releases the perfect sized tie for the each application.

This generation of the MAX® Rebar-Tier produces ties that are approximately 50% shorter in height, allowing for thinner concrete pours. Also, the ends of each tie are positioned downward to increase safety. Additionally, wire spools now produce up to 240 ties (when tying D12 x D12 rebar).

The TwinTier’s added features also include a jaw that is constructed to tie D10 x D10 up to D22 x D22 rebar. This wide jaw accommodates larger

gauge rebar while its slim arm offers the freedom to work in tight spaces.

The TwinTier’s quick load magazine makes changing wire spools a piece of cake, and its frontward position provides improved balance/ ergonomics, making flatwork easier.

A low “battery power consumption” design allows the tool to produce 5000 ties per charge using a 5.0Ah, 14.4volt Lithium-ion battery, which recharges in just 60 minutes.

The tool’s 6-step torque adjustment dial allows its user to adjust the strength of the tie based on the application. Steel, electrogalvanized and polyester (“poly”) coated wire are all available for use with the MAX® TwinTier™.

The MAX® TwinTier™ works at double the speed and produces double the number of ties from a single roll of wire than the previous model and far exceeds that of any of its competitors.

Overall, no matter the application, the MAX® TwinTier™, reduces the time it takes to complete a job, saves businesses money by cutting man hours needed for each project and increases the productivity of its workers.

For more information visit the SIFCO websitewww.sifco.co.nz

TOGETHER WE CAN HELP DECARBONISE AOTEAROA NEW ZEALAND

At Holcim New Zealand, building progress means low carbon and high performance cement products for all homes, buildings and infrastructure.

It means advice, tools and resources to help you specify your next project with confidence. It means solutions that are right for you each and every time. We are building progress for New Zealand.

For more information

www.holcim.co.nz

PACIFICA TOWER TAKES TOP HONOUR AT CONCRETE INDUSTRY AWARDS

Presented at the Concrete NZ Nauhria Industry Awards event at the Royal New Zealand Yacht Squadron in Auckland on 23 March, the award celebrated concrete’s role in one of the first examples of a new high-rise construction method being used in New Zealand.

The judging panel commended the project team, which along with BBR Contech also included Hengyi Pacific, Plus Architecture, BGT Structures, WSP, ICON and Dominion Constructors, for the adoption of innovative design and construction techniques that are emerging in New Zealand.

In particular, the judging panel felt the use of in-situ post-tensioned concrete floors was an elegant solution to both architectural and

structural performance requirements for multistorey buildings.

The six-day floor cycle achieved during construction – where a new floor/storey was erected every six days – is testament to the careful consideration of structural design and construction methodology, as well as the skill and expertise of the project team.

Concrete NZ chief executive Rob Gaimster believes the Pacifica Tower sets a new standard for multistorey reinforced concrete builds, demonstrating concrete can be used for the tallest commercial and residential structures in New Zealand.

“The Pacifica Tower is a prominent and celebrated addition to the Auckland skyline, and all those

THE PROJECT TEAM RESPONSIBLE FOR AUCKLAND’S PACIFICA TOWER, NEW ZEALAND’S HIGHEST RESIDENTIAL BUILDING, HAS TAKEN HOME THE 2023 NAUHRIA PREMIER CONCRETE AWARD.

Image: Tom Roberton.

involved can be proud of our biggest city’s newest landmark,” says Rob.

“It is also an example of how the implementation of technologies such post-tensioning and high strength mix designs will be part of concrete’s ongoing decarbonisation journey,” says Rob. On their way to the top prize, the Pacifica Tower team also won the Firth Industries - Excellence in Commercial Concrete category award, with the Judges commenting:

The Pacifica Tower exudes excellence, showcasing the forefront of concrete design and construction for multi-storey buildings. The project is commended for the adoption of innovative solutions, particularly the post-tensioned floors, which provide an example for other building designs to follow. The Pacifica Tower is a worthy winner of the 2023 Premier Concrete Award. The Awards set a new benchmark for excellence in all aspects of concrete design, construction, rehabilitation, research, and innovation, while also recognising the leaders and teams who are building and preserving New Zealand’s low carbon, built environment of tomorrow.

Alistair Bennet (Firth Industries) presents Derek Bilby (BBR Contech) and John Bolland (BGT Structures) with the Excellence in Commercial Concrete Award.

Rakesh Nauhria presents Derek Bilby (BBR Contech) and John Bolland (BGT Structures) with the Premier Concrete Award.

HOLCIM - EXCELLENCE FOR ARCHITECTURAL CONCRETE (MONTE CRAVEN AWARD)

HYNDS PIPE SYSTEMS FOR TE PAE NORTH PIHA SURF LIFE-SAVING TOWER

The brief was for the lifeguard tower at North Piha - one of the most beautiful but dangerous surf beaches in New Zealand – to be a robust, low-maintenance building that would withstand the severe coastal environment. As the site is remote, precast concrete was chosen for factory manufacture and assembly on-site. The tower is made up of 10 bespoke elements, with the shaft sitting on an in-situ concrete foundation to support the podium elements that cantilever towards the sea. The result is a facility that meets community needs now and into the future.

JUDGES’ COMMENT

The Te Pae North Piha Surf Life-Saving Tower deserves to be put on a pedestal. A striking new feature that provides an essential facility and acts as a beacon for visitors to the beach, the distinctive form sits in contrast to the beautiful, rugged backdrop. There are so few moving parts, it has an efficiency and conceptual sanctity about it.

PROJECT TEAM

• United North Piha Lifeguard Service

• Crosson Architects

• BGT Structures

• Scarbro Construction

• Hynds Pipe Systems

• Peter Fell Ltd

Andy Campbell (Holcim NZ) presents the Excellence in Architectural Concrete Award.

Image: Sam Hartnett

GOLDEN BAY - EXCELLENCE IN CONCRETE INFRASTRUCTURE

FULTON HOGAN TAYLORS JV FOR THE WAIMEA COMMUNITY DAM, TASMAN

The dam is one of the region’s most important infrastructure projects and the largest dam built in New Zealand for over 20 years. The project team developed new approaches to achieve a high-quality concrete outcome. Key to success was placing over 30 thousand cubic metres of concrete in a remote location for a range of structures, which included a diversion outlet, starter dam, plinth, spillway and the embankment’s concrete face.

JUDGES’ COMMENT

The scale and complexity of this project is impressive - constructed using slipform from over 30,000 m3 of concrete, batched on site due to the remote location, with 35-50 percent fly ash replacement. The challenging construction environment and performance requirements necessitated a high level of skill by both the design and construction teams.

PROJECT TEAM

• Waimea Water

• Fulton Hogan Taylors Joint Venture

• Damwatch Engineering

• Allied Concrete

Simon Harper (Golden Bay) presents the Excellence in Concrete Infrastructure Award.

GOLDEN BAY - EXCELLENCE IN CONCRETE INFRASTRUCTURE - HIGHLY COMMENDED DOWNER NZ FOR THE TEKAPO A, INTAKE AND SHAFT, CANTERBURY

This unique engineering project protects one of the South Island’s key hydro-power schemes by allowing the flow of water to Tekapo A, Power Station to be stopped in an emergency shutdown. Engineering smarts were developed that maintained live operations throughout construction. These included using shotcrete to build the shaft in layers, expediting the construction programme and building a permanent stent to sustain power generation.

JUDGES’ COMMENT

The Tekapo A, Intake and Shaft needs to be recognised with a commendation for its innovative construction methodologies that resulted in significant time and cost savings. A challenging brief, with tight tolerances, required minimising interruption to the existing intake tunnel, and only offered a short window of time to fit the new gate.

PROJECT TEAM

• Genesis Energy

• AECOM

• Downer New Zealand

• Parfitt Construction

• Kiwi Concrete

• Complete Reinforcing

Simon Harper (Golden Bay) presents Mark Hedley (Downer NZ) with the Excellence in Concrete Infrastructure – Highly Commended Award.

The entire complex was conceived as a journey through nature, emulating the context of the Canterbury Plains as they meet the majestic alps. The main feature is the hard landscaping, which uses shotcrete and decorative concretes. A striking element of the facility is the cave system, which features complex shapes formed using large bags of sawdust as the backform.

JUDGES’ COMMENT

The landscaping elements of the Ōpuke Pools are particularly striking, with its clever use of decorative concrete elements and the bespoke designed cave system that exudes the “wow” factor. The selection of concrete for durability considerations was critical to the design and will result in a facility that meets the long-term requirements of the client.

PROJECT TEAM

• Methven Adventures

• Bradford Group

• Sheppard & Rout

• Allied Concrete

• Peter Fell Ltd

Chris Brockliss (GPIL) presents Simon Elliotte (Allied Concrete) with the Excellence in Concrete Landscaping Award.

Image: Jason Mann

the hillside and for the finished internal walls. The structure itself was insulated and left exposed, allowing concrete’s thermal mass to optimise a passive solar design that allows for comfort all year round. Resilient in the face of strong winds and seismic threats, the concrete also offers honest beauty, with the strong timber grain shuttering giving an aesthetic that is raw, much like the environment. In short, the home is efficient, permanent, and stylish.

JUDGES’ COMMENT

Scarborough Béton Brut is an outstanding example of the use of concrete in a residential house. Impressive aspects of the project included the challenging in-situ construction of the walls, and the high-quality finishes achieved with the rough sawn timber shuttering. Architecture and concrete construction at its finest.

PROJECT TEAM

• Young Architects

• Hoogervorst Builders

• ENGCO

• Peter Fell Ltd

….. and subsequently presents it to Greg Young (Young Architects).

Dene Cook accepts the Excellence in Residential Concrete Award on behalf of Young Architects from Greg Durkin (BCITO Te Punkenga) …..

Image: Dennis Radermacher

FORMSHORE - EXCELLENCE IN CONCRETE REMEDIATION AND REUSE DOWNER NEW ZEALAND FOR CITY RAIL LINK (CRL) C1, AUCKLAND

The CRL Contract 1 and enabling works at Britomart involved extending the rail network from Britomart Station underneath the historic Chief Post Office and Lower Queen Street, one of the busiest areas of the Auckland CBD. The construction of twin rail tunnels beneath the Post Office presented challenges for the project team, which led to innovations such as post-tensioning, cement jet grouting and the construction of concrete diaphragm walls as part of the underpinning works.

JUDGES’ COMMENT

This is a remarkable achievement, with the building remaining undamaged and preserving the heritage features. The CRL is a critical piece of infrastructure and to construct this underneath a historic building without demolishing or significantly altering the building fabric is an outstanding example of remediation and reuse.

PROJECT TEAM

• Auckland Transport

• Soletanche Bachy

• Aurecon

• Freyssinet

• Downer New Zealand

• Allied Concrete

• Acrow

Andy Robertshawe (Formshore - centre) presents the Excellence in Concrete Remediation and Reuse Award.

DOWNER NEW ZEALAND FOR THE DOWNTOWN INFRASTRUCTURE DEVELOPMENT PROGRAMME, AUCKLAND

This 350-million-dollar redevelopment of the downtown area had an ambitious timeline, with the America’s Cup and other international events on the horizon. There were numerous large concrete-based components erected and cast over the water, and significant architectural concrete finishes that enhance the streetscapes. Notable amongst these were the seismic strengthening of the 100-year-old seawall on Quay Street and the Te Wānanga Downtown Public Space - the project’s centrepiece.

JUDGES’ COMMENT

The project’s merging of the need to replace the existing seawall with the creation of a new public space deserves applause. The engineering of the critical seawall infrastructure is largely hidden, but the project leaves behind a legacy space that is beautifully designed, drawing you out to the peripheral edge to engage with the landscape.

PROJECT TEAM

• Auckland Transport

• Tonkin & Taylor

• Aurecon

• HEB Construction

• Soletanche-Bachy

• Downer NZ

• Allied Concrete

• Firth Industries

William Ford (PowerPac Group – second right) presents the Excellence in Concrete for the Community Award.

POWERPAC GROUP - EXCELLENCE IN CONCRETE FOR THE COMMUNITY - HIGHLY COMMENDED AURECON FOR NGĀ HAU MĀNGERE, AUCKLAND

In partnership with mana whenua, the project team replaced the 105-year-old Old Māngere Bridge with a new, stunning piece of structural engineering which, at 260-metre-long, has an elegant, curved design with a wide deck that allows pedestrians and cyclists to travel safely. The cornerstone of the bridge is a dramatic 60-metre central arch, supported by a concrete superstructure, which provides a fitting sense of scale to the neighbouring motorway bridges. Challenges during construction included the tidal environment and the complex structure.

JUDGES’ COMMENT

This project receives a commendation as it rated highly across several of the award categories, including Excellence in Concrete for the Community, Excellence in Concrete Infrastructure, and Excellence for Architectural Concrete.

PROJECT TEAM

• Waka Kotahi NZTA

• Aurecon

• Isthmus

• Pete Bossley Architects

• McConnell Dowell

Nga Hau Mangere project team celebrate with the Excellence in Concrete for the Community – Highly Commended Award.

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CANZAC - EXCELLENCE IN CONCRETE INNOVATION ALLIED CONCRETE FOR ECRETETM

With a reliable supply of ground granulated blast furnace slag now available in New Zealand, Allied Concrete undertook an R&D programme to develop a range of lower embodied carbon concretes known as ecreteTM, which are being used on a limited scale in Auckland with wider release planned for later in the year. These concretes are designed to utilise SCMs and other concrete mix technology to achieve lower carbon outcomes through cement substitution of up to 60 percent.

JUDGES’ COMMENT

The extensive research undertaken to develop the ecrete mixes is noted, with impressive results achieved across a range of performance metrics. Such innovations to develop low-carbon concrete mixes will be critical to achieving concrete industry emissions reduction targets.

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KIWI RESEARCHERS FIND COSTEFFECTIVE SOLUTIONS TO STRENGTHEN EARTHQUAKE PRONE BUILDINGS

RESEARCH FUNDED BY TOKA TŪ AKE EQC HAS DEMONSTRATED THAT WRAPPING WEAK SPOTS IN CONCRETE WALLS WITH CARBON-FIBRE STRAPS CAN STRENGTHEN EARTHQUAKE-PRONE HIGH-RISE BUILDINGS WELL BEYOND THE DEMANDS OF THE BUILDING CODE.

The research findings were presented recently by University of Auckland PhD student Victor Li at the New Zealand Society for Earthquake Engineering Conference, and is likely to draw significant interest in this sector as more than 100 multi-storey buildings in Wellington’s CBD alone are identified to be well below modern code.

With so many pre-1982 concrete buildings in New Zealand considered a particular earthquake risk, the research by the team supervised by Dr Enrique del Rey Castillo and Dr Rick Henry and funded by Toka Tū Ake EQC, has been in a race against time to find the most efficient and cost-effective ways to strengthen thin concrete walls.

Dr Enrique del Rey Castillo, Senior Lecturer Civil and Environmental Engineering at the University of Auckland examines a test panel.

Li says that this type of concrete walls can deform out of plane due to their thinness and inherent instability, and just one per cent of lateral displacement can cause catastrophic collapse.

“Technically it’s called ‘axial failure’. It can still happen in a newer building, as we saw in Christchurch’s Grand Chancellor Hotel, but the pre-1982 design methods mean the risk is higher in those older buildings,” says the PhD candidate.

“Up until now there has been no guidance on how these walls could be strengthened, but our research has shown that with the carbon fibre solution, the wall cannot buckle in the out of plane direction,” says Li, who added that the team tested the walls up to twice the building code for seismic resilience.

Toka Tū Ake EQC Head of Research, Dr Natalie Balfour, says that many older commercial buildings are being converted to apartments, so it is vital to ensure that people live in homes that meet modern earthquake standards.

“Toka Tū Ake EQC decided to fund this research because it will deliver practical guidance on how at-risk walls in older buildings can be strengthened cost-effectively. It will also establish a consistent way of doing these fixes across New Zealand,” says Dr Balfour.

Research supervisor Dr Enrique Del Rey Castillo explains that his team wrapped at-risk walls in

carbon fibre and tested 56 different combinations of concrete, steel and carbon fibre to see when and how they would break.

“This gave us the data we needed to model how to strengthen a particular wall. And the results have even been better than we anticipated,” says Dr Del Rey Castillo who adds that practising engineers will now have the scientific data to use the new technology with confidence to repair old walls.

“We presented new guidelines and equations for engineers to use at the recent NZSEE conference, so they can choose the most efficient and costeffective fix for their particular problem wall.”

Dr Del Rey Castillo emphasises that his team has had a lot of support from industry players like Concrete NZ, Mapei, Sika, Holmes and BBR Contech, who are all extremely interested in the research and to ensure that the testing would deliver real-world results.

“Thanks to the input from people working in the industry, we have delivered something that can be put to practical use right away.”

ENGINEER TO USE PRESTIGIOUS AWARD TO FURTHER IMPROVE BUILDING PRACTICES

DR LUCAS HOGAN FROM THE FACULTY OF ENGINEERING AT THE UNIVERSITY OF AUCKLAND SAYS HE’S EXCITED TO USE HIS RESEARCH TO MAKE AN IMPACT ON THE BUILDING INDUSTRY WORLDWIDE.

Structural engineering lecturer Dr Lucas Hogan is celebrating winning the prestigious Toka Tū Ake EQC/NZSEE Ivan Skinner award for his natural hazard research which has changed building practices in New Zealand.

Hogan, a senior lecturer at the Faculty of Engineering, was named as the winner of the annual New Zealand Society Engineering Conference for his extensive work in

understanding the earthquake risk to buildings and bridges across New Zealand and for helping to change building codes.

Hogan says that aside from the recognition, he’s most excited to be able to use his research to make an impact on the building industry worldwide. The prize money of $10,000 will allow him to share his expertise with peers to shape building guidelines in the USA.

Ken Elwood, Chief Engineer at MBIE and Toka Tū Ake EQC presenting the award to Dr Lucas Hogan at the New Zealand Society Engineering Conference (NZSEE). Image. Smoke Photography

“It’ll help fund the travel costs and fees associated with being a committee member of the American Concrete Institute (ACI) which, among other things, writes the building code provisions on how to design resilient concrete buildings and how to assess the seismic performance of existing buildings.

“I’ll be able to work with some of the best minds in the industry from around the world, to write building codes with new cutting-edge developments and improve the state of practice over there.

“Aotearoa New Zealand and California have similarities with their building codes, so I can use this information to improve guidelines here too.”

Toka Tū Ake EQC Head of Research, Dr Natalie Balfour, says that his win embodies the purpose of the award.

“We are familiar with Dr Hogan’s work as Toka Tū Ake EQC funded his research looking into the seismic resilience of bridges. His extensive work is having a direct effect on the engineering industry, which is great to see. This is why we fund the award – to recognise the research that is being put into building earthquake resilience and reducing the impact here in Aotearoa.”

Among his portfolio of work, Hogan has helped Waka Kotahi better understand the seismic resilience of bridges across Aotearoa New Zealand

and was able to assist with Urban Search and Recure (USAR) efforts following the Auckland floods and Cyclone Gabrielle.

In other work, he also helped change engineering practices after highlighting vulnerabilities in the way concrete walls are connected to foundations in common warehouse buildings.

The senior lecturer is most proud of his work on the ReCast project he was involved with that led to improved assessment and strengthening of precast concrete floors in Aotearoa. These floors were prolific in buildings from the 1980s and 1990s and used in approximately 80% of multistorey buildings. The research showed that the design would not hold up in an earthquake and the changes in the building code have resulted in a significant improvement for peoples’ safety.

Thanks to the extensive work from Hogan and his colleagues, changes are being made to benefit our future, which is one of his biggest motivations.

“The biggest thing for us as engineers is to keep people safe, build a resilient society and fight the effects of climate change. If we can make buildings more robust, they can either survive earthquakes better or be built back faster, which helps not only reduce our carbon impact, but means people can return to their lives quicker.”

University of Auckland researchers Dr Lucas Hogan, left, and Dr Max Stephens

SEISMIC TESTING MAY HAVE MAJOR IMPACT ON CONCRETE WALL CONSTRUCTION

RESEARCH INTO THE TECHNIQUE USED TO CONNECT REINFORCED CONCRETE WALLS TO THEIR FOUNDATIONS IS SET TO HAVE A SIGNIFICANT IMPACT ON THE NEW ZEALAND CONSTRUCTION INDUSTRY.

Researchers at the University of Canterbury are conducting earthquake testing to better understand the performance of a construction technique called staggered lapsed splices, which is used to connect the steel bars in reinforced concrete walls to the steel bars coming out of the foundations.

The practice is no longer used overseas, but allowed under the New Zealand building code.

“The connections between the walls and the foundation are created by overlapping the steel bars and they rely on the concrete around the bars to transfer the seismic forces from one bar to the other,” explains lead researcher Professor Santiago Pujol from the Department of Civil Engineering, whose research has been funded by Toka Tū Ake EQC.

“This configuration is economical and easy to build but does not always provide the toughness for

Professor Santiago Pujol discusses the wall tests with PhD candidate Charlie Kerby at the Structural Engineering Laboratory at the University of Canterbury.

the walls to resist the demands of an earthquake,” says Pujol, who adds that structures using this configuration have collapsed in previous earthquakes in Turkey, Chile, Japan and Alaska.

“When these connection fails, the outcomes are often catastrophic.”

Pujol says that New Zealand has fortunately not seen similar catastrophic failures of lapsed spliced walls in the Canterbury and Kaikōura earthquakes, but is vital to test the seismic strength of staggered lap splices in a controlled environment.

PhD student Charlie Kerby is carrying out the testing at the Seismic Engineering Laboratory by attaching the walls to hydraulic actuators which mimic the effects of a major earthquake by pushing and pulling the walls until they fail.

“We are not interested in how much force is needed to make the wall fail, but how much the wall can deform before failure occurs,” says Kerby.

“Buildings need to be able to move with the earthquake and we are looking at how much a lap splice can deform until it fails.”

The research is funded by Toka Tū Ake EQC as part of its contestable Biennial Grants, which supports research in improving the resilience of buildings to New Zealand’s natural hazards to better protect people and property.

“Our organisation invests around $19 million each year into research to better understand our natural hazards. Professor Pujol’s project is a great example of research that identifies

potential risks, but also informs better engineering solutions for reinforced concrete buildings, which many of us live and work in,” says Dr Jo Horrocks, Chief Resilience and Research Officer at Toka Tū Ake EQC.

University of Canterbury researcher Charlie Kerby explains that engineers have alternative options like welding the steel bars together or using a mechanical connection to transfer seismic forces, but says that tradition and economics dominate most of what happens in the construction industry.

“These lap splices have been used for over a century and from an economic viewpoint, an extra meter of steel virtually costs nothing compared to a specifically designed connection.”

Kerby says that the question whether lap splices actually perform well in earthquakes has only been raised fairly recently, so the research at the University of Canterbury will provide vital new insights to inform engineers and construction standards.

Professor Pujol says that his team will not only put the spotlight on a potential problem but also provide solutions for the industry by designing and testing alternative configurations.

“We will find out what works best to enable greater confidence in building design.”

The lines mark the cracks after three days of seismic testing on the concrete wall.

WHY BUILD IN CONCRETE? TO LAST AS LONG AS THE PANTHEON

Greg Young, Managing Director, Young Architects

On such an exposed site, this home must cope with everything the environment can throw at it. The highest wind ever recorded in Christchurch was during the 1975 storm, when 172 kph wind gusts were captured at the aerodrome. The hottest day in Christchurch was in 1973 when the temperature topped 41 degrees. Again, in the 1970’s, the coldest day reached -7.2 oC. Then there were the earthquakes, and the Port Hills fires. How do you find a solution to balance amazing views against the strong arm of the weather? How do you build on a volcano in a way that will protect residents in an earthquake? How do you design a sustainable home that is cool in summer, warm in winter, is durable and is easy to maintain on a steep site?

Scarborough House, the concrete home we designed in the hills above Christchurch, has just won the BCITO Excellence in Residential Concrete Award at the Concrete NZ Nauhria Concrete Industry Awards. This home was designed to resist strong nor’ west winds and earthquakes, to resist fire and to require little maintenance.

It is energy efficient, and resistant to the extreme heat of summer and cold of winter, with the thermal mass of its concrete storing heat during the day, moderating heat loads, and slowly releasing it during the night. By regulating the temperature in the home heating and cooling needs are reduced, lowering energy costs. Despite, or perhaps because of, these challenges the home is still aesthetically pleasing. We used

SCARBOROUGH HOUSE, BUILT HIGH ABOVE SUMNER, IS NESTLED INTO THE 30-DEGREE SLOPE OF A DORMANT VOLCANO. ITS GLASS BOX FRONTAGE ALLOWS BREATH-TAKING VIEWS ACROSS THE PACIFIC OCEAN AND ALL THE WAY UP TO THE SOUTHERN ALPS.

Images: Dennis Radermacher

Breton Brut – French for raw concrete - for its structure and façade. It looks like it has been clad in weathered timber but, due to the concrete’s durability it will last hopefully as long as the Roman Pantheon - still the world’s largest unreinforced concrete structure.

Concrete doesn’t need to be the cold 1970’s motels that you remember.

Sir Miles Warren once described NZ’s timber houses as being built out of “ticky tacky”. Like the outstanding American architect Frank Lloyd Wright known for his innovative and exquisite use of concrete, Sir Miles’ preference was for elegant, exposed, well-designed concrete blockwork and in-situ concrete.

The Christchurch earthquakes proved that brick and concrete block were susceptible to damage (or at least the mortar is) if they were not designed to cope with large earthquakes.

I’ve recently been involved in the restoration of one of Sir Miles Warrens buildings, however, and while the blockwork was damaged the concrete structure wasn’t. If anything, the in-situ concrete was its saving grace.

Italy is also an earthquake prone country, and there are concrete buildings that were built 2000 years ago that are virtually unscathed.

We don’t have any 2000-year-old concrete buildings in New Zealand, but I know of a beautiful concrete home just out of Christchurch that is nearly 150 years old, which has been through many, many earthquakes.

While concrete can cause some concerns regarding emissions from its production, there are now low carbon options available. I know the

industry is already halfway towards achieving a 30 per cent carbon decrease by 2030, on its way to net zero carbon by 2050.

In addition, concrete has its own sustainability credentials such as its energy efficiency and its durability characteristics.

This last factor blows minimum regulatory standards out of the water.

Like all things in construction, you can build to minimum standard, minimum durability, and maximum maintenance - or you can increase the quality of materials and design.

The New Zealand Building Code only requires your home’s cladding to last 15 years, and that’s the length of time that you’ll see a lot of cladding materials warrantees cover, with disclaimers around required maintenance - which most people never do.

We believe this beautiful home in Sumner demonstrates just how sturdy a home in New Zealand can be, by increasing the quality of materials and design. It exceeds minimum building standard expectations by potentially hundreds of years, and will stand up to Canterbury’s harsh extremes while providing a peaceful, beautiful, comfortable haven for its occupants.

The house should stand as a uniquely Christchurch sentence in the story of building in concrete, which stretches from Roman times through architects such as Frank Lloyd Wright and Sir Miles Warren.

This article formed the basis of a Stuff.co.nz story by Colleen Hawkes - Cliffhanger Concrete House ‘Should Last as Long as the Pantheon’. 19 April 2023.

HĀWERA WATER TOWER: A CENTURY AND COUNTING

Fiona Aitken, Chief Executive, South Taranaki District Council

TRAVELLING BACK TO HĀWERA WHEN I WAS A CHILD, WE ALWAYS LOOKED FOR THE GRAND HĀWERA WATER TOWER TO TELL US WE WERE NEARLY HOME.

It was often at night when the concrete tower’s soaring curves were lit up in red, visible across the Hawera skyline.

Later, as a young woman, I worked at the information centre which sits at the base of the tower, and it was part of my job to open the door for people who wanted to climb it. Eventually, I became manager.

Over the years we have celebrated the tower’s 90th and 100th birthdays and changed the colour of the lights at the top of the tower to recognise significant occasions. Thousands of people have made the climb to the top to see the views and take photographs.

For the people of South Taranaki and Hāwera in particular, as well as tourists, the tower is a popular

lookout, an important historic landmark and an enduring symbol that can be seen from land, sea and air.

Our small town of Hāwera, which means ‘burnt place’ in te reo Māori, was built near the site of a village burned to the ground during a feud between warring local hapu. Hāwera continued to live up to its name, suffering several destructive fires in its closely packed town centre during the early years of European settlement.

The tower, finished in 1914, was built partly in response, to provide water for fighting fires in Hawera.

In fact, our beloved tower almost died before it was born. When almost complete, a strong earthquake caused it to tilt some 0.75 m from the vertical. After using steel anchors and carefully undermining and dampening the clay on the low side, the tanks were slowly filled with water, and teams of men righted the tower in seven days. The excavated clay was replaced by concrete with the result that the structure has withstood many subsequent shakes.

The Hāwera Tower has national significance as the first reinforced concrete water tower constructed in New Zealand. It represents a

Water Tower, Hawera, January 1914, Hāwera, by Muir & Moodie. Te Papa (O.001868)

Ralf Kessel (Concrete NZ Architect) presents Fiona Aitken (South Taranaki District Chief Executive) with the 2023 Enduring Concrete Award.

major engineering achievement and has considerable technological importance.

The 54m tower is cylindrical supported by buttresses, changing to an octagonal form with a balcony. Its curved segments were achieved using timber formwork precisely shaped to accuracy using steam. First, the formwork was built up around the steel reinforcement to several metres, then filled with concrete. After a few days’ strengthening, the next step was completed. The ‘kibble’ used to carry the fresh concrete would have been pulled up by hoist.

Today Hāwera enjoys a first-class high pressure water supply leaving the tower, protected by a Category One Historic Places Trust categorisation, to stand proudly over the town with its tanks now removed.

Its longevity and service to the community has just been recognised with the Concrete NZ 2023 Enduring Concrete Award.

We’re proud it now stands alongside other iconic Concrete NZ Enduring Concrete Award winners such as the beautiful Grafton Bridge in Auckland, the graceful Fairfield Bridge in Hamilton and the world-famous Beehive, in Wellington.

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Water tower at Hawera. Image. Caption: Smith, Sydney Charles, 1888-1972. Ref: 1/2-C-11560-F. Alexander Turnbull Library, Wellington, New Zealand.

FIB SYMPOSIUM 2024 HEADING TO AOTEAROA NEW ZEALAND

It is with great pleasure that the Concrete NZ Learned Society announces it host the fib Symposium at Te Pae Christchurch Convention Centre 11-13 November 2024.

fib - Fédération Internationale du Béton (International Federation for Structural Concrete) is a not-for-profit association committed to advancing the technical, economic, aesthetic and environmental performances of concrete structures worldwide.

The Learned Society, and before that the New Zealand Concrete Society, is a long time National member of fib.

The fib Symposium is an annual event that covers issues related to concrete and innovative materials, structural performance and design, construction methods and management, and outstanding structures.

It provides an international forum for scientists, engineers, industrial partners and practitioners to present and discuss the stateof-the-art practice, recent advances, and future perspectives in terms of durability, sustainability and resiliency in civil engineering.

The sequence of devastating earthquakes that Christchurch experienced in 2010 and 2011 destroyed the city centre and required the demolition of hundreds of buildings across the Canterbury region.

However, a decade on, and the city has been rebuilt using seismic resilient designs and innovative construction technologies. As such, the organisers have chosen the title ReConStructResilient Concrete Structures - for the Symposium.

In addition to resilient structures, sustainable design and construction are a key focus of the Symposium, with New Zealand having committed to achieve net zero emissions by 2050, a pledge supported by the concrete industry’s own Aotearoa New Zealand Concrete and Cement Industry - Roadmap to Net-Zero Concrete 2050, set for publication mid-2023.

Therefore, it is the Society’s pleasure to extend an early welcome to delegates and sponsors, both domestic and international, to the Symposium, which will take place here in Aotearoa New Zealand for the very first time. Concrete NZ will share more information as it becomes available, in the meantime visit the Symposium website to register your interest –www.fibsymposium 2024.org

Professor Alessandro Palermo

NZ fib Head of Delegation

University of Canterbury

Associate Professor Rick Henry

Concrete NZ - Learned Society President

University of Auckland

Dr. David Fernandez-Ordoñez Secretary General of the fib International École Polytechique Fédérale de Lausanne

CONCRETE NZ CONFERENCE 28-30 SEPTEMBER 2023REGISTRATIONS NOW OPEN

REGISTRATIONS FOR THE 2023 CONCRETE NZ CONFERENCE, SET FOR 28-30 SEPTEMBER AT CLAUDELANDS IN HAMILTON, ARE NOW OPEN.

Moustafa Al-Ani, chair of the Organising Committee, believes this year’s conference promises to be a calendar highlight, offering an intriguing technical programme, entertaining social activities and extensive networking opportunities.

“We are delighted that registrations are now open for Conference 2023, and look forward to members, and all those from across the construction and infrastructure sectors with an interest in concrete, taking advantage of the early bird registration rate.”

“Announcing that we have arranged for Romilly Madew, well respected CEO of Engineers Australia, to be one of our keynotes should give further impetus to industry to register,” says Moustafa.

Visit the Concrete NZ Conference 2023 website for more information – www.concreteconference.org.nz

ROMILLY MADEW – KEYNOTE SPEAKER

CONCRETE NZ IS PLEASED TO HAVE SECURED ROMILLY MADEW, CHIEF EXECUTIVE OF ENGINEERS AUSTRALIA, AS A KEYNOTE SPEAKER.

Romilly boasts an impressive career to date, having also served as chief executive of Infrastructure Australia, where she was responsible for overseeing the organisation’s role in helping governments prioritise projects and reforms that best serve communities.

Before joining Infrastructure Australia, Romilly was CEO of the Green Building Council of Australia for over a decade.

In 2019, Madew was awarded an Order of Australia in recognition of her contribution to Australia’s sustainable building movement.

Alongside sustainability, Madew is recognised for her vocal advocacy on important topics including diversity, Indigenous engagement, flexibility in the workplace and women in sport.

More keynote speakers will be announced shortly.

ŌTAKI GATEWAY SCULPTURES INVITE TRAVELLERS TO EXPLORE

THE PEKA PEKA TO ŌTAKI (PP2Ō) EXPRESSWAY HAS REDUCED CONGESTION AND IMPROVED TRAVEL TIME. IT HAS ALSO SEEN THE CREATION OF TWO CONCRETE ARTWORKS THAT MAY VERY WELL PERSUADE MOTORISTS TO VISIT, RATHER THAN BYPASS, ŌTAKI TOWNSHIP.

Standing at the east side of the expressway just north of Te Horo, and near The Ramp at the north end, the two sculptures are clearly visible to drivers as they sweep around the Waitohu bend.

The sculptures and the landscaping that surrounds them are a credit to the design and production teams – who worked closely with the artist, mana whenua and community groups – along with the PP2Ō Gateways Steering Group which provided guidance and helped progress the project.

CULTURAL SIGNIFICANCE

The sculptures are located within the rohe (tribal territory or homelands) of Ngāti Huia, Ngāti Pare, Ngāti Koroki, Ngāti Maiotaki and Ngāti Kapumanawawhiti, and represent the three braided waterways that once criss-crossed the coastal plains Ōtaki is built on.

These significant waterways - the Waitohu and Mangapouri streams and the great Ōtaki River - wind together to meet in a circle at the top symbolising Tama-nui-te-rā, the sunny rays of Ōtaki.

The circle also reflects the influences that have shaped the local community from the arrival of tangata whenua to the recent settlement of migrants.

The curving strands also reference kō, a Māori cultivation tool, linking to the rich horticulture history of Ōtaki.

PRECAST SETUP

Designed by Studio Pacific Architecture, each strand of the sculptures stands six-metres high and weighs around four tonnes.

Creating a mould for the precast concrete posed a series of challenges for Emmetts Civil Construction due to the unusual shapes and tight timeframe.

The Emmetts team came up with different design options for the six sections across the two sculptures.

3D printed models were produced to help determine moulding as well as handling during the construction phase.

This was followed by the creation of control sample panels to help refine manufacturing processes, finishing techniques, concrete performance and decide on an anti-graffiti coating solution.

The selected production method and mould design achieved a high-quality finish to both formed and unformed faces of each stem/column section.

One of the most challenging aspects was reinforcing fabrication and placement due to the complex shape of the units.

The reinforcing was modelled to allow for accurate cutting and bending of stirrups and links, all vertical bars and curved horizontal reinforcing were hand bent against basic timber formed templates. Each stem/column was prefabricated utilising a fixing jig, up to the point where it transitioned into the top section.

CONCRETE CONSIDERATIONS

The ‘special’ concrete mix design was key to achieving a high-quality finish to both formed and unformed faces. It also incorporated aggregates from the Ōtaki River for the sculptures to embody the mauri (life spark or essence) of Ōtaki within the sculptures.

INSTALLATION ON-SITE

An effective transportation and erection methodology was also developed – which influenced the permanent and temporary works design requirements.

Lifting eyes and inserts were carefully positioned to avoid visible filling and patching.

With this being a somewhat fragile and uniquely shaped sculpture, protection measures including

CONCRETE MIX DESIGN

Mix: 40MPA @28 days

Cement: Alborg White Cement

Sand: White Sand from Industrial Sands Ltd (J61W)

Aggregate: Ōtaki River Greywacke

Additive: 10% Peter Fell PFL Super White Plus

Finish: Matt, F5 & U3

handling frames, protective wraps and edge protection were implemented to avoid damage.

Noting the quality of finish and exposed public location, it was important to select a graffiti shield product which did not visually change the artistic intent of the design.

As such a wide range of anti-graffiti coatings were trialled on sample panels, with Graffiti Guard by Dulux selected.

ENDURING LANDMARK

Glen Prince, Waka Kotahi NZ Transport Agency Principal Project Manager, believes that the concrete sculptures are an asset on many different levels.

“They’re fantastic landmarks for Ōtaki and the people who worked to create them should feel incredibly proud. It’s pleasing to see how large infrastructure projects like this can also leave behind a wonderful cultural legacy and enhance the environment within the areas and communities they touch.”

PROJECT TEAM

Owner: Waka Kotahi NZTA

Contractors: Fletcher Construction

Emmetts Civil Construction

Architect: Studio Pacific Architecture

Engineer: Dunning Thornton Consultants

Concrete: Firth Industries (Whanganui)

CONCRETE NZ LIBRARY

LISTED BELOW IS A SELECTION OF RECENTLY ACQUIRED MATERIAL BY TH E CONCRETE NZ LIBRARY. MEMBERS CAN EMAIL LIBRARY@CONCRETENZ.ORG.NZ TO BORROW.

CUBE: NEW BUILDING WITH CARBON CONCRETE BY MANFRED CURBACH (EDITOR)

The world’s first building made of “carbon concrete” was officially opened in Dresden at the end of September 2022. This book details the conception, planning and construction of the CUBE up to its completion.

Illustrated with spectacular photography, those who will benefit from Curbach’s work include architects, civil engineers and construction industry experts; namely all those interested in ecologically oriented building innovations and growing the solution space for future construction.

This newly developed type of concrete offers the same structural strength as concrete reinforced with steel rebar but uses far less concrete, researchers claim. The concrete is strengthened with carbon fibre yarn, which is made by binding together many carbon fibres – ultra-thin threads of almost pure carbon crystals – using a process of thermal decomposition called pyrolysis.

RECYCLED AGGREGATE CONCRETE: TECHNOLOGY AND PROPERTIES BY NATT MAKUL

Recycled Aggregate Concrete (RAC) as a sustainable material is gaining increasing importance in the construction industry. This book discusses properties, specifications, and applications of RAC and offers readers insight into current research and advances in the development and utilization of RAC. It shares information gathered about concretes that use RCA, as well as findings and conclusions.

Principles of RAC are discussed, along with advanced behavior and properties, specifications and codes, as well as best practices and the use of RAC in sustainable concrete construction.

This book will be useful for researchers, concrete scientists, technologists, practicing engineers, and advanced students interested in reusing construction waste for sustainable construction practices; it will help them strive toward meeting the UN Sustainable Development Goals.

BRUTALIST ITALY: CONCRETE ARCHITECTURE FROM THE ALPS TO THE MEDITERRANEAN SEA BY DAMON MURRAY (EDITOR)

What makes Italian Brutalist buildings different to their counterparts in other countries? Containing over 140 exclusive photographs – ranging from private homes to churches and cemeteries via football stadia – across every region of the country, Brutalist Italy is the first publication to focus entirely on this subject.

Architectural photographers Roberto Conte and Stefano Perego have spent the past five years travelling over 20,000 kilometres documenting the monumental concrete structures of their native country.

Brutalism – with its minimalist aesthetic, favouring raw materials and structural elements over decorative design –has a complex relationship with Italian history. After World War II, Italian architects were keen to distance themselves from fascism, without rejecting the architectural modernism that had flourished during that era. They developed a form of contemporary architecture that engaged with traditional methods and materials. This plurality of pasts assimilated into new constructions is a recurring feature of the country’s Brutalist buildings, imparting to them a unique identity.

LIBRARY QUIZ

To go in the draw to win a copy of Brutalist Italy: Concrete Architecture From the Alps to the Mediterranean Sea by Damon Murray (editor) answer the following question:

When was the South Taranaki District Council’s Hawera Water Tower built?

Email your answer to library@concretenz.org.nz Entries close Friday 30 June 2023.

Congratulations to Joseph Wakefield of Kirkgate Limited, who correctly answered the Vol. 62 Iss. 02 Library Quiz to receive a copy of Fluid Bodies: Methods For Casting New Esthetics by Rupert Zallmann and Quirin Krumbholz.

CONTACTS

Concrete NZ

Readymix Sector Group

Ph (04) 499 0041

Chair: Kerry Newton

Convenor: Rob Gaimster

Concrete NZ

Masonry Sector Group

Ph (04) 499 8820

Chair: Dene Cook

Convenor: Ralf Kessel

Concrete NZ

Precast Sector Group

Ph (04) 499 8820

Chair: Rakesh Nauhria

Convenor: Dave McGuigan

Concrete NZ

Learned Society

Ph (04) 499 8820

President: Rick Henry

Convenor: Adam Leach

Concrete NZ

Reinforcing Stakeholder Group

Ph (04) 499 8820

Chair: Kelvin Busbridge

Convenor: Dave McGuigan