Concrete Magazine - Volume 63. Issue 01

concrete

VOLUME 63 ISSUE 1

UPFRONT concrete MAGAZINE

IN THE EVER-EVOLVING LANDSCAPE OF TRANSPORTATION NEEDS, CONCRETE ROADS HAVE AN ESTABLISHED INTERNATIONAL PEDIGREE, OFFERING A COMPELLING SOLUTION FOR ROADING AUTHORITIES.

New Zealand, facing challenges like heavier traffic loads, the transition to net-zero carbon, and poor infrastructure investment, is now pursuing the benefits of concrete roads.

NATIONAL INFRASTRUCTURE FOCUS

This growing interest in concrete roads aligns with the new National-led government prioritizing high-quality infrastructure to foster economic growth and improve overall quality of life. A significant initiative involves the establishment of a National Infrastructure Agency, streamlining funding and enhancing collaboration between various stakeholders. The government is also exploring innovative funding tools, and has announced the Roads of Regional Significance.

With a commitment to expedite the consents process, a fast-track mechanism for the construction of essential infrastructure is also being explored. Additionally, the creation of a 30-year infrastructure pipeline reinforces the government’s commitment to building resilient and sustainable infrastructure. All of which sets the scene for investment in the advantages of concrete roads.

CONCRETE ROADS: A WISE CHOICE

Concrete roads present proven economics, making them a costcompetitive and durable alternative to traditional asphalt-surfaced roads. According to a 2020 report by Infometrics, concrete roads are potentially 29.4 percent less expensive than ‘flexible’ alternative solutions over a 40-year lifespan. The 2024 update of this report will feature in the next issue of Concrete

The circular economy aspect adds another layer of sustainability to concrete roads. At the end of their service life, concrete roads can be recycled, aligning with New Zealand’s waste minimization objectives. The crushed concrete can be reused in various infrastructure projects, promoting a sustainable cycle.

Safety is paramount, and concrete roads offer texture for traction, skid resistance, and reduced noise, as well as a brighter surface for improved driver visibility, and enhanced ride comfort.

Concrete roads contribute to fuel savings due to their rigid structure, preventing rolling resistance. Research by the Massachusetts Institute of Technology (MIT) indicates potential fuel cost savings, potentially reducing total transport-related emissions by about 0.5 percent over 50 years in the USA.

The lower carbon footprint of concrete roads further strengthens their case. A study commissioned by the Cement Association of

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+64 4 915 0383 adam@concretenz.org.nz

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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.

© Copyright 2024 Concrete NZ

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Cover Image: Armstrong Rubber Building, USA. Owen Davies. See pages 26-27.

Canada reveals that the primary energy costs of concrete roads over their lifespan are around one-third that of asphalt roads. The difference in New Zealand will be less pronounced with a higher percentage of renewable electricity available. However, this is still an important consideration.

TOWARDS NET ZERO CARBON CONCRETE

Adding weight to the concrete road argument is the industry’s pledge to achieve net zero carbon emissions by 2050. The recently unveiled Roadmap to net zero carbon concrete outlines a feasible pathway, focusing on reducing direct and electricity-related emissions by 44% from 2020 levels by 2030 and achieving a 100% reduction by 2050.

Strategies to lower the industry’s carbon footprint involve the use of waste materials as alternative fuels (both biomass waste and fossilderived waste) in clinker production, as well as the increased use of mineral additions and Supplementary Cementitious Materials to replace clinker in cement. From 2030 to 2050, intensified efforts include the use of Carbon Capture, Utilisation, and Storage.

Accounting for concrete’s carbon uptake ability, a natural process by which the exposed surface of concrete absorbs CO2, is another strategy. In fact, the UN has acknowledged this sequestration mechanism, a significant tick in the plus column for concrete considering the surface area of roads.

OVERSEAS PERSPECTIVE AND ADVOCACY

A keynote presenter at the 2023 Future Roads conference, Eric Ferrebee, Senior Director of Technical Services at the American Concrete Pavement Association, supports the call for concrete innovation in New Zealand’s road infrastructure (see pages 22-23).

Citing the United States, where concrete roads are prevalent, Ferrebee highlighted their versatility, durability, and cost-effectiveness. The longevity and effectiveness of continuously reinforced concrete pavements (CRCP), which do not require transverse contraction joints, also left an impression on Ferrebee during his stop-over in Australia.

NEW ZEALAND WHEELS SET IN MOTION

You don’t have to look far for recent examples of rigid concrete pavements enhancing New Zealand’s roading network, with New Plymouth

based roading contractor Rolco NZ literally paving the way (see pages 18-21).

Tauranga City Council faced challenges in the suburb of Tauriko, dealing with low subgrade strength and shallow services for two roundabouts linked by 300 metres of connecting road. Utilising Roller Compacted Concrete (RCC), Rolco NZ worked with concrete supplier Firth Industries, to provide a thin but strong pavement option with rapid construction times

A VIABLE SOLUTION

As the nation grapples with the twin priorities of addressing deteriorating infrastructure and striving for net-zero carbon emissions, the concrete pavement revolution stands poised to reshape our roading network, providing a pathway to a sustainable and resilient future.

The outlook is bright, with the economic efficiency, environmental responsibility, and climate benefits making concrete roads an entirely viable solution for New Zealand’s evolving transportation needs.

Ngā mihi, Rob Gaimster, Concrete NZ Chief Executive

PANEL

PROPPING &

SHORING TOWERS

TIM KLEIER JOINS CONCRETE NZ

AFTER CONCRETE NZ’S NEW SUSTAINABILITY AND POLICY DIRECTOR TIM KLEIER FIRST VISITED NEW ZEALAND FROM HIS NATIVE GERMANY IN 2017, HE SPENT THE NEXT SIX YEARS KEEPING AN EYE OUT FOR THE RIGHT JOB HERE.

Now freshly settled in Wellington with his family, Tim is looking forward to applying some of the lessons he learned about sustainability during decades working in Germany.

“My father was one of the founding members of the green party in my state. We didn’t have a car –we biked everywhere. Although politics was not a regular topic in family conversations, the sustainable lifestyle got ingrained into my everyday habits.”

Tim started as a draftsman apprentice in the steel industry, before working his way up to product development and project management.

His interest and background in sustainability was even then put to good use helping with progress towards lower emissions. Having spent the past three years as Global Head of Green Steel for SMS group, he has some key learnings.

“From a technical viewpoint, both the steel and concrete industries can reach net zero carbon emissions by 2050.”

“The limiting factor, however, is that the application of new technologies hinges on the willingness of policymakers to create an environment where it makes sense to implement them, and the general public to ask for it and pile on the pressure.”

This is one of his reasons for moving from technology to policy.

“One issue I have repeatedly encountered is that the term ‘industry’ is associated with certain environmental impacts, and that people would rather wish it away, to be replaced by an alternative that looks to be more sustainable at first sight.”

“However, all materials that hope to achieve sufficient scale to supply millions of people

Tim Kleier, Concrete NZ Sustainability & Policy Director

will inevitably become ‘industry’ themselves, contributing to the problem in their own way.”

“As such, the goal is clearly not to maximise substitution, but to minimise emissions.”

“Emerging industries typically don’t exhibit negative effects until later, while many existing industries have gauged their impacts, committed to a decarbonisation pathway and become sustainability leaders, driven by passionate people.”

“We can see this in Sweden, where environmentalists protest against the exploitation of forests after decades of scaling beyond natural borders while the cement industry is on track to deliver the first carbon-neutral, zero-water discharge operations in scale.”

“Globally the cement and concrete industry has recognised its responsibility and is moving towards cleaner ways of delivering their essential contribution to low-carbon, resilient and long-lived infrastructure.”

If there’s one place that can deliver the development of sustainable materials for the benefit of people, planet and a healthy economy, he says, it’s New Zealand.

“We are uniquely placed, in that we are close to nature and can see for ourselves the personal

impacts of climate change. That’s already reflected in the increasing profile here of low-carbon concrete, with demand for locally produced as well as imported products taking off.”

“The concrete industry’s Roadmap to net zero carbon 2050 shows there are proven ways to reduce emissions, but it also demonstrates that it’s not just the technical side that’s the silver bullet, with all levels of government also playing a significant role,” Tim says.

Tim notes that Concrete NZ’s inaugural Sustainability Report also shows the industry’s commitment to fostering a sustainable future, by measuring both environmental and social footprints (see pages 6-7 and 32-37).

“I look forward to supporting the acceleration of this work to improve water efficiency, incorporate recycled materials into concrete production, and safeguard our workforce.”

For now, Tim’s focus is on getting around New Zealand to meet people, visit sites and build up his knowledge of Aotearoa. From there, he hopes to contribute to the momentum to enable the industry to lower emissions towards its 2050 goal.

“It’s a great opportunity to work in the concrete industry, with really exciting times in the sustainability space.”

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CONCRETE INDUSTRY’S SUSTAINABILITY REPORT SETS BENCHMARK

CONCRETE NZ HAS RECENTLY PUBLISHED THE INAUGURAL CEMENT AND CONCRETE INDUSTRY SUSTAINABILITY REPORT, WHICH ACROSS A RANGE OF METRICS DRAWS A LINE IN THE SAND FROM WHERE PROGRESS CAN BE ACCURATELY MEASURED.

Rob Gaimster, Concrete NZ chief executive, points out that along with last year’s 2050 Net-Zero Carbon Roadmap, the release of the Sustainability Report for the Aotearoa New Zealand Cement and Concrete Sectors 2021/22 is another example of industry’s commitment to fostering a sustainable future.

“The Sustainability Report is based on a conviction that to effectively address our environmental and social footprints, we must first measure them with precision,” says Rob.

“Cement, concrete, and concrete product manufacturers in New Zealand have for several decades undertaken measures to reduce the industry’s carbon footprint, improve water efficiency, incorporate recycled materials into concrete production, and safeguard our workforce.”

An updated independent review of industry’s efforts shows that carbon emissions from cement were reduced by 11 percent between 2005 and 2020, despite a significant increase in concrete production during that time.

Photography by Samuel Hartnett

“While we can take pride in our accomplishments, it’s important that we pursue further enhancements.”

“The Sustainability Report outlines the industry’s recent efforts across energy consumption and emissions, water use, waste management, as well as health and safety,” notes Rob.

“By collaborating with industry stakeholders, we have collected data to establish targets that propel us toward our sustainability objectives.

“We have also explored mechanisms for improvement and evaluated how concrete aligns with the United Nations’ Sustainable Development Goals.”

“The report covers the months spanning 2021-22 and establishes a foundation from which we will monitor our progress every two years,” says Rob.

“We have begun collecting data for the follow-up 2023 report, which once complete will be shared with stakeholders across the cement and concrete industry as well as the wider construction and infrastructure sectors.”

Visit the Concrete NZ website to download the report – www.concretenz.org.nz See pages 32-37 for an extract from the Sustainability Report.

LEADERS IN CONCRETE TECHNOLOGY

Introducing DENKA Power CSA S

DENKA CSA#20 is a shrinkage-reducing high-performance additive made with calcium sulfoaluminate consisting mainly of limestone, gypsum and bauxite mixed proportionally. With the above mineral composition, ettringite formation during hydration reactions allows drying shrinkage to be controlled in concretes and mortars. For many decades, Denka CSA#20 has been the ‘go to’ shrinkage control additive for large seamless slabs and the construction products industry.

Early in 2024, CSA#20 is due to be replaced with a new version, Denka Power CSA Type S. Denka Power CSA S is a lower-dosage equivalent that leverages a higher free-lime content to allow it to produce shrinkage compensating ettringite at approximately 1/2 -2/3 of the dose of Denka CSA#20.

Denka Power CSA S performance testing has been conducted in New Zealand using cement

Call the sole agent on 07 575 5410 or visit: www.demden.co.nz

SEMINAR VIDEO COMING SOON!

LEARNED SOCIETY SEMINAR VIDEOS AVAILABLE ONLINE

THE LEARNED SOCIETY’S LATEST SEMINAR VIDEO IS THE ASSESSMENT AND RETROFIT OF PRECAST FLOORS WHICH WAS PRESENTED ACROSS THE THREE MAIN CENTRES AS WELL AS THE NORTH SHORE AND HAMILTON IN LATE 2023.

The seminar provided a summary of the findings from the ReCast Floors project, including proposed updates to current assessment procedures, observed behaviour from large scale testing and field investigation, and retrofit solutions.

The key design criteria for retrofits are discussed as well as design guidance for retrofits used to address the different failure modes in both hollowcore and double tee precast units.

The ReCast Floors project was funded from the Building Research Levy, with additional support from the Earthquake Commission, the University of Canterbury, QuakeCoRE and Concrete NZ Learned Society.

The Assessment and Retrofit of Precast Floors seminar, along with those listed below, are available for paid access via the Society’s webinar portal

•Precast Walls and Connections

•Concrete Materials

•Prestressed Concrete 101

•Industrial Floors

•Strut & Tie

•Assessment of Existing Concrete Buildings Using the Revised C5 Guidelines

Visit the Concrete NZ website for more details –www.concretenz.org.nz

BCITO LAUNCHES NEW RESOURCE TO BOOST

DEAF PARTICIPATION IN CONSTRUCTION

TO COINCIDE WITH NEW ZEALAND SIGN LANGUAGE WEEK, BCITO HAS LAUNCHED A NEW WEBSITE AIMED AT DEMONSTRATING THE OPPORTUNITIES FOR DEAF NEW ZEALANDERS IN THE CONSTRUCTION INDUSTRY.

The Building Abilities site features stories of Kiwis who have succeeded in BCITO apprenticeships and gone on to careers in the building trades, alongside resources from BCITO and Deaf Aotearoa to help learners and employers.

There are more than 4,500 Deaf users of New Zealand Sign Language (NZSL), and around 23,000 New Zealanders across the country use it regularly. However, lack of awareness about Deaf people’s abilities remains a significant barrier to work.

“Sometimes employers have no experience or knowledge of Deaf people and/or NZSL, so they are hesitant. Yet more often than not, Deaf people begin a job, and the employer realises that the Deaf individual is more than capable of doing the same work as their hearing workmates,” says Lachlan Keating, Chief Executive of Deaf Aotearoa.

While exact figures around the number of Deaf people who are unemployed or underemployed are unknown, the employment rate for all New Zealanders with disabilities is half that of the general population. This includes members of the Deaf community.

“Providing all learners with the right resources to have meaningful careers in construction is our reason for being, and we’ve focused on developing strong partnerships with organisations such as Deaf Aotearoa to break down those misperceptions and barriers. At a time when the industry is still facing a shortage of skilled workers, we need to do everything we can to inspire and empower more people to consider a trades career or gain a trade’s qualification,” says Greg Durkin, Director of BCITO.

Barry (Baz) Kay is one of the former BCITO apprentices whose story appears on the Building

Abilities site. Profoundly deaf since birth, he spent more than 20 years filleting fish because a lack of support during schooling had left him with literacy issues and a perception that he’d only be able to do low-skilled work.

Through a family friend who happened to be a builder, Baz found a position as an apprentice at Invercargill’s Trent Builders and received support from BCITO to complete his qualifications in 2019.

“My Training Advisor, Andrew Green (BCITO Principal Advisor - Learners with Disabilities), supported me through the process. He visited me every two weeks to go through the things that were challenging me. This included using imagery to define building terminology and explaining certain words that I wasn’t able to understand. My wife would help out by translating into sign,” Baz explains.

Since then, he’s become a highly skilled carpenter and valued employee, and he’s keen to help dispel the misconceptions employers can have about how much Deaf people can do.

“Deaf people have very good eyes – they’re very visually orientated and are very good with their hands. A lot of Deaf people do have barriers in employment, so it’s worth giving people an opportunity and treating Deaf people the same as hearing employees as well, because the only difference is that we can’t hear,” Baz says.

To access the Building Abilities website and find out more about opportunities for Deaf people in the trades, visit www.buildingabilities.co.nz

FIB SYMPOSIUM & CONCRETE NZ CONFERENCEREGISTRATIONS OPEN

CONCRETE NZ IS THRILLED THAT REGISTRATIONS FOR THE FIB SYMPOSIUM (11-13 NOVEMBER) AND ITS OWN ANNUAL CONFERENCE (14 NOVEMBER) AT TE PAE CHRISTCHURCH CONVENTION CENTRE - ARE NOW OPEN!

FIB SYMPOSIUM

The fib Symposium is an annual event that provides a forum to present and discuss state-ofthe-art practice, recent advances and research, standards and guidelines, and future perspectives relating to durability, sustainability and resiliency in structural and civil engineering.

The Symposium’s technical programme will be headlined by five outstanding construction experts who are set to share their experience and knowledge across a range of subjects, including concrete and innovative materials, structural performance and design, construction methods and management, and outstanding structures.

CONCRETE NZ CONFERENCE

The 2024 Concrete NZ Conference is taking on a twist, condensing into a power-packed 1-day event immediately following the Symposium on 14 November. Expect a diverse lineup of speakers, blending international perspectives with local insights across exemplar projects, research developments, concrete technology & materials, design trends and low carbon initiatives.

Dr. Antonio Nanni University of Miami, U.S.

Dr. Xilin Lu Tongji University, Shanghai, China

Dr.ir. Agnieszka Bigaj-van Vliet Netherlands Organization for Applied Scientific Research (TNO)

Des Bull

Holmes NZ LP, Christchurch, New Zealand

Steve Denton WSP, United Kingdom

Registrations now open

We look forward to seeing you there!

CONCRETE CURING BLANKETS

Concrete curing blankets are a great solution for adverse weather construction projects.

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We design and manufacture New Zealand’s only R-value thermal blankets, which have multiple uses covering: foundations of wind turbines; precast concrete structures; concrete bridge beams; airport runways; water tanks; floors or slabs.

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TRAIN A BCITO CONCRETE APPRENTICE TODAY!

THE CONCRETE INDUSTRY NEEDS MORE SKILLED WORKERS, AND AS NEW ZEALAND’S PREMIER PROVIDER OF QUALITY VOCATIONAL EDUCATION IN THE CONSTRUCTION SECTOR, BCITO IS CALLING ON ALL CONCRETE EMPLOYERS TO BUILD THEIR SKILL BASE.

“Despite construction activity easing recently, there is a steady pipeline of work in the concrete sector.” says Greg Durkin, Director at BCITO.

“Yes, apprenticeships are important, but we also need to ensure our existing workforce stays up to date and for all employers to consider how they can best support their team.”

BCITO provides a full suite of options – from microcredentials, apprenticeships, supervisor training, through to scholarships to support business management courses. BCITO has a long history of quality training with the concrete industry, and a committed training partner for your future success.

“BCITO has shown its ability to provide steadfast hands-on support throughout all the vocational reforms and COVID challenges. BCITO Apprentices are trained by industry and supported by us to add value to your business from the outset,” says Durkin.

Our training model has been developed with you and allows employers to focus solely on the apprentices’ practical skills, this means minimal book work for you. All assessments are managed by your dedicated BCITO Training Advisor, who visits your apprentice/s regularly. We also organise and financially subsidise dedicated block courses for concrete apprentices.

BCITO has been your partner in industry training for over 30 years and continues to support record numbers of apprentices. The Concrete sector now needs more skilled and willing employers to shape the next generation of qualified professionals. Will you be the next BCITO employer?

Visit our website today: www.bcito.org.nz

QUALIFICATIONS THAT FIT WHAT YOU DO

WORK SMARTER

TRAIN AN APPRENTICE

ALREADY HAVE THE EXPERIENCE?

GROW YOUR BUSINESS THROUGH TRAINING

Have your team work smarter, learn up-to-date skills.

Help them learn the skills and become qualified.

Get skills recognised with a formal qualification.

Training an apprentice is an investment in your business and the industry.

HEAVY-DUTY CONCRETE ROADING COMES TO TAURANGA

BERNIE NAPP – CONCRETE NZ, ADVISOR

A HUSBAND-AND-WIFE TEAM, WILLEM AND INGRID DE BOD OF ROLCO NZ, ARE PAVING A NEW WAY FORWARD FOR ROADS IN NEW ZEALAND WITH THE USE OF ROLLER-COMPACTED CONCRETE (RCC) TO RESURFACE A STRETCH OF ROAD AND CONNECTING ROUNDABOUTS IN TAURANGA.

Willem and Ingrid de Bod have recently completed resurfacing two roundabouts and a connecting road in Tauranga.

The job entailed over 10,000 square metres of RCC, produced by Firth Industries, who has been their dedicated supply partner since early 2022.

Concrete NZ caught up with Ingrid, a structural engineer and Rolco’s general manager, at the Future Roads conference in Hamilton.

Around 3 years ago Ingrid’s husband Willem, a civil engineer, was designing heavy-duty pavements for clients who were looking for better alternatives than asphalt and conventional concrete. He did some research, learned about RCC which has a long history of use overseas, tried to find local contractors with no success, and asked himself, why is there no RCC in New Zealand?

The de Bods bought an RCC-capable paver secondhand from a roading contractor in Australia, and modified it for RCC use. “Willem has been over to the US to see hundreds of acres done in RCC, and has had training from RCC specialists from around the world,” Ingrid says.

Their company, Rolco, started out by laying around 1.5 hectares of log yard at Shakespeare Bay for Port Marlborough. From there they have been building concrete roads and pavements for Tauranga City Council and various industrial yards.

“Our clients have been open to alternatives and been really supportive of what we are doing,” Ingrid says. Rolco’s workload has taken off, and to meet the demand, Rolco has invested in more equipment and resources to deliver large projects.

RCC stretch of road at Tauriko near Tauranga.

RCC - FAST-CURING AND LONG-LASTING

A traditional concrete road requires rebar or steel mesh and formwork while RCC requires no reinforcing steel, and no formwork because it deploys a low-slump concrete. The curing time is also very short.

“In Tauranga’s industrial area, we came in on a Friday to mill the asphalt,” Ingrid explains, “on Saturday we paved; on Sunday we did the cutting and finishing. On Monday the road was open. This is the beauty of RCC with low curing time and no reinforcing or formwork required.”

This is a massive change from conventional concrete, she says. Within a week of laying, RCC has a flexural strength of 4-7 MPa, and up

to 70 MPa compressive strength.

So, why isn’t New Zealand full of RCC roads, roundabouts, log yards, airport hardstands, bus lanes, car parks, anywhere that roading takes heavy wear and tear?

Introducing a new product into the market takes time, Ingrid says. We have been meeting with consultants and councils to tell them about the work we have been doing, to teach them about RCC and its benefits and applications. Rolco’s strategy has been to build a track record of success with RCC.

BENEFITS OF TOLLER COMPACTED CONCRETE (RCC)

RCC is ideal in situations where:

•The roading subbase is less than adequate.

•There is concentrated loading, e.g., at intersections, roundabouts, bus lanes, heavily trafficked areas.

•The customer needs a fast construction time

•The owner doesn’t want to come back in a few years’ time to resurface the road or spend money on maintenance and fixing potholes.

•There are shallow services.

•The customer is looking for a sustainable, low carbon solution. RCC can have as much as half the embedded carbon as conventional concrete. RCC is made from 100 percent NZ-made and sourced products, and an RCC pavement can easily be crushed and recycled at end-of-life.

•The customer is after a long-term, lowmaintenance, low-cost solution.

“There are so many reasons why RCC is a perfect solution for New Zealand roads and pavements,” Ingrid says. “Ratepayers deserve better.”

DRIVEN TO SUCCEED

The de Bods’ creation of Rolco is a link in a chain of happy events, which Ingrid says started more than 10 years ago.

“We met at uni; we studied civil engineering together at the University of Stellenbosch in South Africa; we got married and moved to New Zealand. We sold everything, and came with just our suitcases. We moved here for a better future for us and our future children. We have now got our citizenship.”

They started Rolco when their second child was a few weeks old. Rolco attended the first Future

RCC IN DOWNTOWN TAURANGA

Tauranga City Council (TCC) sought an alternative pavement option to deal with low subgrade strength and shallow services at Tauriko, for two roundabouts linked by 300 metres of connecting road.

Rolco was able to offer TCC a shallow pavement option and fast construction times, and gained the contract to build the road and roundabouts with RCC, having the required high flexural strength to resist wear and tear from heavy vehicles. The company completed the contract in late 2023 after laying 10,000 square metres of RCC. The next job: access roads for Sequal Lumber, a timber company in Kawerau, Bay of Plenty.

Roads conference in 2022, and joined as a start-up sponsor for their second appearance in 2023.

Willem and Ingrid now have engineers in their network who are promoting the Rolco product. Rolco has been collecting comprehensive data over the last two years, allowing engineers to make informed decisions, and to make it easy to provide design statements for RCC pavements.

“Now it’s just about informing clients about the benefits of RCC and letting them know that there is a skilled contractor available to build RCC roads and pavements in New Zealand.”

Willem and Ingrid de Bod of Rolco.

PARTNERING WITH FIRTH INDUSTRIES

When Willem de Bod needed a concrete supplier for a log yard he was going to build at the Port of Marlborough, Firth’s engineering team had a ready answer. With a diverse skillset, the team had used RCC previously, and knew exactly what Rolco was looking for.

Tim Bulmer is Firth’s regional materials manager in the Bay of Plenty and Hawke’s Bay, and takes up Firth’s pitch to Rolco.

“We could help with the mix designs. We needed to buy a pug mill, which is basically a mixing plant containing two shafts that rotate with paddles attached, with aggregate fed continuously. We modified the plant, made it work for RCC, and did trials at our innovation laboratory in Christchurch.”

As soon as Firth set up the mill, the company ran test patches of RCC, to determine how the material compacts using different grades of aggregate. Next came a field trial, in which Firth’s plant manager based in Blenheim, Carl Trollip, became closely involved.

“We did an entrance and road for a vineyard near Blenheim,” Bulmer says. “This was a low-risk application to get some familiarity with it. It was pretty good from the get-go.”

RCC needs to be mixed differently from conventional readymix, he says, otherwise, the

cement wraps around the aggregate particles and forms little balls. As a dry product, RCC looks like builder’s mix or a stabilised roading basecourse aggregate. After compaction, it starts to look like concrete; vibration of the surface packs in the aggregate to deliver a creamy finish.

For the Tauranga project, Firth used a state-of-theart concrete plant at Mount Maunganui, which is a batch pugmill. Delivery to site is via 10 to 12-tonne tipper trucks. The company delivered between 800 and 900 truckloads for the job.

“It’s just so easy for us. We can make this concrete without much drama.”

However, RCC’s deployment has not always been plain sailing, Bulmer says. “There is a lot of learning involved in starting something new. I want to emphasise that point. RCC is a new and developing technology in New Zealand. It takes time and experience to lay it well.”

Business is growing all the same. Firth has now set up a pugmill near Kawerau in the Bay of Plenty to supply RCC into forest owners’ log yards.

A CONCRETE TAKE OF NEW ZEALAND’S ROADS

ERIC FERREBEE - AMERICAN CONCRETE PAVEMENT ASSOCIATION

AS THE STATE OF NEW ZEALAND’S ROADS BECOMES A GROWING ISSUE, CONCRETE OVERLAYS AND NEW-BUILD CONCRETE ROADS ARE A SUSTAINABLE, LONG-TERM WAY FORWARD FOR HIGHLY-TRAFFICKED ROADWAYS.

Where I come from, in the United States, concrete roads are used across urban and rural areas with both high (interstate highways) and low (residential streets and county roads) traffic. Ports, industrial facilities, and commercial sites are also places where concrete pavements have been used significantly. Concrete tends to become the paving material of choice when long-life solutions with minimal maintenance are desired. Some States and areas use concrete more than others, as would be expected, but the States that use it regularly have actually seen instances where concrete can provide a low, first cost option before even considering a life cycle cost of the pavement application.

Spending a week in Australia, in New South Wales, mostly within a couple hours of Sydney, I was able to drive around many of the concrete motorways that have been around for quite some time and see some of the similarities and differences between Australia’s and the U.S.’s concrete pavements. Their Continuously Reinforced Concrete Pavements (CRCP) are similar to the roads built in Texas as well as some other more populated cities around the United States.

I saw many plain concrete pavements more similar to the concrete pavements found throughout the rest of the U.S. I was told that in Australia they design their pavements to minimise shrinkage which can help improve the load transfer through aggregate interlock.

I also noticed a fair amount of old concrete roads in cities and towns in Australia. This is a terrific way to provide the travelling public with a long-term solution with minimal disruptions for preservation, maintenance, and reconstruction. Many cities in the U.S. recognise these benefits and take advantage of them. One city in Wisconsin recently finished converting all of their roadways to concrete pavements to take advantage of the longterm benefits.

I also drove over 2,500 km around New Zealand’s North Island, from Auckland to the Bay of Islands,

down to Rotorua, all the way down to Wellington and back up to Tongariro National Park, and finally back to Auckland. While many of these asphalt roads are in decent to good condition, there were always roads that could use some improvements.

As a long, thin country with a low population, intermittent areas of high road use, and a unique combination of environmental challenges such as earthquakes and weather extremes, I see a huge opportunity for concrete pavements and concrete overlays of existing asphalt pavements for the future of New Zealand’s roadways.

Not having much money to spend on roading is one of the biggest reasons why concrete pavements should be used. Long-term solutions like concrete pavements and overlays are essential when money for maintenance and rehabilitation is always lagging behind the actual need for these activities.

Asphalt pavements tend to have shorter lives and require more maintenance and preservation. Adding some concrete pavements to the roadway network changes the balance of remaining service lives of all the pavements. This can be a way to better manage the roading system and spread out when work needs to be done. The Massachusetts Institute of Technology’s Concrete Sustainability Hub (MIT’s CSHub) has done a lot of research on the benefits of this topic.

There are also many other sustainability benefits such as reducing life cycle emissions, improving fuel efficiency of vehicles, sequestering carbon via the surface, and improving impacts related to albedo (light surface color) such as urban heat island impacts. Lower-carbon concrete (where some of the cement is replaced by low-carbon materials without compromising strength and durability) is now available in New Zealand, and is suitable for roading applications.

Finally, improving the state of competition between paving materials – concrete versus asphalt - has

huge benefits for both materials. Indicating a commitment to competition to both industries forces both to improve their materials, their process, and their costs.

That said, the biggest challenges here are likely to include perceived upfront cost and inexperience.

Concrete tends to have a reputation for being expensive. Concrete pavements, however, are frequently competitive in price when looking at life cycle costs. Additionally, there are a few places in the U.S. where concrete pavements and overlays can be a lower first cost. The point is that as experience is built and competition improves, costs will come down and become more competitive.

I see three priority areas for New Zealand roads.

•While driving, I saw a lot of logging trucks and very large, heavy container trucks. With concrete’s ability to bear heavy loads, concrete roads could be prioritised in areas of greatest logging truck use, such as at the entrance to ports and the most intensely used roads favoured by heavy vehicles.

•I also saw a fair amount of older asphalt pavements that are showing some distress. A concrete overlay of asphalt would get an additional 30 years or more of life out of the existing roadways.

•I have also driven through a lot of roundabouts while here and this is one huge opportunity

for concrete pavements. Intersections and roundabouts typically need a long-term, low maintenance solution that can handle the loads of traffic. In the U.S., even States that don’t favour concrete for paving applications will frequently see the benefits of using concrete for intersections and roundabouts to help make sure that they don’t become a future maintenance headache for the roading agency.

Finally, one other major, hot-button topic is the resilience of pavement systems. Concrete roading is an extremely durable solution for dealing with a changing climate such as we’re seeing nowadays. With climate change we are seeing increases in extreme weather events (many water-related).

Concrete offers a solution that is less reliant on underlying layers that can result in increased damage and reduced life in asphalt pavements.

Having concrete pavements and overlays within a network, especially on essential roadways and evacuation routes, can help ensure that a pavement network is resilient and ready as we continue to combat climate change.

OVERALL WINNER

Saeed Rezvanian

Teopanzolco Cultural Center, Mexico

“The Teopanzolco Cultural Center is a triangular concrete building, which adjoins an archaeological site with Aztec ruins. The designers have used triangular geometries that allude to the pyramid-shaped temples. This amazing building has won many prestigious awards for its innovative architecture and use of materials. The roof of building comprises a large stepped concrete ramp and some boys are running and playing on these steps.”

“My photo shows how concrete develops both artistic and functional environments in our lives. I was captivated by the children playing amongst the beautiful structures.”

GCCA’S CONCRETE IN LIFE 2023 PHOTOGRAPHY COMPETITION

WINNERS OF THE GLOBAL CEMENT & CONCRETE ASSOCIATIONS (GCCA) ANNUAL PHOTOGRAPHY COMPETITION CONCRETE IN LIFE WERE RECENTLY ANNOUNCED A SPECIAL EXHIBITION AT THE BRUNSWICK GALLERY IN LONDON.

Open to all photographers (or anyone with a camera phone) around the world, the competition offers the challenge to “take photos of concrete in your life”, along with the chance to win up to $10,000 in prize money.

Over 21,000 people entered the 2023 competition, and after the judging rounds and people’s vote, the winners were selected as follows:

URBAN CONCRETE

Owen Davies

Armstrong Rubber Building, USA

“I was inspired to make this image of the old Armstrong Rubber Building in New Haven, Connecticut after passing it several times driving along I95. The striking geometry and sheer mass of the building drew me to it initially and the bright summer light really accentuated the texture of the wonderfully sculpted concrete facade.”

CONCRETE INFRASTRUCTURE

Andre Hidayat Arrasuli (@andremunay)

New Priok Container Terminal, Indonesia

“I took this photo on the north coast of Indonesia. New Priok Container Terminal is one of the important ports supporting economic activities. I was interested in capturing this when I saw the composition and beauty of this harbour at night.”

CONCRETE IN DAILY LIFE

Hari Wibowo (@mantulphoto)

Aquatic Stadium Gelora Bung Karno, Jakarta

“The photo shows the scene at the Aquatic Stadium Gelora Bung Karno in Jakarta, and paints a vivid picture. The combination of the athletes warming up for the platform diving competition, the architecture of the stadium, the vibrant colours, and the interplay of light and shadow must indeed create a captivating and harmonious scene.”

CONCRETE BEAUTY & DESIGN

Alexander Arregui

Leszczynska (@archibatch)

The Maurerhalle, Switzerland

“This monumental origami-like concrete structure, in which the facade and the roof are unified through the same sheet, brought back vivid memories of my architecture studies, when we explored the structural strength of folded paper as a method of creation. Visited during the Open House Basel event, the Maurerhalle remains to me a highlight and a timeless architectural gem in the city, where sculpture and structure, art and science, merge harmoniously.”

PEOPLE’S VOTE

Muhammad Nurudin (@andukmerah)

The Bali Mandara Toll Road, Bali

“The Bali Mandara Toll Road connects the city of Denpasar, Ngurah Rai International Airport, and Nusa Dua in Bali. In addition to speeding up travel time from the airport and the city of Denpasar to Nusa Dua, the road is a solution to overcome congestion that occurs during the holiday season. Under the toll ring road there are several plots of land planted with mangroves.”

SEISMIC TESTING OF ANCIENT BRIDGE PROVIDES STUNNING RESULTS

EXTREME LABORATORY TESTING ON AN 84-YEAR-OLD BRIDGE AT THE UNIVERSITY OF AUCKLAND HAS PROVIDED PROMISING INSIGHTS FOR KEY INFRASTRUCTURE ACROSS NEW ZEALAND.

“We beat the snot out of it, well beyond the displacement we would expect in a large earthquake, and the structures performed extremely well,” says lead researcher Dr Lucas Hogan.

Funded by Toka Tū Ake EQC and QuakeCoRE, the researchers tested the concrete bridge piers from the deconstructed Whirikono bridge on State Highway 1 south of Foxton, which was replaced in 2020 by a wider structure over the Manawatū River and Moutoa floodplain by Waka Kotahi.

The first part of the research project, in 2020, conducted seismic test on the bridge foundation piles in their original location during the deconstruction phase in what Dr Hogan described as an “unprecedented opportunity for real-life testing on a long bridge”.

The project team transported three of bridge piers to the University of Auckland where they tested the concrete well beyond what could be expected in a significant earthquake.

“The results are really important because these bridges were built by the Ministry of Works in the 1930s across braided rivers around New Zealand,

when they didn’t know much about seismic risks, and our testing shows that even after being exposed to the elements for over 80 years, they have plenty of strength,” says Dr Hogan, who adds that understanding the resilience of these old bridges is important for decision-makers and planning for earthquake response.

“We have seen how disruptive the closure of one of these bridges can be for communities, for example when the Ashburton bridge subsided last year, and drivers had to take a six-hour detour.”

Dr Hogan says that the Ashburton scenario will be multiplied in an Alpine Fault event, “but it is encouraging to know that these old bridges are still up for the job, for the next few years at least”.

Toka Tū Ake EQC Head of Research Dr Natalie Balfour says that it is incredibly rewarding for the natural hazard agency to see its research investment deliver such major benefits for New Zealanders and their infrastructure.

“One of the key areas where we can reduce the impact of natural hazards is to increase the resilience of our infrastructure. When bridges and roads are unpassable, any recovery will be

Dr Lucas Hogan in front of the seismic testing laboratory at the University of Auckland.

significantly affected, as we saw in Kaikōura in 2016,” says Dr Balfour.

Looking beyond the positive test results, the research team has also been exploring retrofit solutions to enhance the longevity and resilience of the old bridges by testing these techniques on the remaining column from the Whirokino Bridge.

Dr Hogan explains how a chance meeting with colleague Santiago Pujol revealed a raft of retrofit techniques the University of Canterbury engineer had developed based on previous research in Japan in the 1980s.

“They had developed affordable solutions, using steel rods and clamps, to strengthen these old 1930s bridges, so they can last a bit longer or when we need to repair any minor damage after an earthquake,” says the researcher.

Dr Hogan says that his team had been incredibly lucky to be part of a “once-in-a-lifetime” project he hopes will help inform infrastructure decisions for many years to come.

The deconstructed Whirikino Bridge alongside the new bridge south of Foxton, which was replaced in 2020 by a wider structure over the Manawatū River and Moutoa floodplain by Waka Kotahi.

CONCRETE ENTHUSIAST ACKNOWLEDGED WITH GLOBAL ARCHITECTURE AWARD

THE PRITZKER ARCHITECTURE PRIZE ANNOUNCES RIKEN YAMAMOTO, OF YOKOHAMA, JAPAN, AS THE 2024 LAUREATE OF THE PRITZKER ARCHITECTURE PRIZE, AN AWARD THAT IS INTERNATIONALLY REGARDED AS ARCHITECTURE’S HIGHEST HONOUR.

Yamamoto’s work combines public and private realms and is embedded in upholding community life. He defines community as a “sense of sharing one space,” deconstructing traditional notions of freedom and privacy while rejecting longstanding conditions that have reduced housing into a commodity without relation to neighbours.

“For me, to recognize space, is to recognize an entire community,” Yamamoto expresses. “The current architectural approach emphasizes privacy, negating the necessity of societal relationships. However, we can still honour the freedom of each individual while living together in architectural space as a republic, fostering harmony across cultures and phases of life.”

The 2024 Jury Citation states, in part, that he was selected “for creating awareness in the community

in what is the responsibility of the social demand, for questioning the discipline of architecture to calibrate each individual architectural response, and above all for reminding us that in architecture, as in democracy, spaces must be created by the resolve of the people…”

He has evolved influences from traditional Japanese machiya and Greek oikos housing. He designed his own home, GAZEBO (Yokohama, Japan 1986) to invoke interaction with neighbours from terraces and rooftops. Ishii House (Kawasaki, Japan 1978), built for two artists, features a pavilion-like room, that extends outdoors and serves as a stage to host performances, while living quarters are embedded beneath.

“Yamamoto develops a new architectural language that doesn’t merely create spaces for families to

Riken Yamamoto, photo courtesy of Tom Welsh

live, but creates communities for families to live together,” says Tom Pritzker, Chair of the Hyatt Foundation, which sponsors the award. “His works are always connected to society, cultivating a generosity in spirit and honouring the human moment.”

“One of the things we need most in the future of cities is to create conditions through architecture that multiply the opportunities for people to come together and interact. By carefully blurring the boundary between public and private, Yamamoto contributes positively beyond the brief to enable community,” explains Alejandro Aravena, Jury Chair and 2016 Pritzker Prize Laureate. “He is a reassuring architect who brings dignity to everyday life. Normality becomes extraordinary. Calmness leads to splendour.”

His career has spanned five decades and his projects, ranging from private residences to public housing, elementary schools to university buildings, institutions to civic spaces, and city planning, are located throughout Japan, People’s Republic of China, Republic of Korea and Switzerland. Significant built works also include Nagoya Zokei University (Nagoya, Japan, 2022), THE CIRCLE at

POUR IN THE STRENGTH

Harness the increased durability of carbon nanotubes for your next concrete pour.

Tianjin Library, photo courtesy of Nacasa & Partners

Zürich Airport (Zürich, Switzerland, 2020), Tianjin Library (Tianjin, People’s Republic of China, 2012), Jian Wai SOHO (Beijing, People’s Republic of China, 2004), Ecoms House (Tosu, Japan, 2004), Shinonome Canal Court CODAN (Tokyo, Japan, 2003), Future University Hakodate (Hakodate, Japan, 2000), Iwadeyama Junior High School (Ōsaki, Japan, 1996) and Hotakubo Housing (Kumamoto, Japan, 1991).

ABOUT THE PRITZKER ARCHITECTURE PRIZE

Yamamoto is the 53rd winner of the Pritzker Architecture Prize. He was honoured in Chicago, Illinois, United States of America this spring, with the 2024 Laureate Lecture held at S. R. Crown Hall, Illinois Institute of Technology, in partnership with the Chicago Architecture Center, during May.

The annual Pritzker Architecture Prize was founded in 1979 by the late Jay A. Pritzker and his wife, Cindy. Its purpose is to honour a living architect whose built work demonstrates a combination of talent, vision and commitment, which has produced consistent and significant contributions to humanity and the built environment through the art of architecture.

Tianjin Library, photo courtesy of Nacasa & Partners

Future University of Hakodate, photo courtesy of Mitsumasa Fujitsuka

Future University of Hakodate, photo courtesy of Mitsumasa Fujitsuka

ENVIROCore is a range of cement replacements available for concrete manufacturers to deliver performance concrete with a lower embodied carbon impact.

ENVIROCore is a range of cement replacements available for concrete manufacturers to deliver performance concrete with a lower embodied carbon impact.

ENVIROCore is a range of cement replacements available for concrete manufacturers to deliver performance concrete with a lower embodied carbon impact.

ENVIROCore is a range of cement replacements available for concrete manufacturers to deliver performance concrete with a lower embodied carbon impact.

ENVIROCore provides manufacturers the opportunity to lower the carbon of concrete by replacing General Purpose cement with these alternatives. All products within the ENVIROCore range meet the New Zealand Standards.

ENVIROCore provides manufacturers the opportunity to lower the carbon of concrete by replacing General Purpose cement with these alternatives. All products within the ENVIROCore range meet the New Zealand Standards.

ENVIROCore provides manufacturers the opportunity to lower the carbon of concrete by replacing General Purpose cement with these alternatives. All products within the ENVIROCore range meet the New Zealand Standards.

ENVIROCore provides manufacturers the opportunity to lower the carbon of concrete by replacing General Purpose cement with these alternatives. All products within the ENVIROCore range meet the New Zealand Standards.

ENVIROC ore 100

ENVIROC ore 100

ENVIROC ore 100

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Granulated Blast Furnace Slag to provide heightened durability in high wear and harsh areas including marine and highly acidic or alkaline environments.

Granulated Blast Furnace Slag to provide heightened durability in high wear and harsh areas including marine and highly acidic or alkaline environments.

Granulated Blast Furnace Slag to provide heightened durability in high wear and harsh areas including marine and highly acidic or alkaline environments.

Granulated Blast Furnace Slag to provide heightened durability in high wear and harsh areas including marine and highly acidic or alkaline environments.

ENVIROC ore 200

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Fly Ash Products sourced from reputable suppliers to provide improved workability, lower heat of hydration in large mass pours.

Fly Ash Products sourced from reputable suppliers to provide improved workability, lower heat of hydration in large mass pours.

Fly Ash Products sourced from reputable suppliers to provide improved workability, lower heat of hydration in large mass pours.

Fly Ash Products sourced from reputable suppliers to provide improved workability, lower heat of hydration in large mass pours.

SUSTAINABILITY REPORT 2021/22

FOR THE AOTEAROA NEW ZEALAND CEMENT AND CONCRETE SECTORS - REPORT EXTRACT

Photography by Samuel Hartnett

HOW WE’RE BECOMING MORE SUSTAINABLE

THE CEMENT AND CONCRETE INDUSTRY PURSUES SUSTAINABILITY THROUGH:

Alternative kiln fuels

Using alternative fuels, particularly biofuels, in the cement kiln reduces emissions from producing clinker.

Reducing emissions from cement and binders

SCMs and mineral additions (particularly limestone) in Portland cement can replace some cement.

Low-carbon cements and binders

Mineral by-products of industrial processes and naturally occurring minerals replace some cement in concrete.

Water recycling

Concrete manufacturers use rainwater and recycle grey water in readymixed concrete.

Improving concrete technology

Concrete technology will improve concrete’s performance over time.

Recycled materials

Recycled aggregates and other materials, e.g. waste glass, are being used in ready-mixed concrete and masonry.

Reducing emissions from transport

Some members are trialling electric and hydrogen powered vehicles.

Employee wellbeing

Companies are working to improve the physical and mental health of their people.

CONCRETE AND THE BUILT ENVIRONMENT

Concrete plays a major role in New Zealand’s built environment. It is strong, long-lasting and can be formed into almost any shape. Concrete offers outstanding fire safety, noise reduction and efficient heating and cooling. It can also be reused and repurposed at the end of a building’s life.

New Zealand will continue to use concrete for infrastructure. Rautaki Hanganga o Aotearoa –New Zealand Infrastructure Strategy 2022–2052 illustrates the scale of what this country requires:

New Zealand’s population will grow to 6.2 million people (or more) over 30 years.

We will need 115,000 more homes to fix the current housing crisis.

$5 billion of council infrastructure is exposed to sea level rise.

We will need $90 billion to fix water networks. We need to be able to generate 170% more electricity.

THE MATERIAL TOPICS WE’RE FOCUSED ON

IN APRIL 2021 THE CONCRETE NZ BOARD AND EXECUTIVE TEAM IDENTIFIED THE SUSTAINABILITY TOPICS (ECONOMIC, SOCIAL, ENVIRONMENTAL AND GOVERNANCE) THAT MATTER TO OUR STAKEHOLDERS AND OUR INDUSTRY.

Energy and CO2 emissions

Cement and concrete companies need to reduce their carbon footprints.

Freshwater

Concrete producers need to use rainwater and recycled water to be less dependent on town supply.

Socio-economic benefits

The industry needs to continue to employ many people in rewarding careers and produce materials that benefit the economy and society.

Waste & circular economy

Concrete can be reused, repurposed and recycled. The sector is looking to source more sustainable mineral inputs.

Workplace health & safety

The industry is focused on zeroharm workplaces, and employees’ health and wellbeing.

This first Sustainability Report provides a baseline for reporting.1 Concrete NZ is happy to provide more information about the methodology used to collate the data and write this report.

1 In some cases our environmental and social data uses different base years, as this is the best data we have been able to source We will track changes in data against these base years. In future reports, we aim to use common years.

OUR SUSTAINABILITY FRAMEWORK: THE UNITED NATIONS’ SUSTAINABLE DEVELOPMENT GOALS (SDGS)

The 17 SDGs promote an end to poverty together with environmental protection, prosperity and peace for all. In 2015 all 193 UN member states pledged their commitment. Concrete connects with many of the SDGs:

Goal 3 - Good health and wellbeing. Concrete provides thermal mass in buildings (resulting in lower heating and cooling bills) and protects from noise and fire.

Goal 6 - Clean water and sanitation. Concrete is essential to provide drinking water, wastewater and stormwater services.

Goal 7 - Affordable and renewable energy. Concrete contributes to generating and transmitting renewable electricity.

Goal 8 - Decent work and economic growth. The concrete industry provides rewarding jobs and contributes to the built environment which boosts economic wellbeing.

Goal 10 - Industry, innovation and infrastructure. Concrete is used to build schools, hospitals and other public buildings, roads and rail bridges.

Goal 11 - Sustainable cities and communities. Concrete supports urban growth, transport and climate resilience as populations grow.

Goal 12 - Responsible consumption and production. Waste concrete can be recycled, reused and repurposed in buildings, as clean fill to backfill excavations, as roading aggregate and more.

The Global Cement and Concrete Association (GCCA) has found that concrete contributes directly to 80 of the 169 SDG targets.

CREATING A BASELINEOUR EFFORTS IN NUMBERS

ENERGY AND CO2 EMISSIONS

CO2 EMISSIONS

Producing cement, the primary component of concrete, accounts for around 8% of global GHG emissions. In 2020, member companies of the GCCA committed to producing carbon-neutral concrete by 2050, in line with global climate targets.

Our targets are to reduce carbon emissions: 30% by 2030; and net-zero carbon for cement production and concrete batching by 2050.

Between 2005 and 2020 we reduced our carbon emissions by 11% while increasing the volume of ready-mixed concrete produced by 11%. This was achieved by replacing some of the coal used for manufacturing cement with woody biomass and waste tyres, using fuel more efficiently for transport,

reducing construction waste and replacing some cement with low-carbon SCMs.

Source: thinkstep-anz

The three major cement producers/suppliers in New Zealand all have environmental product declarations (EPDs) and are working to reduce embodied carbon. They record embodied carbon in cement for Golden Bay of 733 kg CO2e per tonne of cement, Holcim (897), and HR Cement (811).

SCM UPTAKE EXPECTED TO RISE

Currently, the use of SCMs in New Zealand is very low compared to other countries. It sits at 2.5% of total binders in readymix concrete manufacture. This is set to change. In FY22 mainly fly ash was used, with a growing uptake of GGBS forecast for FY23. The choice of SCM depends on price, availability and the differing substitution rates of each SCM.

ENERGY

The sector’s main sources of energy are coal, waste wood and waste tyres for manufacturing cement, and electricity and diesel for producing concrete and delivering it. Concrete trucks delivering readymix use on average 4.5 litres of diesel per cubic metre of concrete.

The drive to reduce carbon emissions is also linked to improving energy efficiency. Some precast and masonry companies use LPG (liquid petroleum gas) or natural gas to speed the curing of product. Electric heat pumps are an alternative energy source for this.

WASTE & CIRCULAR ECONOMY

The industry is working on solutions to recycle, repurpose and reuse more concrete. Approximately 4% of concrete and bricks ends up in landfill as construction waste. Research into using recycled crushed concrete in new readymix concrete is underway. This material is mostly used as cleanfill and roading aggregate. The industry increasingly uses returns from readymix deliveries by either pouring them into concrete blocks, e.g. for retaining walls, or allowing them to harden to be crushed and used as cleanfill or roading aggregate. Precast manufacturers produce mostly dust and seconds that cannot be sold. They crush these into aggregate for reuse as concrete or form retaining wall blocks.

A programme to inform the wider construction industry about the opportunities provided by concrete as we transition to the circular economy will be implemented in 2024. Targets for our waste and the circular economy will be introduced in the 2024 Sustainability Report.

Concrete and brick waste

# Twelve respondents across industry, excluding cement manufacture. Note: a significant proportion of cement is imported. This data covers 65% of readymix, 90% of masonry, and 30% of precast (Sources: Statistics NZ; Concrete NZ)

MOVE TO MORE SUSTAINABLE ENERGY SOURCES

Precast concrete manufacturer Concretec recently moved from national grid electricity to solar energy at its plant in Pōkeno, south of Auckland. Numbers of electric and hybrid light vehicles are also growing. Hydrogen trucks are being trialled (HW Richardson), as are electric trucks (Golden Bay).

# Ministry for the Environment 2019. Reducing waste: a more effective landfill levy – consultation document

^ MfE calculated the percentage of concrete/bricks in construction and demolition waste at 12%

* Statistics NZ data; Conversion: 1 cubic metre of concrete = 2.4 tonnes of concrete

WATER

Manufacturing one cubic metre of concrete uses around 150 litres of water. Additionally, 20 litres is needed for activities such as washing trucks. Many readymix plants are in rural locations and source their own water, typically rain- or bore water. Most of the freshwater discharged after use, e.g. to wash plant and equipment, is then recycled for concrete production.

While the industry aims to conserve fresh water, it is challenging to measure the water that is used,

discharged or recycled. The FY22 baseline reports on reticulated supply and bore water only. We made an assumption for total water use in the readymix sector, drawing on the above figures.

Water

Readymix reticulated/bore water use298 million litres ^

Readymix total water use

Readymix ratio of reticulated / bore to total water

million litres *

# Twelve respondents across all sectors, excludes cement manufacture

^ Data covers 65% of the readymix sector by volume of production

* Estimate based on 170 litres of water per cubic metre of concrete produced

WORKPLACE HEALTH AND SAFETY

We are aware that we need to make our workplaces safer and healthier. Our main hazards include handling heavy materials, especially at heights, cutting tools and machinery, working with reinforcing steel, and accidents with vehicles

and mobile plants. The hazards and related health and safety risks in the concrete industry vary widely between cement manufacture, ready mixed concrete production, and manufacturing precast and masonry owing to the nature of the sector and level of automation. We expect to have a more comprehensive dataset in 2024 as data from other concrete-related sectors is introduced.

# Represents approximately 90% of cement and readymix concrete production in 2022.

For comparison, the Mineral Products Association’s sustainability report for readymix concrete in the United Kingdom recorded an LTIFR of 3.5 in 2019.

We are increasingly focusing on mental health and wellbeing, e.g. a programme at Higgins Concrete and Firth Industries.

NZ’S SPECIALISTS IN ENGINEERED CONCRETE

With the longest-serving workforce in the engineered concrete industry, our knowledge runs deep, and we’ll share it to make your concrete construction or remediation project a success.

Find out more at

CONCRETE NZ LIBRARY

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

THE PATH TO GREEN CONCRETE

RECENT ADVANCES ON GREEN CONCRETE FOR STRUCTURAL PURPOSES

BY JOAQUIM A.O. BARROS, LIBERATO FERRARA, ENZO MARTINELLI (EDITORS)

This book is mainly based on the results of the EU-funded UE-FP7 Project EnCoRe, which aimed to characterize the key physical and mechanical properties of a novel class of advanced cement-based materials incorporating recycled powders and aggregates and/ or natural ingredients to allow partial or even total replacement of conventional constituents. The opening chapters explain the material concept and design and discuss the experimental characterization of the physical, chemical, and mechanical properties of the recycled raw constituents, as well as of the cementitious composite incorporating them. The numerical models with potentialities for describing the behavior at material and structural level of constructions systems made by these composites are presented. Finally, engineering applications and guidelines for production and design are proposed.

BY JORGE DE BRITO, FRANCISCO AGRELA, RUI VASCO SILVA (EDITORS)

The Path to Green Concrete will enlighten the scientific community on recent developments in this field. Worldrenowned experts summarize recent research findings on alkali-activated materials using aluminosilicate waste precursors, use of novel cost-effective and eco-efficient supplementary cementitious materials, state of the art characterization techniques and assessment methodologies, advances on the use of biomass ashes, steel slags and waste glass, the role of carbon capture in the production of concrete and mortar, development of eco-efficient composites for specialized applications, recycling of the fine fraction of construction and demolition wastes, and also sustainable self-healing concrete. This book will be a valuable reference resource for academic and industrial researchers, civil and structural engineers, manufacturers, and other construction professionals working in the development of sustainable construction materials.

RAW CONCRETE: THE BEAUTY OF BRUTALISM

BY BARNABAS CALDER

The raw concrete buildings of the 1960s constitute the greatest flowering of architecture the world has ever seen. The biggest construction boom in history promoted unprecedented technological innovation and an explosion of competitive creativity amongst architects, engineers and concrete-workers. The Brutalist style was the result. Today, after several decades in the shadows, attitudes towards Brutalism are slowly changing, but it is a movement that is still overlooked, and grossly underrated. Raw Concrete overturns the perception of Brutalist buildings as the penny-pinching, utilitarian products of dutiful social concern. Instead, it looks a little closer, uncovering the luxuriously skilled craft and daring engineering with which the best buildings of the 1960s came into being- magnificent architectural visions serving clients rich and poor, radical and conservative.

LIBRARY QUIZ

To go in the draw to win a copy of Raw Concrete: The Beauty of Brutalism byBarnabas Calder answer the following question:

In Concrete NZ’s recently released “Sustainability Report for the Aotearoa New Zealand Cement and Concrete Sectors 2021/22” what reduction in diesel consumption is the concrete industry targeting by 2030? Hint. See page 36.

Email your answer to library@concretenz.org.nz Entries close Friday 21 June 2024.

Congratulations to Hazel Purcel of SPC Formwork, who correctly answered the Vol. 62 Iss. 04 Library Quiz to receive a copy of Concrete: From The Ground Up by Larissa Theule & Steve Light (Illustrator).

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: Peter Ensor

Convenor: Dave McGuigan