Concrete Magazine - Volume 58. Issue 01.

concrete VOLUME 58 ISSUE 1

READING CONCRETE CAN CONTRIBUTE TO YOUR SKILLS MAINTENANCE

NZ Cement Standard Strengthened NZS 3122 AMENDED WITH NEW SAMPLING AND TESTING PROVISIONS

Industry Association Consolidation AMALGAMATION SCOPED FOR THE LONG TERM BENEFIT OF THE ENTIRE INDUSTRY

ICF Examined Across Four Seasons ADVANTAGES OF INSULATED CONCRETE FORMWORK AS ENJOYED BY HOME OWNERS

THE MAGAZINE OF THE CEMENT AND CONCRETE ASSOCIATION OF NEW ZEALAND

UPFRONT

concrete MAGAZINE

Welcome to this the first issue of Concrete magazine for 2015.

Editor/Advertising:

Guided by encouraging trends during 2014, along with recent high level government forecasts of stable short-term growth, 2015 looks set to be positive for the construction sector.

Adam Leach

In fact, the concrete and wider construction market is giving us cause for optimism. The general air of confidence stems from the upwards trend in the main construction indicators.

Subscriptions:

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

Angelique Van Schaik +64 4 499 8820 admin@ccanz.org.nz

Consents issued and work put-in-place across residential and non-residential areas both demonstrate promising trajectories.

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A nationwide increase in ready mixed concrete volumes has also helped alleviate much of the pressure that had built up over the past five years.

Although as an industry we are progressing well in 2015, it is with a heavy heart that I introduce this issue of Concrete magazine, as over recent months we have said good bye to Nigel Priestley and Sir Ian Athfield.

by CCANZ (Cement & Concrete Association of New Zealand) PO Box 448 Level 8, 142 Featherston St

These two remarkable New Zealanders, who although not directly involved with the concrete industry, helped realise the full potential of our material and in so doing advance the fields of engineering and architecture respectively.

Wellington NEW ZEALAND Tel: +64 4 499 8820

Finally, I would like to congratulate Richard Fenwick and Carl Ashby for being recognised by IPENZ as a Distinguished Fellow and Fellow respectively.

Fax: +64 4 499 7760.

Rob Gaimster

Website: www.ccanz.org.nz

Email: admin@ccanz.org.nz

CCANZ, CEO

ISSN: 1174-8540

NEWS

ISSN: 1179-9374 (online)

CEMENT STANDARD STRENGTHENED Cement supply is a staple of New Zealand’s construction industry. In 2014, over one million tonnes was supplied to the construction and infrastructure sectors.

The structure of the cement industry has changed considerably with cement imports increasingly commonplace. This shift will continue as Holcim move to an import model in 2016.

New Zealand’s cement Standard, NZS 3122 Specification for Portland and Blended Cements (General and Special Purpose) has recently been subject to amendment and the updated version published in December 2014. Whilst NZS 3122 has served the industry well, the amendments further strengthen the requirements for this important construction material.

Disclaimer: The views expressed in concrete are not necessarily those of the Cement & Concrete Association of New Zealand. While the information contained in the magazine is printed in good faith, its contents are not intended to replace the services of professional consultants on particular projects.

The Association accepts no legal responsibility of any kind for the correctness of the contents of this magazine, including advertisements. © Copyright 2015 CCANZ (Cement & Concrete Association of New Zealand)

The Standards committee, consisting of representatives from the cement and concrete industry together with representatives from IPENZ and the University of Canterbury, incorporated into this latest edition requirements for sampling and testing, and a provision to restrict the total alkali content of the cement.

These new provisions, together with their rationale, are described below.

TOTAL ALKALI CONTENT In Table 1, the first amendment introduces a total alkali content requirement expressed as sodium (Na2O) equivalent for type GP (General Purpose) and HE (High Early strength) cement.

Aggregates susceptible to the potentially deleterious effects of Alkali Silica Reaction (ASR) exist in certain parts of New Zealand. Whilst provisions for minimising the risk of ASR are 2 concrete

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Cover image: From Teresa H.R. Lane’s ‘Men at Work’ Exhibition.

NEWS

given in the CCANZ publication TR3 Alkali Silica Reaction: Minimising the Risk of Damage to Concrete: Guidance Notes and Recommended Practice, one such provision is to limit the maximum total concrete alkali content when potentially reactive aggregates are employed. The amendment to NZS 3122 limits the alkali content to 0.6% or less which will assist in achieving the limit on concrete alkali content. Importantly however, it does not replace the need to include the alkali from other sources such as admixtures, and it is imperative that the recommended procedures in the aforementioned TR3 are still followed (as indeed they need to be when cement types GB1, LH2 and SL3 are used).

Interestingly, where there is specific prior agreement and notification of the purchaser or cement user, the cement manufacturer or supplier may supply cement which exceeds this maximum alkali limit. Whilst this may seem counter-intuitive, it should be remembered that where aggregates which are deemed to be non-reactive are used, no precautions are necessary in terms of ASR. Non-reactive aggregates are commonplace in New Zealand.

Under the new amendment, the supplier must report the alkali content to two decimal places, and the highest single value that is acceptable is 0.64%.

SAMPLING AND TESTING Sampling and testing frequencies are now introduced in Appendix E. There were no provisions in previous versions although it should be stressed that the two cement companies, Golden Bay Cement and Holcim (NZ) Ltd, which have historically supplied the lion’s share of New Zealand cement, have always tested and reported routinely.

Furthermore, it is a new requirement that all cement sampling shall be undertaken at the point of entry into New Zealand prior to distribution to the New Zealand market. This ensures complete traceability between the cement consignment and its certification.

It is also a requirement that any cement supplied out of sample date shall be subject to re-sample and re-test by the supplier.

Again this tightens up the previous requirements.

Appendix E gives minimum sampling and testing frequencies for ‘proven’ and ‘unproven’ sources. A source is proven where there is at least six months of data obtained in accordance with NZS 3122.

All testing has to be undertaken by a laboratory independently accredited by a member of the International Laboratory Accreditation Cooperation, such as NATA or IANZ. Unsurprisingly, sampling and testing frequencies are significantly more onerous for unproven sources.

As in previous versions of NZS 3122, cement properties are classified as specified or reportable. Of the eight reportable properties, the supplier will report test results as nominated by the purchaser or user. The supplier does not have to report the reportable properties unless requested.

At a time of dynamic changes in New Zealand’s cement industry it is pleasing to see that the cement Standard has kept pace to help maintain confidence in this vital construction material.

Strengthening existing brick and masonry buildings against earthquake loads Many older brick and masonry buildings now must be structurally upgraded or face an early retirement at the hands of the demolition contractors. Other buildings, such as those damaged by earthquakes need to be strengthened as part of their reinstatement to safe habitable buildings.

The SEISMOLOCK GRC Plaster is formulated to provide a strong bond to the surface of a masonry wall while the embedded layers of fibreglass mesh provide the tensile strength to resist in-plane shear loads and face loads on brick and masonry walls.

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NEWS

NIGEL PRIESTLEY – OBITUARY Internationally acclaimed earthquake engineer Professor Nigel Priestley ONZM died in late December 2014.

Nigel, who was last year made an Officer of the New Zealand Order of Merit for services to structural engineering, revolutionised the design of structures to resist earthquakes.

He studied the behaviour of reinforced concrete columns and some of his research papers are recognised as the basis for current understanding on the topic.

In 1985 and 1986 he was President of the New Zealand Society for Earthquake Engineering. In 1986 he joined the faculty at the University of California, San Diego (UCSD), where he was a Professor for 14 years and continues to be Professor Emeritus.

While there he researched the seismic design of concrete bridges.

Professor Nigel Priestley ONZM

In the 1990s he transformed earthquake engineering by developing PRESSS technology, a design system which allows buildings to rock during earthquakes but remain upright with minimal structural damage. The system employs unbonded post tensioning cables and special ductile joints which minimise movement in small earthquakes and, in larger events, ensure the building returns to its upright position.

As well as improving the safety of buildings, saving lives and reducing the need for repairs, PRESSS technology is efficient and economical due to the use of precast concrete.

Nigel published more than 450 books, including three seismic design books, plus technical papers and reports. He received more than 30 international awards for research and earned honorary doctorates from ETH Zurich and Cujo Argentina.

Aged 16 when he enrolled at the University of Canterbury, he completed his PhD in engineering at the age of 23 then spent 10 years heading the Structures Laboratory at the Ministry of Works where he led studies on bridges and buildings.

Nigel returned to the university’s engineering faculty as a lecturer (1976 to 1986), and during this period conducted research into the seismic behaviour of masonry structures. He was one of the famous UoC professors affectionately known as the three ‘P’s’; the others were Tom Paulay and Bob Park.

During his last three years at UCSD Nigel received a special appointment as a visiting fellow funded by the New Zealand Earthquake Commission. He left UCSD to be Co-Director of the ROSE School in Pavia, Italy where he supervised MS and PhD students, taught earthquake engineering and helped set up the curriculum.

Nigel was a Distinguished Fellow of IPENZ, Fellow of the Royal Society of New Zealand, an Officer of the New Zealand Order of Merit (ONZM), a Life Member and past President of the NZ Society for Earthquake Engineering, and Honorary Member and past Councillor of the NZ Concrete Society.

Nigel gave evidence to the Canterbury Earthquakes Royal Commission and chaired a panel that examined the collapse of the CTV and Pyne Gould Corporation buildings, and damage to the Forsyth Barr building and the Hotel Grand Chancellor. It was this work that led him to be awarded an ONZM, at which time he said his biggest contribution was finding the best way to design structures for earthquake response.

Nigel died on 23 December 2014 after a long battle with cancer.

He was 71. He is survived by his wife Jan and four children. The New Zealand concrete industry extends its deepest sympathy to his family.

In the NZ Listener (Jan 31-Feb 6), Science columnist Rebecca Priestley wrote a touching obituary about her father and his achievements. She works in the Alan MacDiarmid Building at Victoria University, the first multi-storey building in New Zealand to use PRESSS technology.

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NEWS

SIR IAN ATHFIELD FAREWELLED Sir Ian, who was one of the most singular architects in New Zealand over the past half century, died in Wellington on 16 January 2015.

Sir Ian Athfield was born in Christchurch and educated at the Auckland University School of Architecture. He worked as an architect in Wellington for several years before Sir Ian Athfield starting his own practice in 1968, and achieved international recognition in the mid-1970s when his practice won a competition to design a low-cost housing scheme in the Philippines - a project scuppered for political reasons.

Sir Ian’s buildings of the 1960s and 1970s, especially the numerous unconventional houses he designed in Wellington, came to define that architectural moment.

Most prominent, and often most controversial, was his own home above the Wellington motorway, which was, for over 40 years, a “work in progress”. In 2000, the editor of the respected UK magazine, The Architectural Review, described the Athfield House as “one of the most wonderful houses of the twentieth century”.

Athfield Architects grew to become one of the largest and most successful New Zealand architecture practices. The firm’s award-winning work included First Church of Christ Scientist, Telecom House, Adam Art Gallery, Massey University Te Ara Hiko College of Creative Arts, Waitangi Park (with Megan Wraight), the refurbishment of Government House and the headquarters of the GCSB, all in Wellington; Jade Stadium in Christchurch; Palmerston North Library; and Waitakere Council Building (with Architectus) in Auckland. A stream of accomplished houses also flowed from the practice, which has been located in the Athfield House for more than four decades.

W E N

Sir Ian was universally admired and respected within his profession. Sir Miles Warren described him as “New Zealand’s most distinguished and most creative architect”. In 2004 the New Zealand Institute of Architects conferred on Sir Ian its leading award, the Gold Medal for career achievement, and from 2006-08 he served as President of the Institute.

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Sir Ian was made a Companion to the New Zealand Order of Merit in 2004. His knighthood was announced in January 2015 as part of the New Year’s Honours List.

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Photography by Simon Devitt VOLUME 58 ISSUE 1

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CCANZ CONCRETE CONSTRUCTION COURSE CCANZ has developed a Concrete Construction Course designed for those responsible for supervising the receipt and placement of fresh concrete on-site - typically this would be the site foreman (or equivalent) and the formwork carpenter.

Building apprentices and concrete placers would also find the course invaluable.

The aim of the course is to promote quality concrete construction.

Built around NZS 3109 Concrete Construction, the curriculum for the two-day classroom based course will meet both industry needs and the relevant NZQA standards.

The course is comprised of the following 5 modules: 1. Introduction to Concrete

a. Cement manufacture

b. Ready mixed concrete production

c. Constituent materials

d. Applications 2. Properties of Fresh and Hardened Concrete

a. Relevant Standards

b. Fresh & hard concrete tests

3. Reinforcement

a. Reinforcement types

b. Manufacture

c. Handling & installation

4. Formwork

a. Requirements of formwork

b. Formwork materials, systems and design

c. Falsework d. Construction 5. Site Practice

a. Handling & placing

b. Compaction, finishing & curing

c. Hot & cold weather concreting

d. Control of surface finishes & cracks

The popular CCANZ publication The New Zealand Guide to Concrete Construction is an ideal resource to accompany the course. It can be downloaded from the CCANZ website – www.ccanz.org.nz/documents.aspx Venue Auckland Specific venue yet to be arranged.

Date / Time 8–9 September 2015 / 9.00 a.m. to 5.00 p.m.

Registration Fee • CCANZ Members - $880 plus GST ($1,102) • Non-CCANZ Members - $1,100 plus GST ($1,265) To register your place call CCANZ on (04) 499 8820 or email admin@ccanz.org.nz.

Queries about the course content can be directed to Alistair Russell (Manager – Structural Performance & Engineering Systems) on (04) 915 0384 or email alistair@ccanz.org.nz.

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Image. Diederick Van Heyningen

CCANZ WEATHERTIGHT CONCRETE CONSTRUCTION COURSE Following on from the successful collaboration between CCANZ and the Building Officials Institute of New Zealand (BOINZ) in delivering the 2014 concrete masonry course , a one-day course on weathertight concrete construction will be offered in April 2015.

3.

Wall Construction a. Concrete masonry wall construction b. In-situ concrete wall construction c. Precast concrete wall construction

Although designed for BOINZ members the course is open to other building professionals with an interest in appropriate weathertight concrete construction practices.

4.

Wall weathertightness systems a. EIFS system - external insulation b. Plaster system c. Coating system d. Weathertight concrete e. Masonry veneer

Trainees will achieve an understanding of the requirements of weathertight concrete and concrete masonry construction based on the CCANZ publication Code of Practice for Weathertight Concrete and Concrete Masonry Construction (CP 01:2014).

The course also covers the theory that underpins the policies and practice of being a Building Control Officer which is one component of the learning requirements for the Diploma in Building Control Surveying - Small Buildings.

The course is BOINZ standards-based, which means that trainees must attain a pre-determined level of theory-based knowledge and practical skills and be able to competently apply this knowledge in a practical situation, either in the workplace or in a simulated situation.

The course is comprised of the following 8 modules: 1. Scope a. Geometry b. Loads

c. Construction excluded 2. General a. Materials b. Cracking c. Maintenance

5. Flashings

a. Required properties of flashing materials

b. Acceptable flashing materials c. Fixings 6. Concrete roofs and decks 7. Concrete slab-on-ground and footings 8. Construction moisture Venue Room VS 220 School of Architecture Victoria University of Wellington 139 Vivian Street Wellington Date / Time Thursday, 16 April 2015 / 9.00 a.m. to 5.00 p.m.

Registration Fee • BOINZ and CCANZ Members - $535.00 plus GST ($615.25) • Non-BOINZ Members - $735.00 plus GST ($845.25) To register your place call CCANZ on (04) 499 8820 or email admin@ccanz.org.nz.

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Vivienne and Kim – The Winning Team

CCANZ STUDENT WORKSHOP GOES FROM STRENGTH TO STRENGTH THE THIRD CCANZ ARCHENG WORKSHOP WAS

DISASTER RESPONSE

RECENTLY HELD IN CHRISTCHURCH, WITH 22

The event was enhanced by a keynote presentation from the University of Canterbury’s Chris Hawker, the director of the university’s Centre for Risk, Resilience & Renewal (UCR3).

ARCHITECTURE AND STRUCTURAL ENGINEERING STUDENTS FROM ACROSS NEW ZEALAND IN ATTENDANCE. The three-day, all-expenses-paid ArchEng workshop saw the students, paired into cross-disciplinary teams of two, work towards a demanding project brief given to them on the first day. The students were hosted by the Canterbury Polytechnic Institute of Technology (CPIT) with the support of principal sponsor BRANZ. The challenge was focused on the theme of resilience, with each team having to design a structure that could be rapidly repurposed after a significantly disruptive event to provide a service to the community.

The project brief was intentionally open-ended, and a critical part of each team’s strategy was to focus their design on a well defined subset of all the possible aspects of the scenario (such as a flood or fire).

Chris was able to give a first-hand perspective on communities’ immediate post-event needs in his capacity as the primary incident controller, responsible for managing the university’s response team for multiple events over the past four years. These incidents have included five major earthquakes and in excess of 11,000 aftershocks, severe weather events and security threats.

The students were also able to learn from Chris Wilson (of Wilson & Hill Architects) and Grant Coombes (of Engenium) who conducted a guided tour of the recently completed Solid Energy building, which has received a 5 Green Star certified rating for office interiors from the New Zealand Green Building Council.

Since its inception in 2012, the ArchEng workshop has endeavoured to convey the message that the best outcome for the client will only occur when the architect and engineer are committed to working together in a collaborative way.

THE NEXT STEP FOR ARCHENG CCANZ is excited to announce that in partnership with BRANZ, principle sponsor of the ArchEng since 2012, it will take the event to a new materials neutral pan-industry level in 2015.

The workshop was designed to bring together two major disciplines within the construction sector and promote collaboration under a pressured deadline. At the core of ArchEng’s achievements have been the talented students that brought not only their professional skills to the event but their open minds and willingness to learn from an expert well outside of their academic experience.

The vision for ArchEng was always to position itself as the premium annual student workshop for the construction sector. For that reason, CCANZ has agreed to allow BRANZ to take the lead on the event and to become one of the major construction material supporters of the event. CCANZ will project manage the event for the next 3-years.

CCANZ is pleased that the steel and timber industries support the objectives of good design and engineering, and are confident that the workshop participants will take this increased design freedom in new directions, elevating the profile of ArchEng further.

CCANZ is looking forward to promoting the positive design aspects of concrete to the students, and is confident that a concrete design will be a strong contender for the ultimate prize.

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As the students were shown around the Solid Energy building, Chris and Grant highlighted many aspects of the build that required careful dialogue and management between the two disciplines, reiterating to the students that their professional careers will, in many instances, rely heavily on this form of interaction.

AN INTENSE EXPERIENCE For the students involved, the workshop was a very intense experience, particularly as it was from a standing start and with a team-mate they have just met.

While one team walked away with the $5,000 first prize, the students as a whole remarked how much they had learnt from their partner and how they will take the experience, and new friendships, with them into their careers.

The winners of the 2014 event, Vivienne (University of Auckland engineering student) and Kim (Unitec Institute of Technology architecture student), designed a multi-purpose medical facility that could be easily re-commissioned post-disaster by virtue of its structural resilience, which is ingeniously achieved through the building’s floating (but tethered) position in a large pool of water.

To help capture the animated atmosphere of the three-day event, CCANZ once again commissioned a videographer. The resulting short film showcases the talent and energy of the students, as well as more fully exploring the rationale behind their designs. CCANZ encourages readers to watch the three YouTube videos on the CCANZ channel (www.youtube.com/user/cementconcrete) and be inspired by the energy and creativity that the next generation of construction professionals is bringing to the workplace.

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ANOTHER MAJOR MILESTONE FOR HOLCIM THE NEXT STAGE OF HOLCIM NEW ZEALAND’S STATE-OF-THE-ART CEMENT STORAGE DOME AT PRIMEPORT IN TIMARU IS NOW UP, WHICH IS A MAJOR MILESTONE IN THE $50 MILLION PROJECT. Holcim is investing $100 million in building 30,000 tonne new storage facilities in Timaru and Auckland as part of its business strategy of global sourcing for supply into the New Zealand market. Along with the global sourcing, Holcim NZ has comprehensive supply chain management expertise that is critical to the construction and infrastructure sectors.

The construction phase in Timaru will employ 50 people while the facility will employ eight staff once fully operational in the first half of next year.

New Zealand Country Manager Glenda Harvey says the terminal in Timaru provides effective access to the major market of Christchurch, utilising the new $5 million silo capacity completed in January 2014 at the Lyttelton Port of Christchurch.

“This terminal also provides effective distribution to the whole of the South Island market and the lower North Island as well.”

Glenda Harvey says the dome is a first for New Zealand and demonstrates the company’s drive to tap into the best of innovation used by Holcim around the world.

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“The stage today involved putting up the dome, creating the shape for the polyurethane and concrete shells to be added from the inside. The innovation and technology being used is world class and is another example of the benefits Holcim New Zealand gains from the global Holcim family of companies.”

“The company globally invests millions in research and development and sourcing high quality product along with managing transportation and logistics for customers. This reduces risk to customers as Holcim can tap into a wide network to source cement and most importantly make sure it gets to where it needs to when it is needed.”

“This is critically important to the construction and infrastructure sectors particularly with the huge demand post-earthquake in Christchurch.”

Glenda Harvey says as a global leader, Holcim applies stringent quality criteria to its sourcing strategy to ensure that markets receive the best possible product to meet local performance criteria.

K Frame Unit

Training Wall

GOLDEN BAY CEMENT INVOLVED WITH NEW SEA WALL FOR GISBORNE WHEN GISBORNE CONCRETE MANUFACTURER AITKENS CONCRETE WAS APPROACHED BY DOWNER GISBORNE TO PARTICIPATE IN THE REPAIR OF THE AGEING SEA WALL SEPARATING THE GISBORNE HARBOUR AND THE TURANGANUI RIVER, GOLDEN BAY CEMENT WAS AITKENS’ FIRST PORT OF CALL. The concrete dividing wall, constructed in 1924, is a crucial structure separating the river from the harbour, preventing flood water from entering and causing significant damage, not only structurally, but to the many boats currently moored in Gisborne Harbour.

Why Microsilica 600? “It increases the durability of concrete, and provides the ideal solution for concrete plants where silo capacity is limited. This is due to the low SCM replacement blend required,” says David.

Over the years the sea wall has noticeably deteriorated, and with approximately $12 million set aside for the project, Gisborne Council contracted Downer Gisborne to design a reinforced concrete solution. The resulting ‘A’ and ‘K’ frame designs were then tailor-made to provide renewed structural stability to the wall on the harbour side. Once the complex moulds were complete, Downer approached Aitkens Concrete to formulate an appropriate concrete mix with which to construct the units.

“The bracing units contain steel. Concrete must protect steel, therefore the more resistant the concrete is to chloride ingress, the longer-lasting the steel. The sea wall is in a splash zone, which means it is in the tidal zone and is subject to extreme conditions.”

The intended design life of the concrete was 100 years and with a 50 mm cover over the steel a 50 MPa concrete with Microsilica was required.

David Aitken, managing director of Aitkens Concrete, agrees the project has been technically demanding. “Our biggest challenge was being able to produce durable, workable concrete in small quantities,” he explains. “The units do not take a large volume of concrete. We also needed to produce concrete that would achieve the required 50 MPa strength.”

To achieve this task, Aitkens supplied a mix of Golden Bay Cement’s EverSure (Type GP) Cement and 8% Microsilica 600. “To pour the foot sections and top beam we used 50 MPa 19 mm, which was all done on site,” David continues. “A 50 MPa 10 mm mix was used for pouring the ‘A’ and ‘K’ units into moulds at the yard.” Because of the small cross-section of the units - 250 mm x 250 mm - and the high quantity of reinforcement, a high workability concrete was required.

When it comes to reliability, Golden Bay Cement comes up trumps in David Aitken’s book. “We have a lot to thank Golden Bay Cement for,” he says. “They have always been immensely helpful, particularly when we’re dealing with highly technical situations such as the sea wall.”

Golden Bay Cement Regional Sales Manager Michael Long is equally complimentary of Aitkens Concrete. “Aitkens Concrete has been a key account independent customer of Golden Bay Cement for well over 36 years,” Michael explains. “We at Golden Bay regard David and his wife Trudy as personal friends and industry partners, and Aitkens Concrete as a robust and dependable strategic customer with a strong emphasis on technical ability to produce and supply quality concrete to its customers.”

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ONWARDS AND UPWARDS

WE CAN NO LONGER AFFORD TO IGNORE THE NEED FOR MEDIUM DENSITY MULTI-STOREY RESIDENTIAL DEVELOPMENTS IN OUR MAIN CENTRES, WHILE AT THE SAME TIME DESIGN AND MATERIALS APPROPRIATE FOR OUR UNIQUE CONDITIONS MUST NOT BE COMPROMISED. New Zealand is currently undergoing a demographic transformation. The population is aging rapidly, immigration patterns are changing, and the number of couple and single person households are increasing.

be as subtle as our strong connection with the outdoors, and the bulky equipment requiring storage that this creates.

Add to this mix the interrelated factors of sky-rocketing property prices (particularly in Auckland), scarcity of land for development, plus the relatively slow rate of residential construction, and the outcome is both a preference and a requirement for urban (rather than suburban) living.

More immediate considerations in apartment design stem from construction materials issues linked to the leaky building crisis and our heightened awareness of structural requirements post Canterbury earthquakes. While these concerns may prove to be initial obstacles to the uptake of apartment living, they will ultimately help inform the process and enhance the fit-forpurpose, long-term outcome.

QUARTER ACRE CONUNDRUM

APPROPRIATE MATERIAL SELECTION

As we know however, this has not always been the case. In a country where land and timber was plentiful post-war, New Zealand witnessed a burst of activity in the construction of standalone dwellings. This was also a period when the state house became common, and every prized motor car needed a separate garage. The result was your own slice of paradise, a spacious home on a generous section.

Within an overall design that is suitable for the local climate, uses correct detailing and is brought to life by skilled trade professionals, durable construction materials are paramount in medium density multi-storey residential developments. The consequences of any shortcuts in terms of quality materials will be magnified by the scale of an apartment development.

Yet for many the quarter acre dream never lived up to expectations. Their homes proved too cold in winter and too hot in summer, required endless maintenance in the wake of harsh weather, and were isolated from infrastructure and places of work, as well as leisure and recreational facilities.

UNIQUE REQUIREMENTS As current social trends and economic conditions combine to lead us towards more sustainable and affordable medium density multi-storey developments in our cities, there are many considerations that must not be overlooked. Key amongst which is our comparative lack of experience in apartment design.

To adopt wholesale, international practice without a thorough understanding of our own unique demands would be a mistake. While we can certainly take inspiration from exemplar apartment complexes around the world, we must first identify and accommodate our own distinctive New Zealand traits. These can

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The concentration of people in an apartment complex places a premium on rot resistance and fire safety in particular. Materials that inherently offer enhanced protection at no additional cost must be favoured to meet this requirement.

Protection from sound intrusion is similarly important. Recent CCANZ research on the acoustic performance of different construction typologies indicates heavy weight construction to be well suited to managing noise control issues in apartments, particularly at low frequencies.

SEISMIC SYSTEMS Over recent years New Zealand has been living up to its reputation as the ‘shaky isles’, a consequence of which has been a strong emphasis on earthquake resilience. We are seeing the emergence of a new low damage approach to seismic structural design, one which still embraces life safety as a priority, but also seeks to enable continuity post-earthquake through damage minimisation.

A rigid structure on base isolators and concrete piles provides efficient earthquake protection even in areas prone to liquefaction.

A mix of apartment types is key to a diverse and vibrant community.

Base isolation is experiencing a renaissance, while damage resistant design techniques, primarily PREcast Seismic Structural Systems (PRESSS), are also gaining uptake amongst developers of commercial buildings, and are ideally suited for multi-storey apartment complexes.

CCANZ APARTMENT DESIGN GUIDE To assist developers and their design teams maximise the opportunities afforded by the growth in apartments, CCANZ has developed The Apartment Design Guide, which can be downloaded for free at www.ccanz.org.nz.

TM

AN EXCITING FUTURE An example of the welcomed and mature realisation that medium density multi-storey apartments are crucial to New Zealand’s future housing needs is the Christchurch City Council led Breathe design competition.

The majority of conceptual designs submitted demonstrate the exciting possibilities on offer for residential developments to deliver housing options and lifestyle choices based on sustainability, innovation and a strong sense of community.

This new era in residential construction, one that reflects changing attitudes about how and where we live our lives, has to be enthusiastically embraced, and the structures that emerge have to be uncompromising.

Based on an article written by Rob Gaimster that appeared in BRANZ Build 138 - www.buildmagazine.org.nz/articles/show/onwards-and-upwards/

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INNOVATIVE STRUCTURAL ENGINEERING AT CLYDE QUAY WHARF TRANSFORMING A 100-YEAR-OLD CRUMBLING STRUCTURE RIGHT ON WELLINGTON’S PRIME CITY WATERFRONT INTO A MODERN LUXURY APARTMENT COMPLEX HAS BEEN A TRIUMPH OF ENGINEERING DESIGN AND CONSTRUCTION. STRUCTURAL CHALLENGES INCLUDED RE-FOUNDING, REPAIRING AND ENCAPSULATING A SEVERELY SPALLED WHARF, SEISMIC STRENGTHENING, CREATING A LARGE BASEMENT CARPARK BELOW WATER LEVEL, AND RESISTING A HIGHLY CORROSIVE SALT-LADEN ENVIRONMENT.

Photography by Aaron Openshaw

Photography by Aaron Openshaw

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VOLUME 58 ISSUE 1

Photography by Aaron Openshaw

DESIGN The old Overseas Passenger Terminal structure had three parts: the original reinforced concrete wharf dating from 1908, additions to width and length supported on timber piles and dating from the early 1960s, and the terminal building – a concrete structure with a high-stud ground floor space and an upper floor with lightweight walls and roof.

In 2008, developers Willis Bond & Co gained Resource Consent for a major redevelopment with a design by Athfield Architects.

Over the next two years, extensive geotechnical investigations, pile testing and prototype sub-wharf construction were carried out. Then followed two structural peer reviews – one for stability and one for durability and water-tightness of the new partlysubmerged basement carpark.

stands over the basement, seven cores provide access to up to three apartments per level, as well as giving lift access from the carpark. The entire superstructure stands on a grid of new piles and beams slotted through and fixed to the existing wharf.

The basement was designed to solve three critical structural problems: seismic bracing via a deep rigid box, the transfer of column loads away from the superstructure to maintain the historic wharf pile grid, and encapsulating the original spalling concrete wharf to isolate it from the harsh marine environment. Several strategies were used to model the new building’s seismic design, including a Time History analysis of a full 3D stick model, which was subjected to seven earthquake records to verify drifts, check torsional response, diaphragm flexibility, and sensitivity to pile length and soil types.

The new concrete basement was constructed under the existing concrete wharf slab and around the existing piles. New piles stitched alongside existing piles carry the weight of the new superstructure and are rigidly fixed up into the new basement to resist lateral loads. The basement slab comprises 300 mm thick precast sections supported on the new piles via a cast in-situ “stitch” beam. The stitch beam surrounds the existing piles as they pass through the basement floor. Side walls are 250 mm thick, cast in-situ over a 600 mm high precast kicker wall, built into the precast slab sections.

To achieve water-tightness of the partly submerged basement carpark, an inside-out concrete reservoir design was chosen as being the most practical. The basement slab with kicker walls was designed for pre-casting in 17 x 5 m sections to be lowered into the sea and connected via a stitched beam to be cast at low tide.

Transverse shear walls are placed each side of the basement carpark’s central aisle to coincide with concentrically braced frames in the superstructure above. Parking for one hundred cars was provided.

Working safely on the basement carpark required several kilometres of scaffolding to be suspended below the 1908 concrete wharf, but above the changing tide. All workers were required to be swimmers and life jackets were compulsory.

A manned rescue boat was always on hand.

The new 230 m long apartment superstructure was designed with steel frames standing on the wharf. Where the superstructure

The basement structure was designed to resist two tsunami load cases, one to exclude a 2.3 m head of water and the other to withstand an internal flood 1.5 m deep.

CONSTRUCTION

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Photography by Aaron Openshaw

Demolition crews removed all the original concrete cross bracing and the grid of beams in the intertidal zone. Strict environmental measures involved silt booms and rubble catchment methods.

Personnel access and demolition waste removal were through cut outs at each pile location and through the seven lift openings along the length of the carpark.

The carpark needed 210 new driven and bored piles extending down to 35 m deep. Tight tolerances required the new piles to be wedged between the existing concrete and timber piles with only millimetres to spare.

Divers installed FRP jackets and concrete doughnuts below the water line on the old concrete piles to increase their ductility and resilience. Best practice trialling led to the use of plastic formwork for the tremie concrete mixer and underwater grouts.

Thirty-two slabs 17 m x 5 m and 300 mm thick were precast under the existing wharf slab in a space of 1.2 m to clear average wave swells at high tide. Workers there had to set up forms, tie doublemat reinforcing, install PVC water stops, and finish the concrete.

To cast the longitudinal kicker walls in each slab, perfect slump and vibration had to be achieved. The seven lift pits were precast off site, craned into position and cast in with the basement slabs.

Bases of the pits were always submerged in the sea so required firm restraint in case of rough weather.

the incoming tide to restrain the slab from lateral waves and hydrostatic uplift.

With adjacent slabs restrained, each stitch beam was poured, typically incorporating two new driven piles, two bored piles and seven existing concrete piles all keyed with stainless steel dowels.

Like the slabs, the stitch beam had integral kicker pile caps.

Pouring of the mix had to be seamless to fit within the time window and involved much pre-planning with the concrete supplier and the pumping contractor.

Side walls of the basement were completed with special water stop detailing to cover the reinforcing. Then the 3500 m² concrete basement ceiling with primary and secondary beams was remediated using 50 MPa self-compacting or sprayed concrete.

Higgins Concrete produced the high-grade concrete mix for the carpark using Golden Bay Cement’s EverPlus fly ash in the precast slabs and Microsilica 600 in the stitch beams between floor slabs.

Completed ahead of schedule, the new Clyde Quay Wharf development with its internal partly submerged carpark, stands as a tribute to meticulous pre-planning and collaboration between developers, architects, engineers and constructors.

This article is based on the 2014 NZ Concrete Conference paper The Design and Construction of the Clyde Quay Wharf Basement written by Adam Thornton and Ryan Clarke of Dunning Thornton Consultants, and Sean McGuiness of L.T. McGuiness Limited.

Each 100 tonne slab was raised to remove the formwork then lowered into precise position using synchronised hydraulics attached to barrel jacks. Then there was a two-hour race against

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ACCOLADES

FOR ICF FIRST HERALDED AS A NEW GENERATION OF BUILDING TECHNOLOGY FOR RESIDENTIAL CONSTRUCTION, INSULATED CONCRETE FORMWORK (ICF) CAN NOW BE JUDGED FOR ITS DESIGN AND CONSTRUCTION RECORD AND PERFORMANCE IN ALL FOUR SEASONS OF THE YEAR.

Image: Ecobuild Developments.

Image: Ecobuild Developments.

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VOLUME 58 ISSUE 1

Image: Home Trends Builders Ltd.

In 2012 Concrete magazine (Vol.56 Iss.1) reviewed ICF for residential construction with information from two local suppliers - Insulform NZ Ltd and Eco-Block New Zealand Ltd. Four owner/occupiers were recently interviewed on their experience of living year-round in an ICF home constructed using Insulform and Eco-Block systems.

THE SYSTEM Small but subtle differences separate these two alternatives for ICF construction in New Zealand. Both systems involve interlocking assemblies of expanded polystyrene separated by high-density polypropylene webs through which standard concrete is poured to form continuous, structural walls. Reinforcing comes from rebars, or steel fibres added at the mixer.

The two systems differ in their choice of wall thickness and in the design of corner blocks. Both systems provide high-strength concrete walls sandwiched between polystyrene inside and out.

DURABILITY All owners reported no problem regarding the ability of ICF to withstand knocks. ICF was said to have the advantage of “a bit of give” from the expanded polystyrene plus the benefit of a solid wall of concrete behind it. “It is easily patchable.”

One owner, himself a builder, said he has used ICF for intertenancy walls as it meets fire and sound rating requirements “all in one go.”

One home had an ICF retaining wall against a rock bank. Another used standard 150 mm ICF to support two storeys without extra strengthening.

Standard plasterboard fixed directly through the polystyrene was used by all owners as an interior lining.

Owners had selected from a wide variety of options for exterior cladding over the polystyrene. Systems chosen included hard plaster, board and batten, stone and timber. Proprietary metal cladding was used in some places as an architectural feature.

GENERAL IMPRESSIONS Experiences with ICF were related by four owner/occupiers concerning six homes in Wanganui, Wellington and Christchurch.

The homes included both one and two storey.

General impressions were strongly favourable. One owner had felt unsafe in typical lightweight New Zealand homes which “shake in the wind.” Another chose ICF to facilitate airtight passive house design. All believed that ICF out-performs all common alternatives.

THERMAL ENVELOPE All owners praised the unbroken thermal envelope of ICF. They liked the very stable indoor temperature through all seasons and throughout the whole house.

In summer it seemed that the internal daytime temperature remained moderate with minimal overheating, while in winter it generally hovered around a comfortable 20ºC reducing the need for mechanical heating.

One owner saw the extension of ICF into the foundation footing as reducing thermal loss. Another had fitted an insulated door to the integral garage which stayed as warm as the living areas.

SOUND INSULATION All owners praised the sound attenuation of ICF. One home was only 10 m from a 100 km/h road while others were near a motorway and an airport. Some homes had ICF only on the perimeter. Others also had it between rooms, with timber framing used elsewhere.

A feature that impressed some owners was the very low level of sound transfer inside the home. One said a TV could hardly be heard from 6 m away. Another owner with a movie room and master bedroom surrounded by ICF said guests were “amazed at the deadly quiet” in the whole house.

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Image: Home Trends Builders Ltd.

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COST OF BUILD One owner claimed the cost had been similar to lightweight timber frame construction but with the added benefits of “quality and durability that would last for decades with minimal maintenance.” Another claimed he had paid no more for getting a “very stable” home.

A third owner noted the current high cost of timber and labour and claimed that compared with an alternative having the same high R rating he had paid no extra yet got incomparable benefits.

The fourth owner rated the cost of ICF as on a par with timber framing. “But the ICF builder must be organised with power and water conduits set up before filling the form with concrete.”

SPEED OF CONSTRUCTION According to one owner with three ICF builds behind him, the time required for single storey ICF construction was identical to other standard options. However, two-storey ICF construction may have taken a little longer.

Another owner regarded ICF construction as “very efficient time-wise.”

Image: Home Trends Builders Ltd.

The two other owners (both in Christchurch) said that ICF took from 10 to 20% longer to build – but this was offset by “much better performance” in the end result.

BOTTOM LINE Praise for ICF construction was enthusiastic and entirely convincing. One owner had noted criticisms relating to the perceived non-sustainability and health effects of polystyrene.

Offsetting this, he said, is the long-term earthquake resistance and durability of ICF. Being relatively heavy, ICF construction was seen to need secure ground support.

Another owner noted that his very large ICF home came through the Christchurch earthquakes with no damage. It was built on a platform of compacted sand, and still retains its level within 2 mm as determined by laser.

All agreed that ICF is very strong and flexible, allowing endless variations in design and providing a comfortable living environment.

Interviewees were nominated by ICF system manufacturers Bob Blair, of Christchurch-based Insulform NZ Ltd, and by Paul Jones, of Papamoa-based Eco-Block New Zealand Ltd.

Text by Tom Evison, Technical Press Service.

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ART INSPIRED BY THE CONCRETE POUR ART AND ARCHITECTURE ARE NATURAL PARTNERS, BUT WHAT ABOUT ART AND BUILDING? THE PROCESS OF POURING IN-SITU CONCRETE IS EXPLORED BY EMERGING ARTIST TERESA H.R. LANE IN HER ‘MEN AT WORK’ EXHIBITION TO BE HELD FROM 11 APRIL TO 8 MAY 2015 AT MILFORD GALLERIES, DUNEDIN. Lane, a recent Elam graduate, has taken her inspiration from the source – she project managed the build of her own concrete and glass Freeman’s Bay home late last year. Her first series of paintings, which celebrated both the strength and vulnerability of “the pour”, sold out at a group exhibition at the Allpress Gallery last August.

Now she has created a new series of larger acrylic and ink works which depict the co-ordinated theatre of construction. Lane’s interest lies in the physical form, and the action of the body.

The works, an observation of a building site, are kept in a tight palette of earthy orange – the vibrancy of the clay foundations – and cobalt blue that is reminiscent of the plastic wrap that is used to ‘cure’ the poured walls for a week.

Appropriately, the ‘Men at Work’ collection is presented on plywood board salvaged from building sites. “I like the fact the plywood is being recycled and put to good use,” says Lane. “It’s a vigorous process; if something doesn’t work first time, I can sand it off and start again.” The sandwiched edges are beautifully mitred to celebrate the material and the grain is allowed to show through the colour wash of the art.

The yin-and-yang balance of the practical and the creative; of brute physical force set against the delicate choreographed dance of the team makes for an exhibition which lauds the perfection in imperfection.

Lane combines drawn and painted elements to assemble the outlines of an industrial landscape. Washes of colour are used to define space within the picture plane, but Lane does not proscribe its exact nature or function.

Lisa Wilkie of Milford Galleries says: “We look forward to showcasing Teresa Lane’s first solo exhibition. The roles of the workers who populate the paintings are unspecified, but Lane’s vigorous line drawings suggest a robust, physical dynamism.”

ARTIST AND EXHIBITION INFORMATION Teresa H.R. Lane is an Auckland-based artist who graduated with a Bachelor of Fine Arts (Hons) from Elam in 2014. Visit: www.teresahrlane.com Men at Work, 11 April – 6 May, Milford Galleries, 18 Dowling Street, Dunedin.

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Image. John Crawford

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BCITO IN 2015 2014 WAS A BIG YEAR FOR BCITO AS WE CONTINUED TO COME OUT OF THE EFFECTS OF THE RECESSION AND STRONG GROWTH IN APPRENTICE NUMBERS HAS CONTINUED. WE SIGNED MORE THAN 5000 NEW APPRENTICES INTO TRAINING AND ENDED THE YEAR WITH AROUND 9500 ACTIVE TRAINEES. OUR BIGGEST CHALLENGE IN 2014 WAS MANAGING GROWTH WHILE DETERMINEDLY MAINTAINING QUALITY AND SERVICE.

Ruma Karaitiana Chief Executive

Some of this growth has been as a result of having started the year by merging with the Joinery ITO along with DecorateNZ and FloorNZ. The merger brought together great trades and great people. An important part of the next stage was to conduct a comprehensive review of the specialist trades in the joint coverage.

This review took most of the year and consulting with industry and BCITO staff, we looked at each trade. We then considered whether, in this new environment, we could enhance service delivery and educational outcomes.

We’ve introduced some enhancements at the beginning of 2015.

The first enhancement you will notice is a refreshing of our BCITO brand. This is not intended to be a major change but rather to simplify and modernise the look and feel of the brand to make it more friendly and accessible. In particular, we want to emphasise that BCITO is about people and enabling their success. The new branding is now gradually being rolled out.

The changes are more than just about branding. The Specialist Trades Group, which we put in place at the time of the merger, has been disestablished, and two major changes have occurred.

Firstly, the specialist trades field staff have doubled in number and merged into the broader BCITO area teams. Secondly, we have brought together all functions that engage directly with industry into a new Stakeholder Engagement Group including all research, marketing and communications functions.

Importantly this group includes a new team of Industry Advocates, who will be active in the particular trades assigned to them.

They will be liaising with and consulting industry leaders, and stakeholder groups to promote efficient and effective consultation and communication.

2014 was a great year for BCITO thanks to the strong support we have received from industry, matched by the commitment of the BCITO Team.

2014 CEMENT AND CONCRETE TRAINEES

2014 CEMENT AND CONCRETE TRAINEES 160

DEC

154

NOV

136

OCT

135

SEP

130

AUG

143

JUL

141

JUN

134

MAY

129

APR

128

MAR

126

FEB

124 121

JAN

Active Trainees

140

120

100

80

60

40

20

0 JAN

FEB MAR APR MAY JUN

Total Signups YTD

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JUL AUG SEP OCT NOV DEC

Completions YTD

Withdrawals YTD

LAYING THE FOUNDATIONS FOR SUCCESS WITH BCITO WITH UNPRECEDENTED LEVELS OF BUILDING AND CONSTRUCTION ACTIVITY GENERATING AN ABUNDANCE OF NEW OPPORTUNITIES FOR BUSINESSES AROUND NEW ZEALAND, IT’S IMPORTANT FOR BUSINESSES TO ENSURE THEY KEEP UP WITH DEMAND.

Getting ready to hit the books – Quentin Stevenson (far right), Director of Slab Specialists and his apprentices prepare for some classroom training and pizza at their East Tamaki yard after a day of on-job learning.

With over 20 years’ experience working in the building and construction industry, Quentin Stevenson, Director of concrete slab and foundations company, Slab Specialists, is a firm believer in the importance of training in order to keep up with demand as well as keeping on top of the game.

Employing 60 staff, Slab Specialists has offices in Auckland and Christchurch, two of the fastest growing cities currently seeing a boom in building and construction.

Looking to expand the business and cater for the ever-increasing demand for specialist foundations, Quentin currently has 15 staff enrolled in managed apprenticeships with BCITO, the largest provider of trade apprenticeships in New Zealand.

Quentin has created a proven system of learning, combining onsite hands-on development with classroom sessions to give his staff the extra edge. ‘Every Monday night we pull all our apprentices into the office for a training session, over and above their work day,’ said Quentin.

‘It’s very easy to use an apprentice as a labourer, but we try to train well and get into our guys’ heads that they are training to be professionals so that’s the kind of attitude they have to have. Pizza turns up at 6 o’clock so they know if they want a free feed as well they’ve got to be here every Monday night at 6 on time.’

After the usual 3-month trial period, workers get the opportunity to undertake an apprenticeship with BCITO. The combination of Quentin’s rigorous training programme with visits and assessments made onsite by a BCITO Training Advisor has created a loyal and highly skilled team within Slab Specialists. ‘They’re getting paid while

being trained on the job doing a BCITO programme. At the end of it they come out with a recognised qualification which means they can earn some decent money. Our apprentices have a dedicated person on staff who helps them get through their BCITO work over and above the support they get from BCITO,’ said Quentin. ‘This helps create a good environment of professionalism and it helps them to know that they’re actually achieving something.’

Not only has taking on apprentices satisfied Quentin’s labour requirements, it also has had wider ranging benefits for the company and Quentin’s own personal development. “It makes you think yourself because you’re having to train them (the apprentices) so it keeps you on your toes and on top of the latest developments. Some of our more senior guys have huge amounts of experience but they were trained before computers.”

“What I say to our guys is if you work 9-5 and do no extra training after hours you’ll stagnate – you just won’t go anywhere. The people who make the All Blacks, they aren’t just talented, they work hard to get there and then work even harder to stay there,” says Quentin.

“Business is no different, if you’re a professional person you get paid for your labour so the All Blacks just decided to get paid for playing rugby but they put a lot of effort into always training, keeping their game sharp and as a professional builder, you need to do the same.”

If you’re an employer needing to add to your team to meet demand – contact BCITO today on 0800 422 486, they may even be able to find your new apprentice for you through their job matching service.

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AN AGGREGATE OF ASSOCIATIONS OR

SIX INTO ONE DOES GO IF OUR INDUSTRY WANTS TO PROMOTE EXCELLENCE IN ALL THINGS CONCRETE, IN AN EFFICIENT AND COST EFFECTIVE MANNER THAT REDUCES TRANSACTION COSTS AND PROVIDES BETTER VALUE FOR ALL, PERHAPS IT IS TIME TO CONSIDER A SINGLE ORGANISATION AS THE BEST WAY FORWARD. There are at least six core organisations that represent specific cement and concrete sector interests, all of whom fulfill similar roles in the industry. With people capital and financial capital increasingly limited the question has to be asked “can we do better?”

WHAT ARE THE DIFFERENCES BETWEEN EACH ASSOCIATION?

Similar questions have been asked globally, with consolidation amongst concrete related trade associations occurring as a result.

Some stakeholders and industry leaders in New Zealand are also beginning to question the effectiveness of our network.

To understand this, the key differences and similarities between the associations should be examined.

The main protagonists are the Cement and Concrete Association of NZ (CCANZ), Precast NZ (PCNZ), the NZ Ready Mixed Concrete Association (NZRMCA), the NZ Concrete Masonry Association (NZCMA), the NZ Concrete Society, and the NZ Portland Cement Association (NZPCA).

The NZ Master Concrete Placers Association (NZMCPA), the NZ Concrete Sawing and Drilling Association (NZCSDA) and the NZ Concrete Pumping Association (CPANZ) also represent the interests of their respective members in this important sector.

Whilst the associations are differentiated in terms of their target memberships, they have similar names and share a common goal in ensuring the optimum use of concrete – albeit for a defined sector.

With this number of organisations it is not surprising there is some duplication of services, as well as key personnel being stretched across several organisations.

Furthermore, each association competes for membership, sponsorship, event registrations, publication sales et al in what is a small market. Is this sustainable over time?

The status quo must be challenged, and the concrete industry associations encouraged to take up the gauntlet and work collaboratively to define a long-term and sustainable solution.

CCANZ

Concrete Society

It must be pointed out that the current arrangement has served the industry well over the years so why change?

Table 1 identifies the activities of each organisation, together with an indication of the resources allocated to each activity.

From the matrix it can be seen that all six organisations are involved in standards development and advocacy, to a lesser or greater degree.

Five are involved in research, and four in quality related activities.

Whilst four are involved in education and training, two (CCANZ and the Concrete Society) are significantly involved in this area.

It could be argued that both organisations are competing for the same event registrations from a limited pool of registrants and speakers.

Furthermore, both CCANZ and the Concrete Society offer student prizes and host award ceremonies.

History has demonstrated that both CCANZ and the Concrete Society do not have a clear differentiation of responsibilities regarding the connection of industry with academia – who speaks for industry?

CCANZ is heavily involved in the advocacy space. However, PCNZ, NZRMCA, NZCMA and even the Concrete Society have all been involved in advocacy issues as and when needed.

NZPCA

NZCMA

NZRMCA

Standards Development Education & Training Publications Awards Advocacy Research Networking Addressing Technical Issues Technical Helpline Library Services Quality Related Issues Promotion RESOURCE ALLOCATION:

= Key activity

Table 1. Activity/Weighting Matrix 24 concrete

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= Important activity

= Some resourcing provided

= Not resourced to any great extent by association

PCNZ

It is clear to see how the roles of these organisations are blurred in the minds of the wider construction sector and decision makers within government.

WHAT ARE THE DRIVERS FOR CHANGE? Merger theory1 applied to the not for profit sector would suggest that the internal drivers for change include: • the desire to provide more or better services to beneficiaries • the need to increase efficiency through better use of resources • preventing duplication of services • financial difficulties • raising public profile or boosting income • loss of key staff or trustees such as a chief executive or founder trustee • ‘survival’ and ‘rescue’ – an organisation in jeopardy merges with another with similar objectives so that its services continue.

Some of these drivers are applicable to the cement and concrete industry at this time.

Merger theory would also suggest the following external drivers for change: • pressure from funders to reduce duplication

With well over one hundred trade associations representing New Zealand’s relatively small construction market, the Ministry of Business, Innovation and Employment (MBIE) faces a similar dilemma. Clearly the regulator would prefer to speak to one sector association rather than have the same conversation with multiple organisations.

WHAT DOES THE INDUSTRY THINK? The membership of CCANZ and the Concrete Society were surveyed in July 2014 through a ‘survey monkey’ questionnaire.

This sample would have also cut through membership of the NZRMCA, the NZCMA and PCNZ. There were just over three hundred respondents, which demonstrates the level of interest in the topic. The respondents comprised a reasonable cross section of the industry although around 40% came from the consultant engineering community.

They were asked ten questions, with 1 to 5 being of a general nature and not relevant in the context of this article.

Question 6 asked whether six associations are too many. Seventy percent of respondents felt it is. (See Figure 1).

3.9%

1.8%

13.8%

ARE SIX ASSOCIATIONS TOO MANY?

28.3%

• government encouragement

Strongly agree Agree

• competition with similar organisations

Neither agree nor disagree

• stakeholder opinion

Disagree

52.2%

Strongly disagree

• public perception of an overcrowded sector • changing needs of end users.

All of these apply to the cement and concrete industry at this time.

There is also duplication of many administrative functions. Each organisation has its own governance policies, is subject to an annual audit and maintains a membership database. Transaction costs are higher than they need to be.

Furthermore, each has a website and communicates to its membership through a regular newsletter.

So while the system is not broken it could be more efficient and the efficiencies generated could be used to further support the membership of all these associations.

Figure 1. Question 6. Are six associations too many?

Question 7 asked whether the industry could be effectively and efficiently served through a single association. Again, seventy percent of respondents felt it could. (See Figure 2).

2.9%

11.6% 26.8%

Strongly agree

14.9%

Agree Neither agree nor disagree 43.8%

ARE WE ALONE IN THIS ISSUE? Interestingly, the timber industry has similar issues, and recently consolidated several bodies into the Wood Processors and Manufactures Association (WPMA). Furthermore, Roading NZ has recently merged with the Contractors Federation to form Civil Contractors NZ. So it appears this is a question facing not only the cement and concrete industry but other industries as well.

COULD THE CEMENT AND CONCRETE INDUSTRY BE MORE EFFECTIVELY AND EFFICIENTLY SERVED THROUGH A SINGLE ASSOCIATION?

Disagree Strongly disagree

Figure 2. Question 7. Could the cement and concrete industry be more effectively and efficiently served through a single association?

Question 8 enquired in what ways the cement and concrete industry would be better served through a single association.

Centralising technical and administrative expertise and delivering a unified and strong voice were seen as important areas. (See Figure 3).

AN EXTERNAL VIEW – MBIE It has gone down in modern history as one of those famous lines never actually spoken – Henry Kissinger venting his frustration with the clandestine procedures of the European Union by asking “Who do I call when I want to speak to Europe?”

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concrete 25

IN WHAT WAYS WOULD THE CEMENT AND CONCRETE INDUSTRY BE BETTER SERVED THROUGH A SINGLE ASSOCIATION?

• there are too many associations representing the cement and concrete industry

50% 40%

• most respondents were in favour of a single association

30%

• most respondents felt it important to retain the identity of sector groups, through sub-sector committees and Board representation

20% 10%

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A MOVE TOWARDS A SUSTAINABLE FUNDING MODEL

Figure 3. Question 8. In what ways would the cement and concrete industry be better served through a single association?

Question 9 asked how important it was under a single association that cement and concrete industry sectors retain their identity.

Over seventy percent felt it was either important or very important.

(See Figure 4).

UNDER A SINGLE ASSOCIATION HOW IMPORTANT IS IT THAT CEMENT AND CONCRETE INDUSTRY SECTORS RETAIN THEIR IDENTITY?

11.7% 35.5%

16.5%

Very important Moderately important Slightly important

36.3%

Not important

Figure 4. Question 9. Under a single association how important is it that cement and concrete industry sectors retain their identity?

Question 10 asked how cement and concrete industry sectors could retain their identity under a single association. The two most significant choices were sub-sector committees and sector representatives on a Board of the single organisation. (See Figures 4 and 5 respectively).

50% 40% 30% 20% 10%

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CCANZ is a case in point. Any organisation that relies on just one predominant source of funding (in this case the NZ Portland Cement Association) is exposed. This situation is related to the dynamics of New Zealand’s cement sector, which has changed considerably since CCANZ was established in 1988.

Whilst an internal study into the value of CCANZ determined that for every $1M invested in the Association, $24M of industry value is generated, the future of CCANZ remains unclear.

At the same time, the Concrete Society’s reserves are currently healthy through the prudent fiscal management of its Council.

Seminars run by the Concrete Society have been highly successful.

Together with income from the concrete industry conference, the Society has accumulated a reasonable level of equity in recent years.

If CCANZ disappears, a void will be created, and the Concrete Society is likely to be the only organisation that could undertake some of CCANZ’s current activities. It would, however, have to scale up significantly, undertaking roles beyond its original charter.

The benefit to the industry generated by CCANZ over the past 26 years could easily be lost.

Concrete production and construction relies heavily on up-todate Standards, and there are 26 Standards which are directly relevant to the cement and concrete industry, 23 of which rely directly on industry for ongoing support. It is the cement and concrete industry’s intention therefore to establish a concretefocused Standards Development Organisation (SDO) to maintain and develop the current suite of cement and concrete related Standards.

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One reason often cited for non-profit mergers is a dependency on a limited number of funding streams, which increases vulnerability to environmental changes.

The new Standards model under MBIE is unlikely to have the capability to maintain and update the 650 or so construction related Standards. MBIE will doubtless be receptive to initiatives that assist in this regard.

HOW COULD CEMENT AND CONCRETE INDUSTRY SECTORS RETAIN THEIR IDENTITY UNDER A SINGLE ASSOCIATION?

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• some respondents were concerned about losing the independence of the Concrete Society.

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Se

Whilst the authors acknowledge that this was a somewhat simplistic exercise, the following conclusions are tentatively drawn:

Figure 5. Question 10. How could cement and concrete industry sectors retain their identity under a single association?

Over a hundred specific comments were recorded. Over sixty percent were positive in terms of industry association integration.

Most negativity centred on preserving the identity and independence of the Concrete Society.

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EXEMPLAR MODELS OF INTEGRATION • New Zealand Motor Trade Association

The New Zealand Motor Trade Association (MTA) is made up of a number of sub-sectors such as alternative fuels, autorepairers, service stations, electrical, panel beaters, auto body repairers et al. They operate as specialist and ad-hoc committees reporting through to the Board, supported by a national office.

• South Africa – Consolidution2

In South Africa the Concrete Society is pursuing a merger with the Concrete Institute. Writing in the September 2013 edition of the South African publication SAICE , Concrete Society chief executive, John Sheath posits:

“If we really want to promote excellence in concrete in a meaningful and effective way, then it has to be driven through a single organisation, with one congruent voice driving the promotion, training, innovation, research and quality of concrete, whether it be site-mixed, precast or readymix.”

He further goes on to say “What is needed is a concrete consolidation solution, or ’CONSOLIDUTION’. I appeal to other concrete-related organisations to work together and take up the challenge to find the long-term solution.”

Such an association would have one consistent voice driving advocacy, education, training, information exchange, research and quality assurance, whilst serving engineers, architects and anyone with an interest in concrete.

At the same time, the interests of individual sectors (ready mixed, precast, masonry et al) could be effectively served by committees.

Individual sectors would retain their identity and have a Board seat.

In the model proposed, the Concrete Society would be retained as the professional wing of the new association and would have responsibility for matters of training, education and research.

Members

Board

Sheath’s ideology resonates in a New Zealand context but is arguably amplified as there are more cement and concrete related industry associations competing in a smaller market.

Concrete Institute or similar

GAPS IN OUR THINKING There are clearly some barriers to the introduction of a new model.

There are complexities around fee structure and membership base, which will have to be overcome. Some organisations have a corporate membership structure: some based on individuals and some a combination.

The independence of the Concrete Society as a technical society is seen by some as a non-negotiable item. Whilst the authors are cognisant of this it could be questioned why this is so important.

Notwithstanding this, there are models of organisations within organisations that are seen as independent. In a group structure, a parent organisation governs a group of subsidiary organisations which retain their own legal identities. The relationship may continue indefinitely or may be an interim stage prior to full merger.

Alternately there are current working models where a group of organisations which retain their own legal identity are members (or shareholders) of a single association which represents the group’s interest.

Some associations who are supportive of single association, at least in principle, feel there should be change in name to herald a new dawn.

A NEW PARADIGM? A somewhat simplistic potential new model is shown in Figure 6. In essence, each sector retains its identity through sector committees. Each sector would have Board representation.

The Concrete Society would retain its identity and become the professional wing of the organisation, responsible for education, training, seminars and conference.

The work of the sector committees and the Concrete Society would receive administrative support from the new entity’s national office.

SECURING THE FUTURE — ONE ORGANISATION, ONE VOICE If the industry wants to promote excellence in all things concrete, in an efficient and cost effective manner that reduces transaction costs and provides better value for all, the way forward appears to be a single association.

Sector Committees Ready Mixed Concrete

Precast

Masonry

Technical Committee

Specialist Committees

Cement

Concrete Society

SDO

National Office

Training Education Seminars Conference

Technical Committee Industry

Professional

Secretariat support and administration

Figure 6. Potential Organigram for Single Entity

CONCLUSIONS There are too many associations serving New Zealand’s construction industry. Each association competes for membership, sponsorship, event registrations, publication sales et al in what is a small market. Is this sustainable over time and does this provide the sectors they serve with the best level of support and services?

The case for consolidation of the cement and concrete related industry associations is compelling. If the survey recently conducted is representative of the cement and concrete industry’s stakeholders there is considerable support for consolidation.

It is likely a move to a consolidated structure would inevitably eventuate to fill the void if CCANZ disappears.

Whilst this proposal will be a surprise to some, there are a number of organisations that do similar roles in the industry, and resources (human and financial capital) are limited, so can we do better?

Concrete related industry associations must seize the opportunity and work collaboratively to define a long-term and sustainable solution to support the concrete industry.

In the words of John F. Kennedy “change is the law of life, and those who look only to the past or present are certain to miss the future.”

1. Wilder Research (March 2011). What do we know about non-profit mergers? Findings from a literature review, focus group, and key informant interview. Retrieved from http://www.mapfornonprofits. org/wp-content/uploads/2013/10/What-do-we-know-about-nonprofitmergers.pdf 2. Sheath, John. (September 2013). Concrete organisations need a ‘consolidution’. Civil Engineering, 21(8), 5-6.

This article was based on the 2014 NZ Concrete Conference paper of the same name, written by Rob Gaimster (CCANZ), Bob Officer (NZRMCA) and Carl Ashby (NZCS). The paper won the Sandy Cormack Award for best conference paper.

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CCANZ STRUCTURAL ENGINEER ALISTAIR RUSSELL LOOKS AT WHAT NEEDS TO BE TAKEN INTO ACCOUNT WHEN CONCRETING IN COLD WEATHER

COLD WEATHER CONCRETE – WHAT TO CONSIDER? WITH WINTER APPROACHING IT IS A GOOD TIME TO REVISIT ADVICE PREVIOUSLY PUBLISHED IN CONCRETE AND THINK ABOUT THE EXTRA CARE REQUIRED FOR PLACING CONCRETE IN THE COLD. We are fortunate in New Zealand to live in a moderate temperature environment, but in many places morning frosts during winter are common, although these are usually followed by a sunny day.

So with winter upon us, it’s worth refreshing our memories about some of the issues associated with winter concreting. NZS 3109 Concrete Construction provides a definition of unfavourable cold conditions when concrete shall not be placed.

These are: • When the ground is frozen • At temperatures below 5ºC with temperature descending • At temperatures below 2ºC with temperature ascending

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So what is the reasoning behind the above temperature limitations? Let’s first consider what happens to concrete at 0ºC. If concrete is frozen before it sets, the hydration of the cement is suspended, partly because the water within the mix freezes and expands, preventing the reaction from continuing. If the temperature is raised, and the concrete vibrated to remove the pores created by the ice, the cement hydration should continue, producing satisfactory concrete. This only remains true if the concrete is re-vibrated after the ice has thawed.

However, if the concrete has set but not reached sufficient strength, freezing can result in internal cracking and loss of strength. If the freezing only occurs on the surface, it may result in delamination of the top surface. After concrete has attained a strength of approximately 3.5 MPa, it is usually considered to have sufficient strength to resist a freeze thaw cycle.

The requirements of NZS 3109 are there to give some protection against potential freezing of the concrete before it has attained sufficient strength. As a specifier or placer of concrete, what can you do to ensure a fit-for-purpose project in the cold winter months? The best solution is to understand the fundamental principles of concreting in the cold so that the most appropriate solution can be applied to your project. The following are some general comments that are worth considering.

NEVER PLACE CONCRETE ON FROZEN GROUND In New Zealand it should be possible to wait until the ground temperate rises, or the ground can be protected overnight with straw or a similar material to prevent freezing.

USE AIR-ENTRAINED CONCRETE The advantage of air entrainment is that it gives the concrete superior freeze/thaw resistance when it has reached sufficient strength. The concrete will still, however, need to be protected from freezing until it reaches at least 3.5 MPa. CONSIDER THE USE OF SET ACCELERATORS, AND/OR HE CEMENT These will decrease the time to final set, meaning the concrete can be finished and potentially protected earlier. When the concrete is reinforced, it is recommended that non-chloride accelerators are used. Be aware that accelerators have limited effectiveness when mix temperatures are below 5-8ยบC. Also be aware that overdosing with some set accelerators can in fact retard set, so ensure that the dose rate is that recommended by the admixture manufacturer.

There is a tendency in some areas to add set accelerators simply because it is winter rather than based on the expected temperatures during placing and finishing. We can get very warm, low-humidity days in winter. The indiscriminate use of accelerators can lead to problems with premature setting or plastic cracking.

PROTECT THE FRESHLY PLACED CONCRETE In winter, there can be large changes in the ambient day and night temperatures. This can lead to restrained early thermal contraction. The use of early entry saw cuts, or tooled joints, can prevent the formation of ugly random cracking. I have also seen cracking in winter that suggests that the top surface has chilled relative to the body of the concrete, resulting in surface random cracking. Although the insulation value of polythene is negligible,

I suspect that covering with polythene can minimise the wind chill effect and prevent this type of cracking. If freezing conditions are expected and the concrete is unlikely to have attained a strength of 3.5 MPa, insulate the concrete.

PREVENT THERMAL SHOCK If the temperatures are cold and the concrete warm, there is a risk that the removal of formwork can result in surface cracking. (A temperature differential of 20ยบC or more is commonly quoted as the temperature differential at which this phenomenon can occur.)

Always follow the minimum formwork stripping times specified in NZS 3109.

USE WARM MATERIALS TO MAKE THE CONCRETE The use of hot water and aggregates that have been stored in bins can mean that the concrete mix temperature is elevated, resulting in a faster setting time. Talk to your local ready-mixed concrete supplier for options that are practical in your area. Never use water above 70ยบC, and be aware of the safety requirements of using hot water on a construction site.

DO NOT USE UNVENTILATED HEATERS The CO2 given off by some heaters can react with the concrete surface, producing a dusty, weak surface. Always make sure the exhaust gases are ventilated, and do not aim the burner directly at the concrete.

With some simple precautions, it is relatively easy to obtain highquality concrete all year round.

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CCANZ LIBRARY LISTED BELOW IS A SMALL SELECTION OF RECENTLY ACQUIRED MATERIAL BY THE CCANZ LIBRARY. EMAIL LIBRARY@CCANZ.ORG.NZ TO BORROW. ACCELERATED BRIDGE CONSTRUCTION: EXPERIENCE IN DESIGN, FABRICATION AND ERECTION OF PREFABRICATED BRIDGE ELEMENTS AND SYSTEMS

BY U.S. DEPARTMENT OF TRANSPORTATION & FEDERAL HIGHWAY ADMINISTRATION

APARTMENT DESIGN GUIDE

This manual represents the “State of the Practice” with respect to all aspects of accelerated bridge construction (ABC). It covers ABC techniques, project planning and scoping, implementing ABC in a Transportation Agency, prefabricated elements, long-term performance of prefabricated elements, construction and design. The manual can be used by transportation agencies to establish a successful accelerated bridge construction program.

IMPROVING CONCRETE QUALITY BY KARTHIKEYAN H. OBLA Many concrete manufacturers neglect to quantify not only the cost of producing poor quality concrete, but the potential savings in the reduction of cementitious content by focusing on standard deviation and tightening controls, particularly with regards to slump control and moisture contents – this book identifies key areas that manufacturers can focus on to improve and realize these savings.

LIBRARY QUIZ To go in the draw to win a copy of Improving Concrete Quality by Karthikeyan H. Obla answer the following simple question: When was the original reinforced concrete wharf constructed at Clyde Quay in Wellington?

The CCANZ Apartment Design Guide sets out key considerations, and provides recommendations on size, daylight and interior climate requirements, along with effective soundproofing and fire protection.

Email admin@ccanz.org.nz to request your FREE copy of the Apartment Design Guide

Email your answer to library@ccanz.org.nz. Entries close Friday 12 June 2015.

Congratulations to Hannah Sharp of Sills van Bohemen Architects Ltd, who correctly answered the Vol 57 Iss 3/4 Library Quiz to receive a copy of Sustainable Concrete Solutions by Costas Georgopoulos and Andrew Minson.

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www.ccanz.org.nz

NEWS FROM THE ASSOCIATIONS CONTACTS New Zealand Ready Mixed Concrete Association Ph (04) 499 0041 Fax (04) 499 7760 Executive Officer: Adam Leach President: Brian Godfrey www.nzrmca.org.nz New Zealand Concrete Masonry Association Ph (04) 499 8820 Fax (04) 499 7760 Executive Officer: David Barnard President: Mario Fontinha www.nzcma.org.nz Precast NZ Inc. Ph (09) 638 9416 Fax (09) 638 9407 Executive Director: Rod Fulford President: Russell Bennetto www.precastnz.org.nz New Zealand Concrete Society Ph (09) 536 5410 Fax (09) 536 5442 Email: concrete@bluepacificevents.com Secretary/Manager: Allan Bluett President: Carl Ashby www.concretesociety.org.nz New Zealand Master Concrete Placers Association Ph (027) 531 9940 Email: nzmcpa@gmail.com Secretary: Ngaire Riddell President: Rob Buckeridge www.mcpa.org.nz

NEW ZEALAND CONCRETE SOCIETY (NZCS) CALL FOR CONFERENCE PAPERS NOW OPEN The call for papers is open for the Concrete Industry Conference being held from 8-10 October in Rotorua, a thermal wonderland that offers exciting entertainment and activities.

As the conference will coincide with school holidays, it presents an opportunity for delegates to enjoy a family holiday either before or after the conference. The Conference Organising Committee is compiling a varied and appealing partners’ programme.

The conference, at the Rotorua Convention Centre, will follow the traditional and popular format – three half days (Thursday, Friday and Saturday) with social activities on Friday afternoon. Thursday will be party night, with the formal conference dinner and awards presented on the Friday evening.

Conference papers can cover all aspects of concrete construction and associated technologies and can discuss research, design trends, marketing opportunities, recent developments, construction, materials, methodologies and new issues for cement and concrete.

Submissions to the Conference Secretary must include a 300-word synopsis of the paper, a short career history and a written commitment to attend and present the paper at the conference if the paper is accepted. Six to ten-page papers are required and will be published in the conference proceedings.

Deadlines: • Preliminary acceptance of papers • Receipt of papers

14 April 2015 31 July 2015

All accepted papers will be eligible for the NZCS’s Sandy Cormack Award; the author judged to have presented the best paper at the conference will receive $1,000 and a certificate.

The Conference is being jointly organised by Cement & Concrete Association of NZ, the NZ Concrete Masonry Association, the NZ Concrete Society, the NZ Ready Mixed Concrete Association and Precast New Zealand Inc. For more information, go to http://www.theconcreteconference.co.nz/ which will feature additional conference activities as they are confirmed.

COLLINS CONFIRMED AS KEYNOTE SPEAKER Professor Michael Collins, a New Zealand engineer who has earned international recognition and is an award-winning teacher, has agreed to be the 2015 keynote speaker at the Concrete Industry Conference.

Many NZCS members met him last July when he was in New Zealand to present a nationwide series of workshops titled Shear design and evaluation of concrete structures as part of the Society’s 50th anniversary celebrations.

Professor Michael Collins

Professor of Civil Engineering at the University of Toronto, he has made outstanding contributions to the field of structural engineering as an educator, researcher and consulting engineer. His teaching acumen has won him many awards while his analytical and experimental research contributions on the shear behaviour of reinforced concrete and particularly his Modified Compression Field Theory have received international recognition and been incorporated into the design specifications of Canadian, American and European Standards.

He has authored, co-authored and contributed to a number of books. His consulting experience includes work on concrete offshore platforms, high-rise buildings, bridges, dams and industrial facilities, plus he has worked on failure investigations.

On the basis of his “exceptional contributions to Canadian intellectual life”, he is an elected Fellow of the Canadian Academy of Engineering, the Royal Society of Canada and The Engineering Institute of Canada. For his research on shear, he was awarded Honorary Membership (the Institute’s highest honour). Professor Collins also has five best-paper awards from the American Concrete Institute.

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