Construction Engineering Australia V3.04 Aug/Sept 2017 by EPC Media Group

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BRIDGING THE GAP BETWEEN CONSTRUCTION AND THE CIRCULAR ECONOMY

Keynote Speakers Professor Tim Ibell

Professor Karen Scrivener

Ms Louise Adams

Mr Peter McBean

Professor Doug Hooton

Professor Des Bull

Invited Speakers Dr Stuart Matthews

Mr Mike Schneider

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AUG/SEPT 2017 Volume 3 Number4

10 Cover Feature: ResourceCo

14 Product Focus 16 Fibre Reinforcement 22 Equipment Special 26 Project Focus: Solar Playground 28 ACRS Feature

30 Concrete Institute News 36 Acoustic Design 38 Equipment Focus

40 National Precast Feature 48 IPWEA NSW News 53 ACA Corrosion Feature

CIRCULATION 15105 Registered by Australia Post Publication No. 100001889

ISSN 2204-7247

About the Cover ResourceCo’s focus on ‘closing the loop’ on C&D waste streams - together with its work in the fields of site remediation, waste-to-energy and the production of high quality recycled aggregates for concrete construction and asphalt pavements - has played a major role in bridging the gap between construction and the circular economy throughout Australia and beyond. Turn to Page 10 for the full story.

EDITORS COLUMN

Finding Opportunity from Adversity

Combining urban security with a boost for the arts Dear Readers, It’s a sad fact that the spate of horrendous vehicle-based terrorist attacks that have plagued many of the world’s cities in recent times – together with the murderous vehicular rampage that occurred in Melbourne in January this year – have caused governments and authorities around the world to rethink the design of their cities and public facilities. Where we once praised an abundance of open space, pedestrianized areas, ‘vehicle-free’ precincts and built environments which incorporate a sense of ‘urban oasis’ and community, many are now viewing these public spaces as potential ‘problem areas’. Hardly surprising perhaps, when one considers the apparent ease with which some of the vehicle-based attacks occurred. It is also understandable, that in the aftermath of these attacks we have seen the rapid deployment of an array of ‘preventative’ measures – mostly in the form of blocks, bollards and barrier devices. Indeed, in Australia alone, over the past few months we have seen the rapid deployment of literally thousands of concrete blocks, steel bollards, fences and other barrier devices in pedestrian precincts and around major sporting and entertainment venues across the country. While for the most part these devices have provided an effective short-term response, few would argue that in the majority of instances, these devices are having a significant negative impact on the overall aesthetic and appearance of the surrounding areas. What’s more, in some areas (such as along Melbourne’s CBD and Southbank Precinct) this negative aesthetic impact has been 2

Construction Engineering Australia • Aug/Sept 2017

further exacerbated by the unwanted addition of inappropriate, and in some instances, highly offensive graffiti. Unfortunately, one of the other major issues with these ‘security’ installations is that they provide a stark reminder of the measures that have to be put in place to minimise the risk of further attacks. While it’s clear that doing nothing to minimise the risk of further vehiclebased attacks is not an option, I believe it’s also clear these measures cannot be considered as a permanent solution – lest we surrender our cities and public facilities to a permanent underlying ‘fear of attack’. That is, after all, the primary motive of those who would perpetrate these heinous crimes… to limit freedoms and create a culture of fear. I feel certain that I am with the majority of Australians in wishing that these types of attacks had never occurred anywhere. And I for one, would not wish the pain and anguish caused by these attacks on anyone. However, wishing that something was not so, will not undo what has been done and in the cold, hard light of day, this is the world we live in. Now, without wishing to be in any way, shape or form glib or disrespectful, I also believe that we must try and find a way to deal with the underlying security and public safety issues, without transforming our urban environment and public facilities into something resembling a demilitarised zone littered with ugly concrete blocks, chain mesh fences and endless rows of bollards. In short, we need to find some form of opportunity from this horrible adversity. With that in mind, I believe that we can transform this need for additional security measures into possibly the

largest-ever investment in sculptural public art that Australia has ever seen. And I’m not suggesting that we provide one or two well-known or renowned artists with couple of multi-million dollar commissions – in fact, I’m suggesting exactly the opposite. Australia is home (and always has been home) to a vibrant and active arts community. From indigenous art, to street art, contemporary art to traditional art, students to masters, Australia has an abundance of artists. What’s more, with arts funding being what it is, many of our artists never get the opportunity to develop and produce as many pieces as they’d like, or for that matter, display them publicly. While this is clearly not the path that anyone would have chosen to boost public art, we must make the best of the hand that we’ve been dealt. Let’s turn this adversity into an opportunity – an opportunity to give much need boost to arts funding; an opportunity to provide new and emerging artists with a chance to develop public commissions; an opportunity to enhance our cityscapes with an abundance of sculptural art; and the opportunity to bolster public security without succumbing to a ‘siege mentality’. After all, using art to make our cities even more enjoyable would be diametrically opposed to the original intentions of the perpetrators of these horrendous crimes.

Anthony T Schmidt Managing Editor

INDUSTRY NEWS

ABOUT CIAT

INTERNATIONAL COOPERATION: CIAT AND BDAV SIGN COLLABORATIVE ARRANGEMENT The global reach of Architectural Technology/Building Design has been further extended following the signing of a Collaborative Arrangement between the Chartered Institute of Architectural Technologists (CIAT) and the Building Designers Association of Victoria (BDAV). The Arrangement provides for collaboration on matters relating to Architectural Technology and Building Design and allows the two organisations to share relevant information, knowledge and best practice for the betterment of professionals, the built environment and the wider society. The areas of collaboration include sharing expertise and fostering professionalism regarding education, practice, technical and certification activities and performance

standards, and working together to foster cooperation within allied professional bodies, government authorities and others. Speaking of the collaboration, Gary Mees, President of CIAT said: “The Arrangement demonstrates the implementation of CIAT’s vision for the global reach of Architectural Technology and the Institute’s aim to align, collaborate and partner with innovative bodies such as BDAV.” “The importance, value and impact of Architectural Technology and of its kindred discipline, Building Design, are critical to ensuring that projects are realised efficiently and effectively, with the performance of buildings relating to function and form optimised,” Gary Mees added.

The Chartered Institute of Architectural Technologists (CIAT) is the lead qualifying body for Architectural Technology and represents those practising and studying within the discipline. CIAT qualifies Chartered Architectural Technologists, MCIAT, and professionally qualified Architectural Technicians, TCIAT.

ABOUT BDAV BDAV is the peak industry body for building design professionals in Victoria, Australia. BDAV represents building designers, draftspersons, interior designers, service designers, architects, town planners, builders, surveyors and energy assessors.

BDAV President, Lindsay Douglas said: “BDAV is one of Australia's lead bodies for building design professionals and we are excited to share knowledge, expertise and best practice in our field with a progressive, like-minded organisation such as CIAT.” “We are confident this Collaborative Arrangement will better serve the needs of all members, and advance the practice and profession of Building Design and Architectural Technology in our countries in years to come,” he concluded.

HELPING COUNCILS TO SAVE MONEY ON ‘SMART CITY’ STREET LIGHTING PROJECTS The Institute of Public Works Engineering Australasia (IPWEA), the peak body that advises local, state and federal governments on best practice engineering, has released the long-awaited Model LED Public Lighting Specification and its companion, the Model Public Lighting Controls Specification. IPWEA CEO Robert Fuller said the Model Specifications will remove the uncertainty around street lighting procurement, which has resulted in impediments, inefficiencies and cost overruns from poorly drafted and often technically inconsistent specifications. “These new specifications will be a ‘game changer’ for accelerating the rollout of LED lighting and smart controls across Australia and New Zealand, helping all parties successfully navigate the maze of new lighting technology,” Mr Fuller said. LED and smart controlled public lighting technologies have advanced greatly in recent times and provide many features and advantages for improving amenity, safety, environmental and financial outcomes for communities. IPWEA modelling shows that if every street light in Australia and New Zealand were converted to LEDs, councils would 4

Construction Engineering Australia • Aug/Sept 2017

slash $120 million off their annual street lighting bills. However, the features that provide these benefits also add complexity to the specification and procurement process, making the process difficult for all parties involved. Currently, only 10% of Australia and New Zealand's street lights have been converted to LEDs. Mr Fuller added: “Early LED specifications often resulted in inefficient procurement processes that were costly for suppliers to respond to, raised the risks of inappropriate or poorly performing outcomes for buyers, and often resulted in less than fit for purpose outcomes. “Overall, this inefficient process has impeded the timely uptake of LEDs and controls for public lighting despite the many demonstrated advantages they provide.” The Model Specifications provide an informative, structured template that is focused on the technical aspects for local governments, main road authorities and electricity distribution utilities, allowing them to prepare their own customised specifications within a structured public tender.

There has been exhaustive Australian and international input into the specifications to ensure they reflect industry best practice. “The peer review of the specifications has been so overwhelming positive that we have already had requests to trial these on projects in Europe,” Mr Fuller said. The Model Specifications are part of the Street Lighting and Smart Controls Programme (SLSC) which has been funded by the Australian Federal Government, Department of the Environment and Energy, to improve energy, environmental, economic and social outcomes. The specifications – which have already been downloaded more than 1,000 times since their release – can be downloaded from the SLSC website (www.slsc.org.au or www.slsc.org.nz) and are being supported by free industry webinars.

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INDUSTRY NEWS

CHANGES TO GREEN STAR SET THE SCENE FOR CARBON ZERO BUILDINGS In its latest updates to Green Star, the Green Building Council of Australia (GBCA) sends a signal to the market: carbon zero buildings are coming. After a lengthy industry consultation period, the GBCA has released new versions of the Green Star – Design & As Built and Green Star – Interiors rating tools which promise to drive the uptake of low-carbon buildings, incentivise new industries and challenge the market leaders to innovate. Among the key changes to Green Star, are: • minimum requirements for greenhouse gas emissions for 5 and 6 Star Green Star buildings • measures to build industry capacity in air-tightness testing • a new materials pathway to incentivise the use of sustainably-sourced structural timber and • new requirements to enhance the health and wellbeing of construction workers. “While some of these changes are small, they will continue to build capacity and drive innovation in sustainable design and construction,” says the GBCA’s Head of Market Transformation, Jorge Chapa.

Minimum requirements for greenhouse gas emissions A project with 5 Star Green Star certification is now required to achieve three Green Star points in the ‘Greenhouse Gas Emissions’ credit, and be 25 per cent more efficient than a benchmark building. A 6 Star Green Star building must achieve a minimum of six points and demonstrate efficiency of almost 40 per cent above the benchmark. “Our analysis has found that 95 per cent of Green Star-certified projects meet these criteria, so it’s not a big change at the moment. However, it sends a signal to the market that we are prioritising carbon. We expect to strengthen these requirements further over time,” Mr Chapa says.

Air-tightness testing Changes to the ‘Commissioning and Tuning’ credit have been made to accelerate the uptake of air-tightness testing. A new ‘Air Permeability 6

Construction Engineering Australia • Aug/Sept 2017

Performance Testing’ requirement is now part of a core component of the credit, contributing to the achievement of two points. “This is about building industry capacity and educating project teams about the value of air-tightness testing,” Mr Chapa explains.

Structural timber A new ‘prescriptive pathway’ for the use of structural timber aims to incentivise the material’s use. While the initial intention was to recognise engineered timber, such as Cross-Laminated Timber and glulam, after seeking industry feedback the scope of the credit was expanded to include all sustainably-sourced structural timber. “We have always recognised the use of sustainably-sourced structural timber, but until now project teams needed to undertake a full lifecycle analysis to achieve Green Star points. This change makes it easier for project teams to gain points using responsibly-sourced timber, just the way we encourage the use of sustainable concrete and steel.”

Enhancing the workplaces of construction workers The ‘Construction Environmental Management’ credit has been renamed ‘Responsible Construction Practices’, with a new point available for project teams that can demonstrate high quality staff support through health and wellbeing programs. “Research has found the mental health of employees on construction sites does not meet that of other industries. This change to Green Star is about recognising that a building is not truly sustainable if it doesn’t look after the workers who constructed it,” Mr Chapa says. Other small changes are being made to Green Star. New Innovation Challenges on Carbon Neutrality will be introduced in the coming weeks, while others are being rolled into existing credits; and loop holes are being removed that enable double counting. Registrations under the legacy versions of the rating tools will be accepted until 30 September, after which time all projects will be registered under Green Star – Design & As Built v1.2 and Green Star – Interiors v1.2.

Project teams working with legacy tools will be able to upgrade their Green Star submission on a credit-by-credit basis. “As Green Star evolves, we continue to look for new ways to collaborate with the industry to find sustainable solutions. While we won’t compromise on the integrity of the rating system, we are flexible in how we work with project teams to get the best outcomes for industry and the environment,” Mr Chapa concludes. About the Green Building Council of Australia The Green Building Council of Australia (GBCA) is the nation’s authority on sustainable buildings and communities. The GBCA’s mission is to accelerate the transformation of Australia’s built environment into one that is healthy, liveable, productive, resilient and sustainable. The GBCA works with industry and government to encourage policies and programs that support its mission. The Council educates thousands of people each year on how to design and deliver sustainable outcomes for Australia’s buildings and communities. And it operates Australia’s only national, voluntary, holistic rating system for sustainable buildings and communities – Green Star. For further information, please visit: www.gbca.org.au

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INDUSTRY NEWS

NEW PLAN FOR SOUTHBANK UNVEILED The City of Melbourne has unveiled artist’s impressions and a video of its $35 million plan to create new public open space in Melbourne’s most densely populated suburb. Melbourne Lord Mayor Robert Doyle AC unveiled the plans to create 2.5 hectares of new public open space on Southbank Boulevard and Dodds Street as part of the recent Eco City World Summit 2017 event. “In Melbourne and in other cities around the world, governments are looking to turn underutilised roads and car parks into important green space,” the Lord Mayor said. “The new public open spaces and neighbourhood parks we’re creating in Southbank will improve public amenity for the 20,000 residents and 50,000 office workers in the city’s most densely populated suburb. “The new public space planned for the front of the ABC alone would be roughly the same size as the City Square. Dodds Street will be remade into a public space that can cater for everything from street

performances to farmers markets and medium scale music festivals at the doorstep of the Victorian College of the Arts.” The Draft Concept Plan includes 10 key actions with a three-stage construction plan that will see the project completed in 2020. Key aspects include: • 1.05 km of dedicated, separated bicycle lanes • Water sensitive urban design and flood mitigation • Upgraded tram and bus stops, including the potential for ‘green’ tram tracks • Improved biodiversity through extensive planting and a new generation of diverse trees with seasonal variation and yearround interest • A critical neighbourhood space for Southbank. Chair of the City of Melbourne’s Environment Portfolio Cr Cathy Oke said the project is part of an ongoing urban design program that has seen more than 80 hectares of underutilised asphalt and other infrastructure transformed into public open

space over the last 30 years. “Converting grey to green supports the City of Melbourne’s strategies for managing the urban forest, climate change, water, biodiversity and wellbeing,” Cr Oke said. “Green spaces reduce stormwater volumes, reduce the impact of development on ecosystems, increase biodiversity, provide habitats for wildlife, keep our soil moist and reduce the urban heat island effect.” The reconfigured Southbank Boulevard will continue to accommodate current traffic volumes. In 1988, Southbank Boulevard carried 40,000 to 50,000 vehicles a day. The boulevard now carries 13,000 vehicles a day after direct access to the central city was closed following the construction of Queensbridge Square in 2001. The new open space will support the increased residential population in Southbank, which is forecast to rise by 175 per cent over the next 15 years.

TWO POWERFUL INFLUENCES IN INDUSTRY JOIN TO HELP BUILD AUSTRALIA’S FUTURE A new partnership between the Australian Made Campaign and Master Builders Australia aims to boost exports and the use of locally made products by the building and construction sectors. The initiative will encourage building and construction firms to source Australianmade goods and assist local businesses in marketing their products and services to export markets. Australian Made Campaign Chief Executive, Ian Harrison, said Australianmade often translated to better quality and durability. “Australia’s extremely stringent quality and safety manufacturing standards have helped establish our reputation for wellmade products, that last,” Mr Harrison said. Recently released Roy Morgan research* found 75 per cent of Australians preference Australian-made building and construction goods, making local content an important selling factor for businesses. “Manufacturers and developers promoting goods as genuinely Australian should

Construction Engineering Australia • Aug/Sept 2017

leverage country-of-origin branding whenever possible,” Mr Harrison said. “Research shows the Australian Made logo is recognised by 99 per cent of Australians, and has been found to increase sales in export markets as well, so it should form an important part of any marketing strategy. As a registered certification trade mark it defends the authenticity of Australian goods.” Master Builders Australia Chief Executive, Denita Wawn, said the organisation was proud to be working with the Australian Made Campaign. “Formalising the longstanding relationship between Master Builders Australia and the

Australian Made Campaign demonstrates our commitment to local industry. This initiative will greatly benefit Australian manufacturers and the broader building and construction industries,” Ms Wawn said. The Australian Made logo will be central to the branding of Master Builders Australia trade missions and exhibitions to be carried out in 2017/18. Master Builders Australia has opened its Export Diagnostic Program to businesses keen to participate in the export promotions. The Program assists companies in determining whether they have the right tools in place to be successful overseas, and aids in the development of export strategies. “Leveraging Australia’s excellent reputation via events like these can help grow market share abroad, making businesses far more import-resistant,” Ms Wawn said. To find out more about Master Builders Australia’s Export Diagnostic Program and all upcoming events, visit www.masterbuilders.com.au.

WHAT YOU THINK IS THE END IS JUST THE BEGINNING.

Here at ResourceCo, we believe there’s no such thing as waste. It can almost always be recycled, reused or reduced to protect the earth’s limited resources. If you have a waste problem, we’ll take it away, then bring it back as something better. Construction & Demolition Materials Recycling Alternative Fuels & Carbon Abatement Transport & Logistics Solutions Asphalt Recycling Concrete Recycling Bulk & Engineered Fill Supply Fixed & Mobile Pre-mixed Concrete Batching Commercial & Industrial Materials Recycling Aggregate, Screenings & Asphalt Based Product Supply Disposal, Treatment & Management of Waste Soils Mine and Quarry Rehabilitation Management of Project Specific waste Tyre and Conveyor Belt Recycling Renewable Energy Carbon Abatement Sales & Auditing End of Life Landfill

Call 1300 696 733 or visit resourceco.com.au

TOMORROW’S SOLUTIONS. TODAY

COVER FEATURE

Bridging the gap between CONSTRUCTION and the

CIRCULAR ECONOMY

stablished in 1993, ResourceCo has been leading the way in Construction and Demolition (C&D) materials recycling for almost 25 years. Indeed, ResourceCo’s focus on ‘closing the loop’ on C&D waste streams - together with its work in the fields of site remediation, waste-to-energy and the production of high quality recycled aggregates for concrete construction and asphalt pavements - has played a major role in bridging the gap between construction and the circular economy throughout Australia and beyond. A far cry from its relatively humble beginnings in Adelaide as a mobile crushing business for concrete and construction materials, ResourceCo has grown to a company employing more than 400 staff, operating from 21 locations in three countries, including locations in five Australian states, Singapore and Malaysia.

Construction Engineering Australia • February 2017

Through expansion, acquisitions and the development of new businesses, ResourceCo has gained an enviable reputation for excellence. It is recognised locally and internationally both for its own work, and for its successful long-term joint venture partnerships with multi-national environmental specialists SUEZ (through SUEZ Australia) and global cementindustry leader Lafarge, and in Australia with Adelaide Brighton Cement. ResourceCo Managing Director, Simon Brown, commented: “From the outset, ResourceCo’s primary goal has been to recycle, re-use and re-manufacture traditionally disposed of materials into higher value end products.” “We recognised that we needed to be smarter about how we use the earth’s limited resources, and that we can no longer simply discard materials just because they’ve been used before. We did not accept that the price of economic

growth was environmental damage – or that we had limitless supplies of energy or raw materials.” “With that in mind, we focused on finding smarter, better ways of using what we have and finding viable alternatives to disposal. Through constant investment in research and development we continue to develop new and innovative technologies that can efficiently transform recovered materials into usable products,” he said. ResourceCo currently processes over 2 million tonnes of materials annually, recycling in excess of 95% of all incoming materials. “Our ultimate goal is to achieve a ‘zero waste’ solution,” Simon Brown added. “We don’t see recycling as merely a business, but as an essential for the sustainability of our planet, our economy and our future.”

COVER FEATURE

QUALITY – THE KEY TO SUCCESS Needless to say, one of the keys to the company’s outstanding success and growth is its focus on quality - in terms of both processes and products. Together with its strict quality control and production procedures under its accreditations to ISO 9001 (Quality Management System), ISO14001 (Environmental Management) & AS4801 (Occupation Health and Safety Management System), ResourceCo’s products are manufactured and tested to ensure that they meet the requirements of all appropriate Australian Standards. Eddy Crosato, Divisional Manager, ResourceCo Concrete Division, commented: “As is the case with any construction materials, when it comes to recycled products, quality and consistency is of paramount importance. We need to be sure that every product we produce complies fully with all relevant Australian Standards.”

SA’s LARGEST RECYCLER OF C&D WASTE ResourceCo operates permanent processing facilities at Lonsdale and Wingfield and is South Australia’s largest recycler of construction and demolition waste, producing over 500,000 tonnes of recycled aggregate materials per year. Source materials consist of crushed concrete, bricks and asphalt generated from small to large-scale demolition projects. Incoming product is received and categorised as either ‘clean’ concrete containing less than 5% foreign materials, or ‘unclean’ concrete, containing mixed quantities of brick, rubble and soil. Oversize concrete consisting of footings and large slabs is pulverised to a suitable size prior to processing. Once received at the processing site, ferrous and non-ferrous metals are

“It’s not good enough to expect that a product can be marketed on a ‘feel good factor’ simply because it’s recycled or has recycled content,” he said. “Construction materials such as recycled concrete aggregates, recycled asphalt aggregates and concrete mixes containing recycled aggregates not only have to be able to perform as specified, they also have to be consistent across all batches.” “Our customers need to be confident that every batch of material that they receive from us - whether its recycled aggregate for road base or premixed concrete - delivers the quality and performance that they’re expecting… without exception,” Eddy Crosato added. With that in mind, ResourceCo has placed a significant emphasis on developing solutions that encompass all aspects of the recovery, recycling and re-use process. This enables the company to ensure that quality is being strictly controlled and maintained at each stage of the process.

removed, together with organic materials such as wood and other non-recyclable materials. The materials are then screened and graded into specific sizes for use as recycled aggregate, road base and sand, or as clean, wet or mixed fill materials. ResourceCo supplies a range of recycled products to the construction and infrastructure sectors, including: • 10mm and 20mm Concrete Aggregates • PM1/20RM Base Course (Equivalent to Class 1 Pavement Materials) • PM2/20RG Sub Base (Equivalent to Class 2 Quarried Pavement Materials) • PM3/20RG Sub Base (Equivalent to Class 3 Quarried Pavement Materials) • 10mm and 20mm Drainage Aggregates • Non-Specified Rubbles & Fills • 7mm Sand

ResourceCo operates two pugmill plants in SA (at Wingfield and Lonsdale) and can supply cement treated and Optimum Moisture Content (OMC) materials on demand from Wingfield. The company has obtained performance based mix design certification from DPTI for its 20mm Class 1 Recycled Material, with recertification in effect since April 2015. This certification was achieved through repeated laboratory testing carried out by both DPTI and ResourceCo’s independent NATA approved laboratory, within DPTI R15 specifications.

From the outset, ResourceCo’s primary goal has been to recycle, re-use and re-manufacture traditionally disposed of materials into higher value end products ResourceCo Managing Director, Simon Brown Construction Engineering Australia • Aug/Sept 2017

COVER FEATURE

QUALITY CERTIFIED CONCRETE MIXES ResourceCo was the first concrete company in South Australia dedicated to maximising the use of sustainable aggregate and sand in the supply and manufacture of concrete and is recognised nationally as a leader in the field. Indeed, ResourceCo is listed as a Global Green Tag™ Gold Standard certified product for its 20 MPa and 32 MPa concrete products produced with recycled aggregate. Made from clean, sustainable aggregate, ResourceCo Concrete provides a high quality alternative to standard concrete. By reducing carbon intensity during production, ResourceCo Concrete provides a carbon footprint reduction of up to 65% in comparison to quarried alternatives, without any compromise in compressive or tensile strength or mix performance. With ever-increasing demands for sustainable construction, ResourceCo’s

Construction Engineering Australia • February 2017

‘Green Concrete’ mixes are assisting builders, developers and governments to comply with the Green Star environmental rating system developed by the Green Building Council of Australia (GBCA) – particularly when it comes to residential construction. In fact, over 70% of the company’s 20MPa Green Concrete is being used for residential slab construction. ResourceCo also provides a range of specialist concrete mixes, including: • Fibre reinforced concrete (steel or polypropylene) • Structural fill (products for backfill applications) • Decorative concrete (integrally coloured mixes, exposed aggregate mixes, polished concrete mixes) For further information on the full range of ResourceCo products and services, please visit: www.resourceco.com.au

COVER FEATURE

TOTAL PROJECT SOLUTIONS

n keeping with its focus on maximising reuse, recycling and construction efficiency whilst also minimising the amount of waste being disposed of at landfill, ResourceCo Material Solutions provides complete material supply, transport and disposal solutions for site remediation, rehabilitation and development projects. With services individually tailored to meet the needs of each project, ResourceCo’s ‘Total Project Solutions’ approach help clients large and small to realise each site’s potential, using the best options to benefit their business and protect the environment. This includes, where feasible, assesses the potential for remediation, reuse or recycling of collected materials.

From the initial site assessment, through to material supply, removal and disposal, ResourceCo has more than 24 years’ experience in earthworks projects, including major infrastructure and construction projects, site remediation works and greenfield developments. ResourceCo specialises in dealing with contaminated sites, helping clients to develop best practice plans to manage the safe removal, treatment and final disposal of all levels and categories of contaminated material, including Asbestos. If required, contaminated waste materials can be transported to appropriate disposal sites and/or treatment facilities using accredited, EPA-licensed vehicles.

ResourceCo Material Solutions provides complete material supply, transport and disposal solutions for site remediation, rehabilitation and development projects.

The company operates a fleet of more than 1,000 vehicles nationally, and all work is completed under strict independent Environment, Safety and Quality accreditation systems.

FUELLING THE FUTURE PROCESS ENGINEERED FUELS (PEF) ResourceCo is also a market leader in alternative fuels manufacturing and is a pioneer of waste-to-energy generation in both Australia and Southeast Asia. Working closely with Adelaide Brighton Cement Ltd, ResourceCo developed Processed Engineered Fuel (PEF) as a partial replacement for fossil fuels in the Adelaide Brighton cement kiln. The process harnessed the energy contained in combustible material that would have traditionally gone to landfill and resulted in the commissioning of Australia's first PEF manufacturing plant in South Australia. Established in Wingfield in suburban Adelaide at a cost of over $20 million, the first SUEZ-ResourceCo plant sorts, sizes and extracts combustible material from commercial waste streams in order to manufacture Processed Engineered Fuel (PEF). The first plant of its kind in Australia, the facility has the capability to process up to 300,000 tonnes of raw material per

annum into approximately 150,000 to 200,000 tonnes of PEF. ResourceCo is currently finalising the construction of a second PEF facility in NSW. Located in Wetherill Park in Sydney’s west, the new $30 million plant is scheduled to open in 2018 and will process a minimum 150,000 tonnes of waste annually - producing PEF and recover other commodities such as metal, clean timber and inert materials from the C & D waste stream.

Artist’s impression of ResourceCo’s new $30 million PEF facility in Wetherill Park in Sydney’s west.

TYRE DERIVED FUELS (TDF)

Together with its work on PEF, ResourceCo - through its wholly-owned subsidiary Tyrecycle – is also a leader in the field of Tyre Derived Fuels (TDF). Tyrecycle is the largest collector and recycler of End-of-Life (EOL) tyres and conveyor belts in Australia. Scrap and imperfect tyres are collected from manufacturers, retail partners, local councils and other sources and processed at secure facilities across Australia in accordance with environmental regulations (including all EPA and Council Approvals). These tyres and conveyor belts are repurposed in several ways. They can be broken down into rubber crumb and used for road repair and construction, playground surfaces, new tyres, brake pads and sporting surfaces. They can also be turned into rubber granulate, Tyre Derived Aggregate (TDA) and Tyre Derived Fuel (TDF), used mainly in cement kilns and energy generation applications.

Construction Engineering Australia • Aug/Sept 2017

PRODUCT FOCUS

BATCH PLANT PUMP DEPOT Australian Pump is working with industry leaders to develop a national batch plant pump support program. The company has now established a new depot in Central Queensland. Dowdens Pumping and Water Treatment, located in Mackay, will offer full pump support local concrete batch plants. The team at Dowdens has come on board with Tsurumi submersibles, proven worldwide to be the most suitable pumps for this tough application. “Dowdens Mackay has a reputation for professionalism, customer support and application expertise. They were a natural fit for our batch plant support program,” said Aussie Pumps Bob Massiah. “Their staff understand the need for fast action in response to customer needs” he said. Local independent batch plant operator Tandy Concrete, met with Dowdens and Aussie Pumps’ Bob Massiah. Tandy is increasing capacity at their plant and are keen to use Tsurumi KTZ submersibles. Tandy’s Allan Kay

is eager to reap the benefits of reduced costs and upgraded reliability at all their Central Queensland concrete batch plants. Tsurumi Pump is the world’s leading manufacturer of submersible pumps and has developed the KTZ range specifically to handle the super tough conditions found in batch plants. Tsurumi designed the KTZ series to efficiently pump cementitious laden liquids. The pumps incorporate wear resistant high chrome iron impellers that enable solids in suspension to pass smoothly through the pump. “Reliability is a real cost saver for batch plants,” said Massiah. “Tsurumi pumps are built to withstand abrasive conditions therefore they work better and last longer,” he said. The KTZ series offer capacities of up to 2,400 litres per minute flow, and heads as high as 48 metres. The complete series includes discharge bores from 50mm (2”), all the way through to 150mm (6”).

Allan Kay, NQ Area Manager for Tandy Mackay, expects to increase plant efficiency and remove pumps issues by using Tsurumi KTZ pumps for batch water.

The KTZ series are fitted with 3-phase, heavyduty 2 pole high efficiency motors with thermal and amperage protection against dry running or overloading. The 4 pole motors mean the pumps are running at sedate 1450 rpm affording a considerably longer service life. Australian Pump has no doubt that as their local batch plant support program roles out across the country more ready mix sites will benefit. They will have access to the right pumps, available for immediate installation. The program is expected to make a real difference in reducing downtime and increasing reliability. For further information on the full range of Tsurumi submersible pumps or details of local specialists batch plant distributors, please contact Australian Pump on T: 02 8865 3500 or online at: www.aussiepumps.com.au

NEW CRIBBING AND JACKING BLOCKS CAN TAKE THE HEAVY LOADS SAFELY AND RELIABLY The Cribbing and Matting Company, one of industry’s leading suppliers of cribbing and matting products in the South East Asia region, including Australia and New Zealand, has added the proven Dura Crib Prime Cribbing Blocks to its comprehensive range of jacking blocks and stabilising tools. The lightweight, splinter-free, non-absorbent and environmentally sustainable Dura Crib Prime Cribbing Blocks are designed to be used whenever a person is working on or near a structure or work piece being stabilised in a wide range of industries, including mining, materials handling, building, construction and manufacturing. Engineered for maximum durability and tested under the guidance of Australian Standards to ensure optimum safety and risk management, the Dura Crib Prime Jacking and Cribbing Block is an excellent alternative to timber dunnage and blocks used in jacking and stabilising of heavy loads. Made from recycled plastic, the Dura Crib Prime Cribbing is not only far safer than timber, as it won’t splinter or rot, it is also great for the environment. 14

Construction Engineering Australia • Aug/Sept 2017

The pyramid profiles on the two surfaces of the Dura Crib Prime Crib provide a secure base and top that can interlock at any angle, with the three side notches interlocking for ultra-secure stacking performance. The positive interlocking of the cribbing, by gravity and friction forces, produces excellent stability and load bearing capacity. The Dura Crib Prime Cribbing Block is certified load rated with a working load limit (WLL) of 60.8kg/cm2, with a maximum working load capacity 58,800kg. Exceptional for four point and nine point cribbing stacks, the cribbing offers stack load capacities of between 58,800kg and 132,000kg. Cribbing and Matting Co’s Managing Director, Tony Brooks, explains that the high performance Dura Crib range was developed to replace older, weaker wood cribbing systems with constant cracking and varying and unpredictable load-bearing capabilities. "Not only is wood impossible to authenticate for Working Load Limit, wooden blocks require ongoing replacement involving extensive handling, consumption and disposal of a finite resource.

Mr Brooks says the use of timber blocks being used for jacking is a thing of the past, and is declining in many industries throughout Australasia and South-East Asia. Available in hi-visibility yellow or standard black, the cribbing is manufactured from 100% recycled high density polyethylene (HDPE) construction for durability and tested under the guidance of AS1170.0.2002 and AS2498.3.1998. Light weight and resistant to fuels, oils and most common industrial solvents and chemicals, the cribbing is backed by a 50-year warranty against splitting, rot, fluid absorption, termites and mould. For more information, please contact the Cribbing and Matting Company on: Phone +61 (0)2 9674 7428, email info@ cribandmatco.com.au, or www.cribandmatco.com.au.

FIBRE REINFORCEMENT 20 Years on and still going strong. Even after 20 years of exposure to heavy traffic and a harsh marine environment, the pavements reinforced with Novomesh® 850 system fibres are all in sensational condition.

20 YEARS ON

AND STILL GOING STRONG Although at the time, steel fibre reinforcement for concrete had already been used extensively though the UK, Europe and the USA, in 1997 when the developers of what was to become the Rivergate Marina in Brisbane decided to use a combination of steel fibre and polypropylene microfibre reinforcement for the roadways throughout the precinct, it was considered a somewhat ‘novel’ approach to concrete reinforcement in Australia. Indeed, given the precinct’s harsh marine environment (near the mouth of the Brisbane River under the Gateway Bridge) and the predicted heavy traffic loads - with constant heavy vehicle traffic to and from the marina and the surrounding industrialised precinct – the choice of fibre reinforcement for the precinct’s concrete roads and hardstand areas was not without its critics at the time. 20 years on, however, it’s a different story! The decision to utilise the Novomesh® 850 combination fibre reinforcement solution has been more than vindicated by the concrete’s outstanding performance over the past 20+ years. Andrew Hockey, Northern Regional Manager with Propex Concrete Systems, commented: “While there can be no doubting that fibre reinforcement has had its fair share of detractors over the years, projects like the Rivergate Marina provide conclusive proof as to the outstanding performance capabilities of our Novomesh® combination fibre systems in real world applications.” “Even after 20 years of heavy vehicle traffic and exposure to the harsh marine

Construction Engineering Australia • Aug/Sept 2017

environment, the roadways are all in sensational condition. No cracking, no spalling and only minimal surface wear,” he said. “In fact, the majority of the roads and hardstand areas throughout the Rivergate precinct don’t look any more than a couple of years old,” he added. The Novomesh® 850 fibre reinforcement system is an engineered blend of steel and polypropylene fibres that delivers the ideal combination of plastic shrinkage and plastic settlement crack control, with outstanding

Using the Novomesh® 850 fibre reinforcement system eliminated the need to transport, cut and place crack-control steel wire mesh.

abrasion resistance, superior concrete toughness and high-performance steel fibre reinforcement. Easy to use, pour and finish, the Novomesh® 850 fibre reinforcement system is compatible with all concrete admixtures and performance enhancing chemicals and is ideally suited for use in a wide range of applications, including: • Road Pavements • Commercial and light industrial slabs on ground • Equipment foundations

FIBRE REINFORCEMENT

• Hardstand areas • Composite metal decks • Overlays The steel fibres provide the high-performance structural reinforcement for the concrete slabs. Together with the outstanding postcrack performance, the steel fibres can also deliver significant time and cost savings, by eliminating the need to transport, cut and place crack-control steel wire mesh. The steel fibres also overcome the risk of problems occurring as a result of incorrect placement of wire mesh within the concrete slab.

Manufactured from 100% virgin polypropylene, the Fibermesh 150 graded monofilament fibres deliver a reduction in shrinkage and settlement cracking; as well as a significant improvement in both the impact, shatter and abrasion resistance of the hardened concrete. The fibres are supplied in easy to handle, fully-degradable bags which can be added to the concrete mix either at the batch plant or in the truck. The mixing action distributes the fibres evenly throughout the concrete, resulting in an homogenous mix.

Novomesh 850 concrete mix is easy to place, screed and finish, without any problems of exposed fibres.

Still looking good after 20 years of service.

Importantly, the fibres have been specifically designed to eliminate issues such as ‘clumping’, with the Novomesh 850 concrete mix remaining easy to place, screed and finish – without any problems of exposed fibres. Indeed, the quality of the finish achievable with Novomesh 850 fibre reinforcement is clearly evidenced at the Rivergate precinct. With a pavement thickness of 350mm, the roadways throughout the Rivergate precinct were designed to cater for axle loads of up to 145 tonnes. The Novomesh™ 850 system used for the Rivergate precinct incorporated a blend of Novocon XR 1038 undulated steel fibres at a dosage rate of 30kg/m3 together with 0.9kg/m3 of Fibermesh 150 12mm micro monofilament polypropylene fibres. For further information, please contact Andrew Hockey, Northern Regional Manager, Propex Concrete Systems, M: 0408 261 911, E: andrew.hockey@propexinc.com.au

Construction Engineering Australia • Aug/Sept 2017

FIBRE REINFORCEMENT

HELIX MICRO-REBAR CREATES A SOLID PATHWAY TO INNOVATION With increasing labour costs in Australia, builders and developers are being required to look for new ways to streamline efficiencies. Despite the Australian construction industry’s supposed desire to adopt innovative building methods early, many modern building methods continue to be expensive and labour intensive. Often these fail to address important environmental challenges and durability issues that can affect building structure. In concrete reinforcement, too many engineers and construction companies continue to rely on traditional mesh and rebar to reinforce their concrete. Congested building sites and costly delays from working with conventional reinforcement may not be delivering the level of innovation required for today’s fast-paced building sites. The construction industry is demanding greater construction speed, cost reductions, increased safety for workers and fewer construction defects. However, according to former construction industry chief financial officer and CEO of progressclaim.com Lincoln Easton - whose company recently conducted research into the construction industry - not enough is being done to embrace innovation, and thereby cater for such demands.

Helix Micro-Rebar addresses the need for cost and time efficiencies. Engineers can design with Helix in the same way as with rebar. 18

Construction Engineering Australia • Aug/Sept 2017

“The hearts and minds of our industry are sold on innovation, (but) these feelings aren’t yet translating through to action and change which needs to be driven from the top down,” Mr Easton said. “It’s time for leaders in the construction industry to radically rethink attitudes.” Easton explained that by dedicating resources and gaining expertise, the implementation of innovation can be managed. Helix Micro-Rebar, a 25mm twisted steel wire reinforcement with properties that liken it closest to rebar in strength and durability, delivers genuine innovation in concrete reinforcement without requiring time to implement. With Helix’s ability to be used as a complete replacement of mesh and rebar, it is rapidly becoming specified by engineers and demanded by construction companies across Australia, either for entire projects or specific applications. But perhaps the biggest appeal of the product, and reasons for its success, is the fact that it is designed with in exactly the same way as rebar. Engineers have access to simple CPD training and software that allows them to design with Helix very quickly, and to have full control over their Helix designs. Helix Micro-Rebar increases concrete strength and delivers crack resistance to the ongoing benefit of the building occupants after completion of a structure, and can even provide structures with the ability to withstand natural disaster such as earthquakes and hurricanes. The product provides significant reduction in costs from the elimination of the entire labour-intensive process of offloading, laying and tying rebar and mesh. Cost benefits

can increase significantly where Helix allows for reducing pavement thickness. “We began using Helix to remove any steel placement errors and safety risks which can occur while working in underground conditions. Helix has worked with excellent results for our slabs, it reduces man hours, decreases time between pours on multipour projects, increases productivity, reduces our costs, produces a stronger slab and totally eliminates manual handling and trip hazards associated with traditional reinforcing. Helix is now the first choice for concreting works on our mine site.” Projects Coordinator, MAJOR MINING COMPANY

For more than 15 years, Helix Micro-Rebar has been used in virtually every type of application ranging from structural foundations to slabs and suspended slabs, structural and retaining walls, piers and precast. Helix structures range from residential apartment blocks and warehouses, to mining and heavy load applications. Testimony to the ingenuity the product offers are many of Helix’s larger projects, including the Seattle Great Wheel ferris wheel built in an area of seismic activity, and Helix’s replacement of conventional reinforcement in the strip footings and slab of Movie World’s latest Sound Stage on the Gold Coast. One of the latest Helix structures is a new 93,000 square metre Amazon Distribution Centre in Michigan, taking its place in the top 10 largest warehouses in the world. The following are some examples showing how Helix Micro-Rebar may replace conventional reinforcement in certain applications, and the cost savings that can be made:

FIBRE REINFORCEMENT PICTURED LEFT(clockwise): Small but effective - Helix Micro-Rebar with a 5 cent coin to show its comparative size; Helix Micro-Rebar reinforced Strip Footings in the Movie World Sound Stage, Gold Coast QLD; Helix Micro-Rebar-built 93,000 square metre Amazon Distribution Centre in Michigan, USA.

Walls – 8kg/m3 of Helix replaces shrinkage steel, saving 20% Pad Footings (600mm) – 10kg/m3 of Helix replaces N16-250 Each Way Top & Bottom, saving 30% Slab on Ground (150mm) – • 6kg/m3 replaces SL82 Mesh Central, saving 20% • Alternatively, 10kg/m3 of Helix replaces SL82 Mesh Central plus reduces slab thickness to 125mm, saving 35% “Our decision to use Helix in our 4.5 m bored piers for a Health Care Facility saved us from lengthy delays after discovering ground water. As the holes were collapsing, we would not have had time to install a reinforcement cage and get the concrete in the hole before it collapsed. With Helix we could pour concrete into the holes as soon as they were cleaned out. Helix had enough capacity that when we then installed the full length I beams, these didn’t even require extension despite the extra depths we had been required to dig.” Angus Maley, Construction Manager, CONCRIB

Crack control is a major construction industry challenge and one that Helix

Micro-Rebar is in a unique position to capitalise on. Use of traditional steel fibres to reduce conventional reinforcement may help lower costs, however it does not provide the superior crack control properties of Helix which also reduces concrete cancer and concrete spalling. Each piece of Helix bonds to the matrix over its full length and must untwist as it pulls out of the concrete, unlike steel fibres where pullout is governed by friction. This superior bond with the concrete improves the materials properties of the concrete prior to a crack forming, providing a proactive reinforcement. After a crack forms, Helix provides a stable capacity, which is the reason why engineers can design with Helix in the same way they design with rebar. If there is one thing to be understood from this, it’s that Helix Micro-Rebar is very different from fibres requiring much lower dosages and providing a greater opportunity to replace all conventional reinforcement, greater strength and durability and easier finishing given that the Helix pieces settle naturally below the

surface. It’s also the only product on the market that is zinc galvanised providing greater longevity. Onsite, Helix provides advantages over conventional reinforcement by minimising site deliveries, keeping sites free of tripping hazards, removing the potential for placement error and helping avoid weather delays. The Helix is simply added to the concrete mix at the batch plant, poured into the element, and the concrete is finished in exactly the same way as concrete that doesn’t contain Helix. Helix Micro-Rebar has three major distribution centres across Australia, and 30 operations globally. The growing demand for Helix Micro-Rebar will see the company continue to expand as more engineers specify the product, joining in the global success of this easy to implement building innovation and delivering a superior product to the Australian market. For further information, please contact Helix Steel on, T: 1300 4 HELIX (1300 4 43549) or visit: www.helixsteel.com.au

HELIX MICRO-REBAR TM

making concrete reinforcement faster, cheaper & stronger › REPLACES CONVENTIONAL REINFORCEMENT › REDUCES PAVEMENT THICKNESS › ALLOWS FOR SIMPLE DIG AND POUR › CUTS PROJECT SCHEDULES AND COSTS › PROVIDES SUPERIOR CRACK CONTROL › DESIGNED WITH IN THE SAME WAY AS REBAR

Since each piece of Helix Micro-Rebar must untwist as it pulls out of the concrete, unlike fibres Helix works to control cracks before they begin. After cracks form, Helix provides a stable capacity allowing engineers to design with Helix in the same way as they design with rebar. Helix Steel provides simple CPD training and software allowing engineers to design with Helix quickly and to have full control over their Helix designs.

Helix Micro-Rebar is 25mm pieces of zinc galvanised, twisted micro reinforcement with properties that liken it closest to rebar in strength and durability. It is being specified by engineers and demanded by construction companies across Australia and has been used for over 15 years in virtually every application.

have you joined the ‘revolution in reo’? 1300 4 HELIX | HELIXSTEEL.COM.AU follow us on: Construction Engineering Australia • Aug/Sept 2017

The SMART MONEY in Road Safety...

is on SMART CUSHION • Less Waste

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DESIGNED FOR SAFETY · Low ride down accelerations on vehicle occupants in end-on impact. · Reduced spare parts inventory: In almost 50% of all resets to date, the only replacement parts needed are two 1/4” shear bolts. · Increased crew safety: The average reset/repair time (often with just a one person crew) is 56 minutes. · Reduced call outs increase crew safety: To date there have been no call outs for side angle impacts, a similar pattern to that in the USA. · Reduced lane closure time: Fewer call outs and faster repairs keep traffic lanes open for longer · Happier motorists: Fewer lane closures, less blockages and faster repairs. · SMART DESIGN, SAFER SITES FOR ROAD CREW and SAFER MOTORING

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To date 30 Smart Cushions have been impacted, one of these has been impacted 11 times. The total cost of all Spare Parts used in 54 resets is $7,438.00 at an average of $137.74 per reset.

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EQUIPMENT SPECIAL

HINO 300 SERIES 4X4: MORE OF EVERYTHING More power and torque, more gears, more comfort and more safety than its rivals, that’s what Hino Australia’s first 300 Series 4x4 light duty truck will deliver when it lands in dealerships later this year. Hino Australia has revealed the full specifications of its much-anticipated 300 Series 4x4 ahead of the display of the new vehicle at the AFAC conference for fire and emergency service professionals in Sydney (4th - 7th September). “Quite simply, we believe this is the best light duty 4x4 truck on the Australian market,” said Daniel Petrovski, Manager, Product Strategy for Hino Australia. Devised in response to the demands of Australian customers for a better light duty 4x4 truck and comprehensively tested in an Australian field test program over a number of years, the Hino 300 Series 817 4x4 sets a new benchmark for light duty 4x4 truck specifications and driving performance. The Hino 300 Series 4x4 is available in single cab and crew cab configurations, both powered by a 165hp (121kW), 464Nm, 4 litre diesel engine mated to a 6-speed manual overdrive transmission and a dual range 4x4 transfer case – this driveline combination offers exceptional flexibility and efficiency both on and off-road. Operational safety is class leading with the standard inclusion of Vehicle Stability Control (VSC), a first for a Japanese-built truck in this category, together with 4-wheel-disc brakes and a reversing camera. 22

Construction Engineering Australia • Aug/Sept 2017

MORE GEARS The Hino 300 Series 817 4x4 combines a sixspeed manual transmission with a dual-range transfer case and selectable 4x4. “With a six-speed overdrive manual transmission mated to a Hino transfer case with superior low range gearing of 2.2:1, the Hino 300 series 4x4 has the widest spread of ratios and the lowest crawl speed in its class. “This means the 300 Series 4x4 can crawl slower off-road than its rivals providing better vehicle control in tricky off-road conditions, which is a key measure of performance in that market. The driveline combination also improves fuel efficiency, reduces noise levels and increases comfort levels during long distance driving by lowering the engine rpm at highway speeds. When 4x4 is engaged via the transfer case, drive is delivered 50/50 to the front and rear axles. Free-wheeling hubs are a standard feature and are manually locked, once engaged 4x4 can be selected on the move by the driver, via a button on the dashboard. High or low range is also driver selectable via a button on the dashboard - the vehicle must be stationary to change ranges. The selection of 4x4 and high low range are indicated to the driver within the vehicle's instrumentation display.

MORE SAFETY “The Hino 300 Series 4x4 is now the safest Japanese-built truck in its class, with an

impressive list of standard features including driver and passenger SRS airbags, Vehicle Stability Control, cruise control, 4-wheel disc brakes and reverse camera,” continued Mr Petrovski. Moreover, it is the only 7,500kg Gross Vehicle Mass (GVM) 4x4 truck in Australia with VSC and reverse camera as standard features. Working in conjunction with the brake and engine control systems, VSC helps prevent the truck from potentially rolling over when entering a corner too fast by monitoring the steering angle, wheel rotation speed, yaw rate and lateral G forces. The VSC can take the appropriate action required such as reducing engine power and/ or applying individual brakes with the intent of keeping the vehicle upright and safely negotiating the corner. VSC is also able to enhance vehicle stability on slippery surfaces and other such situations by autonomously reducing engine power and applying the brakes to individual wheels, helping to prevent the truck from sliding in a direction contrary to where the driver is steering. “The Hino 300 Series 4x4 will be the only 7,500 GVM 4x4 with 4-wheel disc brakes, which reduce stopping distances, and increase servicing efficiency, which we know is key for our customers in remote locations. Adding further to the best safety package in class, a reversing camera that includes night vision and a microphone, to assist the driver when manoeuvring the vehicle is fitted as a standard feature. Driver and passenger SRS airbags complete the safety story.

MORE COMFORT Based on the familiar Hino 300 Series design, the 300 series 4x4 has significantly increased ground clearance over a standard 300 series 4x2 model, this facilitates greater approach and departure angles, and increases ramp over angle for off-road driving. When designing the vehicle, driver comfort was a priority – the ergonomically designed interior features a magnetically dampened driver’s suspension seat and updated instrumentation and switches for 4x4 operation. Importantly with the increase in ride height, a great deal of work went into ingress and egress, the Hino 300 Series 4x4 features a surefooted step arrangement and long hand grips for three points of contact when entering and exiting the truck via the slip resistant access steps.

Another design feature is the new model’s 840mm wide chassis with rivet-less top flange and grid hole design, which allows for easier body fitting. The 300 Series 4x4 is tailored to the harsh applications that it will operate in, with reinforced multi-leaf front and rear suspension tuned for occupant comfort, performance and durability, on and off-road.

MORE POWER AND TORQUE The Hino N04C 4 litre diesel engine delivers 165hp (121kW) at 2500rpm and 464Nm of torque at 1400rpm, both of which are more than its Japanese 4x4 competitors. The Hino N04C engine is Euro 5 ADR 80/03 emission compliant and utilises the Hino Diesel Particulate active Reduction filter (DPR), which has proven its reliability in Australian applications over the past 10 years. “The Hino DPR captures over 95% of the exhaust particulates (soot) and is designed to be automatically self-cleaning (regenerating) without the need for driver intervention”

MADE 4 AUSTRALIA The extensive in-field Australian testing that the Hino 4x4 has undergone underpins its ‘Made 4 Australia, Made 4 Work’ positioning. “Selected Hino customers have been evaluating prototype trucks on and off-road on some of Australia’s harshest bush tracks, trails and roads over a number of years, and they haven’t missed a beat,” continued Mr Petrovski. “Together with Hino Motors Japan, we have developed and delivered a truck that incorporates our customers’ specific requests and requirements. “For instance, in response to customer feedback, the Hino 300 Series 4x4 will be the only 7,500kg GVM 4x4 truck with 4-wheel disc brakes, which reduce maintenance costs and replacement complexity when compared to the brake drums of our major competitors. “The Hino 300 Series 4x4 will set new market leading levels of onroad and off-road performance, safety specification and driver comfort exceeding anything offered in the market today,” he concluded. The Hino 300 Series 4x4 will be begin arriving at selected Hino dealerships in October 2017 and comes with a 3 year/100,000km warranty (whichever occurs first) For more information, visit www.hino.com.au

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Construction Engineering Australia • 22/02/2015 Aug/Sept 2017 10:10 23 am

EQUIPMENT SPECIAL

GASWORKS’ ISUZU SERVICEPACK

A BEACON IN ROUGH WEATHER We’ve all seen the increased incidence of extreme weather events around the world and Australia is no stranger to the powerful forces that can wreak havoc on urban and regional centres alike. Highly capable emergency response services play a key role in the safety of communities, and in Queensland, one such organisation is Gasworks. Wayne Braden is the founder and national CEO of Gasworks, a gas-installation company that proudly provides expert emergency assistance for gas pipelines across Queensland, working from its head office in the Brisbane suburb of Yatala and bases in Gladstone and the Gold Coast. Most recently, Gasworks’ highly trained response team was crucial during Cyclone Debbie and the subsequent flooding across the eastern coast. Gasworks’ strong community focus and quality workmanship have made them a state icon, and Wayne’s personal dedication to his customers is apparent when he talks about his company. “I founded Gasworks 20 years ago because I love the industry and I care about what it stands for,” Wayne said. “The gas industry is great to work in if you love helping people. “We currently employ over 30 staff, and have jobs all over the country, providing hot water, battery, industrial and commercial installations. 24

Construction Engineering Australia • Aug/Sept 2017

“But the fastest growing part of the business is our emergency response team.” The star of this response team’s fleet is an Isuzu NLR 45-150 Servicepack. Gasworks had the Servicepack specifically fitted out by Brisbane Isuzu with a vast array of emergency lighting to complement the practical Servicepack body – allowing Gasworks to provide a literal beacon of light as storms whipped across Queensland. “The Servicepack’s our main emergency response vehicle, that we use to fix gas leaks and pipeline faults due to flooding or storm damage.” Wayne said. “It’s reliable, can hold all our gear and it’s equipped with a wide range of flashing lights. “The truck handled the cyclone weather amazingly – I recently drove it to a flooded shopping centre to respond to a gas leak and the owner said, ‘I know you’re here but I can’t see you.’ “As soon as I turned the lights on he could see me 300 metres away. “The Isuzu dealership did everything for us, they put lightbars on the top, down the sides and on the back, which illuminate a huge area around the vehicle and are what people look for in an emergency.” The Servicepack’s rated at 4,500 kg GVM, and with plenty of power and torque (110 kW @ 2,800 rpm and 375 Nm @ 1,600 rpm) it’s got the grunt to handle the dicey conditions in extreme weather events. And with a factorybuilt body covered by Isuzu warranty, the entire truck is built to withstand the harshest conditions. “We’ve had the Servicepack for less than eight months, but it’s already been to every state except Western Australia.” Wayne said. “We use it to provide emergency response capabilities to large commercial sites. Should something go wrong, the Servicepack’s ready to respond.

“We bought our first Isuzu about 15 years ago. We’ve had a few over the years and they’ve all been great. It’s travelled huge distances and has been tremendously reliable.” “The Isuzus are amazing compared to the other brands I’ve owned, they always handle the payload and perform really well.” The Servicepack’s the ultimate workhorse for businesses seeking the flexibility Isuzu’s Ready to Work range offers. The NLR Servicepack features a 2.08 m x 1.0 m (L x W) central storage area with chequerplate floor and six tie-down points, a 2,500 kg rated towbar with integrated rear step and an Isuzu reversing camera. It has the capacity of a fully powdercoated steel service body with seven centrallylockable, individually lit, storage compartments and the practicality of a truck with a short wheelbase, while being driveable on a standard car licence. “Isuzu’s reliability is fantastic,” Wayne said. “We’ve had the Servicepack serviced by Isuzu all around Australia and we’ve never had a problem. “The first week we had it, we drove it through central Queensland to Darwin, then down to Adelaide via Alice Springs, then to Victoria before driving back to Queensland through New South Wales. “The Servicepack did it all without a hitch – our driver said he enjoyed it.” The rough Australian landscape requires capability and durability in equal measure, which is why the Servicepack is the natural choice for businesses requiring a vehicle that’s tougher than a utility and has a greater payload. “We used to use utes, but the business outgrew them,” Wayne said. “We needed the payload the Isuzus offered, and all the toolboxes were made up and ready to go, so the truck perfectly suited our business. “Isuzu has offered us incredible support while we’ve been driving around the country and I’ve been really impressed with their customer service team. “When we get in, we always know it’s going to work. It’s going to meet the challenges we throw at it and it will keep our drivers – and the public – as safe as possible,” he concluded.

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C&P2017: includes:

Quality Technical Program • Various Forums • 72 Booth Trade exhibition • Awards dinner • Social & Networking functions • Partner Program

PLENARY LECTURERS Maria Forsyth Australian Laureate Fellow Chair Electromaterials and Corrosion Sciences Deakin University, Australia

Professor Jing-Li Luo Department of Chemical and Materials Engineering University of Alberta, Canada

Nick Birbilis Woodside Innovation Chair and Head, Department of Materials Science and Engineering Monash University, Australia

Professor Peter Robery Director, Robery Forensic Engineering Ltd

Miles Buckhurst Global Concept Director – HPI Jotun, Norway

Dr Brian Skerry Global Director – Corrosion Programs The Sherwin-Williams Company, USA

FOR MORE INFORMATION & To register go to conference.corrosion.com.au

PROJECT FOCUS

The Coal Flower Project at Cubbies comprises of five sculptural flowers that are nine metres in height. Photo by Benjamin Gilbert.

ENPHASE ENERGY BRINGS SOLAR TO AUSTRALIA’S OLDEST CHILDREN’S PLAYGROUND Enphase Energy, Inc., a global energy technology company and the world’s leading supplier of solar microinverters, announced today that it has integrated solar generation into a new playscape at Australia’s oldest adventure playground in Fitzory, Melbourne. The Coal Flower Project at Cubbies comprises of five sculptural flowers that are nine metres in height. Twenty-five of Enphase’s S230 microinverters have been attached to individual solar panels that are connected to each petal. Commissioned by the Fitzroy Adventure Playground, the playscape was designed by the award-winning Agency of Sculpture.

Twenty-five of Enphase’s S230 microinverters have been attached to individual solar panels that are connected to each petal. Photo by Benjamin Gilbert.

Construction Engineering Australia • Aug/Sept 2017

The Cubbies playscape has served as a communal backyard for children living in social housing at the Atherton Gardens Estate in Fitzroy since 1974. The history of Cubbies is a catalyst for the coal flower concept as these sculptural flowers are growing defiantly in what was once an inner city industrial site. In this post-industrial location, the coal flowers symbolise the world we are leaving to children. Recycled conveyor belts salvaged from the coal industry connect the flowers to show the contrast between the potential of solar and Australia’s declining coal industry. Besides providing expansive shade to the playground, the coal flowers will generate solar power to provide up to 6.8 kilowatts of power. This will exceed the energy requirements of the activity centre with surplus electricity exported back to the grid that will help reduce the operating costs of Cubbies. Children between the ages of 5 to 14 years old, many from refugee backgrounds, use the centre as a gathering point after school and during the weekends. While the main focus at Cubbies is on child directed free play, making friends, learning social interaction and resilience, the centre also runs activities such as dance classes, art projects and cooking classes. David Weston, co-chair of the Fitzroy Adventure Playground said, “The Fitzroy Adventure Playground Committee has always set their sights on building a new high standard and ethical playground. We are delighted to have Enphase Energy as our Energy Technology Partner for the Coal Flower Project.” The Committee is made up of community volunteers and has raised over $360,000 in cash and kind to fund the project. He added, “The Enphase microinverter technology meets stringent safety certification requirements which is crucial as children will be using the playscape. Enphase microinverters offer greater reliability and the quality of their technology

will ensure that our investment in this playscape has the longevity it deserves. This structure will serve the community for many years to come.” Nathan Dunn, managing director of Enphase Asia-Pacific said, “Enphase is delighted to be part of the Coal Flower Project at Cubbies. This playscape is truly unique as this will be the first time our microinverters have been directly installed to generate energy for an Australian playground. Cubbies’ vision for this installation delivers a powerful statement about the future of solar energy and the impact our choices have on the next generation.” The Enphase Microinverter System offers higher performance and smarter insights for rooftop solar PV systems. It is simple to install and is designed to provide installers with the flexibility to optimise their rooftop PV installations. Enphase leads the industry in reliability and quality with microinverters that will reduce installation and maintenance costs and offer greater value to customers.

Recycled conveyor belts salvaged from the coal industry connect the flowers to show the contrast between the potential of solar and Australia’s declining coal industry. Photo by Benjamin Gilbert.

Powering a Sustainable Future

Did you know you can access the latest issue of Construction Engineering Australia via Informit? The Informit Engineering Collection is an ever expanding resource covering aspects of municipal engineering – urban management and planning, civil engineering and construction, environmental management, planning issues and traffic management. The database offers an extensive variety of resources including journals, trade publications, reports and conference proceedings. The Collection guarantees quality through partnerships with peak professional bodies including Engineers Australia and the Institution of Professional Engineers New Zealand, as well as Content Providers including EPC Media Group. The Informit Engineering Collection delivers hard to find content designed to complete and complement all your construction engineering requirements. Other key titles published by EPC Media include: Highway Engineering Australia Waste + Water Management Australia

Besides providing expansive shade to the playground, the coal flowers will generate solar power to provide up to 6.8 kilowatts of power. Photo by Benjamin Gilbert.

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Research for your global future

Enphase Energy, a global energy technology company, delivers smart, easy-touse solutions that connect solar generation, storage and management on one intelligent platform. The company revolutionised solar with its microinverter technology and produces the world’s only truly integrated solar plus storage solution. Enphase has shipped approximately 14 million microinverters, and more than 620,000 Enphase systems have been deployed in more than 100 countries. Visit www.enphase.com/en-au for more information and follow the company on Facebook, LinkedIn, and Twitter.

Construction Engineering Australia • Aug/Sept 2017

ACRS FEATURE

CHOOSE ACRS

BECAUSE NOT ALL PRODUCT CERTIFICATION SCHEMES ARE CREATED EQUAL! When it comes to selecting construction steels, ensuring that they conform with the appropriate Australian and New Zealand Standards is critical. What's more, it's simply not enough to think that just because steel has been ordered to an Australian or New Zealand Standard that the delivered product will automatically conform with that Standard and be fit for purpose. Increasingly, this is not the case: The product may meet the Standard; it may be supplied with documents for “an equivalent standard” (but which standard and is it really equivalent?) or; it may not meet any standard at all. With the building products being used on construction sites now sourced globally, the importance of independent technical validation of materials conformance, and awareness of consequences of failure of these materials, has never been greater. Unfortunately, in some instances, one of the major problems associated with the selection and use of materials that comply

ABOUT ACRS

with all relevant Australian and New Zealand Standards is one of identification or, more specifically, who or what to believe. The same applies for ‘product certification’.

ACRS MAKES IT EASY ACRS certification makes checking for compliance with the relevant Australian and New Zealand Standards easy. It demonstrates INDEPENDENTLY and EXPERTLY that the supplier consistently meets the Standards stated on the certificate. Beyond checking the supplier’s ACRS certificate, product markings and tags, there’s no need for you to make any further checks on ACRS certified materials. • No more checking materials properties against technical specifications; • No more checking batch numbers against the test certificates. The bottom line... with ACRS it’s easy for your suppliers, easy for your customers and easy for you!

Established in 2000 with the support and endorsement of leading engineering and construction groups, such as Austroads, Engineers Australia, Consult Australia, Master Builders Association, and the Housing Industry Association, ACRS (Australasian Certification Authority for Reinforcing and Structural Steels) has become the leader in the field of steel conformity assessment and certification to Australian and New Zealand Standards. Indeed, with over 2,000 audits and 6,000 materials assessments now completed, ACRS is recognised locally and internationally for both its rigorous and practical scheme, and its expertise in the compliance of construction steels to AS/NZS Standards. JAS-ANZ accredited, ACRS is a not-for-profit, independent Authority that provides expert, impartial assessment and certification that gives specifiers and customers the widest available choice of construction steel materials demonstrably compliant with Australian and New Zealand Standards. ACRS presently certifies 62 steel mills and processors, in over 150 production locations in 17 countries.

WHAT ARE YOUR TAGS REALLY TELLING YOU? Your products may arrive with tags, but what do they really tell you? While at first glance the example on the left may appear to tell you all you need to know (there’s even a reference to an Australian Standard) it’s missing some CRITICAL information, including the manufacturer and point of origin. The example ACRS tag on the right provides all of the information needed and, most importantly, the validity of the certificate number and other information can be checked and verified online quickly and easily at: www.steelcertification.com

Construction Engineering Australia • Aug/Sept 2017

ACRS FEATURE

THE ACRS DIFFERENCE ACRS is an independent, not for profit, expert certification body formed in 2000. ACRS specialises in verification of construction steels and associated products. All ACRS auditors are fully-qualified metallurgists with many years of experience working with steels. In addition to factory production control audits and independent testing, the ACRS scheme provides regular review and analysis of all products supplied by the certified supplier under ACRS certification. This makes matching material to conformity documentation simple and effective for the customer and for any verifier. Another commonly encountered industry problem is mixed supply (sometimes called “shandying”), where conforming supply is declared but either only a portion of the product supplied is sourced from a compliant supplier (and the rest sourced from a noncompliant supplier), or alternatively, the material is sourced from a supplier but the product delivered does not consistently meet the Standard. By providing effective continuous review of both the manufacturer and the fabricator/ processor, ACRS certification plays a major role in reducing the risk of 'shandying'.

AREN'T TEST CERTIFICATES THE SAME THING? Test Certificates, ARE NOT the same as ACRS independent certification. Test certificates from the supplier are simply a “snapshot” of the manufacturer’s own test results of the material on the certificate, not its regular supply. ACRS certification demonstrates INDEPENDENTLY and EXPERTLY that the supplier manufactures consistently to the Standards stated on the certificate. Unless you are going to check and validate EVERY single test certificate against EVERY delivery, you should check the ACRS certificates for the manufacturer and supplier instead. For further information about the validity of certification for any materials being supplied into your project, please visit the ACRS website: www.steelcertification.com, or contact ACRS, Phone: (02) 9965 7216.

HOW DO I SPECIFY ACRS CERTIFIED STEELS? The easiest way to manage and minimise the risk of nonconforming construction steels, is to specify ACRS certified steels.

Evidence of compliance with this clause must be obtained when contract bids are received.

SUGGESTED WORDING FOR STEEL VERIFIED BY ACRS AS MEETING LONG-TERM QUALITY LEVELS TO AS/NZS 4671, OR AS/NZS 4672:

SUGGESTED WORDING FOR STRUCTURAL STEELS VERIFIED BY ACRS AS MEETING MINIMUM REQUIRED TESTING LEVELS TO AS/ NZS 1163, AS/NZS 1594, AS/NZS 3678, AS/NZS 3679.1, OR AS/ NZS 3679.2:

Steel reinforcing and steel prestressing materials for concrete shall comply with AS/ NZS 4671 or AS/NZS 4672, respectively. Where applicable, materials shall be cut and bent in accordance with the requirements of the "Material and Structural Requirements for Reinforcing Steel" clauses AS 3600 and AS 5100.5, or the "Reinforcement" Clauses of NZS 3109. Acceptable manufacturers and processors of steel reinforcing and prestressing materials must hold a valid certificate of approval issued by the Australasian Certification Authority for Reinforcing and Structural Steels Ltd (ACRS), or other product certification system as shall be demonstrated to be directly equivalent to ACRS and approved as such in writing by the specifier.

Structural steels shall comply with AS/NZS 1163, AS/NZS 1594, AS/ NZS 3678, AS/NZS 3679.1 or AS/NZS 3679.2, as appropriate. Acceptable manufacturers of structural steel must hold a valid certificate of approval issued by the Australasian Certification Authority for Reinforcing and Structural Steels Ltd (ACRS), or other product certification system as shall be demonstrated to be directly equivalent to ACRS and approved as such in writing by the specifier. Evidence of compliance with this clause must be obtained when contract bids are received.

Construction Engineering Australia • Aug/Sept 2017

Concrete 2017, the 28th Biennial National Conference of the Concrete Institute of Australia, will be held in Adelaide at the Adelaide Convention Centre from 22nd October to 25th October 2017. The conference will also be held in conjunction with the 3rd International Congress on Durability of Concrete (ICDC). The theme for Concrete 2017 is ‘Advances in Concrete Materials and Structures’ and is bringing together leaders in the concrete industry from all over the world to Adelaide. With a program covering advances and innovations in concrete research, design and constructability, delegates will have the opportunity to learn about the latest information and speak to those who are driving these changes. Concrete 2017 is also privileged to be hosting the 3rd International Congress of Durability of Concrete (ICDC). Jointly organised by the Norwegian Concrete Association and the Concrete Institute of Australia, ICDC durability focused streams will be held over the entire 3 days of the conference, focusing on the progress

of concrete durability with respect to materials, modelling, specification, and testing. Delegates will be able to attend these sessions as part of the conference registration. The program is of the highest quality and includes 4 parallel streams running throughout the conference, with over 150 technical papers, supported by 5 key note presentations and 2 invited speakers. The program will cover a wide range of topics including: • Concrete materials • Durability • Concrete structures • Constructability • Major projects & case studies • Repair and retrofit • Precast concrete • Environmental • Innovation • History of concrete in Australia The multidisciplinary theme of Concrete 2017 will provide an excellent forum for networking and education and an opportunity to meet and interact with

practitioners, engineers, scientists, researchers, academics, practitioners and professionals, and also to engage with international delegates connected with ICDC and in the durability field. Whether you attend technical sessions, sit in on multiple committee meetings or network with friends and colleagues this conference will provide you with ample opportunity for professional growth. The Organising Committee and the Concrete Institute of Australia look forward to meeting you at Concrete 2017 and the 3rd ICDC in Adelaide.

KEY NOTE AND INVITED SPEAKERS The wonderful array of key note and invited speakers certainly represent the themes associated with Concrete 2017 and ICDC, and will present on topics that show how advances in the field of concrete across these topics.

Key note speakers 1. Louise Adams, Regional Director for Aurecon in Victoria & South Australia, and Executive Director on the Aurecon Group Board. Presentation: “Disruption and technology – is the consulting/design/construction industry moving forward quickly enough?” 2. Professor Tim Ibell, Professor of Structural Engineering at the University of Bath. Presentation: “Extraordinary

Construction Engineering Australia • Aug/Sept 2017

CONCRETE INSTITUTE NEWS

Possibilities for Concrete Structures” 3. Professor Karen Scrivener, Professor and Head of the Laboratory of Construction Materials at EPFL, Switzerland, and Editor in Chief of Cement and Concrete Research Presentation: “Eco-efficient Cements: potential Solutions for a Low CO2, Ecoefficient Cement Based Materials Industry” 4. Professor Doug Hooton, NSERC/ Cement Association of Canada, Senior Industrial Research Chair in Concrete Durability and Sustainability in Civil Engineering at the University of Toronto. Presentation: “Recognising the Different Forms of Sulfate Attack for Provision of Sulfate Resistant Concrete”

5. Professor Des Bull, Technical Director of Holmes Consulting Group LP. Civil and Structural Engineers and the Holcim Adjunct Professor in Concrete Design, Department of Civil and Natural Resources Engineering, University of Canterbury, New Zealand, and Mr Peter McBean, Joint Managing Director of Wallbridge Gilbert & Aztec. Presentation: “Seismic Design in Australia Post Christchurch”

Invited Speakers 1. Dr Stuart Matthews, Chief Engineer Construction at the Building Research Establishment (BRE) and Convenor of

fib Commission 3: Existing Concrete Structures. Presentation: Introduction to the durability provision in Model Code 2010 2. Mr Mike Schneider, Senior Vice President and Chief People Officer at Baker Concrete Constructions and Immediate Past President of the American Concrete Institute (ACI). Presentation: Case studies and challenges in the USA concrete construction industry The conference will offer delegates the opportunity to connect face to face and share innovative and interesting ideas with this incredible line up of industry experts.

Concrete 2017 Advances in Concrete Materials and Structures REGISTER NOW AT:

www.concrete2017.com.au

Construction Engineering Australia • Aug/Sept 2017

CONCRETE INSTITUTE NEWS

The 3rd International Congress on Durability of Concrete (ICDC) is a wonderful platform for exchanging ideas, knowledge, and research, and for displaying how concrete will continue to provide durable buildings and structures for sustainable development throughout the world. Within the generic durability theme, the Congress will cover more specific topics such as: • Durability design and planning • Cracking and crack control • Design and service life • Exposure assessment • Deterioration mechanisms • Good practice • Modelling of deterioration processes • Performance of existing structures

• In service inspection and testing • Structure health monitoring • Concrete repair • Material properties Along with Key Note Speaker Doug Hooton and Invited Speaker, Stuart Matthews, there are several internationally recognised durability experts presenting at the conference including: • Professor Harald Justnes - SINTEF Building and Infrastructure, Norway • Professor Phillip Bamforth - University of Sheffield on Asset Management and Service Life Protection, UK • Mr Frank Papworth – BCRC - Chair fib Commission 8, Joint Chair fib TG10.1 Durability Action Group, Australia

• Professor Carmen Andrade - Centre for Research in Security & Durability of Structures & Materials, Spain • Mr Joost Gulikers – Rijkswaterstaat Centre for Infrastructure, the Netherlands • Professor Ian Gilbert - Deputy Director of UNSW Centre for Infrastructure and Safety Research, Australia • Professor Frank Collins - Director of Australian Centre for Infrastructure Durability (ACID), Deakin University, Australia The conference will be the biggest congregation of worldwide concrete durability experts ever to come to Australia, and ICDC Chair, Mr Rodney Paull (Chair, CIA Durability Committee) invites you to be in Adelaide in October to be part of it all.

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Construction Engineering Australia • Aug/Sept 2017

SPONSORS Conference Partner

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CONCRETE 2017 PROGRAM The Technical Chair for Concrete 2017, Tom Benn, and ICDC 2017 Chair, Rodney Paull, are pleased to share with you the technical program for Concrete 2017. The three day conference will include four parallel sessions each day, providing delegates with every opportunity to attend papers on topics related to their specialities or key areas of interest. Some highlights that delegates can look forward to are: • The Durability stream running throughout the conference in conjunction with ICDC includes: Dr Philip Bamforth in a double session on “Revision to CIRIA C660 and the implications for the design for early-age thermal crack control”, as well as an Early Age Cracking theme, Design Life theme and Modelling theme with local and international experts. • Mr Shan Kumar, recently voted by Engineers Australia as one of the country’s most innovative engineers, is presenting his paper titled “Innovative Prefabricated Concrete Construction in High Rise Buildings”. • Mr Mike Schneider, past President of ACI and Senior Vice President at Baker Concrete Constructions in the USA, will be presenting on “Challenging Concrete Construction Projects in the USA”. This will include Baker Concrete Constructions' work on the Miami Museum of Science which showcased a martini glass shaped concrete ocean aquarium tank! To learn more about the details program and to start making your plans for Concrete 2017 go to: www.concrete2017.com.au/program

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EXHIBITORS 1

Akzo Nobel

Bluey Technologies

DSI Underground

36 - 39

FOSROC

Normet Asia Pacific

ramsetreid

SRG Limited

QuakeWrap

5&6

Max Frank

42 & 43

Sika

PCTE

44 & 47

BASF

Allcon Group Pty Ltd

The Construction Store

9A, 9B, 10

Stanley Black & Decker

Piekko

Aptus

Societe Le Nickel-SLN

Connolly Key Joint Pty Ltd

Available

Biorok Construct

Iccons / United Fasteners

Freyssinet

Cycrete

15 & 16

QUASCO

Available

17 & 18

Xypex Australia

Detection Solutions

Command Alkon

54 & 55

Hilti

Bennett Equipment

56 - 59

Krystol Group

Mapei

60 - 61

Available

Astra Concrete Products

Dayton Superior

V-Rod Australia/Inconmat

Duratec

24 & 27

Ancon

Consystex

Penetron

Phillro Industries

Flexiform Solutions

30 & 31

Ash Development Association; Australasian Slag Association; Concrete Pumping Association of Australia.

Specialist Repair and Construction Products

Mainmark

BOSFA

*Correct as of 23 August 2017

Construction Engineering Australia • Aug/Sept 2017

CONCRETE INSTITUTE NEWS

CONFERENCE WORKSHOPS Cement Chemistry for Engineers Sunday 22nd October Key note speaker, Professor Karen Scrivener, will deliver a full day course on cement chemistry. The course is a one day version of Professor Scriveners widely acclaimed more detailed course on cement chemistry that is conducted through RILEM, and is tailored for engineers, materials specialists, and cement & concrete practitioners. The course will commence at 9.00am and conclude at 5.00pm, and will include the following topics: • Setting the scene – options for sustainable development of concrete to meet the world demand and implications for cement chemistry. • Basics of Cement hydration - Nature of hydrates, thermodynamic prediction of hydrate assemblages, and mechanisms governing kinetics. • Physical structure of cement paste. • Impact of Supplementary Cementitious Materials (SCMs) on hydration and microstructure. • Impact of SCM on Durability, particularly ASR.

fib Model Code 2020 and World Durability Practices: Design Session Sunday 22nd October This special session will review the development of the next fib Model Code (MC2020) and the durability requirements within the code. In particular the workshop will consider the following question – “How do we move forward with design of new concrete structures and the through-life care of existing ones?” This half day workshop will commence at 1.00pm and conclude at 6.00pm, and will feature a “who’s who” of international concrete durability expertise, with an agenda that includes: • Dr Stuart Matthews, BRE-UK, Chair fib Commission 3, Convenor TG10.1 on MC2020 development • Frank Papworth, BCRC, Chair fib Commission 8, Joint Chair fib TG10.1’s Durability Action Group; CIA Durability Technical Committee • Prof. Phil Bamforth, Visiting Prof. University of Sheffield, UK, on Asset Management and Service Life Prediction

• Prof. Carmen Andrade, Centre for Research in Security & Durability of Structures & Materials Spain • Prof. Doug Hooton, Professor and NSERC/CAC Chair in Concrete Durability & Sustainability, University of Toronto, Canada, ACI Director, ACI Committee 201 “Durability”. • Dr Harald Justnes, SINTEF Building and Infrastructure, Norway • Mr Joost Gulikers – Rijkswaterstaat Centre for Infrastructure, the Netherlands • Emir. Prof. Ian Gilbert, Deputy Director of UNSW Centre for Infrastructure and Safety Research, CIA Durability Technical Committee • Rodney Paull, GHD, Chair CIA Durability Technical Committee • Dr Daksh Baweja, BG&E, Ass. Prof. of Civil Engineering, University of Technology, Sydney, CIA Durability Technical Committee For more details and to register go to www.concrete2017.com.au/workshops

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CONCRETE INSTITUTE NEWS

AWARDS FOR EXCELLENCE GALA DINNER The presentation to the winners of the Institute’s Awards for Concrete Excellence will take place at the conference Gala Dinner, to be held on Tuesday 24th October. This prestigious event, to be hosted this year by local South Australian celebrity and comedian Bruno Lucia, is one of the highlights of the conference and will recognise excellence in concrete in several categories. After a wonderful series of State Award ceremonies the finalists in our 5 categories for the 2017 National Awards for Concrete Excellence are:

RESIDENTIAL BUILDINGS • Clifftop House (QLD) – Built Environment Collective & Joe Adsett Architects • K - House (NSW) – MHN Design Union and Partridge Structural • Manly House (NSW) – Partridge Structural

COMMERCIAL BUILDINGS • 1 William Street, Brisbane (QLD) – Mutliplex and Arcadis • BCM Headquarters (VIC) – Crosier Scott Architects and BCM • Curtin University School of Medicine (WA) – Pritchard Francis and Georgiou Group • Flinders at Tonsley, School of Computer, Science, Engineering and Mathematics Building (SA) – Arup, Lendlease, Hassell, and Flinders University

• LaTrobe Tower (VIC) – Hickory Group • Orange Regional Musuem (NSW) – Taylor Thomson Whitting • Prefabricated Concrete for the Song School (SA, WA) – J.Woodside Consulting and SA Precast • Southpoint Stage B (QLD) – Aurecon and Watpac

INFRASTRUCTURE • Barangaroo Reserve (NSW) – Aurecon and Lendlease • Gateway WA (WA) – BG&E, GHD, & CPB • Jubilee Bridge (QLD) – Arup • Reid Highway Bridges over Mitchell Freeway and Malaga Drive (WA) – BG&E and Georgiou Group • Sunshine Coast University Hospital (QLD) – Aurecon and Lendlease • The New Royal Adelaide Hospital (SA) – Wallbridge Gilbert Aztec and KBR • Wynyard Walk (NSW) – Taylor Thomson Whitting and PMS

REPAIR AND REHABILITATION • The Adelaide Convention Centre Plenary Building – The Aggressive Relifing of an Existing Structure (SA) – Aurecon • Webb Dock East Berths 4 & 5 Rehabilitation (VIC) – Freyssinet Australia

TECHNOLOGY AND INNOVATION • 3D Concrete Printing using Cement and Geopolymer Binder Systems (VIC) Swinburne University of Technology

• An innovative light weight concrete panel system for high speed modular construction (VIC) - Associate Professor Tuan Ngo, Professor Priyan Mendis, Professor Jay Sanjayan, Dr Vinh Dao, Mr Nick Scheuer, Mr David Visser • Condition Investigation, Remaining Life Assessment and Inspection Maintenance and Repair Plan for Wandoo B Concrete Gravity Structure (WA) – GHD and Vermilion Oil and Gas Australia • Design of Prestressed Concrete to AS36002009 and Design of Prestressed Concrete to Eurocode 2 (NSW) - Professor Raymond Ian Gilbert and Professor Gianluca Ranzi • The InQuik Modular Concrete Bridging System (NSW) – InQuik and Lifting Point Pre-Form These finalists, along with all the project submissions will feature in the Institute’s Awards for Excellence publication to be handed out at the dinner. The Institute will also formally induct 2 new Life Members, former National President, Liza O’Moore, and long serving Secretary/ Treasurer, Craig Heidrich, along with 3 new Honorary Members, Tony Thomas, Professor Jay Sanjayan, and Professor Priyan Mendis, at the dinner. The National Engineering Bursary Award winner, Dr Ali Amin, will also be recognised for his outstanding thesis “Post Cracking Behaviour of Steel Fibre Reinforced Concrete: From Material to Structure” which he will also present at the conference.

Construction Engineering Australia • Aug/Sept 2017

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ACOUSTIC DESIGN

ACOUSTIC EXCELLENCE AT DARWIN EDUCATIONAL NEW ZEALAND GETS A FACILITY NEW PEAK BODY A unique educational facility, Darwin High School in the Northern Territory is not only surrounded by native tropical vegetation, it’s also located a stone’s throw from the Arafura Sea. The Northern Territory Government recently worked on an extensive project with long-term CSR Gyprock customer and highly awarded Plasterer, Roger Bailey of Bailey Interiors, to help solve a recurring issue with failing ceiling systems. “There was a need to manage the sound reverberation and reduction of noise within the learning environments at Darwin High School, so an acoustic ceiling tile was a necessary inclusion”, says Mark Taylor, Director of Buildings Maintenance and Minor Works, Northern Territory Government. This project was considerably large in scale, replacing approximately 3,000 square metres of ceilings in the administration building of the high school, all whilst working with a limited time frame during mid-term school holidays. From this range of custom made ceiling tiles, Roger Bailey put forward the high quality Shadex option, a 600mm x 600mm acoustic bespoke ceiling tile made with Gyprock Casting Plaster – a grit free speciality plaster that produces a strong moulded product with a clean cast face. Incorporating a 3D grid pattern of tiny square blocks randomly aligned on the tile, Shadex provides a rigid, faceted diamond appearance once installed. “I wanted to ensure that the ceiling tiles created were unique in style, aesthetically pleasing and most importantly, offered excellent sound absorption capabilities”, explains Bailey. The Shadex design offered an attractive ceiling solution with the highest acoustic rating possible to reduce noise transfer and sound reverberation in crucial learning environments. The Northern Territory Government is extremely pleased with the successful outcome and innovative product delivered by Roger Bailey, with the refurbished ceiling improving the overall performance of the administration space. For more information about the Bailey Interiors range, visit the website at: www.australainplasteracoustics.com.au, or for more information about Gyprock, visit the website at: www.gyprock.com.au

Construction Engineering Australia • Aug/Sept 2017

The peak-body committed to supporting the acoustics profession, the Association of Australasian Acoustical Consultants (AAAC), recently announced that it will now represent acoustical consultancies in New Zealand and brings on seven additional consultancies as members of the organisation. The organisation now has 65 member firms, employing approximately 400 consultants reflecting a $90m size industry. Its members are comprised of the most highly qualified and experienced acoustic professionals across Australasia. New members’ projects include Television New Zealand, Auckland’s City Rail Link and Christchurch Convention Centre. The AAAC aims to raise the standards of acoustics practice across Australasia. The peak-body helps to educate industry professionals and the public on the role which good acoustics, and the management and mitigation of noise and vibration play in achieving good design and effective planning in the built and natural environment. New Zealand firms who are now AAAC members include Acoustic Engineering Services; AECOM (Auckland); AECOM (Christchurch); Malcolm Hunt Associates; Marshall Day Acoustics; Norman Disney & Young, SLR Consulting; and StylesGroup. There is growing public awareness of the importance of good acoustical design and this field is popular amongst architects, engineers and other building professionals. AAAC members provide advice to a diverse range of clients from developers and property owners, planners and architects, lawyers, local authorities and private householders, and lead their profession in technical expertise, research, innovation, and development of real-world, practical solutions for application to all types of environments. From minimizing the adverse impacts of noise on the public to ensuring the acoustics design of hospitals, schools and public buildings optimally supports function, productivity and enhances the aural environment is key to the acoustics professionals’ role. The Chair of AAAC, Matthew Stead, says, “for the first time in New Zealand, acoustic consultancies will have their own body which will give access to standardised approaches and procedures, training opportunities and a community of like-minded specialists to network with and learn from. “We’re very pleased to welcome our New Zealand members and are looking forward to learning from our counterparts and colleagues across the water.” Christian Vossart, Senior Acoustics Consultant and Building Acoustics Manager at New Zealand based company Styles Group says, “We’re very happy that the scope of the AAAC now includes New Zealand. We believe the AAAC has a very important role to play in raising the awareness of noise and vibration effects and the increasing importance that good acoustic design plays in our modern society.” The Association of Australasian Acoustical Consultants (AAAC), founded in 1978, is a not-for-profit peak body whose members provide consultancy advice in all areas of acoustics, noise and vibration. For further information, please visit: www.aaac.org.au

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EQUIPMENT FEATURE

FAYMONVILLE PREFAMAX

The NEW Precast Concrete Panel system for Australia Belgium-based specialist trailer manufacturer, Faymonville, is represented in Australia by MRSK Pty Ltd. Director, Mike Dunbar, has been importing, selling and supporting Faymonville products since 2010. Faymonville’s iconic PrefaMax precast In-Loader trailer is now operating in Australia. This system is regarded as the minimum standard for delivery of precast panels throughout Europe. The In-Loader system delivers in several areas, including maximum safety and efficiency.

MANUFACTURE The PrefaMax In-Loader system reduces the requirement for craneage and labour. The precast panels may be placed directly on the In-Loader pallet to cure. The pallets are able to be moved from the manufacturing position into storage by the trailer without the need for any further interaction with labour, forklifts or cranes.

DELIVERY There is no requirement for labour or cranes with the PrefaMax system. The trailer is able to self-load the loaded pallet, utilising a hydraulic suspension system. The precast panels are contained within the trailer and the panels are restrained on the pallet via a “sword and wedge” system. The panels are also clamped via four hydraulic securing devices. The pallet base travels at 260 mm from the ground. A hydraulic tailgate completes the security aspect of the Faymonville PrefaMax In Loader system. This delivers the ability to transport larger panels in the vertical mode, eliminating the requirement for escort services and reduces the requirement to travel inside of curfew times.

Construction Engineering Australia • Aug/Sept 2017

This system delivers, without doubt, the SAFEST method of delivering precast panels.

INSTALLATION The PrefaMax In-Loader system will reduce craneage and demurrage at the installation point. If space permits, the loaded pallets can be staged, and cranes called, when a suitable number of panels are on site. If space is not available to stage, the PrefaMax can be utilised in the same way as conventional trailers with the panels being lifted directly off the pallet. The pallet may be contained within the trailer while the panels are lifted. This operation delivers the safety advantage of being able to sit the trailer on the ground during the lifting process. This ensures the most stable footprint is maintained. The lifting points will also be lower than if the panel was transported on a conventional trailer. Speaking about the Faymonville PrefaMax precast In-Loader, Mike Dunbar states: “In Europe, the In-Loader system is deemed as the minimum standard. In many countries you simply cannot deliver precast panels on an A frame sitting on a drop deck, the risk is deemed too great.” “Once Australian Precast manufacturers, transporters and builders understand the benefits of the In-Loader system, it becomes a no brainer,” he said. “The safety and efficiency benefits of the PrefaMAX In-Loader system deliver on every level,” Mike Dunbar concluded. For further information, please contact: Mike Dunbar, MRSK Pty Ltd, M: 0447 262 338, E: dunbarm@westnet.com.au or visit the website: www.mrskptyltd.com

PrefaMAX the NEW standard for concrete panel transportation in Australia

Australian representative: MRSK Pty Ltd, Mike Dunbar | E: dunbarm@westnet.com.au M: 0447 262 338 W: mrskptyltd.com

NATIONAL PRECAST FEATURE

TECH TALK: A LOOK AT ENGINEERING TOLERANCES FOR PRECAST CONCRETE The first in a series of National Precast Tech Talks. At National Precast, we strive to educate and provide assistance to professionals within the construction industry. We thought we’d create our very own Tech Talk series, whereby we answer some of the commonly asked questions within the precast concrete space—beginning with this inaugural edition focusing on tolerances. Many professions within the civil and structural spaces require an appreciation of the deviations that naturally occur during the fabrication and construction process. Engineering tolerances exist to ensure that the finished product is fit for purpose. There will inevitably be differences between the specified dimensions and the actual dimensions of any precast element. Therefore, it’s important that these variations are recognised and allowed for. Precast concrete is typically manufactured with relatively high accuracy and precision, but designers should take a realistic view of dimensional variability. It is essential to consider this from the start of a project and tolerances should be discussed as early as possible with the selected precaster.

DEFINITIONS: - Tolerance: the permitted deviation from a specified linear, angular or profile dimension or shape. - Building tolerance: the tolerance on the overall building, the building structure, and parts of the building that interface with precast members. - Manufacturing tolerance: the tolerance on the dimensions and shape of a precast element. Precast Concrete Handbook (National Precast, 2009)

WHY ARE TOLERANCES SO IMPORTANT? WHAT ARE BUILDING TOLERANCES? We need to think of building tolerances as the overall tolerance of the structure. Understanding is needed on the tolerance of each individual component, as an accumulation of tolerances can be problematic. General tolerances for concrete structures are set out in AS 3600-2009 Concrete structures, however more stringent tolerances may be required to assure serviceability, fit of components, or aesthetics of the structure. Dimensional inaccuracies of in-situ parts of the structure may affect the erection of precast elements.

WHAT ARE THE DIFFERENT TYPES OF TOLERANCES?

WHAT ARE MANUFACTURING TOLERANCES?

It’s important to acknowledge that some degree of deviation is inherent in all building, structural, and civil works. These variations include not only dimensional, but surface finish and colour as well (which we will cover in a future Tech Talk). As for the various tolerances, there are two general key types, building and manufacturing. Not only should they be tolerated, but they should be respected also.

Manufacturing tolerances can be described as the defined envelope within which the precast element must lie. Manufacturing tolerances include dimensional deviations, non-linearity, non-flatness, lack of orthogonality of the cross-section, and camber deviations for prestressed elements. Experienced design engineers understand that importance of specifying tolerances in the pretender documentation.

APART FROM SHAPE, WHAT ELSE SHOULD BE CONSIDERED? Other considerations are the locational tolerance of cast-in items and reinforcement tolerances. Cast-in items are often used for connections, propping, and lifting, therefore their location is safety critical. An understanding and appreciation of manufacturing will be reflected on the pre-tender documentation. Reinforcement tolerance relates to length, shape, bends, and cover. Unnecessarily tight 40

Construction Engineering Australia • Aug/Sept 2017

tolerances can complicate or even inhibit the assembly of complex reinforcement cages. A designer needs to understand the effect that bends play within the overall reinforcement design. AS 3600-2009 Concrete structures outlines minimum acceptable pin diameters for bending reinforcement. Cover to reinforcement is a critical area for durability and fire performance. Specifying the cover and tolerance is all part of the design phase. If you are in any doubt as to what can be practically achieved, talk to your local National Precast Member.

Simply put, tolerances are important as they ensure components fit together as designed. Difficulties arise where the in-situ part of a structure is built out-of-tolerance and/or minimal consideration has been given for the subsequent fixing of the precast. Therefore, tolerances on the dimensions between parts of the structure and their relationship to each other must be understood and appreciated. These determine, in part, that the structure will fit together, perform adequately in service, and have a satisfactory appearance. A benefit of precast is that you may be able to adjust elements that are yet to be cast, to fit alongside out-of-tolerance components already installed.

HOW DOES PRECAST CONCRETE ASSIST? The position of the precast concrete element, its function, appearance, and the influence of these on the total project typically define the appropriate tolerances. Precast concrete significantly enhances accuracy when it comes to reinforcement and manufacturing tolerances. The controlled conditions, high precision, and high-tech manufacturing within a precast factory allows for sharp detailing throughout the entire process. Therefore, building and manufacturing with precast concrete demands a clear appreciation of the tolerances throughout every aspect of construction.

HOW DO I FIND OUT MORE? For more information on tolerances and advanced knowledge of design, manufacture, and the use of precast concrete, refer to the Precast Concrete Handbook (National Precast, 2009)— available for purchase from National Precast at www.nationalprecast.com.au

NATIONAL PRECAST FEATURE

STATE OF THE ART RESEARCH FACILITY PROJECT: Sarich Neuroscience Research Institute LOCATION: QE11 Medical Centre Hospital, Nedlands, WA PRECASTER: Delta Corporation BUILDER: Esselmont Cockram ARCHITECT: Bateman Architect ENGINEER: Kellogg Brown & Root CLIENT: WA Health Department

Five of Western Australia’s premier neurological research organisations will have a new place to call home and precast concrete sets the backdrop for the design. The new $37.7million purpose-built facility – the Sarich Neuroscience Research Institute – will accommodate Curtin University’s Neuroscience Research Laboratory, the Ear Science Institute of Australia, the McCusker Alzheimer’s Research Foundation, the Neurofinity Surgical NeuroDiscovery Group, and the Western Australian Neurosciences Research Institute. It is named after the philanthropic Sarich family, the project’s major funder.

1,876 m2 of panels were manufactured for the project at Delta’s Herne Hill factory. The off-white panels have a Class 1 surface finish and take prominence, sitting immediately behind a digitally printed glass curtain screen at the front of the building and are framed by contrasting black honed and sealed panels.

BESPOKE PANELS TO SUIT The wall panels were manufactured in various sizes and thicknesses ranged from 150mm to 200mm. The black honed panels were up to 13 metres long and 4 metres wide, while the white off-form panels were up to 7.1 metres long by 2.5 metres high. In addition, nine twin coloured panels were also manufactured, which were up to 6.6 metres long and 2.5 metres high.

STRIKING ARCHITECTURAL FINISHES: OFF-SITE MANUFACTURE DELIVERS SUPERB QUALITY According to Jason Walsh, General Manager of Delta, the quality of the honed and off-form finishes and the ability to manufacture the twin coloured panels to the architect’s satisfaction were critical determinants for specifying precast concrete.

“That’s the beauty of using precast for projects like this one that require such a high level of finish. The steel moulds we use and our quality control system ensures an extremely high finish and a spectacular result. That is something that would be near impossible to achieve from an on-site pour and shows the versatility of precast,” Mr Walsh explained. “While the panels were specified as Class 2, we have achieved a Class 1 finish, which whilst it should only ever be specified for one off elements of a monumental nature, it can be achieved under certain circumstances.”

CONTRIBUTING TO NEW ERA OF RESEARCH According to Mr Walsh, the Delta team takes great pride in the solutions the company offers and the high quality of the results it delivers, and this project is no exception. “The combination of black honed and white off-form finishes on the precast wall panels has resulted in a stunning final result. We are proud to have played a small part in what will be the largest medical, research and educational facility in WA and this exciting new era in world class neuroscience research”, he said.

STUNNING DESIGN OF ALMOST 9,000M2 OVER 5 LEVELS Located at the Queen Elizabeth II Medical Centre at Nedlands, WA, the Institute is a cutting edge medical research centre spread across five levels and includes 8,932m2 of clinical facilities. With the five organisations under its roof, the centre will include rooms for assessments and treatments, along with tissue culture laboratories and facilities for neurodiscovery movement analysis, physiology research, experiments and cryogenic archival storage. Part of the architect’s brief was an operationally efficient, cost effective structure that, while tailored to suit the needs of its tenants, could be readily adapted to suture changes in occupancy, research and practices. The design is spectacular, and Perth-based National Precast member Delta Corporation was awarded the contract to manufacture 117 black and off-white precast wall panels that form an integral part of the structure’s design. In total,

Construction Engineering Australia • Aug/Sept 2017

NATIONAL PRECAST FEATURE Photo courtesy Yarra Valley Water

TERMODECK® TO MANAGE TEMPERATURE AND AIR FLOW

5-STAR WATER UTILITY WITH PRECAST PROJECT: YARRA VALLEY WATER MITCHAM OFFICE REFURBISHMENT PRECASTER: HOLLOW CORE CONCRETE CLIENT: YARRA VALLEY WATER DESIGNER: GHD As Melbourne’s largest retail water utility, Yarra Valley Water provides essential water and sanitation services to more than 1.8 million people. The utility company provides these facilities to approximately 30 per cent of Victoria’s population, servicing an area stretching from the inner eastern and northern suburbs of Melbourne through to the Yarra Valley. When embarking on an expansion of its headquarters in Mitcham, Melbourne, the focus was on minimising environmental impact while also ensuring expansive column-free internal spaces. To achieve this brief, sophisticated simulation tools and modelling were used. Precast concrete walls, floors, beams, columns, lift cores, and stair units became the favoured option and National Precast member, Hollow Core Concrete was contracted for the precast manufacture.

THERMALLY-EFFICIENT DESIGN WITH PRECAST CONCRETE Hollow Core Concrete’s Managing Director, Peter Healy, says the off-site manufactured precast concrete elements were integral to attaining the building’s thermally-efficient design and its wide, open spaces. “The precast façade enabled a high-performance building envelope that was combined with TermoDeck® – an innovative ventilation system that uses long-spanning hollow-core flooring,” Mr Healy explained. “The spans were greater than what would have been achievable using in-situ concrete flooring.”

PRECAST CONCRETE STAIRWAY ‘KEEPIN’ IT WHEEL’ STRINGENT TOLERANCES AND COMPLEX DIMENSIONS – PRECAST SHINES There’s a wide-ranging appreciation for innovative designs using precast concrete. As just one example of how precast can be applied in a slightly different way, the ACT Government is giving Woden commuters another handy way to whiz around. The renewal project for the local bus interchange boasts a functional and visually pleasant feature—a precast concrete stairway that caters not just for pedestrians, but for cyclists too. 42

Construction Engineering Australia • Aug/Sept 2017

TermoDeck® is an energy efficient heating, cooling, and ventilation system that uses the high thermal mass of structural hollow-core flooring slabs to manage the surface temperatures and flows of air within a space. Here, the temperature and energy retained in the building structure is actively controlled. By fan assisting air distribution, TermoDeck® is an effective way of maintaining comfortable and stable temperatures and ultimately results in lower overall energy consumption and reduced peak heating and cooling loads - all while maintaining comfort conditions. Integrating mechanical systems into the fabric of the building not only helped to attain the thermal criteria, but it also provided an integral heating, ventilation, and air conditioning (HVAC) solution. Reducing the ductwork by half, the building’s design allows the hollow-core slabs to simultaneously act as airdistribution paths and control the exposed ceiling surface temperatures. In addition to acting as an air-distribution path for the mechanical systems, the exposed hollow-core concrete slabs also form part of the radiant temperature control mechanism for all spaces; it actively manages the cooling and heating loads.

EXPOSED FINISH The exposed hollow-core flooring adopted a Class 2 finish to the underside of the planks, and according to Mr Healy, using this type of flooring resulted in a neat ceiling surface. “Using hollow-core enabled electrical and data cabling to be concealed. It also helped with acoustics, allowing for the installation of acoustic attenuation to manage reverberation rates in the open-plan office layout,” he said.

DATA MEASURING ENERGY SAVINGS While Yarra valley Water originally targeted a 4-star NABERS Energy performance, the brief evolved into delivering an energy-efficient 5-star Green Star Office V3 outcome. Mr Healy says that the client is satisfied with the end result and that data is being collected to confirm the energy savings. The project’s designer, GHD, predicts that the building should realise its designed energy consumption of 80.8kWH per square metre per year, along with carbon emissions of 58KG per square metre per year - a figure almost 61 per cent less than Australian best practice. When a full year’s data has been collected, GHD will look at opportunities to further improve energy performance.

PROJECT: WODEN BUS INTERCHANGE STAIRWAY & LANDSCAPING PROJECT VALUE: APPROX. $300,000 LOCATION: WODEN, ACT PRECASTER: HANSON PRECAST BUILDER: ACCLAIM CONTRACTORS ARCHITECT: CCG ARCHITECTS ENGINEER: SMEC CLIENT: ACT GOVERNMENT

Ivan Potrebica from Acclaim Contractors said he and the ACT Government are both impressed with the result. “We’re extremely pleased and so is the ACT Government. It’s a bit of a showcase and was a tough ask, with stringent tolerances and complex dimensions. Hanson Precast handled it in their stride,” he explained. “It goes to show what you can do with precast.”

ACT GOVERNMENT DEMANDS LONG LIFE, DURABILITY & MINIMAL MAINTENANCE The list of demands from government projects are rigorous and final and this project was no different. Durability and minimal long-term maintenance costs were at the heart of the ACT Government’s decision to procure the precast stairway. The architect’s vision combined with these demands needed a solution that could produce a high-quality product with superior weathering and corrosion-resistant qualities. The stairway was to be installed with minimal disruption and therefore precast was the only way to ensure all criteria were successfully met.

DESIGN The architecturally-designed stairway improves accessibility and safety for both pedestrians and cyclists. Its innovative design caters for cyclists and pedestrians alike, ‘keepin’ it wheel’ on the user-friendly front. Between two sets of stairs, dual bicycle lanes have been incorporated allowing riders to trundle their bikes alongside them. The complex floating stairway design is striking in appearance while ensuring functionality, allowing cyclists to commute hassle-free with their bikes. National Precast Member, Hanson Precast, was assigned the task of manufacturing the components for the stairway. Hanson’s Project Engineer, Robert Merjane, explains that the stairway’s floating effect would have been difficult to achieve using an alternative building material. “The stairs were architecturally designed to look as though they are suspended. In order to achieve that, clever planning was essential,” Mr Merjane further detailed, “the central stair units are curved along each side to accommodate the bike wheel. The moulding required to achieve that detail was quite intricate. We drew some of the elements in 3D to determine the shape and final dimensions and then custom-made the moulds accordingly.” Hanson’s Canberra Sales Representative, Drew Lincoln, also believes the final result is astonishing.“It’s incredibly rewarding when we get an opportunity to show off what we can do with precast and landscaping, particularly at the high end,” he said.

THE DETAILS From the landings to the surrounding walls, every element of the stairway was manufactured by Hanson Precast. Overall, the project encompasses 59 stair elements with a light acid-etched finish and 13 polished wall panels. The quality control, high tech equipment, and manufacturing precision that was able to be achieved in the factory, accomplished an intricate design that Mr Merjane believes would have been difficult to achieve had the stairway and walls been site-poured. “A high level of finish was one of the main reasons that precast was chosen for this project,”

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Construction Engineering Australia • Aug/Sept 2017

NATIONAL PRECAST FEATURE

PRECAST CONTRIBUTING TO HEALTH, SAFETY, AND THE ENVIRONMENT WITH LOW VOC National Precast Industry Partner, Dayton Superior, is introducing Earth Friendly® and low VOC chemicals to the Australian market—solutions that are found on worldwide construction projects, where performance at the highest level is not only a request, but a key requirement. With their motto being “Perform with Precision”, Dayton endeavours to deliver unwavering commitment to their customers, specifically in terms of safety, pride, innovation, productivity, and success. Available in an array of options, these Earth Friendly® and low VOC chemicals significantly add to precast concrete’s WHSE benefits.

CHEMICALS FOR ALL STAGES OF PRECAST MANUFACTURE AND CONSTRUCTION The use of VOC compliant chemicals in the precast and general building industry is not driven solely by the pursuit of Green Building Council compliance. Worker and owner health, safety, and environmental concerns are major considerations when choosing chemical products throughout the lifetime of a structure. Dayton’s Managing Director, Brent Poll, says it’s imperative to consider the impact of chemicals that are used in construction, from a project’s get go, and what is used in precast has a role to play. “There is no stage in the product life cycle where the choice of chemicals is more important than in a precast manufacturing facility,” he revealed. “Not only do workers benefit from using chemicals that are Earth Friendly® and low VOC, but the end users of the precast structure benefit as well.”

EXPLORING THE OPTIONS Dayton offers a wide variety of products within this space. From sealers and hardeners, to bond breakers and release agents, to evaporation retardants, Dayton’s environmentally friendly chemical products are as extensive as the benefits they provide. Read on to find out more. Clean StripTM J1EF Clean StripTM J1EF is an economical low VOC, Earth Friendly® concrete form release agent. Clean StripTM works to ensure clean and positive

Construction Engineering Australia • Aug/Sept 2017

Clean Strip Application

release from steel, fibreglass, plywood, urethane, and other concreteforming materials and form liners. “As a non-staining, biodegradable product that only requires water for clean-up, this product is better for the environment than alternative chemicals,” Mr Poll explained. Clean StripTM Ultra J3 A premium, low odour, ready-to-use, chemically reactive form release that is low VOC, Clean StripTM is ideal for architectural and precast concrete and for general forming applications. Like Clean StripTM J1EF (above), Clean StripTM Ultra J3 also works to ensure positive release of concrete-forming materials. Additionally, Clean StripTM Ultra J3 prolongs the life of plywood forms and acts to reduce rusting of steel forms. When properly applied, Clean StripTM Ultra J3 is non-staining, reduces the number of surface air voids (bug holes) and will not interfere with the adhesion of subsequent coatings.

NATIONAL PRECAST FEATURE

Sure HardTM Densifier J17 This product is a colourless and odourless solution of special reactive chemicals to penetrate concrete surfaces to seal, densify and harden concrete. Mr Poll says “Sure HardTM Densifier J17 is environmentally safe, water based, low VOC, produces no fumes, and may be used in locations with incidental food contact.”

Panel Treated with Architectural Finish

Sure LiftTM J6LVOC Sure LiftTM J6LVOC is a reactive and membrane forming, low VOC, solvent-based bond breaker. It is a special formula of polymers and propriety ingredients designed to provide clean, easy lifting of panels. This reduces the chance of workers being injured while struggling with heavy precast elements. AquaFilmTMJ74 Concentrate An evaporation retardant designed to minimise moisture loss, AquaFilmTM J74 Concentrate is a proprietary emulsion of unique organic compounds designed to minimise moisture loss from fresh concrete. A concentrate is diluted with potable water at a 9 to 1 ratio, making this an economical product. Mr Poll says AquaFilmTM Concentrate J74 is water-based, low VOC, and contains a blue fugitive dye for ease of visual inspection during application. “By clearly seeing where application has occurred, workers can avoid wet areas and only need to use as much product as necessary,” he explained.

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Lithium Hardener® Lithium Hardener® contains advanced lithium chemistry that hardens and dustproofs new and existing concrete. This easy-to-use water-based solution requires no rinsing and is VOC compliant in all areas of the world.

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IPWEA NSW NEWS

RECOGNITION OF ENGINEERS IPWEA NSW, the state’s leading public infrastructure body, has congratulated the NSW Government for its commitment to providing better and safer public infrastructure for people across metropolitan and regional areas. During August, the NSW Government formally presented a motion to Parliament that, if legislated, would ensure qualified engineers are at the centre of all local government infrastructure projects. The IPWEA NSW President, Board and CEO are pleased that a long and difficult campaign by IPWEA NSW is beginning to show positive results and has called on the assistance of engineers to help embed this motion into legislation. The Notice of Motion records: That this House: (1) Recognises the importance of qualified engineers and calls on the Government to introduce a requirement for all local government authorities to have a suitably qualified engineer. (2) Calls on the Government to recognise engineers as a profession, through a state and national registration scheme, similar to Queensland and as raised at Council of Australian Governments in 2011-12. (3) Supports cadetships for civil engineering across all Government projects, in order to ensure the long-term workforce capabilities. Tribute must be paid to the Members of Parliament who have taken the time to meet with IPWEA NSW, listen and champion this issue through a challenging time for Local Government. In particular, Mr John Sidoti MP, Parliamentary Secretary to Cabinet, Member for Drummoyne, a regular host and supporter of the IPWEA NSW Local Roads Congress.

Construction Engineering Australia • Aug/Sept 2017

Equally encouraging is the bi-partisan support to date, from all sides of Parliament. There is still a lot of work required to ensure this motion is set into legislation. Nevertheless, this motion represents a significant milestone in the recognition of Public Works Engineers for the fundamental role they play in building better, safer and more equitable communities across both city and regional NSW. The effective management of transport and community infrastructure networks by skilled and experienced engineers has never been more critical to the success of our communities and the financial sustainability of government. Whether that be providing a safe and efficient transport network, positive actions to address the road toll, safe high-quality drinking water, effective sewerage treatment to protect public health and our environment, coastal and flood engineering to mitigate the risk of storm damage or other community infrastructure to help drive the NSW economy, improve social equity and community safety outcomes, Engineers are at the forefront of our everyday life. The recognition that all governments need to support cadetships to ensure we have a highly skilled and qualified workforce to deliver innovative and sustainable infrastructure is a common-sense step that bodes well for the future. Like other trades and professions, investment in future skills development, provision of career pathways and improved diversity is an essential action by all governments to provide for our community's future. Over the next few months, IPWEA NSW will continue to build the case to support this motion and have it embedded into NSW legislation. We ask all members to regularly encourage all local Members of Parliament to actively support this endeavour.

FULLY FUNDED ROAD SAFETY AUDIT TRAINING Road deaths in NSW jumped by almost 10 per cent in 2016 prompting Australia’s peak public engineering body, IPWEA, to call on the NSW Government to enforce funding commitments to the NSW Local Government Road Safety Programme. Across the State, the number of fatalities resulting from road crashes peaked at 384 in 2016, an increase of 34 compared to 2015, with more deaths occurring on country roads. This is an ongoing concern for IPWEA NSW who has called for it to be addressed as a matter of priority. Through IPWEA NSW’s advocacy work in particular with the Minister for Roads, Maritime and Freight, Melinda Pavey MP and Secretary for Transport for NSW, Tim Reardon, this particular topic has been raised over and over again. In the 2016 IPWEA NSW Local Roads Congress Communique it was adopted that: The Congress fully supports The Local Government NSW (LGNSW) Submission on the NSW Budget for 2016/17 publication in relation to road and transport infrastructure issues. It is noted that there is some uncertainty in the basis for funding of the NSW Local Government Road Safety programme. The Congress calls on the State Government to confirm that funding for the NSW Local Government Road Safety Programme is on a three-year rolling programme basis and that this advice be formally confirmed for councils. Road safety audits form an integral part of the safe system approach to road safety, enabling road safety risks for all road users to be identified and addressed. Over time road safety audits will help contribute to an improved road environment and road safety outcomes. Road safety auditing and safe system training will

IPWEA NSW STATE CONFERENCE 2017 ENGINEERING, TAKING NSW FORWARD

bring many benefits to local government in terms of increased awareness of road safety issues and measures for addressing them on the local road network. In 2017 at the annual IPWEA NSW Local Roads Congress, IPWEA NSW was proud to have Transport for NSW announce that the NSW Government has acknowledged IPWEA NSW’s role as the main provider of road safety training and has offered IPWEA NSW funding amounting to $380,000 to support road safety audit training for two employees at no cost in every NSW Council over the next two years. IPWEA NSW’s advocacy and meeting with Government to concentrate on road safety enabled IPWEA NSW to achieve this funding. This will allow Councils to review their entire local road network with new eyes and integrate road safety into everything they do. Often this means making small changes to achieve far better outcomes. There will still be significant challenges in meeting the NSW road safety targets of a 30 per cent reduction in injury crashes compared to 2011 outcomes. There is a need for more road safety auditors equipped to identify road safety deficiencies and areas of risk that could lead to road crashes. IPWEA NSW, as outlined in the adopted 2017 Communique, now calls on all Councils to support this innovative training program and to develop formal road safety plans to help reduce the traumatic impacts on our communities of injury and fatal crashes, now costing an estimated $7.5B a year. NSW Police advises that more and more accidents are occurring due to a lack of grip on local roads. IPWEA NSW is and will continue to encourage NSW councils to refocus their budgets to fully fund their road resurfacing programs to save lives and ensure local roads are fit-for-purpose. IPWEA NSW will continue its advocacy work as well as engaging with NSW councils, hoping for a positive outcome within the next 18 months.

The IPWEA NSW State Conference is growing in size and reputation. The 2017 event will bring together technical partners and stakeholders who are engaged in infrastructure, asset management, road and rail safety, transport, water and waste water, risk management, the environment and sustainability, technical innovation and technology. The conference, to be held between November 8 and 10 at Crowne Plaza Hunter Valley, encourages representatives from across the profession and local government to exchange ideas and contribute to discussions on how engineering can take NSW forward and build communities. The conference offers a broad range of topics and sessions with speakers from The Impossible Institute, NSW Police Force, Consolidated Land and Rail Australia, Transport for NSW, Australian Driverless Vehicle Initiative and Traffic Engineering Centre and Tamworth Regional Economic Development amongst others. The final afternoon will see a panel session on Infrastructure and Community Safety facilitated by Fran Kelly. Some of the panellists include NSW Highway Patrol, Office of Local Government, Shadow Minister for Local Government, Statewide Mutual, ARRB, Transport for NSW and NSW Councils. Drawing delegates from across NSW, the conference is of particular relevance to people who provide support to or manage projects within infrastructure and public works; including engineers, public works managers, group managers, supervisors, technical staff, councillors, directors, general managers mas well as other public works’ disciplines including management utilities and State Government departments. Besides the above, the Conference offers an extensive program including: • Executive Master Class Wednesday afternoon on Leadership and Team building by Peter Berry.

• Welcome Reception with peers Wednesday evening • The largest exhibition space to date with extensive outdoor displays • Concurrent streams of technical papers and peer presentations • Outdoor demonstrations and the Highway Patrol’s new Concept Car • Annual IPWEA (NSW) AGM with announcement of new Board • The revered Engineering Excellence Awards Gala Dinner • Highly Commended and Winners in 11 categories including; The Minister for Local Government's Award for Innovation in Local Government Engineering • Workshop for Young IPWEA Members Saturday morning on Leadership and Building Job Relations • Partner Tour Thursday The full conference program and registration details are available at: www.ipwea.org/nsw

Located in the picturesque New South Wales Hunter Valley, the Crowne Plaza Hunter Valley will play host to the Institute of Public Works Engineering (NSW) Annual Conference 2017 from November 8 to 10.

Construction Engineering Australia • Aug/Sept 2017

IPWEA NSW NEWS

WOMEN IN STEM CONGRESS

DIPLOMA OF LOCAL GOVERNMENT OPERATIONAL WORKS IPWEA NSW is a Registered Training Organisation (RTO) that offers a variety of short but intense courses. These courses are designed to help you develop the skills required in your profession while minimising cost and time away from the workplace. IPWEA NSW recently applied to the Australian Skills Quality Authority for approval to offer a Diploma of Local Government GA50404, this was approved and will be available in the near future. The training can be found listed under training.gov.au. The Diploma of Local Government (Operational Works) reflects the role of personnel working in Local Government who perform tasks involving a high level of autonomy and requiring the application of significant judgement in planning and determining the selection of equipment/ roles, techniques for themselves and others. They are required to develop site-specific work instructions and practises to ensure the implementation of the site management systems, plans and policies. They demonstrate the application of a broad range of managerial, coordination and planning skills. The following courses are included as units of competencies for the above diploma: • Conduct and Lead Road Safety Courses • Manage a Local Government Project • Powers and Duties of a Local Government Engineer • Contract Admin and Contract Law • Timber Bridge Inspection • Supervisors Course 50

Construction Engineering Australia • Aug/Sept 2017

Science, technology, engineering and mathematics (STEM) are increasingly important to the Australian economy to future jobs. The fields of STEM play an instrumental role in designing our future world – they bring us new devices, fresh solutions to global problems and shape the landscape of our everyday lives. As women make up half the population of our world, it is vital that they are able to contribute and influence how it will look. Recent findings, however, show that the ratio of men to women in STEM professions is significantly imbalanced. In an effort to change this, the Australian Government will invest $13 million over five years to encourage women to embark on, and remain in, STEM related careers. IPWEA NSW is proud to host the inaugural Empowering Women in STEM Congress from October 18-19, 2017. The congress will be held in Sydney and will provide an opportunity to hear from accomplished STEM leaders who will share their inspirational experiences. The event aims to provide a positive action with outcomes on both the issue of gender diversity and bridging the skills gap through the introduction of a call-to-action communique. Women make up about 25 per cent of the STEM workforce while 75 per cent of the fastest growing industries require STEM skills. Through our call-to-action communique, we will discuss and debate the following topical areas: • How do organisations engage with the unique perspective of individuals from diverse backgrounds beyond fulfilling quotas?

• How do women balance professional and personal demands in STEM careers and what can employers implement to support women? • With individuals in STEM branching off to less technical roles, how will organisations re-attract these individuals into such roles? • How can the Australian Government support and work with education providers to increase the quantity and quality of STEM graduates from higher education? • Should mathematics be re-established as a pre-requisite for obtaining an ATAR? • How do you design your recruitment strategies to attract and retain women? • Bringing together sector leaders, this national event will strengthen pathways between education providers and industry to ensure Australia acquires and retains the best talent in STEM fields. Leading presenters include: • The Hon Tanya Davies MP, NSW Minister for Women • Dr Mehreen Faruqi, Greens NSW MP • Kerry Lunney, Chief Engineer and General Manager – Technology, Thales • Narelle Underwood, NSW Surveyor General and Director Survey Operations, NSW Spatial Services • Gavin Fox-Smith, Managing Director, Johnson & Johnson Medical • Dr Rochelle Macdonald, General Manager – Engineering and Development, North Queensland Bulk Ports Corporation • And many more! If you want to be part of IPWEA NSW’s upcoming Empowering Women in STEM Congress and contribute to nationwide debate about future government STEM policy, please visit: www.wisecongress.com.au

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C&P2017 TO SHOWCASE CORROSION PREVENTION ADVANCES With the book of soon to be published abstracts, the next Corrosion & Prevention conference hosted by the Australasian Corrosion Association (ACA) is fast approaching. Once again, the annual conference and trade exhibition brings together leading researchers and industry practitioners who combat corrosion on a daily basis. The ACA will welcome delegates to C&P2017 at the International Convention Centre, Sydney (ICC). Recently rebuilt, the ICC opened in December 2016 and is at the heart of its own harbour waterfront precinct, set amongst restaurants, retail outlets and a vibrant public domain on Darling Harbour on Cockle Bay. The venue is only a short walk away from Australia’s largest CBD and surrounding university and cultural quarters. As always, the focus of the ACA's annual conference and trade exhibition will be the safe and effective management of the continuing challenge posed by corrosion. It has been estimated that industries and governments spend billions of dollars every year on corrosion mitigation and repair, making it vital that the latest technologies and practices are applied to managing this insidious threat.

Industry experts will deliver six plenary addresses - including the F P Thompson Lecture - and dozens of seminars across four technical streams, in addition to seven forums. Staged between 12-15 November 2017, more than 500 delegates are expected to attend the conference and extensive exhibition supported of key industry suppliers. The diverse technical streams will showcase the latest developments in corrosion prevention, management and mitigation. The broad themes of the technical seminars are coatings, concrete & asset management, the oil & gas and offshore industry and research. Topics covered will range from buried urban pipeline protection to hands-on applications including advances in sensing & monitoring; asset management; cathodic protection; concrete corrosion and repair; corrosion mechanisms, modelling and prediction; materials selection and design, and protective coatings Professor Maria Forsyth will deliver the Thompson Memorial Lecture in 2017 detailing why chemistry is the best counterattack to control corrosion and extend the life of materials. The lecture commemorates

the work of corrosion science pioneer, P F Thompson, and has been delivered every year at the ACA's annual conference since 1951. C&P2017 will be the premier networking opportunity for delegates to network with colleagues and peers, in addition to being a source for the latest information concerning corrosion prevention, control and repair. For further information, including registrations, please visit the website: www.acaconference.com.au

ABOUT THE AUSTRALASIAN CORROSION ASSOCIATION The Australasian Corrosion Association Incorporated (ACA) is a not-for-profit, membership association, that disseminates information on corrosion and its prevention through the provision of training courses, seminars, conferences, publications and other activities. The vision of the ACA is that corrosion is managed sustainably and cost effectively to ensure the health and safety of the community and protection of the environment. For further information, please visit the web site: www.corrosion.com.au

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wattylprotectivecoatings@valspar.com www.wattylprotectivecoatings.com Construction Engineering Australia • Aug/Sept 2017

ACA CORROSION FEATURE

HYBRID CATHODIC PROTECTION SYSTEMS SAVE A NEW ZEALAND BRIDGE by Corrie Cooke For the first time in New Zealand a local operator has provided a state of the art hybrid corrosion protection system on concrete support piles under a major highway bridge in Auckland. This technology was designed by international experts whose research has revolutionised the understanding of how Impressed Current Cathodic Protection (ICCP) performs. This paper is a summary of the May 2016 one-day seminar Protecting Infrastructure and Assets against Corrosion, which was hosted by the Australasian Corrosion Association’s New Zealand Branch in Auckland. The exciting program development is built on work presented at the Adelaide Corrosion and Prevention Conference in Adelaide in November 2015. The hybrid anode system combines elements of re-alkalisation, cathodic protection and galvanic protection which 54

Construction Engineering Australia • Aug/Sept 2017

can be applied as a global or a targeted protection system for the concrete element or the whole structure. In the UK and Australia, investigations have been conducted into the occasional positive effects of interrupting cathodic protection on reinforced concrete structures. Preliminary laboratory results suggested that applying ICCP to a reinforced concrete structure over a period of time can transform the environment around the reinforcement, even after the protective current had been interrupted. In his presentation Dr Christian Christodoulou, a Technical Director with AECOM Ltd in the UK, whose expertise covers the field of corrosion asset management, repair and refurbishment of concrete structures, noted that, “ICCP has been the most popular electrochemical solution for the repair and maintenance of reinforced concrete structures worldwide.

It can arrest corrosion activity and extend service life in a very sustainable manner, by reducing the need to remove chloride from salt-contaminated but otherwise sound concrete.” Applying cathodic protection to a reinforced concrete structure is accepted as a cost effective way to transform the environment around the reinforcement, and move it from being aggressive to passive. This transition is achieved by chloride ion removal and increased alkalinisation through the reduction of interstitial water and dissolved oxygen. Under these changed conditions, the microenvironment is benign and so corrosion ceases.

ACA CORROSION FEATURE

The key finding of their research was that, in the event of the impressed current system being interrupted for long periods, the steel remained passive for at least 52 months, even in the presence of chloride ions, on highway structures in the UK and Australia. Even in the more aggressive environments associated with marine structures, it was shown that in the majority of cases examined, steel potentials moved towards more positive values that suggest passive conditions were maintained.

THE HYBRID SYSTEM IN NZ Repairing marine structures is especially problematic when they have been made

of reinforced concrete. This is due to a combination of heavy wear and abrasion from wave action and inter-tidal saturation with salt water means that chloride-induced corrosion can advance very quickly. Sika (NZ) Ltd is working with Dr Christodoulou to ensure that the proposed hybrid anode system will work effectively on the Auckland bridge. Some of the original piles were installed over 40 years ago, and appear to have lasted well according to assessments by members of the local Sika team. Utilising corrosion potential mapping, the overall environmental condition of the piles within the concrete proved to be successful. This mapping was conducted at the concrete’s surface with either a silver/ silver chloride or copper/copper sulphate half-cell, in electrical connection to the existing reinforcing. Following installation of the relevant reference electrodes on a predetermined grid design, a series of manganese dioxide anodes were installed. This allowed the designer to measure the effectiveness of both the impressed current and cathodic protection systems, using readings taken from inside the pile structure. These readings were collected via a data-logger and the results were relayed to the designer, which facilitated the optimal placement of the hybrid anodes. Following confirmation of this plan the anodes were then installed in drilled holes and connected via titanium wire. The advantage of such installations is that in each location the designer has the ability to adjust the amount of current to selected zones, depending on whether the area is predominantly a tidal, splash, or atmospheric zone. Once a suitable current has been passed in this impressed current phase and the zone is appropriately passivated, the power supply can be removed from the appropriately passivated zone and a galvanic phase of protection is initiated. Traditionally the options available to asset owners for chloride or carbon contaminated concrete have included: • Breaking out and replacing all of the contaminated concrete, which is a cost prohibitive exercise. • Application of a surface applied corrosion inhibitor (SACI) - with a short term (10 years) life span and limited penetration with chloride rich concrete environments.

Construction Engineering Australia • Aug/Sept 2017

ACA CORROSION FEATURE

• Re-alkalisation or chloride extraction can be difficult to achieve success and to effectively monitor. • Impressed current cathodic protection – drawbacks with on-going costs of monitoring, control, power supply and cable maintenance

PATCH REPAIRS In the case of marine structures, steel is typically de-passivated by chlorides migrating through the concrete from the external environment, building up in sufficient concentrations at the steelconcrete interface to damage the naturally protective iron oxide film. Once de-passivated, iron oxides and hydroxides develop at the anode as a result of oxidative hydrolysis of the primary corrosion products. The concomitant massive volume expansion provides the driving force for the spalling of the concrete cover on the steel reinforcing bars, exacerbating the corrosion problem.

Construction Engineering Australia • Aug/Sept 2017

Concrete patch repair is a common technique for this challenge, involving the removal of physically deteriorated concrete, cleaning the steel reinforcement and replacing with a repair mortar.

However, in many cases further corrosion is soon observed around concrete patch repairs. This phenomenon is usually known as incipient or ring anode formation.

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