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CIRCULATION 15105 Registered by Australia Post Publication No. 100001889

ISSN 2204-7247

October 2015 Volume 1 Number 5

12 Cover Feature



Project Feature: Italy Pavilion

24 Worksite Safety: Doka 28 Structural Formwork


30 32 Formwork Special: Barangaroo 34 Innovative Solutions 36 Feature: World of Concrete 2015


40 National Precast Feature


About the Cover

Developed with a focus on ensuring that schools, councils and developers are able to get the most out of their available space, Aussie Outdoor Design offers an array of outdoor recreation solutions, including multi-use sport courts, play equipment, specialist surface solutions and even outdoor gym equipment. Modern, attractive and safe facilities which attract community patronage and encourage more of an active outdoor lifestyle. Turn to Page 12 for the full story.


Improving Safety and Amenity along Bike Paths and Recreational Trails From relatively simple paths, through to fully-engineered paved bikeways (complete with bridges, underpasses and even floating and/or elevated ‘boardwalk’ sections) bike paths and recreational trails now represent a significant infrastructure investment for councils and road authorities throughout Australia. In addition to these ‘purpose-built’ facilities, there is also an extensive network of ‘on-road’ dedicated cycle lanes - ranging in size from small, partial-lane, through to full-lane, and even ‘half-road’ bike lane space allocations. In fact, in many areas, the bike path and lane network has been developed to such an extent that it now transcends a simple recreational facility - moving instead into the realm of a significant and legitimate transport corridor. Not surprisingly, the development of high quality bike path infrastructure has played a major role in encouraging people to take up recreational cycling. It is also a key factor in the steady increase in the number of people now using bicycles to commute to and from work and for other regular journeys. One only has to look at the growth in usage along major bicycle infrastructure corridors to appreciate the positive impact of these facilities. What’s more, the continuing massive growth in bike sales throughout Australia, make it clear that we can expect a constant and steady increase in cycling over coming years. Interestingly, the increase in bicycle infrastructure, together with the massive increase in the popularity and use of these facilities, has raised a number of important 2

Construction Engineering Australia - October 2015

issues - particularly in relation to managing usage and safety issues. First and foremost is the question of ‘traffic’ speeds and hierarchies. Even though the majority of these facilities have been designed for use by both pedestrians and cyclists - with many line-marked in an attempt to separate the two - the apparent lack of understanding of how this ‘shareduse’ system should work often results in an extremely dangerous situation for cyclists and pedestrians alike. This problem is further compounded by the significant speed variables that prevail both between and within the two user groups (eg. walkers vs joggers / slow cyclists vs fast cyclists) and between other users such as roller-bladers and non-motorised scooter riders. The other major issue facing legitimate users of bike paths and recreational trails is the number of motorised vehicles attempting to use these facilities. By this I am, of course, referring to the myriad of motorised scooters, skateboards, pushbikes and mini bikes now available in the marketplace. While in some areas these vehicles can be purchased and operated legally by minors without a license in an off-road situation (due to their small engine capacity), it appears that many owners of such vehicles believe that this is tantamount to an invitation to use them along bike paths and recreational trails - despite the fact that many of these vehicles are capable of achieving speeds well in excess of 40kph - a speed which is clearly inappropriate for a shared-use path where pedestrians may be encountered at any time.

With an ever-increasing number of people now using bike paths and recreational trails on a regular basis, I believe that the time has come for us to make every effort to educate the community as to the correct use of these facilities. Although it may seem fair to assume that most people would know (instinctively or otherwise) how they should behave when using these facilities, and what rules apply both in terms of acceptable usage and traffic rules - the evidence would suggest that this is regrettably not the case. Put simply, I believe that if we are to succeed in encouraging more people to use these facilities, either for recreation and fitness or as a legitimate form of sustainable transport, we need to ensure that these facilities are well managed, well maintained and safe for all to use. And for this to happen, we will also have to invest in an education campaign that teaches people how to use these facilities correctly and safely.

Anthony T Schmidt Managing Editor


We value your opinion and welcome your feedback and input.


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Sydney implementing energy master plan Making it easier for businesses to become carbon neutral Reforming the National Carbon Offset Standard and the Carbon Neutral Program will – according to Federal Environment Minister, Greg Hunt - make it easier for businesses to become carbon neutral. A range of organisations are already carbon neutral. Certified organisations such as Qantas, National Australia Bank, and Melbourne City Council together offset around one million tonnes of emissions per annum under the Carbon Neutral Program. Reforms to the scheme would, Minister Hunt said, make it easier for organisations to become carbon neutral, with the aim of significantly increasing the number of participants and emissions savings. “The government will work with an industry partner to grow the Carbon Neutral Program, enhance consumer understanding of the National Carbon Offset Standard Trade Mark and boost benefits for program participants. “It will also streamline reporting and auditing procedures, improve guidance on emissions reporting and revise the list of offsets eligible under the National Carbon Offset Standard.” Mr Hunt said new versions of the National Carbon Offset Standard and the Carbon Neutral Program Guidelines would be released in the coming months. The National Carbon Offset Standard provides a benchmark for organisations in Australia voluntarily seeking carbon neutrality for their operations, products, services or events. The Carbon Neutral Program gives organisations the opportunity to have their operations, products services and events certified as carbon neutral, offering consumers wider carbon neutral purchasing choices. The Emissions Reduction Fund has already delivered 47 million tonnes of emissions reductions to date. The Renewable Energy Target will double renewable energy in the next five years.


Construction Engineering Australia - October 2015

Businesses and residents in the City of Sydney can increase energy efficiency and save more than $600 million in power bills by 2030 under what council describes as a ground-breaking plan. The City of Sydney has approved a final version of the Energy Efficiency Master Plan that shows by 2030, the building sector could save 31 per cent of its energy use, even with an expected 29 per cent increase in floor space. Approval of the plan in late August came as state and federal governments stepped up efforts to increase energy efficiency. The Council of Australian Governments (COAG) Energy Council is backing a move to increase Australia’s energy productivity by up to 40 per cent by 2030. Adoption of the energy efficiency plan also coincided with international recognition of the City’s efforts to improve energy efficiency in buildings. The US-based Carbon Neutral Cities Alliance has allocated the City $60,000 to fund a project to make high rise apartment blocks energy neutral. Sydney Lord Mayor, Clover Moore, said implementing the Energy Efficiency Master Plan would be another important step in the City’s actions to slash carbon emissions. “Cities account for 80 per cent of global carbon emissions. Our efforts to increase energy efficiency and cut carbon emissions are vital in the fight against climate change,” the Lord Mayor said. “All levels of government need to work together to combat climate change. I’m pleased with the recent decision by the Council of Australian Governments to adopt a national energy productivity plan that reflects many aspects of our own plan to make more efficient use of energy.” “The research underpinning our plan shows that while it will cost almost $400 million to implement measures to increase energy efficiency, the savings in energy use will be more than $600 million meaning a net benefit of more than $200 million by 2030,” the Lord Mayor added. In developing its Energy Efficiency Master Plan, the City of Sydney conducted a detailed analysis of energy use and

greenhouse gas emissions for its buildings. The research led to a range of actions including: • Safeguarding energy and emissions savings by maintaining existing core programs and standards; • Improving compliance of building standards and codes; • Providing education and training for planners, property owners, tenants, building managers and assessors; • Improving energy efficiency in buildings through retrofit and tune-up programs; • Making it easier to access finance and incentives for improved energy efficiency; • Developing new energy efficiency ratings; • Increasing minimum performance of new buildings; • Improving equity by advocating on behalf of low-income households; and • Showing by doing, through best practice for City-owned buildings. The City has already retrofitted 45 of its properties to reduce electricity and water use and generate operational savings of over $1 million a year. “We have the most ambitious emissions reductions target of any Australian government – to cut emissions by 70 per cent by 2030, based on 2006 levels,” the Lord Mayor said. “By retrofitting swimming pools, community centres and libraries for optimum energy efficiency, we have reduced greenhouse gas emissions across the City’s buildings by 29 per cent. We now want to see these savings expanded across the entire city.” “The City is taking action and working with businesses to reduce emissions through programs including Smart Green Business, CitySwitch and the Better Buildings Partnership,” the Lord Mayor concluded.



Major upgrade to bushfire monitoring capability A new, improved bushfire monitoring system will be in place for the 2016 disaster season, transforming the existing delayed monitoring service into a more responsive emergency management tool for firefighters. Geoscience Australia’s Sentinel Hotspots system will receive a major upgrade as a recipient of the 2015-16 National Emergency Management Projects (NEMP) grants. The monitoring system currently provides information about potential bushfire hotspots to emergency service managers and the general public across Australia through the use of satellite imagery. Geoscience Australia CEO, Chris Pigram, said the upgrade to the Sentinel Hotspots capability would provide Australia with observations 144 times a day, opening opportunities to monitor change as it happened. “The increase in frequency from sixhour updates to 10-minute updates will enable emergency services to monitor fire development in near real-time.” Dr Pigram said when natural disasters occurred, timely and accurate decisions had to be made by emergency management authorities to ensure the safety of


Construction Engineering Australia - October 2015

individuals and to minimise impacts on property and infrastructure. “Emergency services will be able to draw upon Sentinel when deciding where and how to prioritise resources when they are in most demand. “This is particularly important where there are multiple fire fronts or large scale incidents across state and territory borders,” Dr Pigram said. The new Sentinel capability, which is due to be operational by June 2016, is made possible by the Japanese Government’s $927 million investment and Japanese industry’s technical excellence in developing the Himawari-8 satellite. The satellite was launched in October 2014. Dr Pigram said governments, land planners, emergency managers and communities needed to know the risk and potential impacts of natural hazards in their area. He said the new Sentinel capability would boost the availability of information for bushfires. In addition to the $260 000 to upgrade Sentinel, Geoscience Australia also received two other NEMP grants to enhance its community safety programs: • $130 000 for developing flood vulnerability models for non-residential properties; and • $200 000 to improve national situation awareness information and systems. The flood vulnerability models work will build upon Geoscience Australia’s existing building vulnerability expertise. Dr Pigram said a gap existed in understanding the vulnerability of nonresidential properties, such as those for commercial and industrial use. The vulnerability models developed would help individuals, asset owners and all levels of government to better understand the cost of floods. The national situation awareness information and systems work would strengthen and expand the availability and consistency of situation awareness information shared by the states, territories and Australian Government for decision making in response to natural hazard events and disasters. Dr Pigram said by improving the timeliness and accuracy of information this project would enhance governments’ ability to respond to disasters and activate consistent and targeted financial assistance.

200-year-old boundary tree heritage-listed The beginnings of the fledgling Swan River Colony have been celebrated with a WA State heritage-listing of a rare surviving boundary tree, still growing on the banks of the Upper Swan. Western Australian Heritage Minister Albert Jacob said bushfires, lightning strikes and development of the area had taken a toll on the native flooded gum. Despite this, as intended by Governor Stirling, the tree still marked the boundary between some of the earliest land grants in the Baskerville area. “This tree represents one of the earliest efforts by the British settlers to mark out the area that would become Perth,” Mr Jacob said. “That this eucalyptus tree still functions as a boundary marker almost 200 years later shows how our land allocation today is still tied to the work of early colonists.” The tree is in an area first explored by Captain James Stirling in 1827, who returned as the first Governor of the Swan River Colony in 1829. Within a few months of landing in 1829, Stirling and Surveyor-General John Septimus Roe travelled with a group of settlers up the Swan River, where this tree was one of a number marked as the boundary points between the original land grants provided to settlers. The tree was identified by University of Notre Dame Australia archaeologist Dr Shane Burke and local historian Harold Loton, who nominated the place to the State Register. “We are fortunate to have such committed professionals and locals who have gone to great lengths to uncover these important links to the early days of British settlement,” the Minister said. “It’s quite unusual for single trees to be recognised on the State register; however this tree is very rare as a place directly associated with founding members of the colony Captain James Stirling and John Septimus Roe.”


Concrete and rubber delivers explosive shock resistance Although concrete is the most popular construction material, it has some limited properties: low tensile strength, low ductility, low energy absorption, and shrinkage and cracking associated with hardening and curing. Recent applications of the recycled tyre rubber in concrete show promise to improve these weak characteristics of concrete. Many experiments have been to find out appropriate methods of rubber application. Commonly, fully replacing aggregate or sand with rubber is not appropriate because the loss of strength is too severe. However, with a small portion of aggregates replaced, the loss in compressive strength is found not to be significant. Ductile rubberised concrete could also have important benefits in absorbing explosive attacks on buildings according to the US military. Ordinary concrete is not very

good at absorbing sudden shocks, the kinds that come from explosive impacts – in fact, like glass windows with their lethal shards of glass, hard concrete spalling fragments can become deadly missiles in an explosive event. While being resilient to some extent, rubberised concrete can deliver a keenly ‘sort-after’ ability to absorb shocks that can turn conventional concrete into dangerous flying rubble. Current research suggests that rubber should not exceed 17-20 percent of the total aggregate volume. Testing shows that the use of rubber in the concrete mix can reduce drying shrinkage, brittleness, and elastic modulus, which holds hope for improvements in the overall durability and serviceability of concrete. Plus, this could be the answer to dispose of the millions of unwanted used tyres that clog landfill and are an environmental nightmare.

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This is considered as one of the major environmental challenges facing municipalities around the world because waste rubber is not easily biodegradable even after a long period in a landfill. Used tyres soon choke landfills - if piled up they create a fire risk and can house vermin, snakes and mosquitoes. Rubberised asphalt has been used for decades on roadways. Scrap tyres are also used to help fire cement kilns, but the quantities involved are nowhere near enough to reduce the ever-growing used-tyre mountain. Using scrap tyres in concrete converts waste into a resource and allows end users to offset their carbon pollution, lower their carbon footprint and possibly earn carbon credits by using rubberised concrete technology/products in their projects.

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Australian economy impacting the construction industry but the long-term future looks brighter The Australian economy is going through a difficult period in the aftermath of the mining boom – and the tough times are set to continue for a little while yet, according to leading industry analyst and economic forecaster, BIS Shrapnel. But according to the company’s Long Term Forecasts 2015-2030 report, the soft period will last just three years before rebounding to a solid five-year GDP growth average – led by a fall in the exchange rate which in turn will result in the structural change required to lead Australia back to competitiveness. “The next three years will be tough for parts of the economy as the country makes the structural shifts required,” said Richard Robinson, Associate Director of Economics at BIS Shrapnel. “And a return to competitiveness will not be uniform across the country.” BIS Shrapnel forecasts that growth will rebound over the September and December quarters and lift growth back above two per cent. Overall, the Long Term Forecasts: 20152030 report forecasts GDP growth to be 2.5 per cent in 2015/16. The reversal of net exports will add to the other predicted negatives: the continuing

downturn in mining investment, private infrastructure construction and public sector building activity. “Offsetting these declines will be expected modest increases in private non-residential building and public engineering construction activity, with solid growth in dwelling investment (including alterations and additions activity) and consumer demand the main growth drivers at present,” said Robinson. “That said, net exports will be a key driver of growth over the medium term.” BIS Shrapnel’s forecast is for GDP growth to average 3.1 per cent over the next five years, but warns that this projection will depend on a late decade, broad-based rebound. “On the bright side, the recovery in dwellings investment is now well entrenched,” said Robinson. This upswing was delayed due to weak housing market sentiment and excessive caution by investors. However, with the expectation of low interest rates for an extended period, and a growing deficiency of stock, a solid increase in dwellings building is now well under way and will build momentum from here.

The report forecasts there is another 18 months of strong residential building along with improved alterations and additions activity before the current dwelling investment cycle runs out of puff. But this upswing will not be uniform between regions, with sizeable stock deficiencies set to drive the markets – in particular, in parts of Queensland and New South Wales. Private non-dwelling building is also likely to experience solid growth over the next two years. But that will be offset by falling government building – in particular, in hospital projects. A healthy pipeline of projects in the offices, retail accommodation, warehouses, aged care and entertainment and recreation segments will push overall building higher this year and next. However, completion of these projects and absence of new ones will cause activity to decline from 2016/17. The longer term outlook is positive, as improving demand across non-mining industries will see capacity constraints emerge and prompt the next round of investment in commercial and industrial buildings later this decade.

“Council’s original decision to approve this development, which was subject to appeal to the Planning and Environment Court, will be set aside and a new assessment will be made,” Ms Trad said. “I have notified all stakeholders, including the applicant, the council and submitters of my decision to “call in” the proposed development.” The global solar power company, FRV, plans to invest up to $400 million to develop 340 hectares of farmland – it predicts the

large scale solar farm would generate enough renewable energy to power around 65,000 Queensland homes. The solar farm would also provide 200 jobs during construction, up to five permanent jobs and provide indirect ongoing benefits to local business, contractors and suppliers. “This project has the ability to diversify Burdekin Shire’s local economy by providing a safe, reliable and affordable alternate energy source,” Ms Trad said. “As the Minister for Planning and Infrastructure, I want to ensure the economic and environmental interests of this part of the state are promoted and the impacts on the viability of important agricultural industries are carefully considered.” Ms Trad is required to make a decision on the development’s future by 10 November 2015.

Burdekin solar farm development ‘called in’ The development of one of Australia’s largest solar farms – in Queensland’s Burdekin Shire - has been “called in” to ensure the potential economic and environmental benefits of the project are balanced with community concerns, including possible impacts on cropping land. Queensland Minister for Infrastructure, Local Government and Planning, Jackie Trad, made the decision at the end of August after considering submissions and a request from the Burdekin Shire Council. 8

Construction Engineering Australia - October 2015


ACA Corrosion & Protection 2015 Conference to highlight best practice in corrosion management Corrosion has a major economic impact on industry and the wider community. How to manage this corrosion is a challenge for owners and managers of assets ranging from suburban industrial units through to oil and gas production platforms. The design, construction and operation of buildings, processing facilities and support infrastructure represent major investments by companies, organisations and governments. Corrosion will affect these at varying rates over time, depending on the material used, the types of corrosive agents in the environment and the physical processes and mechanisms involved. In order to promote a better understanding of corrosion, the Australasian

Corrosion Association (ACA) will host the Corrosion and Prevention 2015 (C&P2015) Conference that allows all industry stakeholders to meet and discuss a wide range of topics. In one stream, asset and facility management and maintenance professionals will benefit from opportunities to hear presentations by, and speak with, corrosion specialists about the importance of design, operation and repair in corrosion control. The second stream will focus on the Oil & Gas industry with technical papers from a crosssection of the industry highlighting how costly corrosion can be for the sector. C&P2015 will be held in Adelaide between 15-18 November. Seminars

and technical papers will provide opportunities to explore best practice in corrosion management, environmental protection techniques, public safety and economics. A panel of industry experts has been assembled by the ACA to discuss the challenges and the importance of maintaining vital infrastructure. Attendees will have the opportunity to ask questions and debate the latest techniques and practices with representatives of water and port authorities, major national consulting companies, suppliers and companies including Santos and Chevron. The P F Thomson Memorial Lecture - the keynote address of every C&P Conference since 1951 - will be delivered by Dr Robert Francis covering the latest research into galvanic corrosion. The ACA will also host an Introduction to Corrosion seminar on Tuesday 17 November. This has been designed for both experienced engineers and those new to the industry wanting to learn about, or refresh their knowledge of, metallic corrosion and the means to control it. For registration details and conference program, please visit the web site:

Australia-China dialogue promotes regional infrastructure investment China will send representatives to the Northern Australia Investment Forum to be held in November. The forum will focus on investment opportunities including resources and energy, agribusiness and food, and major infrastructure in northern Australia. China’s participation in the event was announced in mid-August by the then Treasurer, Joe Hockey, and Minister for Trade and Investment, Andrew Robb, when they hosted the second annual Australia China Strategic Economic Dialogue with Chairman Xu Shaoshi of China’s National Development and Reform Commission. Mr Hockey and Mr Robb said the Australia-China bilateral relationship was vital to growing Australia’s economy and creating jobs for Australians, and was worth more than $150 billion in two-way trade. 10

Construction Engineering Australia - October 2015

“The Australian Government has worked hard to ensure that this relationship continues to deliver economic benefits, including through the historic ChinaAustralia Free Trade Agreement.” The ministers said infrastructure investment was critical to the government’s economic plan. They agreed at the Economic Dialogue to work closely in addressing the needs of regional economies, in particular exploring opportunities to develop new infrastructure in areas like northern Australia. The Australian and Chinese governments will also form working groups to explore opportunities in northern Australia and the region, including the potential role of the $5 billion Northern Australia Infrastructure Facility and the Asian Infrastructure Investment Bank (AIIB).

Mr Hockey and Mr Robb also agreed to pursue avenues for further two-way investment to diversify the Australia-China trade relationship and create opportunities in the services sector. Australia will host in the first half of 2016 an Australia Week Roundtable in Beijing, which is expected to attract over 700 Australian businesses and connect them with key Chinese stakeholders.


Everything from the

Ground Up


hen it comes to encouraging outdoor activities - be it sport, exercise or just good old-fashioned play - the quality, safety and appearance of the facilities and equipment are of paramount importance. In a world dominated by screens (TV, computer and mobile devices) and a myriad of indoor entertainment options, getting people involved in outdoor activities requires much more than simply allocating a grassed or paved area, installing a seat and a swing and calling it a recreation facility. This is particularly true for children and older members of the community, where safety and security are a significant concern - not only in terms of the overall area, but also in relation to the safety and quality of any play or sports equipment provided. Outdoor play and recreation facilities need to be attractive, safe, accessible and usable year round; and the equipment provided needs to be safe, practical, good quality and easy to use. And when it comes to play equipment, it has to be attractive, engaging, usable and most of all - it should be fun. After all, that's what play is all about! Importantly, outdoor recreation facilities - be they sports facilities, playgrounds or general recreation areas - that are not up to community expectations in terms of quality, safety and amenity, will not only not get used, they can represent a serious liability, rather than an important community asset. Put simply, poorly designed and/or poor quality facilities are not only a wasted investment, evidence clearly shows that under-utilised public areas such as this also

stand a better than average chance of being vandalised and attracting undesirable / anti-social behaviour. With that in mind, an ever-increasing number of councils, schools and residential property developers are now looking to create outdoor sports, playground and recreation facilities which cater for the needs of the widest possible community demographic. Facilities which extend far beyond the traditional playground or sports court, these innovative facilities bring together play equipment, multi-use sports courts and even outdoor gym equipment in a modern, attractive and safe environment which has been designed to attract community patronage and encourage more of an active outdoor lifestyle. Speaking about the growth in demand for these new 'next generation' outdoor recreation facilities, Jason Day, Business Manager with leading outdoor recreation facilities company Aussie Outdoor Design, explained: "Whereas in the past, the majority of outdoor recreation facilities were fairly limited in their focus - for example sports courts that were generally only suited to one specific sport, or playgrounds that were only suitable for a limited age group - the focus now is on developing facilities that meet the needs of the largest possible demographic. Fully integrated facilities that provide a fun, safe and attractive outdoor environment for all ages and encourage high levels of patronage and participation." "When designed and built correctly, quality outdoor recreation facilities can provide much more than a simple playground or sports court," Jason added.

"When designed and built correctly, quality outdoor recreation facilities can provide much more than a simple playground or sports court." 12

Construction Engineering Australia - October 2015

"They can become an important 'community hub'. A safe and attractive place where people can meet and feel part of the community and, importantly, feel proud of the facilities that are available in their community."

SYNTHETIC GRASS, SOFT IMPACT RUBBER SURFACING AND THERMOPLASTIC MARKINGS Aussie Outdoor Design offers an extensive range of specialist surfacing solutions for playgrounds and outdoor recreation areas. From synthetic grass and soft impact granulated CSBR and EPDM rubber surfaces, through to high performance surface coating systems and heavy duty thermoplastic pavement markings, there is a surfacing solution to suit all outdoor recreation facilities. Not surprisingly, together with the focus on robust performance and longevity in harsh outdoor conditions, the Dream Time product range has been developed with a focus on bright colour and fun, attractive designs, with customised graphic solutions to suit all ages and applications. "When it came to developing our Dream Time range, we placed a specific emphasis on ensuring that we could deliver high quality solutions that were also affordable - both in terms of the initial installation and ongoing maintenance," Jason Day said.


SPORTS FIELDS AND MULTISPORT COURTS Developed with a focus on ensuring that schools, councils and developers are able to get the most out of their available space, Aussie Outdoor Design's Prime Time range of sports field and multisport court surfaces deliver the ideal combination of robust performance and versatility. Together with the wide array of line marking and surface colour options, Prime Time multisport courts are designed and installed 'from the ground up', complete with adequate drainage and lighting. Aussie Outdoor Design also design and deliver full size synthetic sports pitches to suit all sporting disciplines. With a range of synthetic surface options, including synthetic turfs that have the look and feel of natural turf, these full size sports fields are also designed and delivered 'from the ground up' with everything from drainage through to lighting, including impact absorbing under-layers built to FIFA or IRB specifications. Larger open areas with synthetic grass can also be line marked to provide smaller areas for junior games or other variants such as Futsal.

"As well as being up to 30 times more durable than painted markings on asphalt or concrete, our range of high quality thermoplastic markings can also provide a range of fun activities in the playground. From traditional games such as hopscotch, through to educational grid games and counting games, these vibrant markings can really brighten a playground area and 'bring it to life'," he said.

Together with the fun aesthetic of the thermoplastic markings, the Dream Time synthetic turf and soft impact granulated rubber surface range can play a critical role in eliminating trip hazards on asphalt and concrete paved areas, and dirt patches in grassed areas.

Construction Engineering Australia - October 2015



Pictured above: An example of one of Aussie Outdoor Design's natural recreation environments.


NATURAL ENVIRONMENTS AND SENSORY GARDENS Outdoor recreation and learning areas can also include natural environments that blend natural vegetation and sensory items with creative structures - allowing children to play and learn at the same time. Aussie Outdoor Designs is a leader in the field of sensory gardens and outdoor learning areas, with designs that include indigenous vegetation (trees, shrubs, grasses and flowers), timber structures, boulders, textured pathways and natural water features. Each design is individually created, with elements incorporated to meet the client's specific needs, including: • Outdoor Learning Structures • Outdoor Blackboards • Vegetable Gardens • Sensory Gardens • Sensory Walls • Textured Pathways • Water Play Areas • Sounding Items


Construction Engineering Australia - October 2015

Developed with a focus on encouraging fun and fitness, the Raptor range of playground and fitness equipment helps children to develop physical coordination, strength and flexibility. All equipment in the range is manufactured to Australian Standard AS4685 specifications, and is built to withstand not only the daily rigours of the playground, but also the harsh Australian environment. The play areas are designed

to provide maximum accessibility, with pathways and equipment to provide a fun and engaging all-abilities playground. Options include: • • • • • •

Climbing Equipment Balance Beams Fitness Equipment Sensory Panels Inclusive Play Equipment Access Ramps

ABOUT AUSSIE OUTDOOR DESIGN Established in 2005, Aussie Outdoor Design is at the forefront of outdoor recreation and sports facility design, installation and maintenance, and has gained an enviable reputation for quality and customer service. Headquartered in Penrith in Sydney's outer-west, the company initially focused on providing artificial turf and specialist sports court surfaces for schools, councils and sporting clubs. The success of these early projects saw Aussie Outdoor Design quickly expand into a 'full-service' sports and recreation facilities provider, assisting and advising an ever-increasing number of Local Governments, State and Catholic schools, construction companies and developers. Over the past decade, the company's service offering has expanded from supplying and laying artificial turf and specialist sports and recreation surfaces, to include full development, design, installation and maintenance solutions for sports and recreation surfaces; thermoplastic and specialist surface markings; splashpads/water play areas and architectural play zones; sensory gardens; multi-use sports courts; play equipment; and even outdoor gym equipment. "From the outset, our goal was to provide our clients with a 'one stop shop' for their outdoor sports and recreation facilities - from consulting, through to design, delivery and maintenance," Jason Day said. "In keeping with this focus, we also place an emphasis on ensuring we stay at the forefront of product developments - both in terms of surface technologies and equipment," he added. "This enables us to provide our clients with the best value for their money, and in turn, helps them to ensure that the facilities they are providing deliver the best value for their community." Aussie Outdoor Design products and services meet the requirements of Australian Standards AS4422 and AS4865. All services are also fully compliant with the OH&S requirements for schools and local government.



In keeping with its focus on delivering the latest in equipment and features, Aussie Outdoor Designs is now also offering a full range of high performance outdoor gym equipment. Manufactured to the strictest quality standards, the TGO range of high performance outdoor gym equipment provides an active outdoor community gym to meet the needs of a wide range of ages and abilities. From treadmills, exercise bikes and cross trainers, through to exercise frames, weight/resistance training equipment and training benches, this innovative equipment is proving to be extremely popular with young and old alike. Indeed, the locations featuring the new outdoor gym equipment have all seen a significant increase in patronage since it was installed.

FULLY INTEGRATED DESIGN AND DELIVERY In keeping with its focus on providing a 'One Stop Shop' for all outdoor sports and recreation needs, Aussie Outdoor Design can take care of all aspects of the project - from development, design and planning, through to construction, landscaping and ongoing maintenance. As well as providing an efficient single point of access for all aspects of the project, this 'One Stop Shop' approach enables councils, schools and developers to achieve a fully-integrated outdoor recreation facility with a cohesive design that blends a

range of features and equipment to meet the needs of all users. For further information on the full range of Aussie Outdoor Design's products and services, please call: 1300 887 025 or visit:

Construction Engineering Australia - October 2015




Abbey Vahtrik from Tennyson, NSW, checks out an Aussie Fire Chief as the family prepares their survival plan in time for the fire season.


Firefighting authorities around the country are warning of a potential catastrophic fire season. Early warnings based on the deepening El Nino effect and unseasonably high rainfall over summer have put key east coast areas and southern states in danger of potentially the worst fire season in decades. Australian Pump Industries, one of Australia’s leading pump manufacturers and distributors, has fast tracked their seasonal bushfire survival programme with a view to ensuring that farmers and other property owners get the best protection. Known as ‘Aussie Fire Safe’, the programme details a wide range of initiatives combined to defend property, crops, livestock and people - providing useful and practical advice on preparing for the fire season ahead, including selecting appropriate fire fighting equipment.

At the forefront of Aussie Pumps’ fire fighting equipment range, the Aussie Fire Chief has been lauded internationally and is widely regarded as a benchmark for lightweight portable fire pump design and performance. According to Aussie Pumps, it is the only product of its kind in the world that comes with a five year warranty, a sure sign to the user that the Company not only believes in the product, but stands behind it 100%. The Fire Chief was developed for Australian bushfire fighting conditions and is built to international ISO quality standards. “Buying a product that works is the first and most important fundamental in choosing a fire pump” said Aussie Pump’s Product Manager Brad Farrugia. “We hear horror stories about people who buy sub-standard fire pumps and then find they don’t perform when the chips are down,” he said. The first fundamental for a fire pump is its ability to self-prime fast and effectively. The Aussie Fire Chief will prime first time, every time and will draft water through a vertical lift of 7.6 metres. It produces a very impressive 450 litres per minute maximum flow and offers delivery heads in the standard version of up to 75 meters (100 psi). The Fire Chief can be powered by either a petrol or diesel drive engine. The standard petrol drive is a 5.5hp genuine Honda engine with low oil protection. The pumps come with an set of steel skids and anti-vibration mounts. The mounts have been designed to extend engine life by dampening vibration, whilst the skids provide a level and stable platform for the pump to operate from. “Some pumps don’t come with any kind of standard skid arrangement,” said Farrugia. “That means that if for some reason the pump is pulled off balance, say with a fire hose being tugged, the engine oil cut-out can activate, stopping the pump at a potentially crucial point in the firefighting process,” he said. The heart of the Fire Chief is a huge 7” one piece closed style impeller. It is superbly balanced for maximum performance. The impeller runs in a heavy duty volute that produces outstanding hydraulic characteristics. Both pump and engine are Honda approved and match tested to give consumers the very best outcome. Big 2” suction flanges also standard equipment on the Aussie Fire Chief. The massive check valve can be easily serviced by removing the flanged suction port, a unique Aussie Pumps feature. The pump also comes with metal caps and chains on the discharge ports, a feature found normally only on professional firefighting equipment. “The Fire Chief is designed to out-perform and out-feature all others,” said Farrugia. “The secret of its high performance is the huge ‘big belly’ body that provides clear water passages to allow more water through the pump, providing excellent flow-pressure characteristics.” “The whole concept of the Aussie Fire Chief comes out of dialogue with farmers and homeowners,” Brad Farrugia added. “Our motivations are not cost reduction, but rather performance. We believe our machines will stand any test and will out-perform and outlast even twin impeller pumps of similar horsepower.” Further information on the Fire Chief and copies of the free Aussie Fire Safe Survival Guide are available from Aussie Pump distributors and outlets throughout Australia and the South Pacific, or by visiting: 16

Construction Engineering Australia - October 2015

Can you take the risk that you might be using non-compliant steel?

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Non-compliance is just not worth it. Get the facts. Demand the ACRS Certificates of Product Compliance.

Call ACRS on (02) 9965 7216, email or visit ACRS – The Australasian Certification Authority for Reinforcing and Structural Steels Ltd ABN 40 096 692 545


Italy Pavilion – Milan Expo A stunning expression in concrete never before realised The external facade of this six-storey building in Italy features over 900 panels made from a special type of air-cleaning concrete. This may be the future of concrete for facades. The design chosen for the Italy Pavilion at Milan Expo 2015 was the winning project in an international competition adjudicated by Expo 2015 S.p.A. in May 2013. In total, 68 architectural practices took part; the winning design came from Nemesi & Partners. “We imagined an architecture that would represent the idea of being together and the ability to recognise themselves as a community through an innovative, contemporary building taking into account the great tradition of the Italian architecture,” said Michele Molè, founder and director of Nemesi. The Italy Pavilion consists of the creation of Palazzo Italia (built area 14,400 square metres with six levels) Just seven months evolved the preliminary design to constructability. Then 14 months of


Construction Engineering Australia - October 2015

construction used over 200 professionals that involved Italian companies to build the pavilion of 27,000 square metres in total, for the most part exhibition spaces.

ARCHITECTURE OF THE ITALY PAVILION Palazzo Italia is a genuine landmark on the Expo site, standing out because of its architecture and its location on one of the four cardinal points - the northern one. It also provides a scenic backdrop for Viale del Cardo which runs right across the site. Palazzo Italia reaches a height of 35 metres, the highest building within the Expo site. It’s the only permanent architecture at the Expo.

Palazzo Italia draws on the concept of an “urban forest”, with the “branched” outer envelope designed by Nemesi to simultaneously conjure up primitive and technological images. The weave of lines creates a play of light, shadow, solids and voids that generates a sculpture-like building with clear hints of land art. For Nemesi, the spark for Palazzo Italia was a concept of cohesion in which the force of attraction generates a rediscovered sense of community and belonging. The internal piazza represents the community’s energy. This space - the symbolic heart of the complex - is the starting point for the exhibition route, in the midst of the four volumes that make up Palazzo Italia.


2015 These four volumes house the Exhibition zone (West), the Auditorium and Events zone (South), the Office zone (North) and the Conference and Meeting zone (East). The volumes are symbols of giant trees, with massive bases that simulate great roots plunging into the earth. Seen from the internal piazza, they open up and become longer as you look up, visually forming a canopy beyond the giant glazed roof.

FUNCTIONAL LAYOUT OF PALAZZO ITALIA Nemesi designed the exhibition layout of Palazzo Italia to be a gradual journey to discover and understand the shapes and contents of this special architectural landscape. The route starts from the internal piazza, a great hall in which visitors are welcomed. The curved, inclined elevations give the volumes a sense of fluidity and dynamism, forming a space of genuine beauty. The great flight of steps that rise up from the square, crosses this area longitudinally to visually connect all the floors. The triple-height space from the second to the fourth storey is like a giant “hanging” shell that, visible from the piazza, houses the Exhibition zone.

 Innovative and sustainable approach: Palazzo Italia is the symbol of the contemporary factory, an Italian architectural and constructive challenge, a work characterized by experimentation and innovation in terms of design, materials and technologies used. Palazzo Italia was designed and conceived as a sustainable energy building - almost ‘zero new energy’ thanks to the contribution of photovoltaic glass in coverage and photocatalytic properties of the new concrete for the outer casing. The rich weave of branches that forms the outer envelope helps to highlight the sculpted shapes of Palazzo Italia. Nemesi used a unique geometric design to create this outer “skin”. The full 9,000 square metres of the façade of Palazzo Italia is clad in more than seven hundred BIODYNAMIC concrete panels with Italcementi’s patented TX Active technology. When the material comes into contact with light, it can “capture” pollution in the air, transforming it into inert salts and reducing smog levels. The mortar used is 80 percent recycled aggregates, including scrap material from marble quarries in Carrara that helps add more lustre than in traditional white cement. This new material is also very “dynamic”, enabling the creation of fluid designs like the complex shapes used for the panels that are part of the construction of Palazzo Italia. All panels for the envelope are unique pieces realised by precaster Styl-Comp.  Innovative branched panels: The 700 panels comprise a total surface 9,000 square metres with more than 7,000

computer generated panel dimensions for each individual panel. The individual panels range in size up to 4 x 4 metres, and weigh between one and four tonnes. The branched panels utilised a total of over 2,000 tonnes of BIODYNAMIC concrete in their manufacture.  Innovative glass roof: The roof for Palazzo Italia - an innovative “sail” - was designed by Stahlbau Pichler. It’s an interpretation of a forest canopy, with photovoltaic glass and flat and curved geometric shapes (often squares). Together with the building’s envelope of “branches”, it’s a manifest expression of innovation in design and technology. The roof reaches its architectural height above the inner piazza, where a massive glazed conical skylight “hangs” over the square and the central steps, radiating natural light. The 4,000 square metre roof glass roof - 650 square metres of which is photovoltaic glass - weighs 450 tonnes and is supported by over 400 tonnes of steel.

AIR PURIFYING CONCRETE The façade of the future here now! The external facade of the six-storey Palazzo Italia features over 900 panels made from a special type of air-cleaning concrete. This may be the future of concrete for facades. “In direct sunlight, the active principle contained in the material ‘captures’ pollutants present in the air and converts them into inert salts, helping to purify the atmosphere from smog, and ensuring that the façade is self-cleaning,” the architects explained.

Construction Engineering Australia - October 2015



While the facade creates a unique geometric texture of shadow and light within the building, the internal structure of the Palazzo Italia was inspired by traditional Italian villages, featuring a central square surrounded by four blocks that provide additional spaces for social events, offices, meeting rooms and temporary restaurants for Expo 2015 attendees. Nemesi & Partners won an international competition held to decide who would design the pavilion. Since then, they have worked with a group of engineering firms and sustainability consultants to ensure the 9,000 square metre building was complete in time for Expo 2015. The smog-filtering facade used 2,000 tonnes of concrete. Around 80 percent of this air-purifying concrete is made from recycled materials, such as scraps of Carrara marble. In addition, the Palazzo Italia has a photovoltaic glass rooftop to generate solar energy during the day. Inspired by nature, the facade’s design resembles large tree branches which wrap themselves around the modern building. According to the architects, this design acts like an ‘urban forest,’ not only by providing an aesthetic look but also by mimicking the role of trees, which naturally help to clean the ambient air. “The overall concept of the architectural design of the Italian Pavilion is that of an urban forest in which the building, through its skin and its volumetric arrangement, takes on the features of an architectural landscape. The branching pattern of the external cladding of Palazzo Italia coherently interprets the theme of the tree of life, inserting it in the form of a petrified forest,” the architects said. Palazzo Italia is one of the central features of Milan Expo 2015. The pavilion will remain in place after the Expo finishes, preserved as an icon of sustainable design.

CONSTRUCTION DETAILS The volumetric building system produces a dynamic and interactive architecture, capable of exchanging energy with the outside world. The tree-forest concept actually takes shape also, and more importantly, from the development of technological, engineering and energy solutions making the building an environmental osmotic organism, interacting and exchanging energy through multiple systems like the photovoltaic glass 20

Construction Engineering Australia - October 2015

foliage-canopy structure. It is arranged in an innovative geometric pattern favouring soft lines and curves, which captures solar energy and contributes to the microclimate of the square below. Palazzo Italia is in its way a “Natural Architecture”, combining poetic design and technological experimentation in a spectacular and energy sustainable body. Palazzo Italia is organised into four blocks, real urban scenes defining the great space of the central square, a place and a symbol of community and welcome. The building hosts exhibition areas, offices, institutional and event spaces. The exhibition path runs through the entire building, accompanying visitors to gradually discover its different angles and textures. The exhibition path is a real experiential discovery journey within the tree-building, which digs its roots into the ground and frees its branches and foliage into the sky, massive at its base but delicately light at its upper parts. The visitor passes through all four levels of the exhibition area, to reach the rooftop terrace, and come back down to the central square through a new and different path. The architects imagined the exhibition of Italian Palazzo as a gradual discovery and conquest of the forms and content of this architecture-landscape. The route begins in the inner square, a large hall for the reception of visitors, where inclined surfaces and curves give fluidity and dynamism to the architectural massing drawing a striking space. The grand staircase rises from the square longitudinally through the space and visually connects all the floors. From the second to the fourth level, triple-height, a large shell “suspended” and completely visible from the square houses inside the Exhibition Area.


The innovative white concrete panels for the outer “tree” façade are unique pieces different from each other, realised with the amazing technology of Styl-Comp. The unique and original geometric texture of the panels evokes the random intertwining of branches, creating an architecture in architecture.

THE SECRETS OF PALAZZO ITALIA Outstanding products and next generation technologies were used for the construction of the symbol of Expo 2015. The Italian Pavilion in figures: 

9,000 square metres outdoor surface area

900 plane and curved panels

600 “tree-branch” planar precast concrete panels and 300 different “tree-branch” corner panels, all different to one another

4 x 4.2 metres typical size of each panel

10,560 hours of research dedicated to the project

15 researchers involved in developing the new product

2,000 tonnes of biodynamic cement used


The entire outdoor surface and part of the interiors consist of BIODYNAMIC concrete panels, obtained using StylComp technology from the new material developed at i.lab, the heart of Italcementi’s research and innovation. The product’s name is a summary of its innovative performance features. The “bio” component is given by the product’s photocatalytic properties, originating from the active principle TX Active which is titanium dioxide, patented by Italcementi. In direct sunlight, the

active principle contained in the material “captures” certain pollutants present in the air and converts them into inert salts, helping to purify the atmosphere from smog. Proprietary technology (based on nano-sized particles of titanium dioxide) is what makes this cement special. The technology can be applied to white or grey cement and it works like any other Portland cement: it can be used in all varieties of concrete, including plaster. The titaniumbased catalyst is not spent as it breaks down pollution, but continues to work.

Typical products are oxygen, water, carbon dioxide, nitrate, and sulphate. Because rain washes away the pollution from the concrete surface, buildings stay cleaner and do not require chemical applications that are potentially harmful to the environment. Maintenance costs are reduced. Additionally, the concrete is made from 80 percent recycled aggregates, part of which consist of scraps from the cutting of Carrara marble, and therefore provide a superior brilliance and brightness compared to traditional white cements. The “dynamic” component is a specific characteristic of the new material, whose particular fluidity allows the creation of complex shapes like those found in the Palazzo Italia panels. Thanks to the concrete’s high self-flowing workability, BIODYNAMIC is able to self-compact in the panel formwork. The concrete panels are designed and manufactured by Styl-Comp that forms the final design of the panel, ensuring an extraordinary surface quality.


The new material also features outstanding workability and resistance compared to ordinary concretes. Its initial slump is three times greater (300 mm vs.100 mm); it is twice as resistant to compression (over 60 MPa compared to 30 MPa of conventional concretes) and with twice the flexural strength (over 10 MPa against 5MPa for conventional concrete).

PROJECT: Design commencement: 2013 Start of works: January 2014 End of works: March 2015 A NEW ACHIEVEMENT FOR ITALIAN RESEARCH AND DESIGN As the company that developed the transparent cement solution for the Italian pavilion at the Shanghai Expo 2010, Italcementi immediately seized the new challenge, relying on its 150 years experience in the world of construction materials. “From the silver medal at the 1867 Universal Exposition in Paris, through the international success of the Italian Pavilion, symbol of the Shanghai Expo 2010, to the new biodynamic concrete that characterises Palazzo Italia at the Milan Expo 2015: Italcementi is once again a key player in a Universal Exposition thanks to its innovative products,” said Carlo Pesenti, CEO of Italcementi. “By providing materials for the realisation of the architectural and engineering quality that Italy is able to express, our performance and solutions have contributed to the creation of the symbol buildings of several Expos. From Paris to

Shanghai to Milan, Italian research wins again,” he said. “Our architectural design for the Italian Pavilion takes inspiration from an urban forest” explains architect Michele Molè of Nemesi & Partners, architects. “The branchlike texture of the outer “skin” of Palazzo Italia, the heart of the project, evokes a primitive figurative style, and consistently renders Marco Balich’s Tree of Life theme in the form of a petrified forest. The intertwining lines generate an alternation of light and shadows, of full and empty spaces, from which a “natural architecture” comes to life. The volumetric complexity of Palazzo Italia is based on four main blocks organised around a central void/piazza and connected to each other by bridge elements; inside these blocks are organised the main macrofunctions: Exhibition Area, Auditorium, Offices and Conference Rooms. Just like trees, the four architectural volumes rest on massive supports simulating the huge “roots” of the exhibition pathway on the ground floor; these same volumes, viewed from the central piazza, expand and widen upwards, loosening their light “foliage” across glass surfaces, stretching out their “branches” and dynamically weaving a web that reaches up to the great roof terrace. The outer skin of Palazzo Italia,” concluded Molé, “an essential aspect of the poetics of this design, was made possible by the innovative concrete materials and technologies developed by Italcementi and the precasting of this concrete by StylComp”. On his part, Sergio Zambelli, Managing Director of Styl-Comp, emphasised the ability to “enhance the expressive potential of the cementitious material, creating amazing architectural structures that love light and seem to ask to be caressed”.

THE CHALLENGE OF CONCRETE INNOVATION With biodynamic cement, Italcementi successfully brings innovation to construction materials, a segment that is only apparently “traditional”, and confirms the innovative and creative dimension of products Made in Italy, always ready to accept the challenges posed by the world of architecture. To Italcementi, research, innovation and sustainability are at the centre of its industrial strategy, with investments of approximately 13 million Euros per year in R&D activities, one of the highest in the industry as a percentage of revenue. This marked propensity for product innovation has led over the years to the development of a wide range of unique and innovative products: • photocatalytic cement, based on the TX Active active principle, able to help improve air quality with its de-polluting and self-cleaning properties; • i.light SHANGHAI, the transparent cement used for the exterior walls of the Italian Pavilion at Shanghai Expo 2010, highly appreciated by the world of architecture; • EFFIX for creative applications, used by designers to create interior decoration complements; and • i.idro DRAIN, the draining cement for the construction of roads and pavings that respect the natural cycle of water. The products developed by Italcementi are made available to the world of architecture, with which the company has maintained for decades of close cooperation. Researchers and architects work side by side to find solutions and materials able to meet new challenges and reach beyond the traditional characteristics of constructions materials, setting new standards in safety, durability, design and sustainability.


Construction Engineering Australia - October 2015

The Formwork Experts.

Move Fast. Be Safe! Dokadek 30 – The panel floor system for speed on site

Extraordinary fast forming

Extra-safe working

Easy handling

High forming rate thanks to large, 3m² Dokadek 30 panels and seamless connection with Dokaflex

Panels can be put up and taken down easily and safely without walking on top of the slab formwork

No need to calculate or measure up, as the positions and numbers of props are all made clear by the system

Dokadek 30 is a beamless, handset formwork system designed as a lightweight steel construction with powder-coated frames faced with a wood/plasticcomposite sheet. There are two different working methods: with or without drop-head. Dokadek 30 combines the benefits of a panel floor formwork system with those of a Dokaflex floor-slab formwork. That means its 3m² large panels make it fast in typical zones, yet, thanks to Dokaflex, it is also quick and flexible in the infill areas. Dokadek 30: Slab formwork at its most evolved.

More information at

Doka Formwork Australia Pty. Ltd. | Sydney | T +02 8796 0500 | Brisbane | T +07 3868 1486 | Melbourne | T +0488 100 301 |



Greater cost-efficiency, a reduced risk of accidents and enhanced employee motivation are just some of the advantages of implementing a professional safety concept on the site. When it comes to safety, Doka takes a holistic, A-to-Z approach that runs all the way from product development to safety consulting, and to its extensive range of safety products and services. It’s only when you feel safe that you can concentrate on the job and perform at your best. An obvious truth, but one that particularly needs to be heeded in construction, where the accident rate is double that of many other industry sectors. Study after study has shown that on safe jobsites, people work faster and perform better. Quite apart from the emotional and monetary costs associated with injuries or fatalities, workplace accidents and incidents can also result in significant financial and legal consequences, including extended project delays, larges fines and even criminal charges carrying extended custodial sentences if negligence can be proven. In keeping with its focus on maximising productivity and performance by optimising worksite safety, Doka has developed a range of quick and easy-to-operate safety innovations to suit every type of forming assignment.

ALL-ROUND SAFETY RIGHT FROM THE WORD ‘GO’ A holistic understanding of safety begins right from when formwork systems are still under development. Safety, ease of handling and ergonomic design are among the key characteristics of Doka products. This begins with the choice of materials for the system components, and with the documentation on how the product is used. The use of high-grade materials for all formwork components not only makes them last longer, it makes them safer, too. The Doka product range undergoes continuous testing and development with regard to 24

Construction Engineering Australia - October 2015

safety, and as a result Doka formwork systems are dependable and efficient equipment for every construction project. Doka systems bring together speed, safety and cost effectiveness on the worksite. For a high standard of safety, Doka offers complete systems for floor, wall or column formwork with integrated safety features. Even from the initial planning phase, Doka supports its customers with professional consulting and its extensive world-wide expertise on construction safety. In-depth analysis of the initial situation provides the basis for individualised solutions in which suitable products such as ladderways and protection systems are incorporated into the formwork planning and design - right from the start. Importantly, the safe and efficient usage of formwork systems not only relies on the systems’ design features, it also relies on the system and all components being used correctly. This is why high-quality documentation such as formwork utilisation plans, instruction manuals and safety data sheets are such an important basis for a safe site. In addition, Doka offers a range of additional training and supervisory services, including practical, relevant training by qualified Formwork Instructors (either on-site or at Doka’s dedicated training facility) and training and supervision by Doka’s team of specialist Field Technical Advisers, delivering a high level of safety on-site.

DOKADEK 30 – WALL-TO-WALL SAFETY The Dokadek 30 panel floor formwork system embodies safety right down to the last detail. Specifically designed with a focus on safety and efficiency, the beamless hand-set Dokadek 30 system is very easy to operate, with an erection and dismantling sequence that is so straightforward that even semi-skilled crew members are soon familiar with it.

As well as being extremely safe and easy to use, the Dokadek 30 floor-slab formwork system scores for high speed, not only during setup but also during dismantling. All operations can be performed from the safety of floor level, with no need to walk on the formwork during erection. The panels’ rectangular shape means that it takes users much less effort to engage them in the prop heads and tilt them up safely from below - even when forming higher rooms. When the panels are being engaged, the Dokadek 30 heads hold them and fix them safely into position. Importantly, the integrated anti-liftout guard reliably prevents panels accidentally falling off, while at the same time, automatically securing them against accidental lift-out or being dislodged by sudden updrafts.

MORE THAN DOUBLE YOUR RETURN ON JOBSITE SAFETY INVESTMENTS Safety is not just a jobsite obligation, it is also a key opportunity to boost on-site performance. Why not extract that extra economic benefit from your return on prevention on-site? An international study into the value of Return on Prevention (RoP), with 300 participants in 15 countries, has demonstrated how safety solutions payoff at a cost-benefit ratio of 1:2.2. On the micro-economics level, investments in workplace safety enable will return approximately $2.20 for every dollar spent on workplace prevention per employee per year. Return on Prevention is the key indicator for gauging the economic performance of investments in safety.

WHAT’S YOUR RETURN ON PREVENTION? Disruptions and stoppages on site and time wasted catching up afterwards factor into costs. Worse still, in the short-term and longterm, a business is likely to suffer both the direct and indirect effects of reduced productivity while replacement workers are trained up; loss of company image due to safety concerns; additional administrative costs resulting from incidents; lack of customer satisfaction, completion delays; higher insurance contributions; and much more.

ROOM FOR IMPROVEMENT? If you aren’t there yet, Doka’s safety solutions can help you boost your return on prevention in many ways, with a wide range of safety products and services, and also with great know-how combined with an understanding of your specific savings potential. At Doka, solutions featuring all-round safety are an integral part of the company’s culture. The Doka Safety Network (DSN) provides Doka staff, customers and experts a forum where they can exchange news, views and new ideas about safety. These efforts have won Doka a great many distinctions and safety awards, including the Good Practice Award of the European Agency for Safety and Health at Work, and the Spanish Institute of Building Engineering (CGATE) prize for safety in building construction. Safety is also written large within the company itself. Internal campaigns, and measures that go well beyond what the law requires, send a clear signal. Various initiatives foster awareness of the topic and make an important contribution towards motivating employees. With the ds logo, Doka has created its own distinctive symbol that immediately points both customers and employees to safety-related aspects. For further information, please visit the website:


Doka is one of the world leaders in developing, manufacturing and distributing formwork technology for use in all fields of the construction sector. With more than 160 sales and logistics facilities in over 70 countries, the Doka Group has a highly efficient distribution network which ensures that equipment and technical support are provided swiftly and professionally. An enterprise forming part of the Umdasch Group, the Doka Group employs a worldwide workforce of more than 6,000.

On the other hand, however, good safety practices offer a lot of sustained potential for saving money. Investments in prevention, including personal protective equipment, a safe workplace and safepractice training, will always compare favourably - both financially and in terms of productivity, workplace moral and reputation. An investment in safety and an effective workplace injury prevention strategy will always benefit your bottom line.

Construction Engineering Australia - October 2015



KINGFLOR GOES FROM STRENGTH TO STRENGTH In a market where on-time completion of a commercial development can hinge on factors such as the versatility and strength of structural formwork, Fielders KingFlor is proving paramount to the success of a variety of high-level developments across Australia during 2015. Released in 2000, KingFlor composite steel formwork is the flooring system used between levels on multiple-storey buildings. Not surprisingly, KingFlor’s design, versatility and performance in the field has made it the structural formwork of choice for an everincreasing number of projects both large and small. National Commercialisation Manager at BlueScope Building Components, Nathan Jack, says the adaptability of the flooring system is the reason it has recently been selected for use in several notable developments during the first quarter of the year. “We’re currently working with architects and builders to supply KingFlor to a range of projects across the country, from high-rise office and residential buildings, to car parks and education facilities, with the product consistently improving project efficiencies due to reduced concrete, labour and propping requirements,” said Nathan. “One of the key advantages specifiers have recognised is the versatility in the different deckings available, with five individual profiles including two trapezoidal, two re-entrant profile and a deep deck profile, meaning we’re able to deliver an effective solution regardless of the demands of the project,” he added. The manufacturer has recently been contracted to provide 20,000m² of KingFlor CF210 decking for the prominent $200m Meriton residential tower in North Sydney, the 28

Construction Engineering Australia - October 2015

first high-rise residential building in Australia to be constructed purely from structural steel, eliminating the use of the traditional concrete frame building method. “Historically, the traditional steel construction depth varies from 450mm to 650mm which has generally precluded the use of steel framed structures in apartment building design given the increase in the overall height of the building and therefore the associated construction costs.” “Through the use of the innovative CF210 SlimFlor system, we are able to reduce the construction depth of the flooring down to 290mm which now competes favourably with concrete framed buildings and will contribute to a significantly faster construction time and reduced costs for Meriton,” said Mr Jack. Director at enstruct Group, Tim Boulton who developed and led the structural design and documentation for the project, explains how KingFlor CF210 was the best solution for the revolutionary North Sydney development as a reliable and adaptable decking capable of achieving the spans required within the available floor depth. “The KingFlor CF210 system is a versatile and trusted building solution which has been used widely across UK and Europe for many years in a range of developments. This not only provides us with the assurance of a quality product, but also provided us with the best solution on the market for this project.” “CF210 is a critical key component to the Meriton development thanks to it being a key component of the SlimFlor system when combined with the floor beams which has reduced the construction depth and assisted us in bringing the steel-frame concept to life,” said Tim.

Further adding to its portfolio, Fielders has also been contracted by Crown International to supply 70,000m² of KingFlor KF40 material at the V by Crown apartment complex in Parramatta. Currently in construction, the $309m development will be Parramatta’s tallest building. Standing at 29 storeys high and occupying 500 ultramodern apartments, the tower will boast sweeping views of the Sydney skyline and be superbly finished in a luxurious glazed mirrored exterior. “KF40 was chosen for this project in Parramatta due to its trapezoidal shape, saving the project 16 millimetres of concrete across the entire project of 70,000m². The unique design with wider coverage will not only save on preparatory costs, it also allows for the floor laying to be executed faster,” said Nathan. Both projects in North Sydney and Parramatta are currently in supply and are expected to be completed in early to mid 2016 within a positive timeframe thanks to the improved project efficiencies that the KingFlor system delivers. As part of the KingFlor offering, Fielders offer a full comprehensive suite of technical design tools to support the architect and builders in planning and implementation, allowing the most challenging of structural designs to become a reality. For more information on Fielders KingFlor, please phone 1800 182 255 or visit

ABOUT FIELDERS Operating for 115 years, he diversified Fielders group is part of BlueScope Building Components, a division of BlueScope Steel Limited which a multi-national company distributing a diverse range of steel products to the world. Fielders’ Australia-wide operations across 15 manufacturing sites in four states employ more than 500 people. Its main business is in the manufacture and distribution of a range of rollform metal building products - including roof and gutter material, downpipes, steel flooring systems, carports, sheds and purlins - for the commercial and residential building markets.

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In A ‘Too-Tight’ Timeframe, Use Individuals’ Strengths to Your Advantage by Jordan Kelly, Bid Strategist & Coach When you’re under the pump with a short submission timeframe, your best default strategy for getting a top-notch bid out the door in good time and with the least stress possible is to “go with the current” in terms of people’s natural talents. You can coach people in their areas of weakness to a reasonable degree, but rarely will they be great in those particular aspects of bid production. The fact is, people generally gravitate back to the aspects in which they naturally excel and endeavour to avoid those in which they don’t. And when a bid manager is under the pump, the cold, hard fact of the matter is that he or she simply doesn’t have the time to coach or cajole.

IDENTIFY PRIORITY SKILLS NEEDED The first step is to accurately identify the priority skills required for each part of the submission and the process, giving careful consideration to which individuals possess these. It’s also smart to consider personality traits or work habits that stand to either propel or impede progress towards the finish line. Really think about each person and who (rather than what) they are. ‘Day job’ position titles can be misleading in the context of a bid. Often, the strengths and weaknesses you’d assume of an individual in a particular role just don’t import across into a bid team environment in the way you’d expect them to. I’ll cite as a case study, a small, component operation of a larger organisation with which I had been working. One of the operation’s few ‘white 30

Construction Engineering Australia - October 2015

collar’ staff members (aside from the GM) was assigned as bid manager. It was a pressure cooker timeframe and, a few days after kick-off, the schedule was already floundering. In short, this assumedly ‘natural’ bid manager appointment was a disastrous choice. As it happened, fate graciously stepped in and saw that individual suddenly pulled off onto another contract elsewhere. Because I was working with the team by remote control, there was little choice but for the Construction Manager to take over the bid management role.

that particular operation, was apparently record time. To re-emphasise the moral of the story: When time is unavoidably tight, ensure the highest quality and the least stress by getting to know your ‘human resources’ and letting each wear the cap that most comfortably fits him or her.

‘HUMBLE HAMMER SWINGER’ SAVES THE DAY Fate dealt the bid a lucky hand that day. The previous appointee’s weakness was the Construction Manager’s strength. This ‘humble hammer swinger’ (his own words) made a brilliant bid manager. He was organised, efficient, exercised total diligence in keeping his own commitments, and had an affable but effective way of holding others to theirs. His humility came in handy, too: if he could see anything going off the rails, he was quick to pick up the phone for advice. The fact that he couldn’t string two coherent sentences together on paper turned out to be inconsequential. When the now-former bid manager returned to the team, he gravitated directly towards - and excelled at - the bid’s writing tasks, taking on those that had, in fact, been assigned to the Construction Manager. So, by complete accident, we ended up with a highly functional bid team and a top-notch bid out the door in what, for

Jordan Kelly is a bid strategist and consultant. She is author of ‘Think & Win Bids: Winning High-Value, High-Stakes Bids through Superior Questioning, Listening and Thinking Skills’. CEA readers can subscribe to her free newsletter - ‘The Bid Strategist’ - at

Barangaroo Redevelopment, Sydney, Australia

David Langford, Lend Lease Structures: “The collaboration between Lend Lease Structures and PERI to develop a system which accommodated our comprehensive safety requirements was greatly appreciated. PERI has worked closely with us and their continued site service has been a valuable resource when called upon. The added benefit of Hydraulics on the LPS system enabled us to free up crane time and helped us in achieving our tight program.�

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PERI SYSTEMS HELP TO OPTIMISE CONSTRUCTION TIME AND SAFETY AT BARANGAROO International Towers Sydney Barangaroo South, Sydney, Australia Barangaroo is a 22 hectare, $10 billion project which is located on the north-western edge of the Sydney CBD and the southern end of the Sydney Harbour Bridge. The project is Sydney’s biggest development project since the 2000 Olympics and one of the most significant waterfront regeneration projects currently underway anywhere in the world. It project transforms a former container wharf into a dynamic and authentic public part of Sydney. Barangaroo will create thousands of employment opportunities and is expected to deliver approximately $2 billion per annum into the NSW economy. The redevelopment project consists of three project areas: Barangaroo Point Reserve (North), Central Barangaroo and Barangaroo South. Lend Lease was selected in December 2009 as the developer for Barangaroo South by the Barangaroo Delivery Authority on behalf of the New South Wales Government.

At its heart sit the three commercial towers that make up International Towers Sydney (ITS) and will be surrounded by smaller residential towers and leisure development around its base. It will be a true mixed development comprising of commercial, residential, international hotel, retail, restaurants, cultural facilities and also public space that will be a new Australia’s premier financial and professional services hub for Sydney. It will create one of the greenest environments for future generations. The towers all have a similar foot print with separated low, mid and high rise levels. A Vertical Village is constructed on the mid and high rise, where the low rise lobby terminates. With 49 levels and standing at 217 metres, IT1 is the tallest tower. IT2, which has been leased by Westpac, will be completed to 43 levels, while IT3, which has been largely leased by KPMG, will be terminated at level 39. These three towers have a combined gross

Two loading platforms were supplied per tower, using the RCS (Rail Climbing System) with screens above and below the platform for added safety. (Photo: PERI)

PERI Australia’s GRIDFLEX formwork system was supplied for the construction of the Barangaroo commercial towers with PERI’s tailor-made LPS (Light Protection System) screen system and efficient RCS (Rail Climbing System) hydraulic climbing solution. (Photo: PERI)

floor area of 320,000m² and are joined by a large 3 storey podium. Construction commenced in 2012 and is expected to be completed by 2016 with the adjoining Hotel and residential towers due to commence construction in 2016 and be completed by 2019. For construction of the Barangaroo commercial towers in Sydney, PERI Australia are supplying RCS, LPS and GRIDFLEX systems, which provide a safe, fast and costeffective solution.

SLAB FORMWORK SOLUTION WITH GRIDFLEX PERI Australia supplied GRIDFLEX slab formwork with PEP PROPs for the core Lobby area. The lightweight and readymade aluminium grid elements are erected from below and simply hook into the PEP PROP head, providing a fast and systematic assembly sequence which can save valuable construction time.

EFFICIENT HYDRAULIC CLIMBING SOLUTION A major benefit to the client was the use of PERI’s mobile Hydraulic Climbing feature. The use of this cost-effective system freed valuable crane time that could be used in other areas. In addition, being able to climb on the day of the pour gave additional time advantages so that the formwork cycle could begin early the next day, accelerating the program. 32

Construction Engineering Australia - October 2015


Two loading platforms were supplied for each tower using RCS (Rail Climbing System) with screens above and below the platform for added safety. These platforms enabled the formwork from the Lobby area to be recycled between floors quickly and efficiently.

Pictured (clockwise from top right): Each building requires approximately 240 lineal meters of PERI’s LPS safety screens. The flexibility of the LPS system allowed PERI to deliver a solution that could overcome a number of challenges, including varying floor heights which change from 3.8m to 4.2m to 5.5m.; Specialised screens were also provided to give added protection around the Alimaks; To provide four levels of safety screens plus an additional two meters above the working level, PERI created an 17.5m tall safety screen which could be hydraulically lifted. In addition, the pour sequence at the site meant that the screens were also required to cantilever 6m; To meet the client’s strict safety standards, vertical gaps between screens were covered using a profiled mesh which is clipped into a special profile that was attached to the screen mesh. Allowances also had to be made to provide enough room (up to 750mm) for post-tensioning to occur on the slab edges. (All Photos: PERI)

COMPLETE ENCLOSURE WITH TAILOR-MADE SCREEN SYSTEM PERI Australia also provided Lend Lease with the new Light Protection System (LPS) - the 1st hydraulic screen system in Australia with a single rail. The lightweight LPS screen system delivers a range of benefits, including: • Lightweight rams (man hand-able) and an easy to move pump which is able to lift two screens simultaneously • Unique Mesh panel grid complying with Lend Leases stringent safety GMR • 2.5m wide screens with wings to increase width to 4.8m • Ability for the system to cantilever 1 full floor + 2m handrail (17.5m high screen) • Movable platforms/ flaps to cater for varying slab heights • Unique solution for the upturn beams located around the core, this included a new shoe and the ability to support a steel shutter • Screen pre-assembly and installation. Screen supplied in a lower and upper segment for early installation and off site prefabrication • High strutting, Lobby and Alimak screens as well as loading platforms (3t capacity)


INNOVATIVE ASBESTOS SAFETY SOLUTION DEVELOPED BY QUEENSLAND COMPANY Reynolds Soil Technology (RST) is leading the way in the development of cutting-edge industrial solutions with the launch its new product, Asbestoguard, a spray-on material binding agent that seals off dangerous asbestos fibres at contaminated sites. Asbestos was a material widely used in the last century by manufacturers and builders before it was discovered how harmful it can be when disturbed or broken down for removal. With an alarming amount of asbestos used in old buildings across Australia, a massive industry has developed around the safe removal of asbestos contaminated materials from worksites ranging from major property developments to home demolitions. RST recognised the need for a technologically advanced product that can be sprayed on asbestos contaminated materials to hold the dangerous fine particles in place during the demolition and removal process, improving worker safety. The RST team drew on its expertise in the field as fine particle dust management specialists working in the harshest conditions across the globe to develop Asbestoguard - an innovative asbestos binding agent in the form of a specialty cross-linking polymer emulsion. Asbestoguard is a hard-wearing solution that works on all asbestos contaminated material types in all weather conditions after one application. The University of Newcastle has independently tested the solution and found it to be effective in withstanding wind speeds of more than 100 kilometres per hour. Asbestoguard dilutes in water, allowing for varying binding strengths and longevity 34

Construction Engineering Australia - October 2015

requirements, and is easily applied through any watering system. The Asbestoguard solution can be mixed with another RST product, RT60 Super Wetter, to improve application on hard to wet surfaces and materials. Marking dye can also be added to Asbestoguard to monitor application areas and strengths. Excellent results for contaminated earthworks have been achieved applying Asbestoguard diluted at 1:20 and applied at one litre per square metre of material. If the material to be treated is very dry and water repelling, RST recommends the addition of RT60 Super Wetter at a dilution rate of 1:1000 in the Asbestoguard solution. A multi-award winning global leader in providing comprehensive, environmentally friendly dust, earth and water solutions, RST is excited to launch Asbestoguard into the market as a premium safety solution where asbestos contaminated material is present. RST operations and technical director David Handel said the development of Asbestoguard was focused on minimising health risks and improving worksite efficiency to increase operational optimisation in the demolition and removal of old buildings. “In many areas across Australia, particularly in major capital cities experiencing land shortage, developers are demolishing older style buildings to make way for new developments,” he said. “A lot of these buildings contain asbestos contaminated materials which release dangerous fibres into the air when disturbed or broken down.” “The RST team specialises in the control and suppression of dust particles and saw how this knowledge could be applied to

RST Warehouse Manager Michael Allen with a container of Asbestoguard.

create a solution stopping the release of fine asbestos particles from contaminated materials,” he said. “While most of the demand for this solution is from the construction industry, our aim is for Asbestoguard to be a leading safety solution in any industry where asbestos contaminated material is present at the worksite.” “RST’s extensive range of products have been designed to solve a broad variety of problems related to asbestos management, dust control, road and soil stabilisation, erosion control, water management, sediment control and site rehabilitation in all industries,” he said. “We go out into the field and work side by side with clients to identify their unique challenges and offer solutions, developing products, services or total packages to manage their situations.” “We also offer ongoing on and off site training and support to all of our clients and understand the key to success is ensuring our recommendations are followed through with correct operational support,” David Handel added. RST has more than 26 years of experience specialising in dust, earth and water solutions for mine sites, haul roads, ports and land sites in Australia and overseas. The company’s head office is based at Burleigh Heads, Queensland with an additional office in Carlisle, Western Australia. RST’s international operations extend to regions including South and North America, Africa, Asia and Oceania. For more information please contact Reynolds Soil Technologies, Phone: (07) 5522 0244 or visit


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“The system has worked extremely well, providing a safe, sheltered working environment for our operatives. By the nature of its design, we can achieve a completely sealed wrap around the whole building, protecting the public below” Kevin Dennehy, Atlantic Contracts, Project Engineer

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Ascent Cladding Beams retract for travel to the site, expanding to provide full width screens up to 5.2 metres wide maximising coverage and minimising repetitive lifting over the project duration

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World of Concrete 2015

All things New for Concrete on Show There are several ways to determine the success of an event like World of Concrete (WOC). One way is to look at the numbers. For instance, attendance for the 2015 show earlier this year was in excess of 60,000 attendees - all industry professionals who took the opportunity to catch up with the latest trends in the world of concrete and meet up with their peers and industry leaders. Attendees came from all over the world including as always, Australia. Over 1,300 indoor and outdoor exhibitors at the Las Vegas Convention Centre took up 60,500 square metres of space, while 100-plus skill-building seminars and conference sessions with over 45 brand new topics added to the attraction.

All of those numbers are increases over the previous year. But more important was the attitude, which was the most positive in several years. This should translate into better business for contractors and stronger equipment and materials sales. The attraction for attendees who are looking for new solutions, new technologies and the exchange of ideas is that they find them right there over the five days of the show. Contractors, dealers, distributors, producers, engineers, and architects attend the event for information on the latest commercial construction products, equipment and services. As the only annual international trade show dedicated to the commercial construction

Decorative concrete was once again an extremely popular feature at World of Concrete, with exhibitors highlighting floors, counter tops, and paving in an array of beautiful finishes.

industry, World of Concrete provided an endless show floor full of the latest technologies being utilised today, as well as providing attendees the chance to meet directly with the leading suppliers to the concrete and masonry industries. This year as always, WOC excited the crowds in the outdoor area where they could see the 'best of the best' performing their miracle stuff with concrete right in front of their eyes. The great thing is that visitors can talk to any of the experts and questions. Outdoor favourites such as the Mega Demos, The Producer’s Challenge, The Spec Mix Bricklayer 500 Competition, and Artistry in Decorative Concrete were more popular than ever. World of Concrete is actually the largest convention that Las Vegas hosts – concrete draws more attendees than anything else in town except gambling.


Construction Engineering Australia - October 2015


POLISHED CONCRETE IS TRENDING FORWARD A real highlight leading up to WOC 2015 is the surge in demand for polished concrete floors. The record attendance at the annual Concrete Polishing Forum was another good indicator of optimism for this niche industry segment. A record 170 attendees talked about business strategies among themselves and listened to industry experts speak about different facets of the polished concrete industry.

While everyone wants to learn about the latest innovations in equipment, materials, and technology, Chris Wright, vice president and co-owner of Durable Surfaces Concrete Repair, reminded attendees to pay attention to the basics. Develop good relationships with vendors, hire good employees, buy good equipment, and be sure it’s in good operating condition when you arrive at the jobsite. Wright focused on how to salvage distressed concrete. “There is tremendous opportunity for polishing and staining repaired concrete,” he said. “Residential is a good niche market for distressed concrete. We have educated homeowners that need good polished concrete in their garages and basements.” Stress concrete’s sustainable qualities, said Roy Bowman, owner of Concrete Visions. “Properly refined polished concrete provides the end-user with a clean-looking, aesthetically pleasing, low-maintenance floor,” he said. Always approach a job with an action plan, advised Chris Van Veen

of GranQuartz, a coatings equipment supplier. Van Veen stressed the importance of developing a maintenance program for the client after the job is complete. Polishing contractors usually know the clients better than others who specialise in maintenance, he said.

DECORATIVE CONCRETE WOWS THE SHOW Decorative concrete becomes more hot by the minute, with the World of Concrete again showing outstanding floors, counter tops, and paving. It is always fascinating and instructive to see this work performed before your eyes. The trend in 2015 is to go with thin overlays, although dry shake stencilled or mat stamped remains popular. Colour acid-etch stained concrete was widely shown and has produced some unbelievable results. Acid etch staining of concrete floors is big business in the US. The thing that caught everyone’s attention attending the exhibition was the explosion in stained concrete, in all sorts

Construction Engineering Australia - October 2015



of applications. Visitors saw stamped concrete, slate, stained, overlays, Mexicanstyle tile treatments, flagstone, and marbleised floors. Plain concrete can be given an appealing elegance. In terms of overlays becoming extremely popular, here is a roundup of the new trends:

TOPPINGS AND SKIM COATS There is an explosion in artistic finishes applied as overlays onto concrete slabs. The craftsmanship in the finished product was amazing, so good that you’d be proud to hang it on your lounge-room wall, but of course you can’t, as it is a concrete slab. A number of projects used toppings, which involve stencilling patterns over existing or new concrete. These ultrathin decorative toppings are applied by a trowel or squeegee in layers as thin as half a millimetre. They spread silky smooth and can be taken down to a feather edge. Decorative techniques see them applied in several coats to create colourful overlaid finishes. Some systems come pre-tinted in a wide range of colours while others can be custom tinted by mixing in the desired amount of liquid colouring agent. Interesting colour variations can be achieved by applying layers of different hues. These toppings usually do not contain aggregates, but often other inclusions are added, such as coloured glass marbles to be ground flat and exposed. The topping was coloured with oxides or colour stains - sometimes both. Shallow dividing lines were cut into the concrete, generally with an angle grinder. These lines made the concreted areas look like extremely large floor tiles, but a lot easier and cheaper to do. The lines contribute the essential element of scale. The surface colours sometimes were worked by abrading the surface, or secondary colour overlays were added. The unusual effects were created when metallic powders were incorporated into the surface. These ranged from shiny silver effects to gold, to statuary bronze – all taking a humble concrete floor to a stunning level of finish.

depth gauge for achieving a uniform topping thickness) and then imprinted with stamping mats or texturing skins. These semi-flexible stamping tools are available in dozens of patterns, allowing overlay installers to duplicate the beauty and texture of natural stone, brick, slate, wood planking, and other materials. Overlay thicknesses range from six millimetres to twelve millimetres, depending on the depth of the imprint. Stamped finishes can also be blended with other decorative concrete elements such as exposed aggregate finishes and acid-etch staining. You won’t believe the grained wood floors that are really concrete, or the slate paving - also concrete.

SPRAY-ON SYSTEMS One exhibitor showed techniques using a spray polymerization process that allows you to stamp liquid then stain on top. This is finished off with a patina antique finish. “We put a colour hardener on the surface so it looks like it’s pattern released.” These versatile systems offer a wide array of finish options. Usually they are sprayed evenly onto concrete with an air-powered hopper gun, but they can also be applied as a splatter coat to create a textured, slip-resistant surface or “knocked down”

with a trowel to create a smoother finish. A popular decorative technique is to use paper or adhesive stencils to produce designs ranging from decorative borders and medallions to tile patterns to embossed or inlaid motifs.

SELF-LEVELLING OVERLAYS These flowable polymer-modified toppings have the ability to self-level without trowelling, making them ideal for smoothing and levelling worn or uneven concrete surfaces. Installers simply pour or pump the material onto the surface and then use a spreader to distribute it evenly. The overlay can be left seamless (except at control joints) or used as a canvas for saw cut or engraved designs. Or you can incorporate decorative inlays, such as strips of wood or metal, by adhering them to the base concrete and then pouring the overlay to the level of the inlay. Selflevelling overlays can also be enhanced by staining or dying. In some applications, they serve a purely utilitarian purpose as an underlayment for tile, carpet, or other floor coverings. However, if you want a marblelook floor, a coloured concrete overlay can give it to you at a saving.

STAMPED OVERLAYS A stamped overlay offers all the aesthetic benefits of conventional stamped concrete but is less time and labour intensive to install. The overlay mix is usually applied by a gauge rake (a tool with an adjustable 38

Construction Engineering Australia - October 2015

Artistry in Action - World of Concrete featured man fascinating and instructive displays, with artisans creating designs of a complexity and beauty that needs to be seen to be believed.


THE 4 PS OF SUSTAINABILITY SARAH BACHMANN, CEO, NATIONAL PRECAST The three “Ps” of sustainability are well known - People, Planet and Profit. When it comes to the construction industry, if we are focusing on improving efficiencies, there should be not just three, but four “Ps”. The fourth should be Prefabrication. The construction industry contributes $200 billion to the Australian economy and represents 7.5% of our GDP. There’s no doubt the industry is vital to our future, but there still remain challenges in growing and remaining progressive. It’s a sector that can lead in sustainability with the innovative and efficient use of prefabrication. It’s timely now for the Federal Government to take a lead in the construction industry by recognising the benefits of smarter construction methods, such as those offered by off-site manufacture, including precast concrete. There’s renewed optimism for the future of the industry, encouraged by Prime Minister Malcolm Turnbull’s focus on cities and the built environment. Mr Turnbull says his cabinet is a “21st century government” and that “…liveable cities, efficient productive cities, the environment of cities, are economic assets.” The new Cities and Built Environment Portfolio and its Minister, Jamie Briggs, are evidence the Prime Minister recognises the importance of the construction sector to the economy. It’s widely acknowledged that the global construction industry strives for continuous improvement by adopting new technologies and

innovations. Analysis of increased use of off-site manufactured products has identified significant positive impacts. Precast concrete is an important example of prefabricated products - and it can be used to construct entire structures, both in building and civil applications. It’s manufactured off-site and this results in shorter construction times, simplified construction processes, higher quality and consistency in products, safer construction sites and less waste both on and off site. Slowly, we are seeing the more traditional on-site fabrication of structures shifting off-site, both here and overseas, and the precast concrete industry is a leader in this transformation. Here in Australia, Laing O’Rourke is just one example where innovation ranks high on the agenda, with recognition that using more off-site manufactured products such as precast reaps significant rewards. Concrete products that are manufactured off-site demonstrate enormous efficiencies and benefits for the entire industry and precast concrete is the foundation for sustainable construction in Australia. Locally manufactured using local products, it utilises some of the industry’s most ecological and economical practices. Precast incorporates recycled materials in production and the use of less raw materials results in reductions in construction wastage. The finished product is also environmentally friendly. When used in either residential or commercial buildings,

Off-site manufactured products such as precast offer a myriad of sustainability benefits

Precast makes for safer sites with less personnel, fewer material deliveries and significantly less onsite waste.

precast concrete boasts an extremely high thermal mass. That translates to reduced energy costs for heating and cooling. As well, it is low maintenance, fire safe and extremely long-life and durable. As a leader in promoting innovation and smarter building to the construction sector, and being committed to a transformation of our industry for the future, National Precast Concrete Association shares the new Prime Minister’s view on the importance of the sector. The Government now has the opportunity to show leadership in building sustainability. How better to show it is serious, than by leading by example with new government procured projects… by setting targets for off-site manufacture and using Australian manufactured products. As Minister Jamie Briggs develops his new Cities and Built Environment portfolio, we urge him to recognise the benefits of prefabrication and smarter 21st century methods of construction such as precast concrete. It’s time to adopt the 4Ps of sustainability. It’s where the future of the industry lies.

FIND OUT WHY PRECAST SHOULD BE THE 4TH P OF SUSTAINABILITY Not sure why precast is sustainable or want to learn more about how it contributes to our planet, people and profit? Watch National Precast’s new video Precast concrete – Building a sustainable Australia video via National Precast’s website


Construction Engineering Australia - October 2015


TRINITY HILL ACCOMMODATION AND TRAINING CENTRE Precast contributes to affordable public housing and job creation

Precaster: Duggans Precast Project Owner: Tasmanian Government – Dept. of Health and Human Services Builder: Fairbrother Architect: HBV and CCA in association Engineer: Aldanmark As part of its commitment to providing quality, sustainable services for Tasmanians on low incomes who are, or may become, homeless, the Tasmanian Government is redeveloping the former Adult Education Learning site in Church Street, North Hobart, known as Trinity Hill. As well as continuing its tradition of providing education and training services to the community, the new $13 million dollar Trinity Hill Accommodation and Training Centre will also incorporate 46 independent and supported living units for young people on low incomes, including 16 young people with a disability. Tasmanian Human Services Minister Jacquie Petrusma said there was high demand for the facility. “The training facility will create an opportunity to re-engage with education, training, employment and positive influences that

will help people get their lives back on track,” Ms Pertrusma said. Constructing the project also has economic benefits, creating over 100 direct and indirect jobs and injecting about $34 million into the economy. MAINTENANCE-FREE OFF-WHITE PRECAST AN IDEAL CHOICE With precast walling specified for the fourstorey facility, National Precast member Duggans Precast was selected to supply the panels. Wall panels were manufactured at its Cradoc factory in Tasmania’s Huon Valley. They averaged 2.7m x 4.2m in size and were made using an off-white cement and white oxide. According to Duggans’ Project Manager for Trinity Hill Scott Combes, even though it is white, precast is ideal for this type of building. “The façade is maintenance free and requires no paint or render. In some places of the building however, a clear anti-graffiti coat has been applied to protect from unwanted decoration,” he said. DECORATIVE LIFT SHAFTS As well as the wall panels, lift-shaft panels were also manufactured by the company. According to Mr Combes this was a particularly interesting component of the project. “These tapered as they went up, so panels were angled with mitred corners in almost a pyramid shape. The lift-shaft

Construction Engineering Australia - October 2015



panels were patterned with a circle-like design. We had some MDF stencils made and laid them in the casting bed before applying a chemical retarder and pouring the concrete,” he said. OTHER BENEFITS USING PRECAST The benefits of using precast in construction of this type of project were apparent to everyone

involved and demonstrate the suitability of precast for housing. “Precast keeps the site nice and clear which makes it safer, plus it dramatically speeds up the construction schedule. Panels can be made off-site while the slab and foundations are being poured and then when it is delivered, it goes up very quickly,” said Mr Combes.

“Precast keeps the site nice and clear which makes it safer, plus it dramatically speeds up the construction schedule."

SEISMIC DESIGN & DETAILING SIMPLIFIED The requirement for seismic design, including detailing, applies to all structures in Australia. Just as vertical loads are either permanent or imposed actions, lateral loads can be either wind or earthquake. Even if wind actions are larger than the earthquakes actions, they are separate and completely different design cases, which must be separately considered. Whilst wind actions are common and well understood, earthquakes are not. Unlike wind actions, they are resisted inelastically (and drift can be a problem) and they are fundamentally different to wind actions due to their cyclical nature. The recently published Guide to Seismic Design and Detailing of Reinforced Concrete Buildings in Australia by the Steel Reinforcement Institute of Australia (SRIA) shows how the requirements of the current standards can be met through mostly simple ‘seismic’ details and good detailing practice. Further, it shows how an appreciation of structural performance under seismic action will enable the structure to be designed to withstand the anticipated earthquake actions. The Guide was awarded the 2015 Concrete Institute of Australia National Technology Category Award for Excellence and is available for free download from the SRIA website at 42

Construction Engineering Australia - October 2015

“It’s satisfying to be part of a project that helps people on low incomes, particularly with the training and education facilities on site. Hopefully, it will help turn some lives around, giving people who are in need and at risk of homelessness training opportunities and somewhere modern to live,” Mr Combes said. “We see the potential for many more housing projects like this,” he added.


MEMBER PROFILE: DUGGANS PRECAST A FAMILY OWNED PRECASTER WITH FAMILY VALUES FAMILY VALUES ARE AT THE HEART OF BUSINESS FOR TASMANIAN PRECAST CONCRETE MANUFACTURER DUGGANS. THE LONG-TIME MEMBER OF NATIONAL PRECAST HAS BEEN IN THE INDUSTRY FOR MORE THAN 25 YEARS. BUT LONG BEFORE THAT, DUGGANS ESTABLISHED A SOLID AND TRUSTED REPUTATION IN THE BUILDING INDUSTRY. In 1927 Harry Duggan purchased his first truck at Cradoc in Tasmania’s Huon Valley. Since then, the company has grown from a transport business to a successful manufacturer and supplier of precast concrete. The family connection has been integral to that growth. Four of Harry’s sons worked as directors in the business, and the family tradition remains today. At company headquarters, the Duggan name continues with some of Harry’s grandsons, granddaughter and now great-grandsons involved. Company General Manager, Brent Hardy, says being family owned has shaped the way Duggans does business. “We believe in being a strong corporate citizen in a country community,

both in our values and our employment of locals,” Mr Hardy said. “We want to be respected, trustworthy and work with our clients, not against them, in a competitive market.” The company has sustained consistent growth and value-added to its service offering over the years. The establishment of a hard rock quarry was followed in the late 1970s by Duggans acquiring a concrete batch plant and started supplying the local area with premixed concrete. These divisions continue to supply a large range of products for construction, land development, commercial and civil developments and residential use. PRECAST NOW LARGEST DIVISION It was in the late 1980s that precast was added to the offering. According to Mr Hardy it was the logical expansion to extend business outside the Huon Valley and across the state. Precast is now the largest division of Duggans, employing about 25 of the company’s 60 staff. EXPERIENCED AND VERSATILE TEAM Those staff members have been another important factor in Duggan’s success. The company boasts a low team turnover.

“They’re vital to a growing business. We rely on them for productivity and quality. And they need to be willing to change, develop and grow as the demands of the business evolve,” Mr Hardy said. “We need to be flexible and versatile in the market, to go from houses, to warehouses to multistorey buildings.” The Tasmanian market is competitive and the company has developed a positive profile across the state with a reputation for service and quality. It supplies precast concrete elements to all sectors of the construction industry in all areas of Tasmania. Every day the team strives to fulfill its mission statement; “To be a company that customers prefer to use, employees are proud to work for and one that is respected within the Tasmanian community”. AN OPTIMISTIC FUTURE Mr Hardy expects the building industry to continue to be challenging in the future but he’s optimistic about his company’s role in the sector. “Construction is a difficult and sometimes ruthless industry. But we are there to do the right thing by our community and our clients.” “We want to work with builders to get the best outcome for everybody. That’s what’s important,” Brent Hardy concluded.

Construction Engineering Australia - October 2015


precast... the publications

All you need to

make precast easy

A Little Book of Concrete

his book highlights the many benefits that sustainable, factory-made precast T concrete can offer the architect, the designer, the engineer, the builder, the client, the financier, the insurer and the environmentalist. Hardcopy: PDF:

AU$ 23.12 Free download from our website

Precast Concrete Handbook

n essential resource for any architect, designer, engineer or builder involved in a A precast concrete project, this is the definitive Australian text covering the design, manufacture and installation of precast reinforced and prestressed concrete. The 460 page Handbook covers: • History and application • Design of joints • Products and processes • Thermal and acoustic properties • Materials and material properties • Architectural elements • Tolerances • Handling, transport and erection, and • Analysis and design of buildings • Contractual Issues. • Design of elements • Connections and fixings Hardcopy: CD: Student Edition CD:


200.28 200.28 77.00

Details for Buildings

eveloped for architects, designers and draftsmen, this publication contains over D 50 of the typical details used by National Precast members. Design, erect and build notes are included for each detail. The publication covers details for: • Joints and openings • Panel to structural steel • Panels to flooring • Hollowcore panels, and • Panel to panel • Sandwich panels. Hardcopy: PDF: Individual DWG: DWG Full Set: DWG Set 1 – Single Layer Panels: Joints and Openings: DWG Set 2 – Single Layer Panels: Panels to Flooring: DWG Set 3: - Single Layer Panels: Panel to Panel: DWG Set 4: - Single Layer Panels: Panel to Structural Steel: DWG Set 5: - Hollowcore Panels: DWG Set 6: - Sandwich Panels:

To get hold of these publications and lots more visit


119.76 107.78 11.26 253.35 97.28 105.62 105.62 43.91 125.66 86.70

making precast easy

Recommended Practice: Precast Concrete Sandwich Panels

This publication is ideal for architects, designers, engineers and builders. It has been developed in response to the increased popularity of insulated sandwich panels, as they have become recognised for their superior thermal, acoustic and fire performance. The publication covers: • • • • •

Benefits of sandwich panels Thermal and acoustic performance Case studies Finishes Structural design and detailing

• • • •

Fire ratings Waterproofing Manufacture, and Handling, erection and installation.

Hardcopy: PDF:


91.02 81.92

Recommended Practice – Design, manufacture and installation of Glass Reinforced Concrete (GRC)

I deal for architects, designers, engineers and builders who are involved in a GRC project, this Recommended Practice provides a comprehensive explanation of lightweight GRC. Popular in civil and landscaping applications, GRC also offers a versatile solution for architectural projects. Reinforced with alkali resistant fibres, GRC achieves a strong yet lightweight result that can be formed in thin elements, in any shape, texture or colour. The publication covers: • • • • • •

Materials for GRC • GRC manufacture Curing • Physical properties • Design requirements and procedures • Contractual considerations Hardcopy:

Establishment and quality control of characteristic strength Handling, erection and installation Surface finishes, and Vibration-cast GRC. AU$


Amazing Architecture – Explore the possibilities of precast concrete

erfect for architects and designers, Amazing Architecture highlights the almost infinite P array of shapes, colours and textures available in precast concrete, showcasing its flexibility and versatility through a series of practical and innovative case studies. Hardcopy: PDF:

AU$ 10.94 Free download from our website

Minimising Investment Risk – Why precast delivers on investment

uited to developers and clients, Mitigating Investment Risk details precast’s significant benefits in S terms of cost, construction speed, durability, versatility, build quality, maintenance and sustainability and highlights these benefits through a series of practical and innovative case studies. Hardcopy: PDF:

AU$ 10.94 Free download from our website

Mitigating Construction Risk – How precast concrete reduces cost and improves safety

eveloped for builders, Mitigating Construction Risk details the significant cost, safety, D construction speed, build quality and sustainability benefits that are offered by precast concrete. The benefits are highlighted through a series of practical and innovative case studies. AU$ 10.94 Hardcopy: PDF: Free download from our website

To get hold of these publications and lots more visit

making precast easy


CLOISTERS ARCADE, PERTH Makeover preserves history with modern flair Head Contractor: Probuild Architect: The Buchan Group Engineer: Aurecon Australia Precast Manufacturer: Delta Corporation Perth’s Cloisters Arcade has undergone an $85 million dollar makeover. Originally built in 1858, the unique heritage landmark has undergone a transformation, preserving history and incorporating modern design. An 11-storey commercial tower has been built on top of the existing Arcade, replacing a two-storey building constructed on the site in 1971. The redevelopment includes a realignment of the Arcade to provide a north-south thoroughfare for pedestrians, and transformation of the two-storey office complex to the much larger office and retail centre. The building is owned by the Perth Diocesan Trustees, which has identified the project as having the potential to improve commercial, retail and social environments for the City of Perth. The Arcade runs from Hay Street though to St Georges Terrace and its hoped the redevelopment will reactivate a key CBD site not being used to its full potential. The panels used on the lower section of the development were a full coloured mix, with white concrete and quartz. The panels were honed to expose the aggregate, before being polished for a high quality finish.

CONTEMPORARY FINISHES WITH PRECAST To preserve history and introduce a contemporary feel, the project incorporated the challenges of heritage constraints whilst calling for a modern office tower facade design. 46

Construction Engineering Australia - October 2015

National Precast member Delta Corporation was contracted to supply the architectural wall panels for the east and west sides. A total of 2125m² of polished panels was required. The wall panels were manufactured at 150mm thick, with heights up to 4.75 metres and widths up to eight metres. They were wet cast horizontally in steel moulds. The panels used on the lower section of the development were a full coloured mix, with white concrete and quartz. The panels were honed to expose the aggregate, before being polished for a high quality finish. The upper panels contrast with those in the lower section. They were also manufactured with a full coloured mix, but with black concrete and granite. These panels were also honed and polished. Delta’s Jason Walsh says both panel types also incorporated aluminium feature fins into the

finished face. “The builder wanted high quality architectural cladding and precast was the obvious solution,” he said. “The finish on the panels is sophisticated and contemporary, giving this office tower a modern and unique appeal.” CONSTRUCTION CHALLENGES To reduce any disruption within the environment and car park, the construction needed to take place over three stages. Throughout the redevelopment, the historic Cloisters Building, positioned in front of the Cloisters Arcade on St Georges Terrace, remained untouched. As well, a heritage-listed Port Jackson fig tree was protected during construction. The redevelopment has recently opened and has been very well received, bringing a modern and vibrant environment to the city, while also improving the pedestrian network.


CAMERON CLOSE, SORRENTO Precast perfect for luxury home Precast manufacturer: Hollow Core Concrete Project owner / Builder: Private client Engineer: A. Poon consultants A breathtaking luxury residence in Sorrento, Victoria is earning praise for its impressive build and design. The three-storey home is nestled in sand dunes and its unique construction compliments its surrounds, offering warmth with a contemporary feel. PERFECT FOR COASTAL LOCATION Precast concrete is an integral feature of this striking home. Melbourne-based company and National Precast member, Hollow Core Concrete supplied various precast elements for the project. The building consisted of structural steel, hollowcore floor planks, solid edge balconies and architectural and structural wall panels. One of the most impressive features of this beautiful home is the exterior architectural wall panels, finished with a wood grain pattern. These horizontal planks create the feel of a weatherboard home, but with modern flair. According to Hollow Core’s Operations Manager and site manager for the project Balint Djeri, “These particular walls have both form and function. Not only does the rough sawn timber pattern look great, but the walling has also been designed to be structural and loadbearing.” Hollowcore flooring planks were also manufactured for the project. Mr Djeri says by using hollowcore flooring as well as walling, construction was accelerated from months to days.

“And of course there are other benefits including thermal properties and fire proofing,” he said. “Precast is an ideal choice for a coastal location like this,” he added. “Precast’s durability means it will handle the wet winters and hot summers that are so prevalent in Sorrento. It won’t corrode like wood, it requires no maintenance and there are no salt water corrosion issues either. It has the added features of being fire proof and long lasting.” SITE CHALLENGES OVERCOME According to Mr Djeri, the most challenging aspect of the project was the site. The home was located at the end of a narrow and hilly road, with large overhanging trees. “Manufacturing the walling and flooring away from the site was so much faster and easier than had all the work been done on site, and we finished up with a much better quality outcome,” he said.

The precast components were manufactured with Hollow Core’s state-of-the-art technology at its versatile Melbourne factory. “Once they were manufactured, it was a challenge to get them onto the site and we needed to set up large bog mats for the cranes because of the sandy soil. We had four craneage days and a crew of just five people to erect both the walling and flooring,” Mr Djeri said. “The client was very happy with the time it took for the building. If the concrete had been poured insitu it could’ve taken six months to build and with 10 or 15 people on site for that time.” Precast was chosen not only because of the difficult site access and time saving, but also because of the high quality architectural finishes required, the guarantee of top quality product and the speed of construction. And for Mr Djeri, this was an extremely rewarding project. “If you do a commercial building or a factory it’s a job, but when you create a house that’s so remarkable, in such a beautiful location, it’s truly inspiring,” he concluded.

Construction Engineering Australia - October 2015



SIR WILLIAM GOODMAN BRIDGE A new life for heritage tram bridge, Adelaide Client: City of Charles Sturt Project manager: J Woodside Consulting Contractor: Synergy Remedial Architect: Flightpath Architects Structural engineer: LN Engineering Precast manufacturer: S.A. Precast Built in 1908 and formerly known as the Hindmarsh - Thebarton Tramway Bridge or Holland Street Bridge, the Sir William Goodman Bridge spans Adelaide’s River Torrens and is the second oldest reinforced concrete girder bridge in SA. It is a tribute to its original designer, Sir John Monash, who was one of the early pioneers of reinforced concrete in Australia. Having performed remarkably well for over 100 years, the bridge has in that time had no


Construction Engineering Australia - October 2015

maintenance despite being used for initially for trams, then for motor vehicles, and most recently for pedestrians and cyclists. In 2010 an audit of the bridge by its then joint owners, the City of Charles Sturt and the City of West Torrens, found the bridge to be in a poor state, identifying severe corrosion and cracking which required the bridge to be immediately closed. Since 2010, the two councils worked to determine the best way to provide pedestrian and cycling access across the River Torrens. Several consultant studies considered options and three years of negotiations culminated in West Torrens offloading its share to Charles Sturt and the decision was made to restore and upgrade the existing bridge, rather than building a new one. Construction commenced in early 2014 and involved the replacement of all damaged and concrete with additional steel and carbon fibre reinforcement. Other new work included new handrails, scour control under the bridge and new

lighting and urban works at the ends of the bridge which included a stunning polished precast concrete seat manufactured by National Precast member, S.A. Precast. The project was delivered under budget, on time and was cheaper than a new bridge. Construction of the bridge was completed in September 2014 and since then, it has won a number of excellence awards from the RAIA, the CIA and IPWEA and wons a CCF Earth Award. It has also been short-listed by the Institution of Structural Engineers in the UK in their 2015 structural awards. The final restored and repaired bridge is a brilliant sustainable result for an important heritage bridge. It is an outstanding example of perseverance by those involved to question the original advice, to understand the problems and make the correct decision to restore and repair the bridge. It is a fantastic result, which the owner, public, users, the design team and contractor and subcontractors are rightly proud off.

CONCRETE VISION EBAWE designs, engineers and installs complete production plants for the manufacture of the most varied precast concrete panels. We are the ideal partner for your projects – regardless of size and kind.

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Construction Engineering Australia V1.05 - October 2015  

Australia’s premier construction, civil works and civil engineering publication.

Construction Engineering Australia V1.05 - October 2015  

Australia’s premier construction, civil works and civil engineering publication.