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ABN 85 007 693 138 PO Box 510, Broadford Victoria 3658 Australia Phone: 1300 EPCGROUP (1300 372 476) Int’l: +61 3 5784 3438 Fax: +61 3 5784 2210 www.epcgroup.com Publisher and Managing Editor Anthony T Schmidt Phone: 1300 EPCGROUP (1300 372 476) Mobile: 0414 788 900 Email: ats@epcgroup.com Deputy Editor Rex Pannell Mobile: 0433 300 106 Email: rex@epcgroup.com National Advertising Sales Manager Yuri Mamistvalov Phone: 1300 EPCGROUP (1300 372 476) Mobile: 0419 339 865 Email: yuri@epcgroup.com Advertising Sales - SA Jodie Chester - G Advertising Mobile: 0439 749 993 Email: jodie@gadvertising.com.au Advertising Sales - WA Licia Salomone - OKeeffe Media Mobile: 0412 080 600 Email: licia@okm.com.au Graphic Design Annette Epifanidis Mobile: 0416 087 412

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CIRCULATION 15105 Registered by Australia Post Publication No. 100001889

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Industry News

APRIL 2016 Volume 2 Number 2

10 Major Projects: Melbourne Park Redevelopment


12 Cover Feature: A1 Roadlines 14 Outdoor Assets 16 Worksite Safety 19 Product Focus: Tridon Knipex Pincers 20 Equipment in Focus


26 IPWEA NSW News 28 Civenex 2016 Seminars 30 IPWEA NSW Case Study 34 Project Focus: National Arboretum Canberra

36 Product Focus: Aussie Pumps Batch


Pump Guide

38 Seismic Design 40 Concrete Institute News 46 Project Feature: Broad Museum LA 48 National Precast Feature

About the Cover


Designed with a focus on robust durability and maximum visibility, A1 Roadlines' full range of LED Flashing Arrow Signs has just been awarded full Type Approval from NSW Transport Roads & Maritime Services (NSW RMS). The Type Approvals, which follow on from an extensive testing and performance assessment program, stand as testament to A1 Roadlines' commitment to developing quality products that help to maximise worksite safety. Turn to Page 12 for the full story.


The Urban Oasis

Quality inner-city Green Space critical for building communities Dear Readers, While few would argue the pivotal role of the massive boom in inner-city residential apartment facilities has played in helping to reinvigorate both the economy and appearance of many of our major capitals and larger cities, the popularity of this high-density / high-rise lifestyle also presents a number of significant challenges for councils and other statutory authorities around Australia. While there are numerous planning issues associated with individual projects and precincts, one of the biggest challenges facing Australia’s ‘inner-city’ councils is undoubtedly the requirement for efficient and timely development and provision of services and infrastructure to meet the needs of their rapidly expanding residential population. What’s more, these services and facilities must be delivered without sacrificing the needs of the remainder of the City’s residential and business community, and without alienating the many tourists and visitors that inevitably also play an important role in stimulating the economy in these inner-city areas. Together with transport planning challenges, another major issue associated with the rapid increase of inner-city high-rise living relates to the provision of public openspace areas; in particular, parklands and ‘green’ open-space. While many new inner-city residential developments incorporate a ‘common’ plaza area for residents to enjoy, most of these tend to be paved areas, or at best, are only 2

Construction Engineering Australia - April 2016

designed with minimal amount of ‘grassed’ areas and a limited number of trees. That is not to suggest that these areas are all badly designed or unattractive ‘concrete jungles’ - quite the contrary. Many of these plaza and/or ‘common’ areas are both practical, inviting and aesthetically pleasing. What’s more, in many instances, they provide a ‘central meeting place’ for the high-rise community – in much the same manner as the traditional village green did in the past. They are, in my opinion however, no substitute for natural parkland with an abundance of grass, trees and other plants. Not surprisingly, this lack of ‘green’ openspace, combined with the lack of ‘backyard’ environment, has resulted in a significant increase in demands upon inner-city public parks and gardens in terms of providing a ‘green oasis’ for inner-city residents to enjoy. This also presents a number of significant challenges for inner city councils, including the increased maintenance costs and public safety and security issues. Parks and public reserves, by their very nature, are usually designed with a focus on providing a peaceful and tranquil area which is ‘separated’ from the surrounding area. Unfortunately, this ‘secluded’ nature and often heavily-treed design also provides ample ‘cover’ for any number of anti-social and/or illegal activities. Whilst I wouldn’t dare to suggest that we are now faced with an epidemic of crime in our inner-city parks and gardens, it is a sad fact that, in many locations, there has been a significant increase in the number of crimes,

including drug offences, robberies and assaults being committed. Together with the impact on the actual victims, these crimes also have the effect of making many people ‘too nervous’ to go into the parks for fear of being attacked or ‘mugged’. Unfortunately, this also now applies to an ever-increasing number of bike paths and multi-use trails, following a number of widely-reported serious offences across the country. We must never underestimate the importance of ‘green space’ - both to the environment, and in relation to the positive impact that they have on our mental and physical wellbeing. Good quality public facilities and infrastructure are critical factors in building ‘communities’ rather than just groups of ‘dwellings’. One only has to look at the positive impact that a ‘community garden’ can have – regardless of the demographic or the location. With inner-city living continuing to grow in popularity, I believe that improving safety and amenity throughout our public parks, gardens and recreation reserves and along our multi-use recreational paths must be given a high priority by all stakeholders. After all, these facilities - no matter how tranquil and attractive - are of little value if residents and visitors are too scared to visit or utilise them. .

Anthony T Schmidt Managing Editor

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EDITORIAL FEEDBACK Dear Editor, In reference to your editorial 'Commuter Parking - a critical component of public transport solutions' (CEA magazine February 2016) - At last someone has identified the problem facing commuters from the outer suburbs of Melbourne. I live in the outer northern suburb of Epping, Victoria and a few years ago the state government extended the rail line to South Morang – one of the fastest growing areas in Melbourne. They reduced car parking at Epping station by hundreds of

spaces, restricted on-street parking around the station and then grossly underestimated the number of cars that would be parked at the South Morang Station. The current short term solution has been to turn the Council Offices' land opposite the station into a temporary car park for an additional 450 cars, now an absolute eyesore! It appears to be ‘an Australian thing’ to build new infrastructure that is inadequate before it is finished. We do it with our road networks – build new freeways and then within a few years have to widen them to cope with the

ever increasing number of users only to put motorist through the hell of road works and as you very rightly pointed out in your article, upgrade public transport networks but reduce parking - making it all but impossible for commuters to all be able to use it. I applaud your piece in the CEA February 2016 issue, I just hope it finds the right audience. Leanne Reed Epping, VIC

ACIF Welcomes Australian Infrastructure Plan The Australian Construction Industry Forum (ACIF) has welcomed the release of Infrastructure Australia’s (IA) Australian Infrastructure Plan. ACIF believes that the Australian Infrastructure Plan, when implemented, will result in more local employment in the construction industry, the development of skills and training, particularly for young people, and a longterm plan that will create more certainty for employers and the industry. The report incorporating 78 recommendations provides a coherent and strategic long-term plan based on cost-benefit analysis that will hopefully lessen political influence in providing the infrastructure that Australia most needs. James Cameron, ACIF’s Executive Director, stated, “We applaud Infrastructure Australia on the release of the Australian Infrastructure Plan.” “Infrastructure Australia is something that other countries wish to emulate, as it is a body which makes recommendations based on long-term social and economic benefit, rather than short-term political gain.” “This initial 15 year plan by Infrastructure Australia is a bold and definite statement by IA of where Australia should be heading in terms of infrastructure priorities, and we strongly encourage Federal and State Governments to take note and 4

Construction Engineering Australia - April 2016

implement Infrastructure Australia’s recommendations.” “Universities, technical colleges and employers must have some level of certainty of demand in order to know where to prioritise education and skills development, and this plan provides that.” “ACIF would also like to see more Australian labour, manufacturing and products used on local projects and we encourage Australian governments to do their best to ensure this occurs on these projects recommended by Infrastructure Australia.” “Product conformity and product compliance are also issues for Australian Governments to consider with these projects, and are important for their short, medium and long-term success.” “ACIF agrees that we must encourage strategic and integrated planning, and notes that Infrastructure Australia states that the average Australian household will be $3,000 a year better off by 2040 if this priority list of infrastructure is built.” “ACIF welcomes the commitment of IA to improve decision making in infrastructure planning, procurement, delivery and operation. ACIF’s work with the Australasian Procurement and

Construction Council on best practice procurement and the implementation of Building Information Modelling will be valuable resources in achieving IA’s aims.” “I look forward to working with Federal and State Governments to encourage debate into fair and equitable ways of funding the infrastructure Australia needs,” Mr Cameron added.

Where business gets done. 18 &19 may 2016

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Come and see what all the talk is about. CIVENEX 2016 is Australia’s premier infrastructure expo. As a visitor, you’ll see live demonstrations and the latest innovations, hot rod displays, vintage machinery and education seminars. Your chance to win a hot lap in a V8 supercar. As an exhibitor, you’ll be marketing your products to decision-makers and experts in their fields. For further information on visiting or exhibiting at CIVENEX 2016, please contact CIVENEX Event Manager: • Email: civenex@ipwea.org • Ph: 02 8267 3005



Public Lighting Conference Healthier Heads to Sydney buildings on the horizon for Australia Following its outstanding success in New Zealand, the award-winning Australasian conference and exhibition for road lighting authorities and professionals will be held this year in Sydney, Australia, on 2-3 November. Public Lighting 2016 will focus on developing lighting infrastructure as an energy efficient platform for smart city development, but will broaden its scope to include all public lighting, such as parks, sports fields, car parking, sporting complexes, safety and security lighting. Announced by the Institute of Public Works Engineering Australasia (IPWEA) together with management consultancy, Strategic Lighting Partners Ltd, the conference builds off two highly successful Road Lighting conferences held in Auckland New Zealand, in 2014 and 2015 that introduced almost 500 attendees from the public lighting sector to the advantages of LED street lighting. Managing Director of Strategic Lighting Partners Ltd, Godfrey Bridger, said, “We’re delighted that IPWEA has partnered with us in a joint venture to bring this significant conference to Sydney.” IPWEA Australasia CEO Robert Fuller said, “As the peak industry body advising all levels of government on infrastructure asset management we saw this as a leadership opportunity to partner with the international expertise offered through SLP. It is clear that the two previous road lighting conferences organised by SLP were highly praised by attendees, trade show exhibitors and sponsors. IPWEA and SLP will ensure that the Sydney conference is an outstanding cutting-edge event for the lighting sector.” The inaugural Road Lighting 2014 conference and exhibition was the “Special Event” winner at the 2014 Public Relations Institute of NZ (PRINZ) Awards. Attendees overwhelmingly rated both the 2014 and 2015 conferences as ‘excellent’ and an event they would definitely attend again. “LED lighting technology is growing rapidly worldwide. It’s now time to examine these international, Australian and New Zealand developments in public lighting particularly in parks, reserves and sports fields in addition to road lighting which will be showcased in the Public Lighting 2016 conference,” said SLP Director Bryan King. The 2016 Sydney conference will feature an international line-up of speakers to examine how cities are joining the “LED revolution” not only to improve energy efficiency, reduce costs and improve road safety, but also to move towards the Smart City concept – an electronically controlled, efficient, digital lighting infrastructure that can be adapted to respond to prevailing traffic and weather conditions and that can be used as ‘real estate’ for mobile networks and other income-generating services through smart control systems. “This is the dawning of a new era in public lighting for Australia and New Zealand,” concluded Fuller.


Construction Engineering Australia - April October 20162015

The healthy building movement in Australia received a boost recently, with the Green Building Council of Australia (GBCA) and the International WELL Building Institute™ (IWBI™) announcing a new partnership. The GBCA and IWBI have agreed to work collaboratively to promote health and well-being in the design, construction and operations of buildings, fitouts and communities in Australia. The GBCA launched the Green Star rating system in 2003, and since then has certified more than 1,050 buildings, communities and fitouts throughout Australia. IWBI administers the WELL Building Standard™ (WELL), a performance-based system for measuring, certifying and monitoring features of the built environment that impact human health through air, water, nourishment, light, fitness, comfort and mind. The two organisations announced the new partnership at the Green Cities 2016 conference in Sydney, after signing a memorandum of understanding which outlines their commitment to work towards common goals. “A truly sustainable building not only addresses environmental impact, but social and economic impact too. Green Star’s focus on indoor environmental quality provides a critical foundation for human health and well-being – one which WELL enhances through its dedicated focus on evidence-based medical and scientific research and measurable performance,” GBCA’s Chief Executive Officer, Romilly Madew said. “We are excited to be joining forces with IWBI to elevate the focus on buildings that are efficient, productive and healthy for the people who live and work in them,” Ms Madew added. “Joining forces with the Green Building Council of Australia will help grow the healthy building movement by bringing health and wellness into Australia’s indoor environments through the WELL Building Standard,” said IWBI Founder Paul Scialla. “With this agreement, we see tremendous opportunity for the wellness, sustainability and real estate communities in Australia to come together to support human health through the buildings where we spend more than 90 per cent of our time.” The organisations will now work together to identify opportunities to align the two rating systems, develop events and education offerings, and promote building practices that improve the health and well-being of occupants. Green Business Certification Inc. (GBCI), which provides third-party certification for the WELL Building Standard, will also support efforts to promote and deliver WELL across Australia. “Increasingly, Australians recognise that our buildings have a dramatic impact on our health and well-being. This new partnership is an important step towards designing and building places that are sustainable, productive and healthy,” Ms Madew concluded.


Arup voted Top 100 Graduate Employer Arup confirmed its place as one of Australia’s leading graduate employers when the Top 100 Graduate Employers were announced in Sydney by The Hon Christopher Pyne MP, Leader of the House and Minister for Industry, Innovation and Science. Arup was voted number one by students in the civil engineering, building services and construction sector ranking and 26th overall across all graduate employers Australia-wide. “Students highlighted they were looking for leadership, training and development, personal development and innovation from their employers. It is wonderful to be so highly regarded for these traits amongst the country’s best known and prestigious

employers of graduates,” said Diana Cross, Head of HR, Arup Australasia. “Consistent draw cards for our graduates are Arup’s innovation, the great projects we work on and the opportunity to have a life-long and diverse career. As we continue to invest in finding and retaining the best talent, we hope we will continue to be the number one choice for graduates in our sector,” said Diana Cross. The Top 100 Graduate Employer Rankings are based on the results of a survey conducted annually by GradAustralia and completed by over 6,000 university students. The survey explores career motivations and expectations, and asks students to nominate graduate employers that most appeal to them. Minister Pyne unveiled the Top 100 employer results and thanked employers for their focus on graduate development. “The Government is building a national agenda around science and innovation, so it’s important to commend these employers for their focus on nurturing young talent and fostering new ideas and innovation. The graduate programs being recognised tonight are further investment in our future leaders,” said Minister Pyne. Students can register interest for Australia’s 2017 graduate programme. Applications opened on the 23rd of March.

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Construction Engineering Australia - April 2016


Melbourne Park Redevelopment MELBOURNE PARK REDEVELOPMENT, ROD LAVER ARENA Upgrading Rod Laver Arena was a priority to ensure that the Melbourne icon retains its status as one of the world’s leading sports and entertainment venues. The $338 million second phase of a $700 million overall project at the home of the Australian Open will transform its facilities. The Major Projects Victoria refurbishment will shore up Victoria’s position as an events hot spot, strengthen Melbourne's title as the sporting capital of the world, and create up to 1,300 jobs in the construction phase. Plans include a newly-designed southern annex to become the main entrance to the arena. A more efficient loading bay will mean shows can bump in and out faster, ensuring Rod Laver Arena can host the biggest acts in the world. Melbourne Park stages more than 200 events every year. The Victorian Government is making sure Rod Laver Arena continues to host the biggest blockbuster sporting and entertainment events in the world. Improved eateries will offer diners a wider variety of options and new outlets at floor level will mean guests no longer have to go back to the concourse to buy food and drinks. John Eren, Victorian Minister for Tourism and Major Events, commented: "We’re transforming Rod Laver Arena to ensure we can continue to attract the biggest and best in sports and events in the world, which creates jobs and helps keep our economy strong." “This refurbishment will give Victorians and our guests a better viewing experience, helping cement Melbourne’s place as the events capital of Australia and the sporting capital of the world.” Victorian Minister for Employment, Jacinta Allan added: “This major investment in Melbourne Park will create around 1,300 jobs during construction alone – a massive win for Victorian workers and the economy.”


Construction Engineering Australia - April 2016

The $338 million allocated to Stage 2 promises to further enhance the world class precinct with: • A pedestrian gateway from the heart of Melbourne to Melbourne Park over Batman Avenue • An eight storey Administration and Media building • Improvements to patron comfort and amenities in Rod Laver Arena. Melbourne Park currently hosts over 200 events a year, providing $421 million in economic benefit to the State and creating 3,140 FTE jobs. These ongoing improvements will ensure that Victoria can continue to host important international events such as the Australian Open for many years to come.

BATMAN AVENUE BRIDGE – MELBOURNE PARK REDEVELOPMENT Major Projects Victoria is delivering a bridge for pedestrians and cyclists as part of Stage 2 of the Melbourne Park Redevelopment. The bridge will provide the public with direct access from Lower Terrace, Birrarung Marr over Batman Avenue and into Melbourne Park. Once completed, the bridge will significantly reduce the amount of time it takes to walk from Flinders Street Station and Federation Square into Melbourne Park, and will provide a more enjoyable entry experience for people attending the Australian Open.

The design for the bridge is by John Wardle Architects and NADAAA in collaboration. The bridge will be a stylish addition to the precinct, not to mention making it much easier for people to get to and from Flinders Street Station. Works on Stage 2 are expected to be complete within five years. Scheduled for completion in time for the 2017 Australian Open, the bridge will enhance the experience for people attending any event at Melbourne Park while complementing the landscape and providing a new vantage point over Speakers’ Corner.

ADMINISTRATION & MEDIA BUILDING – MELBOURNE PARK REDEVELOPMENT Major Projects Victoria is delivering an Administration and Media Building as part of Stage 2 of the Melbourne Park Redevelopment. The building will be home to Melbourne & Olympic Parks staff, Tennis Australia staff and hundreds of media personnel that flock to Melbourne every summer for the Australian Open. Designed by Hassell in partnership with ARUP and constructed by Built, the new eight storey building will change the landscape of Melbourne Park. It is scheduled to be completed by the end of 2016. The new Batman Avenue bridge will provide pedestrian and cyclist access to Melbourne Park.

An artist's impression of Melbourne Park's proposed Adminstation and Media Centre.

MARGARET COURT ARENA The $200 million completed works as part of Stage 1 includes a retractable roof at Melbourne’s Margaret Court Arena (MCA) that completely closes in under five minutes to protect players and spectators. It was a complete success during the Australian Tennis Open. The roof formed part of the multimillion dollar redevelopment at Melbourne and Olympic Parks which also includes a revamped MCA seating bowl for 7,500 spectators, new air conditioning and acoustic technologies and concourse

connectivity to the adjacent Rod Laver Arena. The retractable metal roof was designed to complement the existing architecture, particularly the larger adjoining Rod Laver Arena. The roof, was designed with guidance from Aurecon and Walter P Moore engineers, is a unique system which sees only two downturned operable trusses, spanning the width of the MCA (on each end), supporting the bulk of the operable roof. Each truss is connected to a 57m x 32m operable lateral panel which is joined to

seven adjacent gable roofs sections that make up the bulk of the MCA roof. The whole structure is driven by drive bogies and has a tiny straight-line dimension of 1.25 m between the top of the operable roof panel and the top of the fixed roof. While the primary function of the redeveloped Margaret Court Arena will be to stage major matches of the Australian Tennis Open, the multi-purpose venue will also host netball, basketball, major concerts and entertainment events. All images in this article are courtesy of Major Projects Victoria.

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ARROW BOARDS AWARDED RMS TYPE APPROVAL Seen as another major 'feather in the cap' for leading traffic control and linemarking equipment specialists A1 Roadlines, the company's full range of LED Flashing Arrow Signs has just been awarded full Type Approval from NSW Transport Roads & Maritime Services (NSW RMS). The Type Approvals, which follow on from an extensive testing and performance assessment program, stand as testament to A1 Roadlines' commitment to developing quality products that help to maximise worksite safety.

When it comes to improving worker Occupational Health and Safety, few would argue that road construction and maintenance worksites present one of the most difficult and challenging OH&S environments around. Indeed, the issues surrounding both worker safety and driver behaviour within worksites have been a major concern for road authorities, contractors and law enforcement agencies for many years. Needless to say, one of the key factors in improving worksite safety and worker OH&S is to ensure that road users can see the 12

Construction Engineering Australia - April 2016

worksite and/or plant and equipment clearly – in all ambient light and weather conditions. This is particularly important on busy roads which generally have an abundance of signs, lights and other distractions. With that in mind, the A1 Roadlines team set out to develop a range of flashing arrow signs that would not only be robust and reliable enough to stand up to even the toughest operating environments, but most importantly, would help to maximise worksite visibility for approaching vehicles. Janine Goodsell, Manager, A1 Roadlines, explained:

"Despite their relative simplicity, flashing arrow signs play a critical role in worksite safety and as such, their performance in the field is paramount." "Whether it's a vehicle mounted unit or a stand-alone trailer mounted unit, at many worksites, the flashing arrow sign is often the primary traffic control / warning device. They provide drivers with an advance warning of an impending hazard and, importantly, directional information to assist in diverting and controlling traffic around construction or maintenance activities."

The Type C LED Flashing Arrow Sign is also available for Truck or Trailer Mounted Attenuators

"And that's why high visibility is so important," Janine added. "Put simply, the more visible the sign, the earlier it can be seen and the more warning the driver has. This, in turn, allows for earlier lane changes and smoother transitions past the worksite." Available is a choice of five models, including single-sided, double-sided and as a fully self-contained trailer mounted unit, A1 Roadlines Flashing Arrow Signs are fully-compliant and certified to NSW RMS Specification FAS/5 for Illuminated Flashing Arrow Signs (Ed 1/Rev0) and Australian Standard AS4192:2006. For further information on the full range of A1 Roadlines Flashing Arrow Signs, please contact: A1 Roadlines Pty Ltd, Ph: (03) 9765 9400 or visit the website: www.a1roadlines.com.au

Flashing Arrow Signs Type A and Type B The Type A or Type B LED Flashing Arrow Signs are designed to be vehicle mounted

and give advance warning of a short-term road closure. They are available in single or double sided and operate from 12V to 24V systems without voltage converters. The arrow controller is lightweight and available for single or double-sided arrow signs.

Features • Easy to use one touch controller, with real time display • Arrow can be changed at the push of a button • In built LED diagnostics • Automatic dimming • Heavy duty military specification wiring connectors • Optional power lift control

Modes of Operation • Arrow Right • Arrow Left • Double-Headed Arrow • Non-Directional Warning

Flashing Arrow Signs Type C The Type C LED Flashing Arrow Sign meets AS4192-2006 Illuminated Flashing Arrow Signs and Roads & Maritime Services Flashing Arrow Sign Specification FAS/5. Type C LED Flashing Arrow Sign Trailer is a self-contained item of plant supplied on its own trailer with back-up battery supply powered by two (2) 80W solar panels positioned flat on top of the arrow sign to attain the optimum solar energy regardless of trailer direction. Used in conjunction with other signs and devices it provides advanced warning and directional information to assist in diverting and controlling traffic around construction or maintenance activities. A lockable steel enclosure protects the controller and batteries from the elements and vandalism.

Modes Of Operation • Arrow Right • Arrow Left • Double-Headed Arrow • Non-Directional Warning

Construction Engineering Australia - April 2016




Sensory gardens designed to provide a little 'peace of mind' While the title might be a light hearted call back to the classic Australian comedy film The Castle, the truth is that the movie's main character, Darryl Kerrigan's search for a little 'serenity' in a busy world, is not far removed from many people's reality - especially for those living in medium and high-density urban areas. Put simply, in our fast-paced, increasingly busy and rapidly expanding inner-city and urban areas, getting a little 'serenity' can be far from easy. Indeed, for many people, even the task of actually getting to somewhere that is relaxing and tranquil can often cause more stress than it's worth. Now, while that in itself may seem to be (to coin another commonly-used phrase) somewhat of a 'first world problem', the inability to find a little tranquillity and 'peace of mind' in an increasingly busy world can, and does, have extremely serious consequences. The increased stress levels associated with constant activity and/or an inability to relax and refocus can have a serious detrimental effect on both physical and mental well-being. So much so, in fact, that many leading mental health researchers are now considering 'mindfulness' and mental relaxation to be one of the most important factors in improving mental health. With that in mind, Sydney-based company Aussie Outdoor Design has developed a range of Sensory Garden solutions that provide an 'mini oasis' where visitors can relax and 'take 14

Construction Engineering Australia - April 2016

a little time out' from the busy world. Jason Day, Business Development Manager with Aussie Outdoor Design, explained: "Unfortunately, with open space being at such a high premium, and traffic and transport being the way it is, for many people living and working in densely populated areas, even getting to somewhere that's relaxing can present a massive challenge." "That's why we've developed the ELEMENTS Natural Environments gardens as a fully-scalable solution that can be established almost anywhere." "Even if there's only a small area available, we can design and deliver a fully-accessible sensory garden with an array of elements that will provide an attractive relaxation and passive recreation area to suit all ages and abilities," he added. Bringing together a mix of sculptural components, creative structures, interactive items and specifically selected plantings - all in a beautiful custom-designed and constructed setting - these sensory gardens combine the natural and built environments to deliver the perfect urban getaway. The ELEMENTS Natural Environments gardens are available with a range of options, including: • Sensory Walls • Sensory Gardens • Textured Pathways • Sounding Items • Vegetable Gardens

• Water Play Areas • Outdoor Learning Structures • Outdoor Blackboards Importantly, every ELEMENTS sensory garden is custom designed and scaled to suit the available space, surrounding area and demographics - allowing them to be easily established in even the most densely populated urban environments. For further information on the full range of Aussie Outdoor Design's products and services, please call 1300 887 025 or visit: www.aussieoutdoordesign.com.au

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



PREMIUM PROTECTION FOR PERTH'S PRESTIGE PINNACLE The skyline of Perth, Western Australia, is constantly changing, with many high-profile projects on the rise. This growth has now spread across the Swan River to South Perth, with the new Pinnacle South Perth project now underway. The $70 million, 20-storey residential tower - the tallest residential tower to receive development approval from the City of South Perth in almost 45 years - not only sets a new standard in sophisticated apartment living, it is also setting a benchmark in construction safety and efficiency, thanks to Doka’s Screen Protection System.

The latest flagship project from international developers Zone Q Investments Pty Ltd, Pinnacle South Perth delivers the ideal combination of luxury living, quality facilities and outstanding location. Located at the corner of Charles Street and Labouchere Road, opposite the Zoo in South Perth, Pinnacle South Perth is sure to become one of the most sought-after addresses in the west. Designed by award-winning architects Hassell, the Pinnacle South Perth development incorporates a mixture of one and two bedroom apartments as well as penthouses. It also includes a $30 million seven-storey commercial tower, a ground level retail offering and communal facilities including an indoor/outdoor deck with heated waterfall edge pool, a barbecue terrace, gymnasium, chef's kitchen and dining/function space. Every apartment at Pinnacle has been architecturally designed to maximize space and comfort, and will be beautifully appointed with high quality fixtures and fittings befitting of such a prestige development. Construction of the 20-storey residential tower is now underway, and is scheduled for completion in late 2016. To streamline construction and maximise safety on the site, the project's formwork contractor, Advance Formwork, is utilising Doka's state-of-the-art Protection screen Xclimb 60 system with Xbright frames and perforated enclosure sheeting, together with the high performance Doka TLS (Table Lifting System). The Xclimb 60 system provides contractors with a safe and enclosed working environment which helps to mitigate the risks of working at height, while also providing protection for those working below from falling objects such as tools. A loading platform can be integrated into the protection screen for fast, efficient and safe repositioning of slab formwork, tools and other materials. All protection screens were installed in just three days, thanks to Doka's supervision an off-site pre-assembly. 16

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Advance Formwork selected Doka as the formwork provider because, based upon the longstanding relationship between the two companies, they knew Doka had the knowledge and equipment to make the job work. Doka was able to supply the necessary equipment for the job as well as the pre-assembly service, all for a competitive price. "We see Advance Formwork as our key partner to our Western Australia business, and we'll endeavour to have many more successful projects with them,” said Jan Pienaar, Head of Sales with Doka Australia.

Doka's Protection screen Xclimb 60 with Framed enclosure Xbright and perforated enclosure sheeting is helping to streamline construction and maximise safety on the Pinnacle South Perth site.

PRACTICAL SOLUTIONS FOR A CHALLENGING PROJECT Doka Australia worked in close partnership with Advance Formwork to develop a number of practical solutions for the Pinnacle South Perth project, including a hydraulic protection screen system with integrated TLS (Table Lifting System) platform to provide storage and lay down space outside the building perimeter at great heights. “Our experience, to date, with the Xbright 60 screens has far exceeded our expectations,” said Karl Morrison, Manager, Advance Formwork. "What's more, the service provided by the Doka team, both on site (JP du Toit, Site Supervisor) and over the phone (Jan Pienaar, Thusitha De Alwis and Michael Fitzthum, Senior Engineers), is second to none." With the ability to hydraulically lift up to four screens at once, this new system is playing a major role in keeping the project on schedule. It also highlighted the importance of Doka's expertise and innovative approach to adapting solutions to meet specific customer and market needs. Michael Fitzthum, Senior Project Technician with Doka Australia, commented: "The Pinnacle South Perth project offered a number of challenges, both from a planning perspective, and in terms of providing a practical and functional formwork and safety solution." "One of the biggest challenges was to ensure that we had good lines of communication open, thereby ensuring that we could deliver a system that met all of the client's needs. This is particularly important given the tight lead times and construction schedule for the project." The first system of its type in Australia, Doka Protection screen Xclimb 60 provides a cost-effective and versatile solution that can be easily adjusted to suit varying external factors and clients' preferences. The Xclimb 60 screens provide the ideal combination of strength and safety, whilst still allowing a good level of daylight to pass through providing a safer working environment with minimal need for artificial lightning. Like all Doka safety systems, Xclimb 60 is easy to plan, use and operate in all weather conditions, including strong wind and rain. The modular system with perforated sheets is extremely robust and can withstand high wind pressures. Additionally, using Doka Xclimb 60 screens eliminates the need for “follow-on-scaffolders” to dismantle scaffolding as construction progresses. The self-climbing system can be easily adapted to varying layouts and inclinations, and is suitable for use even with complex high-rise projects like the Pinnacle South Perth.


BOOSTING SAFETY AND PRODUCTIVITY As well as boosting safety on the site, Doka Australia came up with a number of innovative solutions to increase construction productivity. "Due to changes in the slab geometry, we have designed big screens that are better suit the project. Importantly, our design also gave us the flexibility to deal with smaller openings for hoists and our table lifting system,” Michael Fitzthum said. The Advance Formwork team preassembled of all formwork elements off-site, thereby ensuring the highest level of quality, accuracy and productivity on site. JP du Toit supervised the team, which assembled 1,060 square metres of protection screen panels in less than 250 man hours to meet the delivery deadline. For the Pinnacle South Perth project, Doka Australia designed a number of new system components, and developed fully-equipped foldable platforms which reduce the time for final assembly on site. The project was also the 'Australian premiere' of the 0.6m connecting profile and the new lifting karabiner, which is used to manipulate the preassembled screen parts until the assembly is completed. “Importantly, a lot of the new innovations, details and solutions from the Pinnacle South Perth project can now be utilised for future projects in Australia,” Michael Fitzthum concluded. Karl Morrison added, “The ease and speed with which the screens are assembled and installed was surprising." "Furthermore, we believe that the increased safety the system offers to the project, together with the presentation of the screens with their vibrant yellow colour, will have a positive follow-on effect for both ourselves and Doka in the Western Australia market - for this and future projects,” he concluded. For further information, please visit the website: www.doka.com.au The Xclimb 60 screens provide the ideal combination of strength and safety, whilst still allowing a good level of daylight to pass through providing a safer working environment with minimal need for artificial lightning.


Project name: Pinnacle South Perth Location: South Perth, Western Australia Type of project: Residential building Project completion: 2016 Footprint: 1,060 sqm Formworker: Advance Formwork Systems used: Protection Screen Xclimb 60 with Framed enclosure Xbright and perforated sheet enclosure sheeting with TLS

Construction Engineering Australia - April 2016



WHY YOU SHOULD STICK TO YOUR CORE BUSINESS “Your health and safety is more important than trying to save a bit of time or money, trying to make a good impression on your boss, or putting yourself at risk to assist a co-worker.” After several incidents involving workers who were injured after doing tasks outside their scope of work, SafeWork NSW Director, Regional and Response Operations, Tony Williams, urged workers to think twice before attempting work they are not trained to do. One of these incidents involved a warehousing company that recently attempted to install their own pallet racking during a move to another location. They had seen it done before and thought they could do it themselves instead of hiring a professional. This resulted in one staff member, hoisted up by a forklift, standing on a second level beam of the racking in order to assemble additional racking components. The 25-year-old male worker fell around 3.5 metres, hit his head on the concrete floor and sustained serious brain injuries. In another example, a 49 year old fumigator died after he attempted to remove the wheel assemblies on a tyre containing compressed air. He was assisting a tyre fitter who was having difficulty removing the wheel assembly when the fumigator offered to help. The wheel parts exploded with such force that he was propelled 10-15 metres away and pronounced dead on site. Attending inspector Brett Martin said the area had already been quarantined by SafeWork NSW and the police when he arrived on the scene. “I’ve investigated a lot of incidents in my 30 years on the job, but this was truly a bad day for everyone involved,” Brett said. “And like many workplace incidents, this tragedy was avoidable – all the manuals say to deflate the tyres first and he would have known that if he was a tyre fitter. “It’s very sobering to think that worker might have been alive today if he was using the right equipment, and following the operation and maintenance manual. “It just wasn’t his job to do. “I would advise anyone thinking of giving another worker a hand to think twice if they are not trained.”

SafeWork NSW Director, Regional and Response Operations, Tony Williams said workers should stick to what they are trained to do. “Going outside your core business activities can place yourself and staff at increased risk. Not having the experience required means you may not identify potential risks or consequences. You therefore have a higher chance of getting hurt,” Tony said. “Do what you know and don’t be tempted to have a go.” Whatever industry you work in, if you are unsure of how to do something or you have not had the proper training, talk to your supervisor about your reservations. If you are asked to do something you are uncomfortable doing because you are not qualified or don’t have the proper training, remember: you have a right to say no to unsafe work. Speak to your supervisor or health and safety representative if you have concerns about doing work outside of your expertise or training, or visit: www.safeworkaustralia.gov.au

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Construction Engineering Australia - April 2016

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INTRODUCING THE KNIPEX END NIPPER 280MM Improved reach. Better handling. Knipex end cutting nippers are unrivalled in the Australian concreting industry and remain the preferred end cutting nipper within the trade. With their unmatched precision and long service life this makes them the best-selling concretor nippers in the world. Knipex have extended their range of the famous 68 Series end cutting nippers to now include a 280mm length. In the past Australian concreters found using shorter length end nippers made it difficult to create the necessary tension, and caused the user to strain. This latest Knipex 280mm end nipper eliminates that problem and allows for much improved reach when lacing concreting reinforcing steel with binding wire and is ideal for tying deep mounted steel rods. The slim head shape provides optimised movement when tightening steel mesh knots, and the high

leverage joint significantly minimises hand strain whilst creating tension, even when thick binding wire is used. The combination of these two features reduces the effort required when performing concreting work and allows better handling overall. Knipex end cutting nippers are made from high-grade tool steel, forged and oil-hardened, with cutting edges designed for soft and hard wire. This latest 280mm edition has a capacity from 4.5mm soft wire up to 3.2mm hard wire. The family of end nippers now includes sizes 160mm, 180mm, 200mm & the new 280mm. Tridon are the exclusive distributor of Knipex in Australia. To see the full range of Knipex concreting pliers, or to find your nearest Knipex distributor, contact Tridon Australia on 1300 362 263 or visit: www.tridon.com.au

Construction Engineering Australia - April 2016



EXCAVATOR BUCKETS – THE REAL STORY A bucket is just a bucket - or is it? No matter the make of machine, the performance, efficiency, economy and reliability of your excavator is determined by the bucket doing the work. And when it comes to selecting the right bucket for the job at hand, there's definitely more to it than meets the eye. Adrian Mason from high performance attachment specialists eiengineering, explained: "In all of our tests, we have found that buckets with a good digging design will be up to 30% more productive than buckets with a poor digging design - and that not only saves on time, it also significantly reduces machine wear and tear." "When the machines were fitted with eiengineering buckets, they dug easier and more comfortably, dug quicker through the ground and dug more efficiently needing less power, which means less fuel," he said. "And these results weren't from one or two types of machine doing specific jobs... They were conducted on a wide range of machine types in a variety of operating conditions." "Perhaps most importantly, our customers are also reporting productivity gains of up to 30% out in the field - and when all's said and done - that's where it really counts," Adrian added. The tests were carried out on various brands and types of excavators, with capacities ranging from 1 tonne to 20 tonnes and the savings are the same across all classes. (Follow the link at the bottom of this article to view the tests on YouTube and see the results for yourself). Needless to say, these types of productivity gains and costs savings don't only make a huge difference to the contractor’s bottom line - they also help to significantly reduce the overall cost of building works. If you are a head contractor, builder or customer, you want to be confident that your work is done quickly and efficiently with the least possible costs, without sacrificing job quality. Buckets that offer greater productivity move through the ground easier, using less 20

Construction Engineering Australia - April 2016

power and fuel. This of course, means that there is more available power when the going gets tough and the ground gets harder or drier. "As is the case with most things, when it comes to excavator buckets, you only get what you pay for. Buckets are a critical component and need to be considered as such," Adrian Mason said "Put simply, there is a massive difference between something that is 'cheap' and something that is 'good value' - especially when it comes to excavator buckets," he added. "A good quality, well designed product can offer outstanding value for money and make a very real difference to the bottom line - both for the contractor and the project. But you need to know what to look for." eiengineering buckets deliver a range of benefits, including: • Greater digging efficiency:- the design also means less strain and wear and tear on the parts of the machine, so you generally find there is less breakage on machine components • For the excavator owner:- greater productivity means cash in the pocket, as greater productivity directly equals profit! • For the head contractor:- helps job timelines - as well as the bottom line • For the customer:- Increased productivity and reduced costs, mean savings on he job • For the machine owner:- jobs get done quicker with less costs, so you can make more money. "But don't take our word for it," Adrian Mason said. "We urge everyone, go to YouTube and search eiengineering or following the QR Code on the right and see the buckets in action for yourself - you're sure to be astounded at the results." "Better still, why not specify eiengineering buckets on your next job, and start reaping the benefits straight away", he concluded. For more information and details on the full eiengineering range, please visit: www.eiengineering.com.au

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As the saying goes, seeing is believing - and the best way to assess the performance is to see it for yourself! To view the eiengineering buckets field tests, either use the QR Code below, or visit: YouTube.com and search eiengineering

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IVECO LAUNCHES WORK-READY DAILY TIPPER AND TRAY RANGE Iveco is making it more convenient than ever for buyers of its awardwinning Daily range to purchase a car licence cab chassis variant and have it on the worksite without delay, following the introduction of its new work-ready factory Tipper and Tray models. Cab chassis buyers have traditionally had to purchase their body separately, often experiencing delays during body fitment and subsequent waiting before the vehicle is put to work and is earning revenue for the business owner. The Daily work-ready models address this, featuring high quality European tipper and tray bodies and can be driven straight from the dealership showroom to the work site once registered and insured.

THREE-WAY TIPPER Iveco is the only light commercial manufacturer offering a work-ready three22

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way tipping body, providing the convenience of a factory-fitted steel body with the added benefits of both rear and side (left and right) tipping functions. The generously proportioned tipping body measures 3700mm (l) x 2100mm with 400mm sideboards and tailgate, providing an estimated payload of 1500 kg. The Tipper also includes a full headboard providing excellent protection to the back of cab area. Full-steel construction using 1.8mm plate and corrosion inhibitor treatment ensures durability, while the subframe is hot-dipped galvanised and powder coated. The body is specifically designed for the Daily cab chassis resulting in superior fit, finish and functionality. Sideboards and tailgate feature galvanised steel locks which are flush mounted when locked for improved safety. The sideboards and tailgates can also be quickly removed if the job requires it. Other body features include builtin anchor points which are also fully

retractable and flush when not in use. For increased safety during tipping, the body features a tilt limit stop cable and safety pole. Operating the tipping body is easy via a hand-held remote, and the raise time is fast with full tilt at only 25 seconds.

CONVENTIONAL TRAY The Daily factory Tray provides a huge 4092 mm (l) x 2072 mm tray with 400 mm sideboards and tailgate, ensuring there’s plenty of room for materials and equipment. Also standard is a full height headboard for extra back of cab protection. Combining a hot dipped galvanised and powder coated steel subframe with anodised aluminium tray base, sideboards and tailgate, the tray is light weight yet durable. Internally the base is further reinforced with a 15mm marine plywood liner with scratch-resistant and non-slip phenolic film. Sideboards feature a smooth, non-sharp finish with flush locks and can


be easily removed without tools. The tray includes several fully retractable and flush anchor points. As with the tipping body, the tray is also specifically designed for the Daily cab chassis and as an added bonus incorporates a built-in, lockable toolbox. The bodies are fitted to Iveco’s popular 50C17 Daily model, providing buyers with all the benefits of the recently-released Daily range. The vehicles are equipped with a powerful yet fuel efficient 3-litre turbo diesel Iveco engine producing 125kW and 430Nm and feature a car licence-friendly 4,495kg GVM. An optional 5,200kg GVM is also available. A further benefit of the range is a generous 3,500kg braked towing capacity. Coupled to the engine is a choice of Iveco’s smooth-shifting 6-speed manual transmission, or the market-leading 8-Speed ‘Hi-Matic’ full automatic transmission, which provides super crisp gear changes for seamless power delivery. Standard safety features in the range include front and rear disc brakes with ABS, front, passenger and curtain airbags, stability control and hill holder. On the inside the models provide a comfortable, sophisticated and car-like driving environment. The cabin is well-equipped with intuitively-placed instruments and controls and an efficient climate control system. Other benefits include 4-speaker audio system with FM/AM tuner, CD/mp3 player, mp3 player with USB drive, AUX input and Bluetooth connectivity. Radio and phone controls can be accessed by the steering wheel.

BONUS ACCESSORIES Making Iveco’s work-ready Daily Tipper and Tray models even more appealing to buyers is the inclusion of $2,500 worth of bonus genuine accessories, designed to even further improve the Daily’s functionality for the job and sharpen its looks. Included in the package is a polished alloy nudge bar, a 3.5t rated tow bar kit, bonnet and head lamp protectors and floor mats. Prices for the work-ready range start at $54,000 drive away for the Tray model and $64,000 drive away for the Tipper. Iveco is also offering competitive finance rates from 1.99% over 3 years* to make the purchase even easier. As an added bonus, a 5 year / 200,000 kilometre extended warranty also applies to the work-ready range. *Terms and conditions apply.

Construction Engineering Australia - April 2016



GO THE EXTRA DISTANCE WITH BIG RED L.E.D DRIVING LIGHT BARS Big Red’s new range of 12/24 volt L.E.D driving light bars is set to provide drivers with all the best qualities of traditional L.E.D light bars, coupled with the extra power and distance required in on-road driving applications where long, clear vision is needed. This combination has previously been difficult to achieve without investment in more expensive, top-ofthe-line equipment, but Big Red’s unique ‘Magnifier Optics’ technology makes it possible. Magnifier Optics is specifically designed to control the light output of the L.E.Ds, concentrating it into an extra distance beam. When combined with high power 5W Lumiled L.E.Ds, the result is a large volume of light able to reach almost 800 metres at 1 Lux. The lamps are available in single and double row designs with a total of four models on offer. Starting the range is a versatile 20” (508 mm) single row bar equipped with 18 x 5W Lumiled L.E.Ds (90W total) casting 6000 Lumen of bright white light and achieving 430 metres of penetration at 1 Lux. For additional power a 26” (660mm) single row is also available featuring 24 x 5W Lumiled L.E.Ds (120W total) shining 8000 lumen and reaching 500 metres into the distance at 1 Lux. For even greater visibility, there’s the 20” (508mm) double row bar fitted with 36 x 5W Lumiled L.E.Ds (180W total) generating 12000 Lumen and allowing the user to see 700 metres ahead at 1 Lux.


Construction Engineering Australia - April 2016

Big Red’s range topper is the 26” (660mm) double row lamp equipped with 48 x 5W Lumiled L.E.Ds (240W total), shining an incredible 16000 Lumen and achieving an amazing 780metres of strong visibility at 1 Lux. As well as their impressive light output, the Big Red L.E.D driving light bars have also been designed and manufactured with demanding Australian conditions in mind. All models feature precision extruded die cast aluminium housing and virtually unbreakable polycarbonate lenses. Further benefits include fully sealed construction to IP68 and the inclusion of pre-wired, weatherproof connectors with an integrated breather vent designed to eliminate pressure build-up on the bars’ seals. For secure mounting, all bars feature robust stainless steel mounting brackets and hardware while the unique, multiangle mounting system allows convenient horizontal surface mounting to vehicles. The lamps are ideal for users spending extended periods driving on-road at night including professional drivers using secondary roads with the potential for animal strikes. Big Red’s innovative new extra power and distance L.E.D driving light bars are backed by a generous 3-year warranty and are available from all leading transport, automotive and four wheel drive outlets throughout Australia.

AWD GROUP TO LAUNCH LIUGONG AT THE INAUGURAL DIESEL DIRT & TURF EXPO The AWD Group is excited to announce they will be launching their range of LiuGong Construction Equipment at the inaugural Diesel, Dirt and Turf Expo, which will be held at Penrith Panthers from 15-17 April. Building on over 15 years of local experience supplying Dieci telehandlers to the Australian market, the AWD Group has set its sights on becoming one of Australia’s leading providers of capital equipment and their recent partnership with LiuGong Machinery Corporation for the distribution of Excavators, Wheel Loaders, Skid Steer Loaders & Forklifts in QLD, NSW, VIC & NT will take them one step closer to that. AWD Group Chairman Paul Jenkins explained: “We are very excited about this opportunity to bring world class products to Australia – we see this as an opportunity for the existing LiuGong customer base in Australia to receive increased parts and service support in the eastern states.” “Given that the Expo will be showcasing a huge range of industry leading equipment, we felt this was the perfect platform to launch our newest equipment range to the market," Paul Jenkins added. For further information, please visit: www.awdgrp.com.au


With class-leading payload, volume capacity, power, torque and industry-leading 8-speed Hi-Matic full automatic transmission, it’s no surprise the new Iveco Daily was recently awarded 2015 International Van of the Year. With its solid steel C-section chassis, the complete range of Daily van, cab chassis and factory-fitted tray & tipper models maintain their truck-like strength while also providing a comfortable and sophisticated car-like driving experience that feels right at home on all road conditions.

For a limited time, every new Daily purchased with 1.99% p.a. finance comes with an Extended 5 Year/200,000km Warranty.* Call 1800 4 IVECO for your nearest IVECO Dealer to discover the Daily range of vehicles or visit www.iveco.com.au

*Terms and Conditions apply. Finance provided by CNH Industrial Capital Australia Pty Limited (AFSL 286664) to approved business applicants only. 1.99% interest rate based on a Loan and Goods Mortgage over a 36 month term with 0% deposit and a 30% balloon (of net amount financed), available on MT151-D Generation IVECO Daily including factory fitted tray and body models. (excludes Daily 4x4 model). Offer available until 30 June 2016 at participating Iveco dealers. For 5 year extended warranty refer to the IVECO Warranty Statement of Terms and Conditions & IVECO Extended Warranty Statement Terms and Conditions. (excludes Government and Fleet Buyers). Contact your local IVECO Dealer for full details.


IPWEA Engineering Excellence Awards

Winner of Minister's Award – Non-Senior Staff Member

Nominations have opened for the 2016 IPWEA NSW Division Engineering Excellence Awards which promote and recognise excellence of Local Government and Public Works Projects. "The Awards recognise inspiration, innovation, development and completion of projects and technical management by our Members, " IPWEA NSW CEO John Roydhouse said. "Each project nominated for an Award showcases the individual and team aspirations to improve the community in which we live. All NSW Councils are encouraged to nominate projects. No project is too small or too big for the Awards," he said. Category 1 of the Awards, Design and Construction of a Local Government/Public Works Project is divided into completed project cost categories: Under $1 million, $1-5 million and over $5 million. Other categories include New Techniques, Water Innovation, OH&S, Excellence in Road Safety Engineering (General and in Local Government), Environmental Enhancement, Multi-disciplinary Project Management, a Young Achievers Award and Public Works Leader of the Year. The award winners will be announced at the IPWEA NSW Engineering Excellence Awards Gala Dinner on October 27 to be held at Crowne Plaza, Hunter Valley during the IPWEA NSW State Conference 2016. Award Winners will be considered for the National Public Works Medal presented at the IPWEA National Conference 2017 in Perth IPWEA NSW members are invited to nominate by April 29. For further information, contact IPWEA (NSW) Event Coordinator, Carina Jakobsen.

Nicola Daaboul, who has provided inspiration in her speech to the IPWEA International Conference in Rotorua and IPWEA NSW State Conference in Terrigal, was recently awarded the NSW Minister for Local Government's Annual Award for a Non-Senior Staff Member. Nicola is an inspiration to young women seeking a career in the traditionally male-dominated field of engineering. She has spoken at national engineering conferences about leading innovation and excellence in this area, and more recently presented at the IMFE World Congress on Municipal Engineering and has embarked on an ambitious program to streamline Bankstown City Council’s works ordering and customer request processes, all whilst undertaking a fulltime course load for her three university degrees. "Nicola has gone above and beyond her expected role to make a significant contribution to her council, community and the local government. Nicola is currently participating in the IPWEA Young Engineers Mentoring Program amongst other young and aspiring engineers. Nicola is a young emerging leader in the industry who will provide a valued contribution to this industry," IPWEA NSW CEO John Roydhouse said.

IPWEA NSW Industry Forums The IPWEA NSW has just completed its 2016 round of 11 Regional Forums which again provided educational opportunities across the State. At each one day Forum delegates were updated on current industry issues and were introduced to innovative solutions that can be beneficial in their workplace. Speakers in the dynamic and comprehensive day programs gave insights into local engineering projects and provided an opportunity to share knowledge in an informal environment. Each forum provided an opportunity for elected representatives, whether they be a Mayor or State Parliamentarian to meet and greet public works professional The 2017 Round will be held in February/March next year. They are open to IPWEA members and non-members. 26

Construction Engineering Australia - April 2016



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Speakers at CIVENEX 2016 Australia's premier infrastructure industry Expo, CIVENEX, will add seminars to the 2016 program to enhance its information supply to industry members who attend the event at the Hawkesbury Show Grounds at Richmond on May 18-19 2016. Seminar speakers will include officials from the NSW Independent Commission Against Corruption to advise industry on avoiding inadvertently breaching rules on dealing with government. Other speaker's topics will include Sustainable Public Infrastructure Development, worker safety and maximising productivity in fleet usage. For 61 years, CIVENEX has been the 'go to' Expo not just for suppliers and buyers along the infrastructure chain in New South Wales, but right across Australia with exhibitors showcasing offerings of all sizes, from the largest earthmoving equipment down to computer software. The NSW ICAC speaker will be Senior Project Officer, Adam Shapiro, who will explain how Public Sector agencies have implemented corruption prevention and risk management strategies and reveal some of the reasons why corrupt conduct continues despite prevention efforts. "Corruption usually occurs where there are weaknesses in operational arrangements and a failure to make proper use of the controls inherent in well-designed and managed systems. My speech will be aimed 28

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at executive and senior managers who have operational responsibility for work areas that have significant risk for corruption," Mr Shapiro explained. Ken Kanofski, the Chief Operating Officer at Roads and Maritime Services, who is responsible for managing and operating the 18,000km state road network will talk on Sustainable Public Infrastructure Development. His role encompasses investment prioritisation, daily operation of the network and working with the private sector with new, innovative and cost efficient project models for effective motorway delivery. "In the next 20 years the NSW population will grow by 2.2 million, with 1.8 million in Sydney which will have huge impacts on the number of car and truck trips. To support this growth, further development is required to ensure the existing network continually meets customer needs," he said. "In June last year, the NSW Government announced a record $7.5 billion investment in roads, maritime and freight infrastructure, up $2 billion on the previous year. The next five years are a â&#x20AC;&#x2DC;once in a generationâ&#x20AC;&#x2122; chance for Roads and Maritime to help the people of NSW through delivering or contracting for some of Australia's largest infrastructure projects including WestConnex and NorthConnex." "But there is a critical need to ensure existing infrastructure works more

efficiently, so investments are also being made in measures such as pinch points, clearways and better use of technology including Smart Motorways - to be introduced first to the M4 to slash peak period travel by up to 15 minutes," he added. The NSW Government has recognised the leadership in State and national infrastructure of CIVENEX by supporting the Expo through use of the State logo in all promotions of this state significant event. Don Geering, Manager Access and Innovation at Transport-NSW will discuss Unleashing the power of Local Government in providing improved Road Freight movement. He noted that freight delivery, including by road, will double in the next 20-30 years. "The challenge faced by Government and industry is how to safely and sustainably improve the productivity of these movements? Road infrastructure is split between a multitude of owners with no effective effort so far to create or fund the networks needed to deliver improved end-to-end freight movements, including integrating between different transport modes," he noted in a talk that will examine recent initiatives to address this issue, including web based route and infrastructure assessment information to support local councils and facilitate StateFederal cooperation.


Stephen Grundy of Pinpoint Communications, who for 10 years has implemented GPS and Telematics systems to help organisations solve field workplace challenges will speak on Field worker safety on site and on the road. He will provide valuable case studies from Local Government and the Utility sector to demonstrate the outcomes of implementing a lone worker and duress system and give examples of how it has increased security and investigation claims and ultimately saved lives. Mr Grundy will host a second session on Business improvement for fleet and plant utilisation and productivity in which he will demonstrate how local government and utilities are using Telematics to both monitor and measure the utilisation of fleet and plant and also to make better decisions about work practices and capital investment in new plant and fleet. Matthew Turner, a co-owner of the leading plant risk assessment company, Plant

Assessor Limited, will talk on Practical Plant safety Management based on his extensive experience in general management and the building and implementation of safety systems. Plant Assessor is a leader in plant safety, and Matt is responsible for researching and publishing various papers related to practical plant safety management. He will walk the audience thought the Plant Safety Management Model his company prepares to help owners, operators and industry safety professionals simplify plant safety systems and make them more effective. The Plant Safety Management Model identifies three key elements of a plant safety management system, Safe Plant, Safe Environment and Safe Operator and the complex operational, maintenance, hazard awareness and OH&S regulatory requirements that they encompass. The CEO of the NSW Institute of Public Works Engineering (IPWEA-NSW), John

Roydhouse, said CIVENEX was where industry meets the Federal, State and Local Government bodies that generate infrastructure and where Private-Public Partnerships have their genesis, which explains the ongoing annual interest and the number of product launches held during CIVENEX by exhibitors. "That so many overseas suppliers seek display space at CIVENEX is testimony to New South Wales leading infrastructurelinked commerce in Australia," Mr Roydhouse said. "Any business or employer involved in Civil Construction, Outdoor Design, Supply & Hire, Plant and Machinery, Materials Handling, Software, Communications, Technical Services, Water Issues, Waste Management, Fleet, Maintenance, Road and Drainage cannot afford to miss CIVENEX, May 18-19 at the Hawkesbury Showgrounds near Clarendon Station." Entry is free and pre-registration available on line at: www.civenex.com.au

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Construction Engineering Australia - April 2016



Narrow, cracked and damaged section of Mt Keira Road near Wollongong.

Bringing an Old Hazardous Mountain Pass to Life Using a Combination of New and Old Technologies Highly Commended and placed second in the "Excellence in Road Safety Engineering" category of the 2015 IPWEA NSW Engineering Excellence Awards, the hazard reduction and rehabilitation works which enabled the picturesque Mount Keira Road near Wollongong to be safely reopened, not only breathed new life into an old and previously hazardous mountain pass, they also provided a valuable insight into the many challenges that need to be overcome when working in a such as geologically challenging environment. Construction Engineering Australia (CEA) magazine gratefully acknowledges authors Peter Tobin from Wollongong City Council and Mark Roebuck from NSW Public Works, as well as IPWEA (NSW Division) for allowing us to reproduce this paper for our readers.

SYNOPSIS The site: An old mountain pass of strategic importance in a sensitive environment. The problem: Geotechnical hazards – rock fall from above; slumping and settlement from below and a poor pavement being narrow and winding with poor sight distance. The plan: Geotechnical hazard reduction to 360m of weathered sandstone cliffs and new embankment support to 200m of road; in-situ regrading of the road pavement to an improved alignment with 1.5 metre width. The team: A blend of Council’s engineering staff, NSW Public Works, Specialised Geo and other consultants and contractors. NSW Public Works provided project familiarisation / review of project scope, preparing tender documentation, contract procurement, project and construction management, contract administration & WHS and Environmental Inspections/Audits. The result: Work completed ahead of time, balanced earthworks, under budget of $2.7m. The public have regained an alternate vehicular access route into and out of Wollongong. The road also serves as a popular tourist drive providing access to the National Park and Mount Keira lookout that provides sensational views of the city of Wollongong and surrounds.


Construction Engineering Australia - April 2016

BACKGROUND Mount Keira Road was closed to traffic in December 2012 due to the high risk posed to road users and Council’s road maintenance crews from falling rocks and boulders. Wollongong City Council advised that the road between Queen Elizabeth Drive and Gipps Road (which includes the subject site) has a traffic volume of approximately 700 vehicles per day (AADT) during a 7 day study period in August 2011. The road is not a regular bus route however is utilised by tourist charters to access the historic and scenic lookout as well as large groups of Scouts and Girls Guides of which both groups have camp sites along the road. Council closed the road for public safety reasons that heightened public interest from the local community to expedite the re-opening of the road as well as increasing media coverage of the issue. Council were not in a position to immediately allocate resources and maintenance funding to the project due to the size and scale of works. Council engaged a geotechnical consultant to provide an assessment of works required to reduce the slope instability risks via engineering solutions. Council also required the recommendations resulting from this report to be carried out as soon as possible due to the public interest and were preparing to engage suitably qualified contractors to complete the works, enabling the road and associated upper and lower embankments to be repaired and re-opened to the public.

SITE DESCRIPTION The location of works includes some 500m of rockfall hazard reduction works, road embankment improvement, kerb and guardrail reconstruction, and around 2,100m2 of road pavement reconstruction. In this location, the road meanders on an embankment very close the bottom of a 60m high sandstone cliff with overhanging boulders. The road embankment itself was constructed as an early haul route using cut-and-push methods such that the inside lane is constructed on sandstone bedrock

1,800m² TECCO mesh and underlay was installed along the section.

The project also included the installation of 400m3 of no-fines concrete.

and residual soils, yet the outside lane is built on various ripped bouldery fills which settled over time as the fill materials weathered. The worst section requiring immediate reconstruction was 180m, which in combination with the elevated rockfall risk eventually forced the road to be closed. The settlement of the outside lane had got to a point where the road camber was 14 degrees, heavily tension cracked and severely undulating. Radial tension crack sets had developed over 50mm wide in places with 50mm steps. Deeplift asphalt repairs over time were found to be over 650mm thick in recovered drill cores, and as a result the guardrail on the embankment lip had progressively subsided to be much lower than the road crown. Tourist buses using the outside lane were tilted such that passengers at the left rear were actually sitting out over the guardrail!! The road was also very narrow at 5.5m in places with no shoulder forcing vehicles to use the centre of the road to smooth the curves and avoid rockfall debris at times. Coupled with lack of access and sight distance for frequent cyclists and walkers and the use by professional luge riders this amounted to an unacceptable and elevating public risk.

PROJECT SCOPE AND OBJECTIVES The overall objective of the project was to reduce the risk of rockfall, road collapse and widening of the road to provide safer public access between the top of the escarpment and Wollongong. Council at the time did not have the required in-house project management capability or experience to procure and manage these works and engaged NSW Public Works whom nominated Mark Roebuck as the project manager and is a current member of IPWEA. Council and NSW Public Works reviewed the documentation and recommendations prepared by the Geotechnical consultant, Douglas Partners Pty Ltd and decided to break the project up into three phases of work. A contract was prepared and tendered that contained the first two phases of work whilst it was decided to utilised a combination of in-house resources and unit rate contracts

Construction Engineering Australia - April 2016



3,500 lineal meters of 75mm soil nails were installed along the section, some reaching lengths of over 12m

Road shaping post stabilisation

to complete the road works. The contract work phases consisted of the following geotechnical engineered solutions: • Hand scaling via rope access and long reach excavator • Supply and installation of rock catch fences • Supply and installation of galvanised rock dowels • Supply and installation of dowel/mesh supported shotcrete • Supply and installation of rock fall mesh • Supply and installation of vertical column cave support The second phase of lower embankment stabilisation works included: • Clearing of vegetation including specified trees • Removal and storage of existing road guard rail • Regrading of embankment slope • Removal of vegetation and spoil from site • Supply and installation of bored PVC slotted incline drains • Supply and installation of anchors • Supply and installation of scour protection matting and slope stabilisation mesh • 1.5 m approx. of concrete road widening

drillers, was instrumental in achieving efficiencies when installing multiple 6m+ anchors, as it allowed the contractor to install at a higher production rate, therefore reducing the drillers time on the face. This provides a safer working environment whilst making it more economical for Council. Specialised Geo also utilised innovative techniques to install the 2-3m near vertical no-fines concrete road widening wall along the lower embankment. These techniques allowed the constructability of the wall to be done in a way that greatly reduced the risk exposure of the workers. In approximately 200m of road way the contractor installed: • 1,000 lineal meters of 100mm rock bolt • 3,500 lineal meters of 75mm soil nails some reaching lengths of over 12m. • 1,800m² TECCO mesh and underlay • 400m3 no-fines concrete Specialised geo completed the engineering solutions to enable a safe interface between road users and the natural environment or “Engineering for Nature”.

Pavement Stabilisation The third phase involved the reconstruction of the pavement out to the new road width of 6.2m, install the required delineation (signs and lines), guard rail and general roadside maintenance to allow the road to be re-opened.

CONSTRUCTION PHASES Geotechnical and Embankment Works Undertaken by Specialised Geo Pty Ltd between December 2013 and June 2014, works included all components of work within phases 1 and 2. Specialised Geo is an Australian owned company specialising in geotechnical solutions for civil, construction, mining and maintenance projects. We have particular expertise in working in difficult, hazardous and inaccessible sites throughout Australia. The contractor worked collaboratively and efficiently with all components under the contract. As is the nature of these types of projects a large component of the works is ’unknown’ pending the scaling and vegetation clearing required to gain access to the rocky cliff faces. Specialised Geo worked diligently, cooperatively and economically under the terms of the contract to complete the works and any additional work as it became apparent. Various methods were utilised to complete the works including crane box systems, EWP, rope access, technician portable and the use of a purpose built "drill platform" that was suspended from a crane. The rig that consists of 3 identical drill rigs manned by three 32

Construction Engineering Australia - April 2016

Due to the camber of the road it was initially reasoned that milling and levelling of the existing pavement would provide a good sub-base for an imported DGB20 pavement and estimates were prepared on this basis. The initial estimate for 150mm DGB20 pavement over milled and recompacted sub-base was $330,000. Later in the design phase due to the increasing height of the concrete embankment edge, we looked to reducing the amount of additional load on the embankment by fully recycling the existing pavement. In May 2014, WCC Geotechnical Services undertook a stabilisationspecific investigation, and utilised a new and innovative approach that should be adaptable to other stabilisation projects once fully verified. The stabilisation works earned Wollongong City Council a National AustStab Australia award during 2014 winning the Excellence in Recycling in Stabilised Pavements in Local Government. Stabilisation was undertaken over only three days by Downer EDI and the final cost of the stabilisation, seal and asphalt was $112,000, about 1/3rd of the initial estimate and a saving of about $200,000.

OUTCOMES Following completion of the upper and lower slope stabilisation works, the road profile was modified to accept the new, final road surface. Installation of road gutter drainage systems, a new guard

rail along the length of the works and final re planting and mulch application to the lower slope embankment and base will complete the picture. The public have finally been allowed access again to a necessary and popular local tourist drive. The road not only provides a good secondary access route in and out of Wollongong, it is also of great benefit to Wollongong’s emergency services, which is particularly important heading into the bushfire season. Mount Keira Road is utilised for a variety of public events throughout the year, is popular with cyclists and walkers and is welcome back by the community at large. Council have promoted and run a community event to encourage fitness and the use of Mount Keira Road and the inaugural “Keira Challenge” was held as the official opening of the road 9 November 2014.

ABOUT THE AUTHORS Peter Tobin – Wollongong City Council Peter Tobin has been a Geotechnical Engineer with the Wollongong City Council (WCC) since 1982 and has held the position as Senior Geotechnical Engineer for many years. He is a graduate of the University of Wollongong with Masters Degree in Engineering (honours). The WCC local government area is one of the most challenging from a geotechnical point of view, as there are 100’s of mapped/known landslides, with 10,000’s of houses built either over or adjacent to these susceptible areas. Peter’s expertise ranges from Landslide Risk Assessment to Road Pavement and Surfacing Design to Emergency Management Practices, all of which he needs to call into play not only day by day but more importantly when weather events adversely affect the Wollongong area. Peter has also written many papers over the years covering the above, and is regularly sought after to make presentations on all of the above, as well as the Legal Considerations which go hand in hand with his role as a Council Officer Specialising in Slope Management and Road Pavements.

Mark Roebuck – NSW Public Works Mark Roebuck is an experienced civil engineer and leader with a wide range of experience in all aspects of local government engineering. As Regional Projects Coordinator for NSW Public Works in the South Coast Region (SCR), Mark leads a team of 9 Engineers delivering roads and related infrastructure projects for State Government and Local Government clients. Mark has held positions including Business & Resources Manager, SCR – NSW PW, Manager Operations for Wingecarribee Shire Council where he managed 150 staff and all capital and maintenance budgets and the role of Divisional and Traffic Engineer for Wollongong Council where he worked his way through from a cadet. Mark is an active member of IPWEA and has previously chaired the Illawarra group of IPWEA members.

Completed works

Construction Engineering Australia - April 2016


PROJECT FOCUS Large terraced earth sculptures form the major arrival sequence into the Arboretum. At the base, a carefully designed irrigation system directs water to the dam to redistribute back into the Arboretum. Photo: John Gollings / Courtesy: National Aboretum

PRIDE OF PLACE THE NATIONAL ARBORETUM, CANBERRA Winner of the World Architecture Festival for Landscape 2014, the National Arboretum Canberra surrounds visitors with panoramic views, stunning architecture and the natural beauty of trees and gardens. It is a 250-hectare must-see attraction in Canberra created after the fireravaged area was burned out as a result of the Christmas 2001 and 2003 Canberra bushfires. The amazing result after spending $67million and plenty of hard work is an outstanding place to visit, being a world-class extensive project for the research and display of endangered trees and shrubs.

DEVELOPING THE SITE Work commenced in 2005 and major civil works commenced in 2010. The terraced Central Valley near the Village Centre, a reconfiguration of 40,000 cubic metres of earth over seven hectares, was Australia's largest sculpted earthwork since the Sydney Olympics. Planting began in 2005 not long after the bushfires, so the ensuing 10 years of growth now demonstrates that vision. The Village Centre, Margaret Whitlam Pavilion, Pod Playground and Icon Water Discovery Garden, have all been completed. Substantial progress has been achieved in road, track, signage and car park improvements and in lighting, watering harvesting and recycling, irrigation and water storage. The Village Centre is the first point of arrival for many visitors at the Arboretum, a light-filled, spacious building with panoramic views over Canberra. The Village Centre provides a variety of high-quality visitor services and facilities, including a restaurant, cafe, gift shop, information hub, and the National Bonsai and Penjing Collection. Other highlights include the unique nature-themed Pod Playground, Margaret Whitlam Pavilion, the Canberra Discovery Garden, outdoor sculptures and great picnic spots and lookouts. The extensive site works included the creation of roads and paths while terraforming the landscape while keeping to the natural shape of the land. Provision was made to control overland drainage and to harness water for irrigation purposes. A large dam at the lowest point is supplemented by water-harvesting strategies including swales, irrigation systems connected to a bore, and large storage and irrigation tanks. A formal grand sweep of curving terraces was created that 34

Construction Engineering Australia - April 2016

visually lead up to the main terrace. The entry road follows the outer edge of the sweep, opening up views into the Events Terrace at the centre of the site. The work included services, site lighting, directional signage, a connection to Tuggeranong Parkway, and ample parking for visitor cars and tourist coaches. Parking is also distributed along the sweeping roads throughout the site.

ITS GENESIS After the destructive bushfires of 2001 and 2003 the Australian Capital Territory Government launched a two-stage national competition in 2004. The ‘100 Forests, 100 Gardens’ joint proposal by landscape Architects, Taylor Cullity Lethlean and architects, Tonkin Zulaikha Greer, won the International Design Competition for the new national arboretum. The design team stated that they planned the site around ‘a chequered’ grid, setting out the trees and shrubs in an undulating ‘combed’ pattern of rows and grids, said to reflect the water axis established by the designer of Canberra, the famous architect Walter Burley Griffin. The dominant pattern is large-scale strips of forests, separated by open grassed strips to create the inventive pattern. This open layout allows the visitor to experience each selected species, now numbering over one hundred botanical species. The designers aim is to create ‘100 forests - and 100 gardens’ focusing on threatened, rare, and symbolic trees from around the world.

THE OUTSTANDING RESULTS The Arboretum has truly outstanding views and an open-air stage and a large grassed amphitheatre. The buildings include the Village Centre, an innovative timber structure housing a cafe, restaurant, gift shop and interpretive exhibition, and a smaller event and ceremonial building called the Margaret Whitlam Pavilion. The stonework in the visitors centre is sourced from the outskirts of Canberra. The cafe has the most amazing views over Canberra, with good food and coffee. The multiple vantage points offer a fascinating panorama of Canberra. You can see Lake Burley Griffin, Black Mountain, Civic, Red Hill and Scrivener Dam; even in the far background Mount Stromlo

Left: Located within the National Arboretum the Waterwise Garden exhibits educate visitors on the importance of water and how to conserve water at home. Right: View from the bottom of the central valley toward visitors centre. Visitors Centre by TZG Architects. Photos: John Gollings / Courtesy: National Aboretum

and the Brindabella Ranges. The weather patterns add to the vista with ever changing cloud formations adding a dynamic background to the serenity of the Arboretum and surrounds. Artworks can be seen throughout the site. The Visitor Centre, being the site’s major building has a curved timber roof reflecting the radial profile of the building. Its ten laminated timber beams perch on concrete columns that run in an arc through the restaurant, cafe, information and retail spaces. Ancillary functions such as meeting rooms, service spaces and site administration are housed in side wings. The ceiling features the ten huge curved beams of laminated Tasmanian oak, each a different length, and special insulation panels for outstanding acoustics. The mortared stone walls use 25 million year old olivine basalt from nearby Wee Jasper. The Village Centre is available for hire and accommodates up to 500 guests seated and 900 guests standing.

From the idea of seeds as the beginning of life, the Pod Playground is designed to challenge and excite, encouraging children to climb, imagine and explore. It features giant cubbies, nest swings and banksia pods, surrounded by spectacular views. A grassed amphitheatre with the capacity to seat over four thousand people separates the Visitor centre from the smaller Margaret Whitlam Pavilion. Margaret Whitlam Pavilion offers sweeping views of the lake, city and surrounding mountains. The Pavilion is available for hire and accommodates up to 80 guests seated theatre style and 138 guests standing. The National Arboretum is a place of passive beauty, while being a place of research and a living “seed bank” for endangered species that will preserve our ecological heritage for many future generations. The site includes ceremonial trees planted by visiting heads of government, a prince and ambassadors. It was officially opened in February 2013.


What is an Arboretum An Arboretum is a botanic garden of trees for scientific, conservation, education and research purposes. The National Arboretum has: • 44,000 rare, endangered and iconic trees from Australia and around the world. Trees from over 100 countries. • 94 mostly single-species forests growing across 250 hectares of landscaped grounds. • 31 threatened species of trees, including two extinct in the wild, five critically endangered, ten endangered and 14 vulnerable species. Nine threatened species are native. • At least eight species of frogs and 72 species of birds. • Rich biodiversity and ecology. • Today, over 44,000 rare, endangered and iconic trees from around Australia and the world are growing on site in 94 forests, of an eventual 104 forests. • Two of the forests are nearly 100 hundred years old. Over 44,000 trees from over 100 countries are growing across the huge 250 hectare site, making it one of the world’s largest living collections of rare, endangered and significant trees.

2014 - World Architecture Festival - Landscape of the Year 2014 - The Australian Medal for Landscape Architecture 2014 - AIA ACT Sir John Overall Award for Urban Design 2014 - AIA ACT Canberra Medallion 2011 - AILA Victoria Medal for Landscape Architecture 2011 - AILA Victoria Award for Planning

The Pod Playground consists of a toddler play area (banksias), swing set area, older children (acorn area) and net play to the left of the Acorns. The acorns are housed with custom play items and themed portholes. Photo: Brett Boardman / Courtesy: National Aboretum

Construction Engineering Australia - April 2016



Submersible pumps self-prime and can be used with flexible discharge pipes. This makes the system easy to install and remove when the pits need to be excavated. The pumps self-flush when switched off, thus preventing clogging due to settling solids.

STIRRER PITS Water from stirrer pits has a high cementitious content and, sometimes, highly abrasive slag. The KTZ series can handle solids up to 8mm without issue and again, their wear resistance capability means the pumps last longer than cast iron equivalents.

BATCH WATER TANKS & SLUMP STAND The KTZ series offer capacities of up to 2,400 litres per minute flow and heads as high as 48 metres. This means loading batch water from the holding tanks is fast - cutting the waiting times for trucks at the hoppers and slump stands. 2”, 3” & 4” pump configurations are available to suit the existing pipework.



Australian Pump Industries, working with leading concrete companies, has put together a batch plant pump selector. Aimed at improving reliability and cutting maintenance costs, the guide identifies the correct pumps for the various stages of water recycling. “The abrasive nature of batch water means that pump selection is key to improved plant efficiency,” said Aussie Pumps Neil Bennett. “Our extensive research into these plants has resulted in an easy to use guide that takes the mystery out of pump selection,” he said. When recycling grey water, the pumps must be able to handle cementitious laden liquids with stones and grit mixed in. The Tsurumi range of KTZ dewatering and slurry pumps are specifically designed for this type of application. Tsurumi Pump is the world’s leading manufacturer of submersible pumps, with an annual manufacturing capability of over 1.4 million pumps. With over ninety years’ experience, they have developed a comprehensive range of robust, super-efficient pumps for use in concrete batch plants. The KTZ series incorporate wear resistant hi-chrome iron impellers that enable solids in suspension to pass smoothly through the pumps. “Reliability is a real cost saver for batch plants," Neil Bennett said. "These pumps are built to withstand abrasive conditions therefore they work better and last longer.” "We’ve found many instances where cast iron sewage pumps, suited to passing soft compressible solids, have literally been eroded away by the sand and grit," he added. "The KTZ series means there is no need to compromise and use unsuitable pumps."

FIRST FLUSH & WEDGE PIT PUMPS First flush and wedge pits collect grey and sand laden water. Although settled, this water can still be abrasive. The KTZ pumps, with their hichrome iron internal parts, are ideal for recycling it into the batch. 36

Construction Engineering Australia - April 2016

“We’ve found a lot of misapplied pumps in ready mix plants around the country,” Neil Bennett said. “Failure rates for these pumps are high and when a pump is down time it’s costing money and productivity,” he added. The Tsurumi HSD slurry pump is ideal for emergency deployment. This portable, single phase ‘plug and go’ pump can be thrown into a pit quickly if a pump goes down or in a flood situation where solids contaminated water needs to be moved. The HSD pump has a hi-chrome impeller and built in agitator to move silt and sand. It can be supplied as a manual pump or with a float controlled auto on/off function. “Tsurumi have made their name supplying pumps for the concrete industry around the world,” said Bennett. “We want Australian plants to get the cost cutting benefits these pumps bring,” he said. For further information on the full range of Tsurumi submersible pumps, or for copies of the Batch Plant Pump Selector, contact Neil Bennett at Aussie Pumps on 02 8865 3500.

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SEISMIC DESIGN OF REINFORCED CONCRETE BUILDINGS IN AUSTRALIA Seismic design of reinforced concrete buildings is an area that is generally not well understood by structural engineers in Australia, since they often receive minimal training in this area. There are conflicts between the concrete structures and earthquake loading Standards, and the reinforcement detailing requirements within the Standard are often difficult to interpret and apply with confidence. There is a statutory requirement under the National Construction Code (NCC) to design and detail the majority of buildings in Australia for earthquake loading. To address this important and often overlooked requirement, the Steel Reinforcement Institute of Australia (SRIA) has published the new Seismic Guide and in conjunction with the Concrete Institute of Australia (CIA) and supported by the Australian Earthquake Engineering Society (AEES) are providing a series of informative seminars to be held in all capital cities. While targeted at design engineers and dealing with some of the most common issues faced when designing buildings for earthquake loading, the seminars will also be of interest to building owners, builders and anyone wanting to learn more about how earthquakes impact buildings. Attendees will learn about simple detailing that can be incorporated as a life safety measure in these extreme events. Simple reinforcement detailing such as the provision of a few extra bottom bars (tensile membrane steel or structural integrity reinforcement) or column fitments have proved effective in real events Figure 1. Seminar speakers include experts in the fields of earthquake design and research

and reinforcement detailing, including Paul Somerville (AECOM and Risk Frontiers, MQU; President of AEES), Peter McBean (Wallbridge & Gilbert and also representing AEES), John Woodside (J Woodside Consulting and principle author of the new Guide), A/Prof Helen Goldsworthy (University of Melbourne), Scott Munter (Executive Director, SRIA) and Eric Lume (National Engineer, SRIA). The comprehensive program commences with the earthquake risk in Australia and introduces the SRIA’s new Guide to Seismic Design and Detailing of Reinforced Concrete Buildings in Australia (Second Edition) developed to address this important issue. This is followed by six coordinated presentations to cover the following key design areas: • Historical and scenario earthquakes in Australia and the probabilistic seismic hazard analysis which forms the basis for the AS 1170.4 hazard map • Earthquake design principles including the role of ductility in seismic design, the importance of understanding drift compatibility, some limitations of current design methods and an overview of displacement-based design methods • Review of the new Guide, focusing on the major design issues related to various building components such as regularity of the structure, diaphragms, footings, stairs and ramps, precast and tilt-up considerations, non-structural parts and components and a mention of AS 3826 Strengthening of existing buildings for earthquake

• Reinforcement detailing of beams, columns and beam column joints and confinement reinforcement (fitments) for ordinary and intermediate moment-resisting frames (OMRF and IMRF) • Current research issues that are relevant to a seismic design practice in Australia and the latest international approaches for determining suitable performance objectives for design, how site specific factors can impact on the expected maximum displacement response of the structure, how structures behave in the non-linear range, structural walls and ductility • Lessons learnt from Christchurch and recommendations for column design; load paths and transfer structures; integrity reinforcement; interaction with non-structural parts and components; configuration and the benefits of redundancy • An Australian seismic design case study – new Royal Adelaide Hospital Ample question time is available at the end with drinks and cocktail food provided afterwards for continued networking and discussions with any of the speakers. The seminar will not only improve your understanding of the important seismic design and reinforcement detailing issues, but provide the opportunity to discuss structures with some of the country’s leading experts in the seismic field. Attendees will leave with a clear practical understanding of the simple measures that deliver a significant improvement to seismic performance plus the latest design guide materials for future reference.

Figure 1. Tensile membrane steel prevented failure of car park slab in Christchurch. (Images courtesy Peter McBean, Wallbridge and Gilbert).


Construction Engineering Australia - April 2016


NATIONAL SEMINAR SERIES | APRIL & MAY 2016 To address the very important and often overlooked requirement of seismic design and detailing for reinforced concrete buildings the Steel Reinforcement Institute of Australia (SRIA) has published the new Guide to Seismic Design and Detailing of Reinforced Concrete Buildings in Australia. To support this, in conjunction with the Concrete Institute of Australia (CIA) and the Australian Earthquake Engineering Society (AEES), SRIA are providing a series of informative seminars to be held in capital cities.

To register or to find out more please visit www.concreteinstitute.com.au/SeismicDesign


$200 $200 $200 $250

CIA Member SRIA Member AEES Member Non-Members


26 April 02 May 04 May 09 May 10 May 16 May

Canberra Adelaide Melbourne Brisbane Sydney Perth Supported by:



Top photograph: Newcastle Workers Club, NSW (Photograph courtesy Newcastle Council Earthquake Collection, Newcastle Region Library Ref No. 046000544 )


CONCRETE 2017 SAVE THE DATE Hot on the heels of the wonderfully successful Concrete 2015 conference in Melbourne the attention is now starting to focus on the 28th Biennial Conference of the Concrete Institute of Australia – Concrete 2017 in Adelaide. The conference theme “Advances in Concrete Materials and Structures” will give concrete researchers, designers, and practitioners from all over the globe an opportunity to showcase innovation and trends in the design, research, construction, maintenance, and repair that are making a difference around the world. The conference is also host to the 3rd International Congress on Durability of Concrete (ICDC), an international forum for exchanging research results and displaying how concrete will continue to create durable buildings and structures for sustainable development in both local and global contexts. Concrete 2017 will offer participants from around the world an opportunity to connect face-to-face and share innovative and interesting ideas from the latest advances in concrete materials to the design and construction of fascinating structures. The multidisciplinary theme of Concrete 2017 provides an excellent forum for networking and education and an opportunity to meet and interact with engineers, scientists, researchers, academics, practitioners, and professionals, from Australia and overseas. Whether you attend technical sessions, participate in interactive forum discussions, or network with friends and colleagues, this conference will provide you with ample opportunity for professional growth. The logo for the conference represents all the things that make Adelaide a great venue – home to world leading concrete structures like the Adelaide Oval, great networking and social gatherings over wonderful food and wine, all taking place at their world leading conference venue – the Adelaide Convention Centre. The Conference Organising team, headed by Co-Chairs, Professor Julie Mills (Uni SA) and Associate Professor Rebecca Gravina (RMIT), are already working on building upon the success of Concrete 2015 and bringing a world leading concrete conference to Adelaide. The call for abstracts will go out on 11th April 2016, and Concrete 2017 will take place from 22nd to 25th October 2017. Put the dates in your diaries! 40

Construction Engineering Australia - April 2016

CONNECT WITH CONCRETE 2017 Stay up to date with all of the Concrete 2017 news on the web and social media: Web: www.concrete2017.com.au Twitter: @Concrete_2017 Facebook: www.facebook.com/Concrete2017 LinkedIn: www.linkedin.com/company/ concrete-2017-advances-in-concretematerials-and-structures-

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Opened in 2014, the Brisbane West Wellcamp Airport (BWWA) is Australia’s first public airport to be built in 48 years.


EFC Geopolymer Project | Pavements at BWWA Project Brisbane West Wellcamp Airport (BWWA) is Australia’s first public airport to be built in 48 years. BWWA opened on 17-11-2014, marking a very significant milestone in engineering — the world’s largest modern geopolymer concrete project. Construction of the 435 mm aircraft pavements was undertaken using a geopolymer concrete that contained absolutely no Portland cement. It was supplied by Wagner’s under the brand name “Earth Friendly Concrete” (EFC). Pavement areas included: • Turning node: 16,000 m2 • Taxiway and aprons: 32,000 m² • Hangars: 2,500 m² In the lead up to the project both product testing and construction trials were undertaken in parallel to ensure that the EFC mix could meet the performance criteria of the contract specification as well as be placed in the intended method using a slip form paving machine. This successful application of a geopolymer concrete into a major pavement project follows 9 years of 42

Construction Engineering Australia - April 2016

product development and project work by Wagner’s. Custom made admixtures and comprehensive testing work with the geopolymer binder system used in EFC has been a major contributing factor in producing a commercial concrete that can be produced and delivered using existing practice. Other structures on the project constructed with EFC include sewer tanks, an entry bridge, kerbs, road barriers and site cast panels. Using EFC instead of conventional concrete reduced CO2 emissions by 6,600 tonnes. The low shrinkage and high flexural tensile strength of the EFC mix made it an ideal choice for the aircraft pavements. The project has been presented many accolades for its innovative use of geopolymer concrete, including a highly commended citation in the Sustainability Category at the Concrete Institute of Australia’s Awards for Excellence in Concrete in 2015, and has been nominated by the Institute for the American Concrete Institute’s Awards for Excellence program in 2016.

Top: The taxiway and aprons utilised 32,000 m² EFC geopolymer concrete. Above: Low shrinkage and high flexural tensile strength made the EFC mix an ideal choice for the aircraft pavements.


ramsetreid ITW, long term Platinum Members and supporters of the Concrete Institute of Australia, have recently launched a new division in Australia - ramsetreid ITW is a Fortune 150 diversified manufacturing company that was founded on innovation and expanded on the strength of its customer commitment. For over 100 years, ITW employees have kept an entrepreneurial spirit alive that is deeply rooted in the past and firmly focused on its customers. The new division of ITW Australia Pty Ltd, ramsetreid is the business that brings together all the business activities of the Ramset™, ITW Construction Systems, Reid™, Danley™, Modfix™ and Miska™ businesses across Australia and New Zealand. ramsetreid will also be the

company name under which the Platinum Membership of the Institute will be recognised. Firmly focused on customers in the Commercial Construction, Precast, Tilt-Up, Structural Steel and Flooring & Paving markets in Australia and New Zealand, they are a business with a proud heritage of serving the market through core brands – Ramset™, Reid™ and Danley™. They are a local company with an extensive manufacturing, distribution and R&D footprint across Australia & New Zealand. But, being a division of ITW, they also have immediate access to their sister companies globally. This allows them to develop or source the best product and service solutions for customers’ construction projects.

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Construction Engineering Australia - April 2016



CONCRETE KNOWLEDGE IS ESSENTIAL Why does concrete do the things it does? For a product that in its simplest form consists of only 4 materials, it is an incredibly complex and interesting material. Get it right, and you can achieve amazing results. Get it wrong, and the results can be catastrophic. In the previous issue of CEA, the Concrete Institute of Australia’s President, Mr Michael van Koeverden, was quoted: “While advances have been made in admixtures, binder and aggregate production, fitments, testing and repair materials, the root cause behind many of our concrete problems is neglect of the basics. All areas of the concrete industry need to have an understanding of concrete the material and how it works. Designers Professor Ken Hover

Essential testing of a structural concrete beam.

must consider whether their designs can be built. Constructors must ensure they allow for realistic construction time frames with experienced supervision part of the process. Placing, compaction and curing of concrete must be undertaken correctly for all concrete construction. You only get one chance to ‘get it right’, with concrete, so asking the right questions at the right time is essential to getting the right outcome”. From May to July the Institute will present the concrete industry a number of opportunities to seek further training in the area of concrete materials, or to provide their staff with the necessary skills to understand the essentials of concrete materials for design and specification.


Construction Engineering Australia - April 2016

CONCRETE ESSENTIALS The South Australian Branch of the Concrete Institute of Australia is proud to bring its Concrete Essentials course to the industry, and this will be conducted throughout the month of May in Adelaide. Presented over 5 evening sessions, the Concrete Essentials Course will cover a number of important concrete material areas under the topics of cements and supplementary cementitious materials; concrete specification, supply of concrete, concrete mix design and durability; concrete construction; properties and testing of aggregates and concrete materials; and joints and crack control, reinforcement, and sprayed concrete.

Upon completion of the sessions participants will be able to understand the types of cements and supplementary materials available and how they should be specified, the importance of aggregates and additives and the benefits they provide, design and specification of concrete for project requirements, impact manufacture, supply, and placement has on concrete characteristics, appropriate construction and curing techniques to achieve results, industry acknowledged tests and applicability, innovations in concrete technology and how they can be integrated into specification. The course is suitable for all members of the concrete industry and further information can be found at: www.concreteinstitute. com.au/events/450.aspx


WHY DOES CONCRETE DO THE THINGS IT DOES? In late June the Institute will embark on a series of workshops around the country that will look at how micro-impacts on concrete materials in the early stages affect the macro-behaviour and long term properties of concrete. This workshop is designed to provide designers, practitioners, suppliers and contractors of all levels of experience with a better understanding of concrete and the materials used to make it from its most early stages which are its most formative and important times of its life. It will also explore how concrete should best be specified and what the most important aspects are to test for long term performance reliability. The Institute is proud to announce that Professor Ken Hover from the University of Cornell, USA, will be the workshops main presenter. Professor Hover is recognised as one of the most influential people in the concrete industry and few have explained as much about concrete to so many with as much clarity. Amongst many other accolades, Professor Hover has been the top ranked technical speaker at World of Concrete for the last 22 years, and was recognised by Concrete Construction Magazine as one of the 10 “Most Influential Persons in the Concrete Industry”. The workshop will also include Mr Des Chalmers (Cement and Fly Ash Advisory) one of Australia’s most experienced practitioners in this field. Des will relate how international and local work in this area is being, and will be, transferred to designers and specifiers. The event is targeted specifically at any one in the concrete construction industry who may use, produce, place, finish, specify, approve or design concrete. For more details refer to: www.concreteinstitute.com.au/ why-does-concrete.aspx

Essential concrete knowledge was required in the construction of the new Royal Adelaide Hospital. Image courtesy SA Health

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PROJECT FEATURE The Broad struts its stuff, with the famous Frank Gehry designed Disney Concert Hall in the background.

The Broad LA gets cool with a concrete veil and vault

Los Angeles’ newest contemporary art gallery, the Broad, sits across the street from Frank Gehry’s amazing shiny Walt Disney Concert Hall. Few buildings could be expected to rival the space-age writhing angles of Gehry’s iconic 2003 structure, but the Broad certainly attempts, presenting itself as a work of art on par with the contemporary masterpieces it was built to house. All this is small change to billionaire couple Eli Broad and his wife, who provided a $200 million endowment - the $140 million museum showcases and stores the couple’s more than 2,000-piece art collection (which is worth a significant amount more than $200 million!). The Broad, was designed by Diller Scofidio + Renfro in collaboration with American firm Gensler. Its designers, Elizabeth Diller and Ricardo Scofidio, have been recognised by the MacArthur Foundation “genius” award, the first given in architecture. With its innovative honeycomb concrete 'veil-and-vault' concept, the 12,000 square metre US$140 million building features two expansive upper level floors of gallery space, with its ground floor given over to open entry and public areas, plus parking under. The parking comprises three basement levels for 364 cars. The building’s street façade is literally an exoskeleton 'veil' of matte white glassreinforced precast concrete carefully 46

Construction Engineering Australia - April 2016

sculpted rhomboidal panels that protect the glass façade from sunlight that might damage the art within. Internally what appears to be white sculpted concrete is in fact glass reinforced gypsum. The veil is made of 2,500 glass fibre reinforced concrete (GFRC) panels and 650 tonnes of steel support structure. The museum’s veil lifts at the corners, being the point of arrival for visitors into the interactive art lobby with its museum shop. A 30-metre long escalator rises from the lobby to tunnel up through the 'vault', delivering visitors into nearly an acre of column-free gallery space bathed in filtered light. Visitors exit the second floor via a winding central stair through the vault that offers views into the vast holdings of the collection. The void to the lobby contains a cylindrical glass elevator. Its design merges the two key components of the building: public exhibition space and collection storage. Rather than relegate the storage to secondary status, the vault, plays a key role in shaping the museum experience from entry to exit. Its heavy opaque mass is always in view, hovering midway in the building. Its carved underside shapes the lobby below, while its top surface is the floor plate of the exhibition space. The vault stores the portions of the collection not on display in the galleries or on loan, but the architects provided viewing windows

Let there be light Drawing natural light into the museum in a way that protects the art within is central to the design. The entire structure, including the carefully calibrated veil structure and skylights, serve as a light filtration device, bringing indirect, diffuse natural light into the galleries in a controlled way. The skylights include blackout shades that enable all or portions of the third-floor galleries to be darkened, giving the museum maximum flexibility to show any medium of artworks. One of the world’s leading day-lighting engineers, Arup in London, oversaw the development and execution of the veil and skylights. The Broad’s second-floor skylights have north-facing openings at a key sun exclusion angle that allow indirect, filtered natural light into the third-floor galleries. The gallery has seven metre-high ceilings, and the roof is supported by two metre deep steel girders. Each skylight is fitted with motorised blackout shades to enable the museum to calibrate natural light when needed. Blackout shades are fully deployed when the museum is closed. Shades can also be individually calibrated and set on one of seven preset positions if less or more light is desired in certain areas of the galleries. The skylight and vertical gallery glass throughout the museum has state-of-the-art UV filtration. so visitors can get a sense of the intensive depth of the collection and peer right into the storage holding. The vault is enveloped on all sides by the veil, an airy, honeycomblike structure that spans across the blocklong gallery and provides filtered natural daylight. The first floor shows collection storage visible to museum visitors through windows in a central stairwell leading from the


third-floor galleries down to the first-floor lobby, administrative offices, and flexible programming space. The top floor has 3,500 square metres of column-free gallery space with filtered natural light from skylights and windows. Public amenities associated with The Broad include an adjacent public plaza, and a new restaurant. The plaza provides for outdoor movies, performances and educational events. The 2,400 square metre Plaza over the underground car park is supported by 18 principal post-tensioned concrete beams seated on reinforced concrete columns, positioned to suit the car parking layout. The Plaza surfaces include decomposed granite, and etched concrete paving. The Broad aims to be in the top tier of eco-conscious museums with its electric car charging stations, bike parking spaces, rooftop drains that provide water for street level gardens that filter runoff, highefficiency plumbing fixtures that help reduce water use by 40 percent, and its easy access to public transit including the new Metro Regional Connector station due to be opened 2020.

THE PRECAST SOLUTION Choosing a product with the demands for hundreds of different unique curved shapes for the exterior skin was a big challenge for the design team. Creating hundreds of conical light openings for the building and replicating the front oculus from a parabolic curve would need a product that was flexible and versatile to adapt to this design shape.

The designers created complete geometric information for each panel in three-dimensional (3-D) computer models first. The precast concrete producer imported this data directly into the tool path software to create instructions for the five-axis, computerised, numerical control machine to carve moulds out of high-density foam. Before skinning in fibreglass, the foam moulds were sanded and sealed to create the negative formwork for the GFRC panels. The high strength of the GFRC skin ensured the additional strength required for the structurally unique shapes. The skin strength and durability allowed for smaller tube framing for the skins, which helped accommodate tight tolerances for panel placement to the structural steel. The panel strength also meets the long life and durability requirements needed at the ground floor where the public has access. The frames had to be fabricated to tight tolerances so the locations of the components and connection points were checked with a total station survey before and after welding. The survey data was imported back into the 3-D model of the frame to verify accuracy. Before spraying the skin, the frames were positioned on the mould, surveyed, and verified against the model. Then the setting jigs were locked into position, and the frames were removed. This step in the process was never required before. The skins were sprayed, and then the frames were replaced into the jigs and resurveyed. Finally, they did a full 3-D scan of the finished product to ensure compliance with the model. Pictures by Iwan Baan.

Building facts and figures • 1.6 million tonnes of concrete were used • 5,000-square-metres of gallery space including 3,500-square-metres of column-free space on the top floor, with 1,500-squaremetres of gallery space on the floor below. • 2,100-square-metres of collection storage space. • The second floor concrete slab cantilevers fifteen metres over the lobby. • The veil is made primarily of 2,500 glass fibre reinforced concrete (GFRC) panels and 650 tonnes of steel. • The veil is supported at three points: the connections at two side streets, and the major 32-tonne, 20-metre-long “touchdown beam” on Grand Avenue which sits two metres below the sidewalk and can support loads of up to 2.7 million kilograms. • The Grand Avenue touchdown beam can rock along a central pivot point allowing the entire veil structure to slightly “see-saw” back and forth along its plane in the event of a major earthquake. Each end of the beam is allowed to move up and down by 15 mm. • The roof includes five 65 metre long steel girders weighing approximately 70 tonnes each. • The roof has a 19-metre cantilever over the top floor gallery. • The roof includes 318 skylight monitors with glazed openings to collect diffused sunlight coming from the north. • 380 different moulds were used for the GFRC panels of the veil. • 30 percent of the total veil moulds are used solely to form the “oculus” portion of the veil to create its intensely curved shape which indents the veil into the building and the vault. • The average GFRC veil panel weighs around 540 kilos.

Project Team

• Veil countries of manufacture: Germany, Czech Republic, and the USA.

Design Architect: Diller Scofidio + Renfro

• The lobby includes 37 glass panels, each measuring 6m x 2m and weighing 700 kilos.

Structural: Saiful / Bouquet Structural Engineers Construction: MATT Construction

• The Oculus Hall includes seven glass panels measuring 5m x 2m and weighing 590 kilos. • The galleries include 52 glass panels that are five metres by 1.5 metres, weighing 440 kilos each. • Glass countries of manufacture: Germany, Austria, USA, and Mexico. • 15,500m2 three-storey subterranean parking garage with parking for 344 vehicles. Construction Engineering Australia - April 2016



NATIONAL PRECAST HIGHLIGHTS URGENT NEED FOR NEW NATIONALLY ADOPTED CODE OR GUIDE With the increased prevalence of structures that include not just precast concrete walling, but flooring, beams, columns, stairs and lift shafts as well, it was decided that an urgent update to the 2003 version of AS 3850 Tilt-up concrete construction was necessary to ensure that it remained relevant for industry. At the same time, and for similar reasons, Safe Work Australia commenced the task of updating the 2008 version of its National Code of Practice for Precast Tilt-Up and Concrete Elements in Building Construction. According to National Precast CEO Sarah Bachmann, Safe Work Australia was urged by the Association to work alongside the Standards Australian BD-066 committee, so that a harmonised set of documents might result rather than two potentially conflicting documents being released into the market. The decision was taken by Safe Work Australia to defer the Code’s revision until the revised standard had been published. In September last year, and after some six years of intense work by the BD-066 committee, the revised AS 3850-2015 Prefabricated concrete elements was published as a two part standard. Throughout the process, National Precast Concrete Association was closely involved with two representatives on the committee - Jeff Stratford and Kevin Crompton. The changes that have evolved in the 2015 standard may be the most important the Australian precast industry and its stakeholders have seen. But as the new standard is being implemented, Ms Bachmann says there is confusion in the market because it has surpassed the requirements of the old National Code – to the extent where the two documents conflict. “As its name implies, the new standard has a much wider reach than the 2003 version – it applies to all prefabricated concrete elements used in building construction, both site-cast tilt-up and off-site factory-manufactured precast. It does not however, apply to civil products or small precast elements such as bricks, blocks and pavers,” she says. She commented that the committee concluded in its deliberations, that tilt-up in the standard is considered more of a lifting method rather than a method of fabrication.

STANDARD NOW IN TWO PARTS Ms Bachmann says that the revised standard has been divided into two parts – Parts 1 and 2. “While the two parts have a similar scope, they each have a very different focus as their target audiences are different,” she says. Part 1 General Requirements, is directed at componentry suppliers, detailing requirements for materials, components and equipment used during the manufacture of elements. Part 1 also addresses several critical


Construction Engineering Australia - April 2016

ambiguities and errors regarding safety that existed in the 2003 edition. Differing interpretations of the testing and statistical methods in the 2003 edition had been causing confusion in the industry around the performance of several products and the revised standard should remedy this. It should provide the construction industry with greater confidence that products and components used in manufacturing elements have been selected and tested in accordance with relevant criteria and comply with a higher standard than in the past. Industry should still, however, request information from the suppliers they choose to use. Part 2 Building Construction, is targeted towards the construction design and documentation of prefabricated concrete, focusing on the interrelation of the various stages of manufacture, construction, transport and erection. It addresses requirements to improve safety and quality of products and provides best practice guidance on design and documentation, casting, transportation, cranage and erection, temporary supports and incorporation of elements into the final structure. The content of the old standard has been considerably expanded to provide greater detail, more examples, additional load factors and an overall update to reflect what is now standard practice in the industry.

STANDARD CLARIFIES ROLES OF THE IN-SERVICE DESIGNER AND ERECTION DESIGNER The Association believes that the revised standard provides much greater clarity around the responsibilities and interactions between two already existing key roles in the project chain – that of in-service design and erection design. In WorkSafe Victoria’s ‘Blue Book’ and the old National Code, these two critical roles are currently referred to as the ‘project design engineer’ (which is in effect the in-service design engineer) and the ‘erection design engineer’. The revised standard refers to them as the In-service Designer and the Erection Designer and Part 2 in particular, further details their responsibilities.

ASSOCIATION MAKES URGENT CALL FOR NATIONALLY ADOPTED UPDATED NATIONAL CODE OR GUIDANCE MATERIAL Since the standard has been published, SafeWork Australia has had on its ‘to do’ list, the development of either a revised Code of Practice or a Guide – the decision on which format the documentation will take, is still to be made.

SEMINARS TO ADDRESS NEW STANDARD AND SAFETY DESIGN Since its publication in September last year, the new AS 3850-2015 is being adopted throughout the country. The implementation of the standard is highlighting requirements within the new standard that are now in conflict with Safe Work Australia’s 2008 National Code of Practice for Precast Tilt-Up and Concrete Elements in Building Construction. Together with the Concrete Institute of Australia, National Precast is running nationwide seminars during August which will address: • the impact of the new standard on precast manufacturers, engineering design and construction; and • the key elements of safe design, including a review of codes and guidance material that are currently available. The seminars are aimed at precast manufacturers, engineers and builders. They are being presented by National Precast’s AS3850 committee representatives: • Jeff Stratford, Business Manager ANZ Precast, Tilt-up & Structural Steel at ramsetreid; and • Kevin Crompton, Director - Operations at Ultrafloor and National Precast Board Member.

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Dates and locations: Monday 1 August Tuesday 2 August Wednesday 3 August Monday 8 August Tuesday 9 August Wednesday 10 August

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The Association believes that this task has now become urgent, to the extent where it is calling for the withdrawal of the current Code of Practice until the documentation is revised to work alongside AS3850-2015. “The goal by updating the standard was never to further confuse the market. But until Safe Work Australia updates the Code or produces a Guide, that is what’s happening – confusion… caused by two documents that in some situations have conflicting requirements. The agreed goal was always to have two complementary documents – the standard, which is the technical guide, and the Code, which would be the supporting ‘how to’ guide,” said Ms Bachmann. “We can’t state strongly enough, the need for Safe Work Australia to urgently complete its revision of the Code or guidance documentation, and to make its publication a top priority.

NATIONAL ADOPTION IMPORTANT The Association is also calling for national adoption of the revised Code or guidance material. “A couple of the States elected not to adopt the current National Code. The Association very strongly believes there needs to be a harmonised national approach by all State WorkCover authorities going forward, and the called-for new Code or guidance material presents an ideal opportunity for this to occur. If we acquiesce and tolerate different codes applying in different states, the unnecessary complexity will simply add to the confusion. “Whether companies manufacture precast, provide engineering services or build, many operate across more than one State or Territory. It becomes confusing for them to know exactly which code to follow. Even though a particular State WorkCover authority might adopt one code, history tells us that when an incident or accident becomes litigious, every code gets brought in to the picture. It would be so much simpler if the States were consistent,” said Ms Bachmann. “Confusion in the market results not only in increased costs, but more importantly, it compromises safety. Every party, from Safe Work Australia, to State WorkCover authorities, to industry associations, to industry practitioners, have a responsibility to work in sync with one another to clarify roles, responsibilities and requirements,” said Ms Bachmann. “All parties need to do everything they can to ensure safe, high quality outcomes,” she said.

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Austral Precast's automated factory in New South Wales utilises state-of-the-art technology and equipment to maximise quality.


AUSTRAL PRECAST The last five years have been an extraordinary time for National Precast member Austral Precast. The foray into precast has proved an exciting opportunity for market expansion on a substantial scale. Operating from four plants across Australia, Austral Precast manufactures a diversified range of customised walling, flooring, framework, stairs, balconies, and other client-specific precast solutions. The company also offers installation services.

LAYING THE FOUNDATIONS With the names Brickworks and Austral steeped in the history of the brick industry, the venture into precast was always going to be a strong one. The move was prompted by the increasing trend to modularise construction in the building industry. “The major difference is that you are not manufacturing for stock, controlling inventory via a minimum and maximum holding system,” said Austral Precast General Manager Andrew Nearhos. “Everything is made to order, which means planning, procurement and coordination between departments is far more important to ensure the on time delivery of products to meet customer expectations”. It was early in 2010 when Brickworks expanded into the precast market, with the acquisition of Sasso Precast Concrete in New South Wales. Further acquisitions of Gocrete and Girotto Precast followed and the company rebranded as Austral Precast. In March 2012, CPS Precast in Queensland was added to the offering. The result is an 50

Construction Engineering Australia - April 2016

extensive company footprint with 200 staff in facilities in Queensland, New South Wales, Victoria and Western Australia.

CHALLENGES AND REWARDS According to Mr Nearhos, the company’s growth has proved sometimes challenging, but very rewarding. “The major challenges come from combining cultures. Culture is hard to charge, so when you have two cultures competing within one business and teams that have their own set way to do things, it can be difficult to have each person fully engaged and aligned with the company’s objectives”. “The reward is seeing what happens when you get the multiple teams engaged, seeing them come together and achieving goals that on their own, wouldn’t have been possible. Seeing them thrive on these achievements and watching the motivation within the team grow is extremely fulfilling.” That team has been integral to Austral Precast’s growth over the past five years. “The key is having the right people on the bus, a clear vision and strategy and a disciplined commitment to execution. I’m a believer that management exists to serve their employees. Giving good service and support to them ensures they succeed. If they succeed in their roles, the business will too,” Mr Nearhos said.

STATE-OF-THE-ART TECHNOLOGY FOR BEST QUALITY The quality of the production process starts right at the beginning for Austral Precast. Mr Nearhos says having on-site concrete batch plants results in a superior concrete quality.

Austral Precast General Manager, Andrew Nearhos.

“Our concrete is poured within minutes of being mixed as opposed to sitting in the back of concrete delivery trucks which at times are held up in traffic. That delay can impact the quality of the concrete when it’s finally poured.” The control over set times ensures a more consistent product, according to Mr Nearhos. The company uses state-of-the-art technology, systems and production techniques with automated production facilities an important investment. “There are a number of advantages, particularly with regards to quality control,” explained Mr Nearhos. “Rather than relying on manual labour to measure and mark panel dimensions and locations of cast-in items with tapes, lasers and plotting machines do this directly from the CAD generated shop drawings. From the same CAD files, mesh welding machines custom-make the steel reinforcement required for the panels… as opposed to manually reading plans, and cutting and tying sheets of mesh together.”

Parramatta, New South Wales and panels, columns and flooring for Nepean Hospital’s Mental Health Centre. Mr Nearhos says a recent highlight was supplying more than 100 double wall panels for Wynyard Station in Sydney, solving a number of design challenges for the builder.



Austral Precast services a range of markets, including multi-residential, commercial, industrial, community and civil sectors. Some of the company’s more notable projects include the architectural panels on Perth’s Sage Hotel, curved roof panels and architectural feature panels at Perth’s Halo Apartments, graphic concrete panels at Queensland’s Westfield Garden City, brick and sandstone-finished panels for multi-story residential towers in

Austral Precast is confident of a strong future. Mr Nearhos predicts the demand for precast in Australia will continue to increase as the construction industry works to reduce the volume of work that is physically undertaken on building sites… to save time, reduce waste and improve quality. “With that demand will come growth, which we intend to be a part of,” Mr Nearhos concluded.

Construction Engineering Australia - April 2016



PRECAST DELIVERS LUXURY HOUSING PRECASTER: Hollow Core Concrete BUILDER: Gaia Construction ENGINEER: Hollow Core Concrete ARCHITECT: Millar Robertson Architects Luxury and functionality have been delivered with the construction of three boutique apartments in the Melbourne beachside suburb of Elwood. The approach to construction was refreshingly different and has resulted in an award-winning development. This project posed challenges from the start. It was an ambitious vision to build three townhouses on a relatively small parcel of land of just 316m2. To achieve that goal, innovative design was required. Precast concrete was a major part of the design solution. National Precast member Hollow Core Concrete was contracted to design, supply and install walling, flooring planks and precast solid slabs.

PRECAST CHOSE FOR MORE THAN AESTHETICS The stunning exterior of the Elwood apartments balances polished concrete panels with a

lightweight timber cladding. The result is a unique combination of textures and finishes. According to Hollow Core’s Peter Dover the development was complex. “It was complicated to put together. It looks good from the outside, but was complicated from the inside.” One of those complications was the accessibility on such a small work site. Precast was ideal for this scenario. The 44 wall panels were manufactured off-site with attention to detail on the quality finishes. “This was a satisfying residential project to be part of. In the majority of projects we work on, the wall panels are covered or painted and in this case they were a feature of the design. They’re wearing well and the house looks really good,” said Mr Dover. Wall panels were not the only precast concrete elements used on the project. 750m2 of precast hollowcore flooring was also manufactured. 12 solid precast slabs were also supplied and installed for the balconies.

TIME CRITICAL FOR CONSTRUCTION While the look and finish of the precast was important, speed of construction was critical. “It was all about the timing,” said Mr Dover. “The builder wanted a fast and efficient construction and we delivered”. The speed of

construction was impressive and the project was completed in just 15 months. Traditional construction methods would have taken much longer. The fast build and striking wall panels have resulted in much more than efficient construction and impressive aesthetics. The choice of precast concrete also ensures a low maintenance and durable finish. The precast is integral to the energy efficiency of the units, which have a high energy rating, maximising passive solar gains and insulation opportunities.

CLEVER CAR PARKING SOLUTION One of the unusual and particularly clever features of this development is the inclusion of two double car stackers. This provision of off-street parking is an innovative solution to the challenges of this small site. Precast concrete was ideal for this part of the build.

POPULAR WITH CLIENT, BUYERS AND INDUSTRY The Elwood apartments have proved extremely popular. The client, Jeremy Gates from Gaia, is rapt with the finished construction. “Even the neighbours have commented on how great it looks and people driving by stop to say how good it is,” said Mr Dover. All the units were sold long before completion. As well, Gaia Construction took out the award for the “Best Multi Unit Development” at the Excellence in Housing Awards for this innovative project. 52

Construction Engineering Australia - April 2016

Assisting in building with strength, wisdom and beauty

Before using these materials for your next building project why not call Ability about abilox®. ®

Ability Building Colours manufactures abilox - an extensive range of seventy (70) fine, UV resistant, inorganic mineral oxide colouring pigment powders from which to choose OR we will make you a CUSTOM colour. ®

Unfadeable abilox powder colourants are added to, mixed in and used for permanently ‘through’ colouring of pre-mixed concrete, asphalt, mortars, paints, other surface coatings, caulks and sealants, applied finishes and other composite products and materials used in the building industries. Individual, colourfast powder colourants, including absolutely permanent ® Cobalt Blue and Chromium Green, are available in the abilox range exstock for immediate shipment to your nominated pre-mix concrete supplier or concrete products manufacturer.

For enquiries call Ability on: (Toll Free) 1800 337 324

Ref: Advert/ability’s abilox® (612050)

Ability Building Colours 133-135 Northern Road West Heidelberg Victoria 3081

Postal address: PO BOX 391 West Heidelberg Victoria 3081

Phone: 03 9457 6488 Fax: 09 9458 4683 Email: service@abilityproducts.com.au www.abilityproducts.com.au

Ability’s – abilox®




Nepean Mental Health Centre NSW PRECAST MANUFACTURER: Austral Precast STAINING SUPPLIER: Nawkaw Australia CLIENT: NSW Health Infrastructure BUILDER: AW Edwards ARCHITECT: Woods Bagot ENGINEER: Hughes Trueman


Construction Engineering Australia - April 2016

Situated on the extensive campus of the Nepean Hospital in the outer western Sydney suburb of Penrith, the Nepean Mental Health Centre includes 64 mental health beds servicing high dependency, acute and specialist mental health services for older persons. The unit includes a dedicated inpatient ward and new facilities for the outpatient day program. The Centre’s design creates what the project architects, Woods Bagot, call a “living architecture.” A facility such as this requires a hard edge for security but the building, both internally and externally, must engage with the patients. The conventional commercial construction methodology contrasts strongly with the non-institutional feel of the interiors, with large areas of glazing and comfortable lounges allowing a visual connection to the three therapeutic internal courtyards. Salutogenic design has been cleverly incorporated into the building; the concept that the quality of the built environment has an influence on our health. At first glance it may seem that precast concrete walling is the antithesis of a nurturing, healing environment but the mellow, tactile exterior walling of the Nepean Mental Health Centre demonstrates otherwise. Manufactured by National Precast member Austral Precast, the precast walling gives the building’s façade a striking appearance. Substantial areas are decorated with a bamboo pattern that is debossed into the concrete surface. The pattern is the result of a rubber formliner that is placed in the base of the casting form or mould. Once the formliner is in place, steel reinforcement is positioned and the form is filled with concrete. When cured, the concrete panel is lifted out and the formliner stripped away, ready for reuse. All precast panels, plain and patterned, are finished in a pleasant coppery green colour, applied on site using the Nawkaw staining process. The use of green, patterned walling is most effective around the building entrances, on the long street elevation and most especially in the therapeutic courtyards where the colour and texture blend happily with the landscaping. It’s well accepted that colour has a direct effect on a person’s wellbeing. Green is the benign colour of nature and has long been favoured as a positive colour, giving permission and safety. The ‘Nepean green’ was custom-formulated to an approved sample. The gold-bronze base is topped with a non-metallic weathered green. In certain lighting conditions the metallic base colour becomes more prominent. The 147 precast panels for the Centre were cast on automated tables at Austral Precast’s state-of-the-art facility in Wetherill Park, NSW. They were then delivered to site and installed by the precast manufacturer. The company is proud to be able to offer a complete end-to-end service from design consultation through manufacture and finishing, to delivery and installation, all with one contract and one point-of-contact and total responsibility.

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“The design sought to create a building that fits with the colour palette of the surrounding environment,” explains Woods Bagot principal Domenic Alvaro. “The copper green colour and natural patina of the precast concrete panels has depth and tactility, providing a unique ‘on weathering’ finish that will continue to evolve over time.” While meeting strict budgetary, treatment, safety and security requirements, the Centre’s use of precast also provides a level of humaneness and connection to landscape that will assist the patients on their healing journey.


Construction Engineering Australia - April 2016

Nawkaw’s colour penetration technology provides an innovative and durable alternative to colouring concrete by traditional methods. For the Nepean Mental Health Centre, Nawkaw used their colour technology to produce the attractive copper green coloured panels.

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 V2.02 - April 2016  

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

Construction Engineering Australia V2.02 - April 2016  

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