Construction Engineering Australia V4.01 Feb/March 2018 by EPC Media Group

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CONSTRUCTION ENGINEERING AUSTRALIA FEB/MARCH 2018

V4.01

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Editorial

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Industry News

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Publisher and Managing Editor Anthony T Schmidt Phone: 1300 EPCGROUP (1300 372 476) Mobile: 0414 788 900 Email: ats@epcgroup.com Business Development Manager Lawrence Whiter Mobile: 0418 543 821 Email: lawrencewhiter@bigpond.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 Gaffney - AmAgo Mobile: 0439 749 993 Email: jodie@amago.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 12400 Registered by Australia Post Publication No. 100001889

ISSN 2204-7247

FEB/MARCH 2018 Volume 4 Number 1

10 Project Brief: New Sydney Green Square Aquatic Centre

Product Focus

16 Cover Feature: Mainmark 20 Innovative Solutions 22 Professional Development 24 Equipment Focus

30 Formwork Feature 32 Concrete Institute News 38 Admixtures

40 National Precast Feature 46 Special Report: Sydney Harbour Bridge Composites

53 ACA Corrosion Feature

About the Cover Ground engineering and asset preservation specialist Mainmark has successfully re-levelled two large commercial buildings using JOG Computer-Controlled Grouting, a non-invasive, highly precise system of grout injection. Mainmark has used the solution extensively in New Zealand to successfully re-level large earthquakeaffected structures including commercial buildings, civil infrastructure assets, industrial sites, heritage buildings and homes, quickly and cost effectively. Turn to Page 16 for the full story.

EDITORS COLUMN

Preventing Australia from becoming a dumping ground for non-conforming construction steels as a result of US tariffs Dear Readers, In recent years, pricing pressures, combined with efforts to maximise margins in what is often a tough and unforgiving marketplace, has seen a significant increase in the amount of sub-standard building materials be used in Australian buildings. Unfortunately, this issue looks set to become more difficult to overcome, thanks to recent major political and trade developments. Before I continue... I refuse point blank to be drawn into any discussions relating to the pros and cons of free trade and protectionism, any opinions that I might have on that matter are, for the purpose of this editorial, completely irrelevant. There are, however, a number of critical global issues which have arisen as a consequence of the recent decision by the USA to impose a levy on steel and aluminium imports – and it’s not only about Australian exports. Indeed, one of the most alarming potential consequences for the Australia market, is the matter of what happens to the 'glut' of material that is no longer going to be imported by the USA. More specifically: • How do we prevent ourselves from becoming a 'dumping ground' for materials originally intended for the US market that may not conform with the relevant Australian Standards? and • How do we protect ourselves without contravening the conditions of our FTA's? Irrespective of whether you agree or disagree with globalisation and free trade, Australia has a free trade policy which severely limits our ability to apply any rules that can be seen as placing a barrier on

Construction Engineering Australia • Feb/March 2018

trade. The only way to limit 'dumping' is to remove the market for products that do not conform with the required Australian Standards. At least that way, we can ensure that there is a level playing field in terms of quality - regardless of the country of origin. Unfortunately, even though that may seem to be a relatively simple solution, there are a number of other matters that need to be taken into account, namely:

relevant Australian Standards. With that in mind, it's important to note that the two things which all buildings being constructed in Australia have in common are:

• How do we ensure that the products being used in Australian buildings ACTUALLY meet all of the relevant Australian Standards? and, perhaps more importantly; • How do we prevent non-conforming materials from being used in Australian buildings and other projects?

I believe that those two mandatory requirements present us with an ideal avenue by which we could, for all intents, eliminate the use of non-conforming building products in Australia – without introducing legislation restricting imports that may contravene the conditions of our FTA's. More specifically, if building approvals and insurance contracts required all construction materials to be independently and expertly certified as conforming with all of the relevant Australian Standards prior to their use in an Australian building, there would be very little latitude for builders and specifiers to use non-conforming products. That in turn should, if not completely, at the very least significantly reduce the amount of non-conforming products being used. After all, this isn't about limiting trade, increasing bureaucracy or burdening people with additional administrative tasks, it's about health and safety - and may even be a matter of life and death.

Take, for example, construction steels and reinforcing. While we, thankfully, have organisations such as ACRS (Australasian Certification Authority for Reinforcing and Structural Steels Ltd) to provide a fully independent, expert assessment and certification for both Australian and internationally sourced construction steels to help builders and contractors ensure that they are getting the Australian Standard compliant materials that they ordered, the fact that ACRS Certification is not mandated, means there are still some projects in Australia being constructed with steels that do not non-conform with the relevant Australian Standards. While I believe the quickest and easiest way to overcome the issue would be to mandate the use of ACRS Certified steel, the only other way to eliminate the use of non-conforming steels is to make it virtually impossible to construct a building using steels that can't be independently and expertly verified as conforming with the

• a requirement for building inspections & approvals during various phases of construction; and • mandatory insurance.

Anthony T Schmidt Managing Editor

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INDUSTRY NEWS

GEELONG CITY DEAL ON THE MOVE WITH KEY PLAYERS OUTLINING THE PATH FORWARD Planning for Geelong’s recently announced City Deal is underway with the Australian and Victorian Governments holding talks with local government and the region’s business and community organisations during February. Federal Minister for Urban Infrastructure and Cities Paul Fletcher said it was vital to tap into local knowledge to identify potential elements of the City Deal. “Geelong is Victoria’s second-largest city and Australia’s second fastest growing city, and its economy is rapidly diversifying,” Mr Fletcher said. “The City Deal offers an opportunity for three levels of government to come together to develop a plan to further stimulate that growth and diversity.” Victorian Parliamentary Secretary for

Image Courtesy of the City of Greater Geelong

Treasury and Finance Daniel Mulino, who co-chaired the meeting with Minister Fletcher, said the Victorian Government was committed to working with the Australian Government and other partners to deliver the best possible deal for Geelong and the region. “It is essential we tailor Geelong’s City Deal to ensure it meets the needs of the community,” Mr Mulino said. “Undoubtedly locals will know best the issues impacting them. Today’s stakeholder forum has given us an opportunity to further refine the details of the Deal, including opportunities for investment and reform, and the governance mechanisms needed for implementation.” Federal Member for Corangamite Sarah

Henderson said she was encouraged by how quickly negotiations had commenced. “Our discussions are focusing on a range of priorities including employment, infrastructure and transport, planning and how as a region we make the most of opportunities in the visitor economy. This is a very exciting opportunity for the Geelong and Corangamite regions,” Ms Henderson said. State Member for Geelong Christine Couzens said she was excited by the employment opportunities that a City Deal could deliver. “It’s great to see the City Deal providing momentum for much needed projects in the area, which will support jobs in our community,” Ms Couzens said.

ACOUSTICS PROFESSION SLAMS THE NATIONAL CONSTRUCTION CODE The Association of Australasian Acoustical Consultants (AAAC) is calling for the impact sound insulation requirement of the National Construction Code (NCC) Part F5.4 to be changed. Currently it allows owners of apartments to install hard flooring that causes unliveable conditions for residents of apartment blocks. As property developers increasingly opt for fashionable hard floors such as timber, polished concrete, and tiles, impact generated sounds heard by residents are so harmful that the AAAC has seen people suffering from emotional trauma and overwhelming legal fees as a result. AAAC Treasurer Richard Haydon says the NCC needs to change and also states that Australian Building Codes Board (ABCB) has overlooked their pleas for over a decade. “We’re seeing more and more owners corporations having to engage in costly litigation to deal with complaints and disagreements as occupants report unbearable noise levels.” “Apartment occupants are entitled to peaceful enjoyment of their space. Instead,

Construction Engineering Australia • Feb/March 2018

their stress levels increase and neighbour relations are strained, as poorly insulated hard flooring is installed, which would otherwise be acceptable, based on ever increasing reliance on the NCC standard.” “The AAAC does not consider the floor impact isolation standard required by the NCC to be adequate to protect the acoustic amenity of apartment occupants,” he added. Peter Knowland of acoustics firm, PKA Acoustic Consulting, has filed a submission to change the standards based on AAAC’s Guideline for Apartment and Townhouse Acoustic Rating. “The guidelines should be changed from Ln,w ≤ 62 to Ln,w 50 or less, which results in 12dB of additional insulation and more akin to residents’ expectation of acoustic comfort. That’s all we’re asking.” “The Australian Building Codes Board has enacted many wise acoustical measures in the last decade, including sound transfer through walls. We believe that a revaluation of the impact criterion will have a dramatic improvement on people’s quality of life,” Peter Knowland concluded.

ABOUT THE ASSOCIATION OF AUSTRALASIAN ACOUSTICAL CONSULTANTS (AAAC) The Association of Australasian Acoustical Consultants was founded in 1978 as a notfor-profit peak body whose members provide consultancy advice in all areas of acoustics, noise and vibration. The AAAC aims to raise the standards of acoustic consultancy and educate industry professionals and the public on the role of good acoustics and its impact on the design and planning in the built environment. The organisation now has 65 member firms, employing approximately 400 consultants reflecting a $90m size industry. Its members are some of the most highly qualified and experienced acoustic professionals in the country. They provide professional unbiased advice and deliver practical innovative and cost-effective solutions for their clients. There is growing public awareness of the importance of good acoustical design and this field is popular amongst architects, engineers and other building professionals. The AAAC has developed a Star Rating System that is used widely across the industry to combat the deficiencies in the Building Code in relation to apartment noise intrusion. For more information, visit: www.aaac.org.au

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Engineering is a competitive career path, presenting challenges to conquer no matter your current position. Succeeding in this field requires more than technical expertise. To become a leader, you must define your values and purpose in preparation for the chance to make a difference. But how do you plan for these opportunities? What do you need to do to engineer your success?

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INDUSTRY NEWS Rune Abrahamsen says that a number of players are vying for the world record for the world’s tallest timber building. Photo: Bjørk Ellingsbø/Anti.

COULD TIMBER ‘SKYSCRAPERS’ BECOME A REALITY? Can you build timber skyscraper taller than 150 metres? “With a wider building, it will be possible to build a timber building taller than 100 metres. 150 metres should also be possible. Possibly even taller.” These are the words of Director Rune Abrahamsen of Moelven Limtre AS. The man behind “Mjøstårnet”, among other things, which when completed in March 2019 will be the world’s tallest timber building. It’s a building that many people in the international construction industry consider to be ‘world-class engineering’. Rune Abrahamsen says that a number of players are vying for the world record for the world’s tallest timber building. Abrahamsen is also finding plenty of support for his project, including from Sverre Tiltnes, Director at government-appointed sustainability consultants Bygg21. “The project is an important contribution to make the international building industry more environmentally friendly,” Tiltnes said. “When one proves and documents that one can build a taller timber building that what one previously thought was possible,

there’s no doubt that this is world-class engineering,” he added. In addition, he believes that for several decades the industry has seen that Moelven has a world leading production environment for wood materials. “I don’t believe that Mjøstårnet could have materialized without Moelven’s experience from the Olympic halls, the airport at Gardermoen and the company’s many groundbreaking bridge projects,” he added. Tiltnes heads Bygg21, which is the government’s instrument to promote an efficient and sustainable industry in Norway. Bygg21 is a partnership between the government and the entire Norwegian construction and real estate industry. Tiltnes previously headed the introduction of the international classification system BREEAM in Norway.

Terminating myths about timber construction Tiltnes says that Mjøstårnet is playing a major role in helping to terminate the myth that wood is not suited for tall buildings. “Unfortunately, many industry players

have previously had an unfounded fear that wood has poor load-bearing properties and high risks in the event of fire. Mjøstårnet is contributing to more people realizing that wood is very safe with regard to fire and has a load bearing capacity that allows for significant heights,” he said. “Together with a number of other stakeholders, we recently launched a digital guide for the use of industrial wood structures. I believe the upcoming world record of 81 metres is just the start of a megatrend,” Tiltnes added. With numerous players now vying for the world record for the world’s tallest timber building, the need has also arisen for a proper definition of a high-rise timber buildings. A while back, Rune Abrahamsen was in Australia to take part in an international workshop on tall buildings. "On commission from the Council on Tall Buildings and Urban Habitat (CTBUH), UK specialist Dr Robert Foster, on behalf of the workshop participants, has put forward a proposal that buildings with braced concrete cores be defined as wood-concrete hybrid buildings." He has reason to believe that this proposal will be adopted in the first half of 2018. If the rules come into force, HoHo Tower in Vienna and Brock Commons in Vancouver will be defined as wood-concrete hybrid buildings rather than timber high-rises. “Both of these projects are nevertheless outstanding examples of how one can achieve major reductions in greenhouse gas emissions by combining materials,” Abrahamsen said.

RAISING THE BOTTOM LINE: NEW REPORT FINDS OPPORTUNITIES IN NEW HOMES Simple energy efficiency improvements in new housing stock can slash energy bills, cut Australia’s emissions by 10.8 million tonnes, and deliver comfortable and resilient homes, finds a new report. The Bottom Line – Household impacts of delaying improved energy requirements in the Building Code, has been developed by the Australian Sustainable Built Environment Council (ASBEC) and ClimateWorks Australia. The report finds that simple energy efficiency changes – such as sealing air 6

Construction Engineering Australia • Feb/March 2018

leakages, installing ceiling fans in warmer climates, and improving insulation in cooler climates – could cut energy consumption for heating and cooling by up to 51 per cent across a range of housing types and climate zones. This is equivalent to at least a 1 star National Housing Energy Rating Scheme (NatHERS) rating. Romilly Madew, Chief Executive Officer of the Green Building Council of Australia, says the report underscores the pressing need for more robust residential energy standards in the National Construction Code (NCC).

“Our residential and commercial buildings represent almost a quarter of Australia’s emissions and over half of the electricity demand, yet they have the potential to reach zero carbon through existing, cost effective technologies,” Ms Madew says. “This means buildings can achieve significant emissions reductions today, while other sectors are still developing new technologies and approaches.

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INDUSTRY NEWS

“This report highlights the urgent need for action in residential buildings by drawing attention to the immediate opportunities for strengthening residential energy standards in the National Construction Code.” The Bottom Line also points out that there is currently no plan to increase residential energy standards in the NCC when it is next scheduled for update in 2019. “The energy requirements in the Code were last updated in 2010. By failing to act now, we will be building to 2010 standards all the way to 2022. This would lead to higher energy costs for households for years to come,” Ms Madew adds. The report, which was produced with the support of the Cooperative Research Centre for Low Carbon Living and the RACV, also

found that better energy standards would improve comfort and health in a changing climate. “Forecasts show that some Australian cities face the prospect of 50-degree days by 2050. We need to update the NCC to ensure that our homes are built to a standard that provides safe indoor temperatures,” Ms Madew says. Energy efficient homes are not only more comfortable and healthy, they also put less stress on the electricity grid, the report finds. This means lowering electricity costs and reducing energy bills, at a time when many families are struggling to cope with rising living costs. ASBEC, of which the GBCA is a foundation member, also emphasises the importance of

policy mechanisms that provide certainty and drive investment in higher energy performing buildings. “Government support can lower the cost of technologies and drive industry capacity. If technology costs are reduced, or industry shifts towards best practice building design, the opportunity could be even larger than that outlined in The Bottom Line,” Ms Madew concludes. The full report will be released in early 2018. The Bottom Line – household impacts of delaying improved energy requirements in the Building Code is available for download at: http://www.asbec.asn.au/wordpress/ wp-content/uploads/2018/02/180208ASBEC-CWA-The-Bottom-Line-householdimpacts.pdf

PRACTICAL ASBESTOS MANAGEMENT RESOURCES FOR COMMERCIAL & NONRESIDENTIAL PROPERTY SECTOR Although asbestos was banned in commercial and non-residential properties in the 1980s, asbestos-containing materials (ACMs) continued to be used in multiple locations throughout an extensive range of properties prior to 31 December 2003, requiring strict regulations for asbestos management in accordance with the Work Health and Safety Act 2011, the Work Health and Safety Regulations 2017 (WH&S) and the Asbestos Codes of Practice. However, compliance has sometimes proven challenging for this sector. If undisturbed, well maintained, and in stable, sealed and good condition, asbestos and ACMs are unlikely to pose health risks. However, risks occur when ACMs are disturbed during maintenance, refurbishment or demolition when microscopic fibres are released and can be inhaled when ACMs are damaged, broken, cut, drilled, sawn, sanded, scraped, waterblasted or if disturbed when using tools - particularly power tools which release a high concentration of fibres. Preventing exposure to asbestos fibres is the most effective means of preventing asbestos-related diseases. With 13 Australians dying every week from asbestos-related diseases, 12 from malignant mesothelioma, and with another 13 diagnosed with this incurable cancer, it’s vital that all those working in the commercial and 8

Construction Engineering Australia • Feb/March 2018

non-residential property sector ensure compliance with regulations to minimise exposure of workers, tradespeople and bystanders. To address the need for improved, safer management of asbestos and ACM in commercial and non-residential property settings, the national Asbestos Awareness Campaign has developed a free, user-friendly asbestos management resource package to help improve regulatory compliance across the sector. In an Australian first, the Asbestos Management Handbook for Commercial and Non-residential Properties provides property owners, managers, developers and workers with essential, practical, user-friendly guidelines and tools to manage ACMs in line with requirements. Designed for a broad audience including property owners, agents, managers, builders, contractors, subcontractors, tradespeople and workers, the Asbestos Management Handbook, Templates and Fact Sheets were developed in consultation with stakeholders from the building, property management and government sectors to improve compliance in the commercial and nonresidential property sector. The Handbook includes a comprehensive list of building types including commercial, industrial, government, recreational,

agricultural, hospitality, health services and education facilities, religious, transport and tourism structures. It details the roles and responsibilities for the management of asbestos and ACM, provides examples of best practice and a comprehensive list and images to demonstrate ACMs commonly found in commercial and non-residential properties. Importantly, the Handbook provides practical guidance on the steps required to adhere to regulations including how to develop and manage an Asbestos Management Plan, an Asbestos Register, the training requirements for workers, and it defines Asbestos Inspections, Surveys, Risk Assessments and the steps required when asbestos removal is in progress. The comprehensive Handbook, Asbestos Management Templates and Fact Sheets can be downloaded from www.asbestosawareness.com.au

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PROJECT BRIEF

SYDNEY’S NEW AQUATIC CENTRE WILL MAKE A SPLASH Work on the City of Sydney’s highly anticipated new aquatic centre in Green Square – the largest to be built in Sydney in nearly 20 years – will soon get underway. The City has signed a contract with Sydney-based construction company CPB Contractors for construction of the Gunyama Park Aquatic and Recreation Centre on Joynton Avenue in Zetland, with work expected to start in early 2018 and be complete by early 2020. At the centre of the new aquatic centre will be a 50-metre heated outdoor pool set within a larger, irregular shaped pool inspired by the ocean pools at some of Sydney’s best-loved beaches. The new complex will cater for the diverse and growing Green Square community and feature: • a 25-metre indoor ‘program pool’ for swimming lessons • an indoor heated leisure water area and hydrotherapy pool • a crèche with indoor play areas • a health and fitness centre • a multipurpose synthetic sports field suitable for use by community sporting teams • sports field change rooms, public toilets and storage facilities • new landscaping, lighting and a new public artwork by acclaimed Aboriginal artist Jonathan Jones. Lord Mayor Clover Moore said the new pool was an important addition for Green Square, an area that will soon be home to more than 61,000 people. “Green Square is one of the fastest growing precincts in Australia, and we’re doing everything we can to make sure it is a wonderful urban neighbourhood with the services and facilities its residents and workers need,” the Lord Mayor said. “The Gunyama Park complex will be a terrific place for locals and visitors alike to exercise, relax and catch up with friends and family. The pool will have something for everyone, from serious swimmers looking to improve their lap times, to families wanting a safe place for their children to learn to swim or play.” “I’m looking forward to seeing this exciting project take shape in the coming months and know the Green Square community will be pleased to see work begin on their new aquatic centre very soon,” the Lord Mayor added. The aquatic centre has been designed by Andrew Burges Architects, whose ‘beach pool’ concept was chosen from more than 140 other entries in a design competition run by the City. The jury, made up of some of Australia’s leading architects, described the aquatic centre as a ‘world class, exciting new project’. 10

Construction Engineering Australia • Feb/March 2018

CPB Contractors Managing Director Juan Santamaria said they were pleased to be selected to build the new aquatic and recreation centre following an extensive competitive tender process. “Our team has both the local and international expertise and project experience to deliver significant value for the City of Sydney,” he said. “Our flexible, multipurpose design will ensure that Gunyama Park is able to host a variety of activities, welcome locals and visitors from across Sydney, and remain adaptable to the city’s future growth requirements and sustainability expectations.” The construction of the Gunyama Park Aquatic and Recreation Centre will be completed in two stages, as the City does not currently own all portions of the land on which the complex is planned. The full aquatic centre, multipurpose sports field and landscaped areas will be completed by early 2020, with an expanded sports field, playground and further landscaping to be completed as the remaining land becomes available. The project will target a five-star design and as-built rating from the Green Building Council of Australia. A cogeneration scheme will heat the pools and supply electricity throughout the complex.

PRODUCT FOCUS

LEFT: Aussie Pumps & TTI have teamed to produce a range of pump/tank trailers and water carts for construction sites.

TTI TANKERS GO AUSSIE Australian Pump have teamed up with Victoria’s leading water cart tank manufacturer TTI (Trans Tank International) to produce a top quality range of pump/tank products for the construction market. TTI chose Aussie’s QP range of pumps because of their reputation and proven record on construction sites around the country. TTI produce tanks from small spray units all the way up to tanks with capacities up to 30,000 litres. Polyethylene means no rust problems and significant weight reduction for the users. That increased payload and durability means years of reliable service.

TTI water carts can be fitted with a range of Aussie QP self-priming centrifugal pumps including the QP303. This 3” pump will move up to 1,000lpm. That means tanks are refilled fast, cutting downtime and increasing the number of cycles when used for site dust suppression applications. Aussie QP pumps are available with Honda petrol or Yanmar diesel engines and as either recoil or electric start. The pumps self-prime better than any other with a direct vertical lift of 7.6 metres. Like all Aussie QP pumps, the QP303 is backed with a unique 5-year pump end warranty. High pressure pumps also available from Australia Pump include the Aussie Fire Chief, the world’s best lightweight portable fire pump. The Fire Chief is claimed to out-feature and out-perform all competitors. The big 7 ½” heavy duty high pressure impeller is superbly matched to either a Honda petrol engine or Yanmar diesel for the absolute best performance. This makes it ideal for installation on road tankers used for dust suppression. Australian Pump, through a unique arrangement with TTI, can offer great pump packages that even include their big 4” transfer pump capable of shifting up to 1,800 litres of water per minute. Further information is available from TTI or from Australian Pump Industries. Please visit: www.aussiepumps.com.au

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Construction Engineering Australia • Feb/March 2018

PRODUCT FOCUS

CSR GYPROCK SUPPORTS PERTH’S MOST ICONIC PROJECT

Perth’s most iconic project, Optus Stadium in Western Australia, opened its doors on the 21st of January 2018 after 36 months of construction. With a ‘fans first’ approach to planning and design, the multi-purpose venue will offer an unrivalled spectator experience for a crowd of up to 60,000 (in AFL mode) with exceptional event atmosphere and cutting-edge stadium design and technology. With the planning of the project being in progress over a 10-year period, the stateof-the-art venue had long been on CSR Gyprock’s radar with the aim to support the project with high performance products. There were a number of other factors that assisted the Gyprock bid to supply this project, including a reputation for innovation and technical leadership – having achieved success in delivering state and national level landmark projects including Royal Adelaide Hospital (RAH) and the Victorian Comprehensive Cancer Centre (VCCC). Gyprock were delighted to be chosen by the wall and ceiling contractor Cubic Interiors WA to supply this project, partnering with Cubic to guide product specification and providing technical support on site. The proximity of Gyprock’s factory in Welshpool, approximately 12 kilometres from the stadium construction site, was also a major catalyst in the tender process, as it helped to save freight costs and lead-time. It also allowed for Gyprock’s technical team to provide on-site assistance as required. 12

Construction Engineering Australia • Feb/March 2018

Gyprock products including EC08 Complete, Gyptone and Rigitone, were specified for the project, with 80 semi-trailer deliveries made, transporting approximately 200,000m2 of plasterboard to the construction site. Gyprock EC08 Complete is a premium plasterboard and made up approximately one-quarter (58,000m2) of the plasterboard product used on the project. It was specifically used in the corridors, lounges, general admission areas and food and beverage outlets due to its superior performance for mould, impact, fire, acoustic and moisture resistance. With consideration of the volume of EC08 Complete required in the project, Gyprock’s Welshpool factory responded by expanding

its manufacturing capabilities to produce the premium plasterboard locally and to specific project requirements, including size of rooms, height and length of walls, and to help reduce wastage on site. Functional acoustic performance was high on the list of requirements for the dining, conference and private entertainment areas of the stadium, but at a competitive cost of the aesthetic finish of the spaces. Balancing acoustic excellence and visual impact, the panel perforations of the Gyprock perforated plasterboard range, combined with the products acoustic fabric lining and insulation as required, deliver reduced echo and noise reverberation to create more comfortable environments. In the corporate suites and entertainment

PRODUCT FOCUS

boxes, Gyprock Gyptone 12mm Square perforated plasterboard was specified for its ability to improve sound attenuation. Providing a grid-like patterned ceiling, Gyptone’s high level of aesthetic appeal was complimented by matching access panels that provide functional access to the ceiling cavity while ensuring an uninterrupted look across the surface.

Throughout the restaurants and the Victory Lounge, Gyprock Rigitone Astral perforated plasterboard was specified for its design and acoustic properties, improving sound quality and delivering a continuous pattern across the whole ceiling. Both Gyptone and Rigitone perforated plasterboard products are lined with an acoustic fabric backing which contributes

to acoustic performance, whilst concealing framework and helping to prevent dust falling through from the ceiling cavity. Another key feature is Activ’Air, a patented technology that converts formaldehyde into non-harmful inert compounds that are permanently locked in the board and cannot be released back into the air. This can reduce the concentration of formaldehyde within an environment by up to 60 per cent when installed in ceilings. “The Optus Stadium project was Cubic’s first landmark engagement with CSR Gyprock WA and we were impressed with Gyprock’s proactive approach – this assisted with a successful handover several weeks ahead of schedule. This was made possible with Gyprock’s fabrication being local and close to the project. I believe this will be the first of many more projects that Cubic and Gyprock will complete,” says Adam Monson, State Manager, Cubic Group. For more information, please visit: www.gyprock.com.au

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COVER FEATURE

Understanding JOG

Computer-Controlled Grouting technology

Saving a multi-storey business complex from subsidence and instability using JOG Computer-Controlled Grouting and TeretekÂŽ resin injection. 16

Construction Engineering Australia â&#x20AC;˘ Feb/March 2018

COVER FEATURE

JOG Computer-Controlled Grouting is customised for the conditions presented on site and is ideal for sandy, silty soils or where heavy slab lifting is required. The process is carried out as one continuous operation, where grout is automatically circulated through narrow injection points, typically 25mm to 40mm in diameter. The injections are controlled using a central computer that can monitor up to 128 points at any one time, allowing the structure to be raised evenly, gradually ‘floating’ it back to level without causing further stress to the structure. According to Russell Deller, Mainmark Group Manager for JOG, “We are very excited to see JOG ComputerControlled Grouting being adopted in the Australian market. It’s a proven solution that can lift very large, tall and heavy buildings with pinpoint accuracy without impacting adjacent structures. In New Zealand, earthquake correction works use the most innovative solutions to remediate buildings. JOG ComputerControlled Grouting was integral to the re-levelling of the Christchurch Art Gallery for which Mainmark won the International Project of the Year at the Ground Engineering Awards in 2016.” In Australia, JOG Computer-Controlled Grouting continues to gain momentum and recognition from within the engineering industry.

round engineering and asset preservation specialist Mainmark has successfully re-levelled two large commercial buildings using JOG ComputerControlled Grouting, a non-invasive, highly precise system of grout injection. Part of a business park in Melbourne, the buildings were remediated in a matter of weeks, which is remarkable given the complexity of the project. JOG Computer-Controlled Grouting is a highly advanced and proven technology. Originally developed in Japan, where it is known as JOG Integrated Computer Grouting, Mainmark has used the solution extensively in

New Zealand to successfully re-level large earthquake-affected structures including commercial buildings, civil infrastructure assets, industrial sites, heritage buildings and homes, quickly and cost effectively. Remediating large structures with weak or unstable foundation ground can be a slow, complex and cost prohibitive process. However, the JOG process uses a very fluid yet fast setting cementitious grout that is quick to apply under precise computer control. No excavation is required, allowing the existing floor slab to remain in place with minimal disruption to the building’s occupants and owners.

The movement due to subsidence was so bad that it caused several ground floor windows to shatter.

Construction Engineering Australia • Feb/March 2018

COVER FEATURE

CASE STUDY: How JOG Computer-Controlled Grouting re-levelled two large commercial buildings in just five weeks Two commercial buildings, part of a complex in the outer Melbourne suburb of Caroline Springs, were suffering from significant foundation damage. The two structures, Building A and Building B, were showing signs of subsidence. Building A is a four-storey commercial building supported on perimeter footing beams. The ground floor is an infill concrete slab laid on ground

The Mainmark team completed the Caroline Springs project in just five weeks.

Construction Engineering Australia • Feb/March 2018

independent of the main structure. Several years of use had caused the building to become unstable, floors to become unlevel and the ground floor began moving independently from the rest of the building. The resulting compression between floors caused some of the ground floor windows to shatter. Building B is a single-storey structure located in the same complex and built on a conventional raft

slab with a deepened edge beam. The ground floor was out of level and a significant void had formed under one side of the building. The body corporate arranged a geotechnical site investigation, which revealed that the foundations of both buildings were built predominantly on a mixture of fill material and highly reactive clay. Water ingress had caused the clay to heave, resulting in differential building movement and damage to the structures. Mainmark was contracted to remediate the problem using a combination of JOG ComputerControlled Grouting (JOG) and Teretek® resin injection. This included the design, supply, installation and survey verification of JOG and Teretek to improve ground conditions, fill voids and, where possible, re-level the commercial properties. Due to excessive water ingress, the scope of work did not include soil stabilisation to the infill slabs as the owner’s corporation was required to let the ground dry and subside naturally. Before commencing the drilling and injection works, a levelling survey was conducted by Mainmark to quantify the settlement across each building footprint and set targets for the two buildings. For Building A, settlement of up to 19mm was found across the ground floor, relative to the structure above. The main objective for Building A was ground improvement and to strengthen foundations between the bedrock and the slab. The works were to take place predominantly inside the building footprint with the aim to prevent further movement of the structure. For Building B, the levelling survey determined that there had been some heave to the centre of the slab with a central high spot of 30mm. A void was also discovered under one side of the building. The key objectives for Building B were re-levelling and void-filling. A target was set to lift the edge beams of the building towards level within a tolerance of +/-20mm. Unlike Building A, for Building B all the injection points were to be located on the exterior of the building.

COVER FEATURE

the injection locations to minimise disturbance to the commercial tenants. Each point was connected to a pump via hoses leading to the building exterior. Mainmark used cable ramps and tape to minimise the visible and physical obstructions while the works were carried out. This allowed the occupants to conduct their business without significant disruption. Two computer control systems were used to gradually and sequentially lift the building while limiting the stress on the structure. The works at Building A were completed over six days with a maximum of 16mm lift achieved at an average of 3.5mm over the building’s footprint. ABOVE (L-R): ; Carefully selected injection locations For Building B, a total of 32 injection points helped minimise disturbance to the commercial were installed with varying diameters of 16mm, tenants; Injection points were drilled at varying depths, 25mm and 40mm. These were drilled at varying the deepest being 3m. For Building B, all points were injected externally, targeting the building’s perimeter depths, the deepest being 3m. All points were strip footings. injected externally, targeting the building’s perimeter strip footings. A maximum 32mm Mainmark primarily used JOG, a non-invasive, lift was achieved at an average of 18mm over highly precise system of grout injection, to the footprint of the structure. Once the JOG remediate both buildings. This technology has re-levelling works were completed, Teretek been used extensively to re-level large, complex engineered resin injection was used to fill the structures, including apartment blocks and office voids under the outer area of the building. All buildings up to 12-storeys. It works by delivering injection works at Building B were completed a mix of high mobility cementitious grout to over the course of eight days. targeted areas of the structure’s footings Overall, the planning and execution of customised for the conditions presented on site. this project was completed successfully with The injection process is fast and efficient, with both buildings responding well. There were no excavation required, allowing the existing several challenges that Mainmark successfully floor slab to remain in place, and minimal navigated, including the unexpected thickness disruption to the building’s occupants and and extreme drilling depths required for some of owners. the injection points. A team of seven Mainmark The cementitious grout is applied through technicians and supervisors worked six days per narrow injection ports, typically 25mm to 40mm week to successfully complete the entire project in diameter, and controlled using a central in less than five weeks. Nightworks were also computer that can monitor up to 128 points at required on one occasion. any one time. The process is carried out as one The remediation carried out on both buildings continuous operation, automatically circulating met the client’s expectations. According to the grout to each point as required, allowing building consultant, Dan Wood from Sherwood the structure to be raised evenly and gradually Constructions, “We chose to work with Mainmark without causing further stress to the structure. as they are widely regarded as leaders in Although similar in nature, the two buildings building rectification works. While JOG is a were treated as separate projects. Building proven technology for lifting buildings, for this A was the first to undergo repairs. Mainmark project it was all about the outcomes and not the installed 74 JOG injection points, 40mm in product. Collaboration and working together as diameter, at varying depths of up to 2.7m in a team is essential on projects like this one and some locations. Injection points were made that’s where Mainmark’s strength was. They had by hand using specialised drills to penetrate a great team and they were able to do the work through to the foundations of the underlying with minimal interference to the occupants.” structure. As injections this deep are rare, extra-long drill bits were custom made for the project. As most of the injection points were inside the building, it was necessary to carefully select

Other recent Australian projects that have used JOG Computer-Controlled Grouting successfully include an aged care complex in Western Australia, where facility owners had considered demolishing the affected building. It has also been used to remediate a warehouse and a number of two storey homes where traditional soil stabilisation and re-levelling methods would have been extremely invasive, time consuming and cost prohibitive. Mainmark draws on decades of industry-leading engineering experience across a variety of sectors including commercial, industrial, heritage, mining and civil, and works in close collaboration with independent, expert consultants to interpret geotechnical information and complete risk assessments specific to a site’s ground conditions. Using these insights, an engineered solution is developed to meet the specific project requirements. For more information about JOG Computer-Controlled Grouting, visit: https://mainmark.com/products/jogcomputer-controlled-grouting or call 1800 623 312.

About Mainmark Mainmark provides a range of specialist ground engineering and asset preservation solutions for residential, commercial, industrial, civil infrastructure and mining sectors. Committed to excellence, Mainmark’s state-of-the-art solutions are backed by more than 20 years of engineering expertise. Mainmark has 15 sites across Australia, New Zealand, Thailand, Japan and UK. Mainmark products and services include solutions for ground stabilisation, void filling, stopping water ingress, raising and levelling on-ground and in-ground structures, fixing anchors into rock faces and embankments, and other related ground engineering processes. In Asia Pacific, the Mainmark group of companies consists of Mainmark Ground Engineering, Mainmark Civil and Mining and other engineering businesses. Mainmark has been recognised for innovation in the industry, winning the International Project of the Year Award at the 2016 Ground Engineering Awards.

Construction Engineering Australia • Feb/March 2018

INNOVATIVE SOLUTIONS

Recover water from concrete slurry in 20 minutes - the McLanahan Concrete Filter Press can transform concrete slurry into a dry cake (between 72 and 78% solids). Depending on the slurry density the filtration process can take between 10 and 25 minutes.

INNOVATIVE HARD WASTE AND WATER MANAGEMENT SOLUTIONS INCREASE BATCH PLANT EFFICIENCY A concrete washout and reclaimer unit combined with an automated recessed plate filter press typically provides a small footprint, high return, low labour solution.

An efficiently designed concrete plant drives significant productivity gains. Today, greater flexibility and efficiency in plant design is made possible by automation and control of inputs, cleaner vehicle flow, lower contaminants and more efficient mixing of the constituent components.

Hard Waste Planning waste management processes when designing a new plant can reduce a plants footprint and improve profitability. It costs money to transport and dispose of hardened concrete waste. 20

Construction Engineering Australia â&#x20AC;˘ Feb/March 2018

CONCRETE COLOUR SYSTEM Creating multicolor permanence in construction

www.multisinox.com We see a lot of real estate allocated to wedge pits, drying bays, water retention pits and slurry pits. By its nature, this type of waste management design interrupts good flow, creates barriers, increases truck and loader movements, introduces many more processes and increases risk. In addition to hard waste, we need to understand the impact of water and water flow on the design. In some urban concrete plants there are water usage constraints and may be considerable concern from locals about the use of town water for industrial operations. Disposal of contaminated water and runoff into drains or natural waterway is also a contentious issue some operators are forced to deal with.

Water Management Whilst many concrete plants use wedge pits to recover water from concrete washout systems, it is extremely inefficient. It can also be seen by locals as water waste rather than water recovery. Removing wet concrete waste is not only very costly but also disposes of water that could be used in the concrete plant. In many plants slurry waster is re used into the batching process which is acceptable in small quantities and in low grades. But as this process continues the suspended particles become concentrated and using this slurry back in the batch plant undermines all of the effort and science that has gone into maximising the effectiveness of the core resources to make high quality concrete.

Multi-Sinox, China's leading manufacturer of iron oxide pigments, produces iron oxide black, red, yellow, orange, brown, tan and beige pigments for use in concrete, cement, asphalt, mortars, bricks, pavers, tiles, flooring, paints, coatings, and other construction materials.

Contact Us Today for More Information: Zhejiang Deqing Multi-Sinox Pigment Technology Co. Ltd. Zhongguan Industry Zone, Deqing 313200, Zhejiang, China T: 86-572-8350506 F: 86-572-8266799 E: sales3@multisinox.com E: concretepigment@hotmail.com www.multisinox.com

Automated and Efficient Concrete Plant Design Current waste management design would normally include a concrete washout and reclaimer unit combined with an automated recessed plate filter press. This combination typically provides a small footprint, high return, low labour solution. It can also be retrofitted to existing plants, usually in the space occupied by wedge pits or concrete bunds. These processes can be integrated into the plant control system or can be separated. In fact, the Truck-Washout and Surry Filtration processes can be completely independent and even be located in different areas of the plant. There are also mobile systems available.

Washout and Concrete Reclaimer Unit The washout and concrete reclaimer station typically offers the opportunity to wash and deliver sand and stones (ideally as separate products) in a state where they can be utilised back into the batch process. The cementitious slurry is delivered to an agitated pit or tank with level sensing capability able to automatically trigger a ‘Filter Cycle’.

Concrete Filter Press A Concrete Filter Press uses pressure to filters the water out of slurry and back into a clean water vessel. The water is particulate-free but will be higher in PH. This water can be dosed “in-line” as it exits the press or can be stored and treated as a batch process in tanks by using acid or carbon dioxide. The cement particles which were suspended in the slurry are captured in the Concrete Filter Press and form a dry cake. These cakes can be re used in other applications, reprocessed or disposed of as dry waste. In a normal filtration process once the cakes are discharged the press goes through a “shake and rinse” process and automatically resets for another cycle until the slurry has been processed.

Construction Engineering Australia • Feb/March 2018

PROFESSIONAL DEVELOPMENT

“A PASSION TO LEARN AND TO TEACH”

ENGINEERING TRAINING – 20 YEARS ON AND STILL GOING Training employees is an important part of any business today and this is no different for professionals working in the various disciplines of engineering. Factors which play a major role in influencing the degree of training one should consider for oneself or for staff include: a) changes to Australian or Overseas Standards; b) changes to Government legislation; c) loss of experienced staff due to relocation or retirement; d) minimizing risk of litigation due to poor or unsafe design; e) lack of knowledge of the theory behind the software being used; f) general safety concerns for staff on site; g) increase personal income by being more marketable; h) enthusiasm to learn and improve oneself.

Construction Engineering Australia • Feb/March 2018

Paul Uno has always had a passion for teaching, education and learning which resulted in the creation of his training organisation in 1998. Initially under the banner Cement and Concrete Services (CCS), Paul commenced with two courses (i) Cement & Concrete Technology & Practice, and (ii) Reinforced Concrete Design Workshop. Year after year he continually added more courses (e.g. Concrete Repair, Prestressed Concrete design, Precast and Tilt Up, Detailing). He responded to positive feedback from attendees who enjoyed his courses, suggesting he expand into other civil / structural course topics beside concrete, e.g. steel, masonry and timber. Whilst still adding new courses to his repertoire, he then decided to expand further into other engineering disciplines with courses that would be more applicable to mechanical engineers, environmental scientists and construction managers. Thus, the course topics of Construction Law, Risk Management, FEA, Metallurgy, Hydraulics, Industrial Buildings and Wind Dynamics were introduced. By 2014 the name ‘Cement & Concrete Services’ was no longer appropriate due to the multitude of workshop topics being run each year that were so diverse in their engineering focus. The company name was then changed to Engineering Training Institute Australia (ETIA) to encompass other areas of engineering. Paul also combined his love of geomechanics to introduce courses addressing Pile Design, Shallow Foundations Design, Industrial Floor Design, Retaining Wall and Slope Stability design. ETIA now has over 32 courses with new topics being added each year. In addition to his work with ETIA, Paul has been actively involved with Universities. He has lectured at UNSW one day a week for the past 20 years. He also lectured engineering students at Sydney University from 1999 to 2015 imparting practical knowledge and experience in an academic environment. He admits that things have changed in the marketplace over the past 20 years: e.g. digital information transfer (webinars and other online training services) but he still feels that direct face-to-face learning is still one of the best ways of learning a topic and being able to ask questions directly to the presenter.

PROFESSIONAL DEVELOPMENT

Over his 40 years in the structural/civil/construction game he has found simple little rules that apply each time. These points are set out below: • Structural Steel Design – always do your serviceability (i.e. deflection) checks first as a steel beam can withstand a very large load before it fails in either bending or buckling modes but will have a very large deflection prior to that point. • Timber Design – always check that the connection has been designed and detailed correctly as connection failures in timber are more common especially due to durability issues (e.g. balconies exposed to the elements). • Reinforced Concrete Design - a simple way to check the moment capacity of a reinforced beam on site is to determine the effective depth of the steel (d) and its area (Ast) then multiply this by 360. When you convert your answer to kNm (i.e. /1000) you will be within about 10% of the correct answer compared to correct formulas or software programs. • Masonry Design - Note that the weakest link in a masonry wall is the mortar. When a standard mortar mix is nominated as 1:1:6 these are the proportions of cement, sand and coarse aggregate – there is no mention of water. This is up to the discretion of the bricklayer! The rough rule of thumb is that the mortar should look no wetter than toothpaste.

• Pool Design - Please note that the current Swimming pool standard (AS 2783) is over 25 years old and some parts of that Code are very dated: e.g. the steel fibres section – ignore it. The other point is that most structural standards would nominate a minimum concrete grade at 32 MPa for any environment exposed to salty or highly chlorinated water – this Code still nominates 25 MPa. • Industrial Floor Design – there are many ways to calculate the thickness of a concrete floor (e.g. Westergaard-USA, TR34-UK, CCAA-AUST) however a simple rule developed by Paul Uno to calculate the concrete pavement thickness t (mm) is to determine the axle load in tonnes (T) then use his formula [ t = 60√T ]. This serves as a good first guess. • Australian Construction generally – many of the structural products used in the construction industry today come from overseas. Some products satisfy Australian Standards but many don’t (e.g. bolts, aluminium cladding, LVL and plywood to name a few). Don’t assume it all satisfies our local regulations – get it in writing from the supplier. For more information regarding design, detailing and general information in the engineering and building game, refer to the many courses on offer from Engineering Training Institute Australia. Visit: www.etia.net.au or call on 02 9899 7447.

Outstanding Concrete Washout Solutions McLanahan’s field-proven concrete and slurry recycling equipment is supported and serviced in Australia by our local team of engineers and service technicians. The McLanahan Filter Press is recognised as the most effective Filter Press for treating concrete slurry.

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Construction Engineering Australia • Feb/March 2018

EQUIPMENT FOCUS

(L-R) Tony McChesney from Compaction Australia and Ian Coleman, Managing Director, Conplant with Conplant Brisbane team.

CONPLANT ACQUIRES COMPACTION AUSTRALIA Conplant expands its fleet and capability with the acquisition of compaction hire specialist, Compaction Australia. Conplant, Australia’s largest compaction specialist, recently announced the acquisition of Compaction Australia, a leading Queensland based compaction hire specialist. Effective as of 1 February 2018, the acquisition is in line with Conplant’s core business strategy of offering the most diverse and comprehensive range of compaction solutions across Australia. “Compaction Australia has a solid reputation for excellent customer service and quality equipment,” said Ian Coleman,

Conplant Managing Director. “The company culture perfectly complements our strong reputation for delivering reliable compaction products with no-nonsense, specialist advice.” Coleman added, "we’ve gained some very experienced and dedicated people which will bolster our unmatched customer service and technical know-how. The transaction was a very logical and natural fit for us.” The acquisition includes low hour highquality Ammann, Caterpillar and Hamm rollers,

field service vehicles, low loaders as well as a number of dedicated employees. This deal and other mid-term plans will see Conplant’s fleet grow to 1,000 rollers this year providing a more diverse pool of products for major projects and contractor needs, as well as, improved availability. “Compaction Australia’s customers shouldn't see any changes, apart from positives ones like access to a wider range of experience and a larger fleet. We’re looking forward to growing the combined fleets to better service Compaction Australia customers as well as our pre-existing customer base." For more information please visit: www.conplant.com.au

ABOUT CONPLANT Conplant is an Australian owned company specialising in the provision of compaction solutions for all sizes of government and private business. Established in 1961, the company has grown to be the largest compaction specialist in Australia offering solutions including hire, sales, parts and service. In addition, the company is the sole Australian distributor for Ammann heavy compaction equipment. Having a national network and with a fleet close to 1,000 rollers, the company has comprehensive experience in delivering services to small, medium and large infrastructure and construction projects.

NEW ENERPAC TELESCOPIC CYLINDERS PROVIDE LONG STROKES IN CONFINED SPACES FOR EFFICIENCY AND SAFETY Telescopic hydraulic cylinders that can lift loads up to 600mm in a single movement are being introduced to Australia, New Zealand and Papua New Guinea by the international leader in high-pressure hydraulics, Enerpac. The RT Series long-stroke multi-stage telescopic cylinders – in capacities from 14-31 tons – are designed for long cylinder strokes in confined spaces. They are particularly suited for extended lift heights when clearance is limited. The telescopic cylinders feature a multistage rod built from a series of nested steel tubes of progressively small diameter. “The longer stroke length of the telescopic cylinders will save operators time and simplify projects by moving loads a greater distance and eliminating the use of temporary 24

Construction Engineering Australia • Feb/March 2018

cribbing,” said Enerpac National Sales Manager Darryl Lange. They also save time and labour and offer WHS benefits by enabling the power and precision of hydraulics to be applied swiftly without the need for multiple setups and plunger extensions required for shorter-stroke types. Their user convenience and WHS benefits are further extended by Enerpac’s 700 bar high-pressure engineering, which concentrates more lifting power into smaller cylinders. RT series’ nitrocarburized surface treatment inside and out provides unparalleled side-load resistance and corrosion protection for safe use in the harshest conditions, such as those encountered in aggressive environments of

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EQUIPMENT FOCUS

building and construction, structural and civil engineering, metal processing and fabrication, mining and mineral processing, oil and gas production, bulk handling, manufacturing and infrastructure development and maintenance, including water, waste water and energy utility installation and maintenance work. Multi-Stage Telescopic Hydraulic Cylinders features include: • Three percent side load of full capacity • Double- or triple-wear bearing support lifting stages

• Tilting saddles with five degrees of maximum tilt • Lifting eyes for safe handling and positioning • Steel cylinder base for maximum strength Performance of Summit Edition cylinders can be further enhanced by the use of the latest Venturi Valve Technology with ZE and ZU pumps. Return Assisted Electric Pumps with Venturi Valve Technology provide faster retraction speed and improve the productivity of single-acting cylinders.

RT cylinders are also complemented by Enerpac pumping solutions proven throughout Australasia for applications prioritising speed, control, intermittent or heavy duty. Pumping solutions include P series Hand Pumps, XC series Cordless Pumps, XA series Air Driven pumps, ZU4 series portable electric pumps, ZE series Electric Pumps and SFP series Split Flow pumps. For more information please visit: www.enerpac.com.au

MINI SERIES AIR HOISTS FROM J D NEUHAUS SET A NEW BENCHMARK IN HOISTING TECHNOLOGY J D Neuhaus, leading supplier of hoists and crane systems have been working in close collaboration with end users to develop the new Mini series of air hoists. This has resulted in an extraordinarily compact and innovative lifting device with an integrated NFC (Near Field Communication) sensor and service app that makes it truly unique in the industry. With various innovations incorporated in the concept, a multitude of improvements and new developments ensure maximum productivity, occupational safety and efficiency. Special emphasis was placed on reducing the end-user’s total cost of ownership (TCO) of the hoist. Reliable processes in the working sequence contribute to increased efficiency, achieved for 100% of the active operation time, by extending the service life significantly. Not only is the hoist optimised for outstanding overall efficiency, but the new Mini is also available around the clock (365/24/7). Unrivalled simple and fast maintenance further enhances efficiency, while also enhanced is highly sensitive, continuous control of hoisting and lowering speeds for which the Mini is known worldwide. JDN has been able to increase the maximum speed at full load, with the Mini 500 achieving a 20% increase over speeds achieved by the previous model. Additionally, the maximum speed can also be adjusted without losing power at a given load capacity, meaning loads are even better protected when necessary, without compromising speed control - combining the advantages of direct and indirect controlling, so that the operator can lift and lower loads smoothly. The new Mini from J D Neuhaus even has something to offer when it comes to 26

Construction Engineering Australia • Feb/March 2018

maintenance, since work can be performed directly on the lifting device without removing it from the beam, drastically reducing downtime during operation. And thanks to the NFC chip, the operator can access devicespecific information and documentation on their smartphone as long as they have downloaded the JDN service app. This saves time and ensures that the necessary documents are available digitally. The number of operating hours until the legally required general overhaul of the Mini has been doubled, allowing the new Mini to stay in operation for 800 hours. Such a development dramatically increases the device’s efficiency compared to the previous model, constituting an important contribution to the reduction of total cost of ownership. The developers at JDN also had some things up their sleeves when it came to flexibility: A standardised “interface” for using various types of hooks, now available in steel and stainless steel. A load jacket and chain made of stainless steel and a motor casing of uncoated cast aluminium make the Mini perfect for use in fields such as the food industry. The Mini offers safety features that are unique the world over including, upon customer request, optional fall supports for both the lifting and lowering phases, capable of holding the maximum capacity of a hoist should it come free of the supporting structure. In addition, the new limit stop offers another safety feature, switching off the hoist and lowering movement as soon as the bumper touches the stop valve. This slows the movement and keeps the chain from getting overloaded. These and other new safety features enhance occupational safety

significantly and minimise safety hazards and wear risks. All in all, the new JDN Mini is a true allrounder and is available in four carrying capacities, 125kg, 250kg, 500kg and 980kg. In collaboration with customers from a wide variety of industries, J D Neuhaus has developed a product designed for the most varied fields of use: it can be operated in wet and dry environments, when it’s hot and cold, in dust-free rooms or under extremely dirty conditions and in areas where an explosive atmosphere (Zone 2) is present. For the first time ever, JDN has also used high-tech synthetic materials in order to replace highenergy materials while also fulfilling the requirements set and reducing the overall weight of the hoisting device. For further information, please visit: www.jdngroup.com

WHAT YOU THINK IS THE END IS JUST THE BEGINNING.

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TOMORROW’S SOLUTIONS. TODAY

PREFABRICATED MODULAR CONCRETE DESIGN & CONSTRUCTION MODULAR CONCRETE - THE FUTURE IN CONCRETE BUILDING For many years concrete construction in Australia has been successfully applied both in-situ and offsite. In recent times, however, the efficiency of these methods is being tested as we strive to meet the growing demand for more rentable building space at a reduced construction cost over a faster time frame. Conventional in-situ concrete construction relies heavily on good workmanship, thorough planning and proper execution subject to weather conditions, traffic interrupting concrete supply and variations in concrete quality over large placements. As we get busier and busier, construction quality plummets and we are left with sub-standard concrete structures, unhappy clients, big repair bills and possible litigation. Modular concrete offers a tangible solution to this dilemma while providing sound economic benefits in greatly reduced construction time, higher concrete quality, and less interruption to the public during construction. New innovative concrete construction technology has given rise to prefabricated high-rise construction and has successfully been applied to several buildings in Australia, with the recently completed, 2017 Award for Excellence in Concrete winner, La Trobe Tower. The Concrete Institute of Australia has brought together a power line up of expert speakers in the design and construction of prefabricated modular buildings, keen to demonstrate the benefits of this construction type, the pitfalls to watch and the best use of hybrid modular and in-situ concrete options implemented successfully nationwide and overseas.

WHAT TO EXPECT

PROUDLY SPONSORED BY

• Gain a practical understanding of the major changes in the Australian prefabricated concrete industry, and how this impacts construction. • The opportunity to hear from leading prefabricated modular concrete practitioners who are covering new ground in Australia. • Discover the latest in tall tower design and construction using innovative methodology. • Case studies on landmark structures highlighting the latest in design and construction. • An excellent opportunity to discuss key aspects with industry experts in an open forum.

WHO SHOULD ATTEND?

This seminar and included content will be beneficial for structural and civil design engineers, as well as construction engineers. We also encourage suppliers, contractors, and concrete practitioners of all levels of experience.

Concrete in Australia | Vol 44 No 1

SPEAKER PROFILES Shan Kumar Head of Innovation and Engineering Hickory Group Shanâ&#x20AC;&#x2122;s expertise in the field of concrete and steel formwork systems is ground breaking, with Engineers Australia recently naming him one of Australiaâ&#x20AC;&#x2122;s most innovative engineers in 2017. He was instrumental in the design and development of an integrated, prefabricated construction method which was used to construct La Trobe Tower, the first high-rise project to use design for manufacture and assembly construction methods.

SEMINAR DATES

BRISBANE MONDAY 30 APRIL SYDNEY TUESDAY 1 MAY MELBOURNE THURSDAY 3 MAY ADELAIDE TUESDAY 8 MAY CAMPBELL TOWN (TAS) THURSDAY 10 MAY PERTH MONDAY 14 MAY

FOLLOW THE INSTITUTE ON

Shanâ&#x20AC;&#x2122;s continuous ingenuity and dedication to this field was instrumental in the successful delivery of 2017 Award for Excellence in Concrete winner, La Trobe Tower.

Professor Tuan Ngo University of Melbourne Infrastructure Engineering Prof Tuan Ngo is the Director of the

Advanced Protective Technologies for Engineering Structures (APTES) Group at the University of Melbourne.

Professor Priyan Mendis University of Melbourne Infrastructure Engineering

Priyan Mendis is a Professor in the Department of Infrastructure Engineering and the Leader of the Advanced Protective Technology of Engineering Structures Group.

PRICING CIA Members

$490

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$210

Non Members

$695

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$710

AGENDA 8.55

Introduction

9.00

Session 1 - Introduction to modular concrete construction.

9.30

Session 2 - Prefabricated concrete modules - their benefits, forms, uses, and restrictions.

10.30

Morning Tea

11.00

Session 3 - Structural design requirements - lateral loads, robustness, seismic and wind.

12.45

Lunch

13.30

Session 4 - Prefabricated modular concrete - including lifting systems, transportation, and placement techniques.

14.15

Session 5 -Sustainability with prefabricated modular concrete.

15.00

Afternoon Tea

15.30

Session 6 -Case Studies including the 44 storey La Trobe Tower.

16.30

Conclusion

For more information, visit our website www.concreteinstitute.com.au/modularconcrete Concrete in Australia |

Vol 44 No 1 9

FORMWORK

AFS LAUNCHES NEW PATENTED REDIWALL® SPEEDY-SNAP-IN™ RANGE Australian permanent formwork system manufacturer AFS has launched its new versatile rediwall® speedy-snap-in™ range. Quick and easy to use, the rediwall® speedy-snap-in™ permanent PVC formwork system comes in an extended range of panel sizes including a 110mm, 156mm and 200mm together with the introduction of a revolutionary new ezy-fit™ corner panel. “Our new rediwall® speedy-snap-in™ system is the simple, cost-effective answer to conventional concrete and masonry,” explains Steve Darwell, CSR General Manager New Business Development. “The new lightweight PVC panels simply snap together by hand and are then ready to be corefilled. You don’t even need a formed deck for installation. In addition, installations can be done with minimal training. It’s that simple.” The speedy-snap-in™ system includes a patented revolutionary 90 degree ezy-fit™ corner panel. The cover section is removable, which allows complete unobstructed access for the trouble-free installation of reinforcement bars. Reinforcement placement in conventional PVC systems is exceedingly difficult and this innovation eliminates the problem. Furthermore, certifying engineers can simply remove the cap to inspect and approve reinforcement placement prior to concrete pouring, which is not possible with conventional systems. 30

Construction Engineering Australia • Feb/March 2018

FORMWORK

A division of building products leader CSR, AFS has developed the new rediwall® speedy-snap-in™ system in consultation with leading Australian builders and formworkers. The end result is a more efficient, versatile and low-maintenance permanent formwork solution for load bearing walls in every situation.

The new rediwall® speedy-snap-in™ system also comes with a full range of new accessories. These include the ezy-fit™ corner profile, J, Y and H joiners and malemale, female-female and spacer adapters, floor track, squint angles and fibre-cement strips for capping off wall ends.

Key Features:

• Available in 110mm, 156mm and 200mm profiles • New ezy-fit corner – an industry first • Lightweight panels offering ease of installation – minimal training required • Tough, rigid, durable panels • Precision-extruded components snap into place, automatically interconnecting for rapid assembly • Large holes for better concrete flow • Kidney shaped hole (200mm) for double, single or single offset reinforcement placement • Water resistant • High quality low maintenance surface that in many applications doesn’t require finishing

The rediwall® speedy-snap-inTM system comes in three panel sizes – 110mm, 156mm and 200mm. Combined with new ezy-fit™ corner panels, the rediwall® speedy-snapin™ system is extremely versatile. It’s clean, even and UV and waterproof surface offers a superior gloss finish, which in many applications doesn’t require any finishing. The tough and robust PVC panels are designed with large kidney-shaped holes for better concrete flow during core filling. The shape of the hole in the 200mm panel allows for double or single reinforced steel placement. It also allows single reinforced steel to be offset to one side to further optimise performance.

Key Benefits:

• Range of new accessories • Cut-to-size option to reduce wastage • Applications include basements, party walls, columns, lift shafts, stair wells, retaining walls, retention tanks, service and stormwater pits, foundations and landscaping walls

ABOUT AFS SYSTEMS AFS Systems is a division of CSR Limited. It was established in 1996 and for more than 20 years has supplied the innovative proprietary walling systems logicwall® and rediwall® for multiresidential and commercial projects throughout Australia, New Zealand, the US, UK and Canada. AFS Systems has a clear focus: To excel in the supply of high quality structural walling systems that provide clients with superior construction solutions, saving them both time and money. AFS is committed to ongoing research and development to meet the sustainability and environmental challenges of the future while remaining at the forefront of the construction industry's walling solution requirements. CSR bought the company in 2014 to complement its existing construction range, which includes Bradford, Cemintel, Hebel, Himmel, Gyprock, Monier, PGH and Viridian. www.afsformwork.com.au

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CONCRETE INSTITUTE NEWS

5TH INTERNATIONAL fib CONGRESS 2018 MELBOURNE, AUSTRALIA The 5th International fib Congress in 2018 is coming to Melbourne, Australia! The congress which will be held from 7th – 11th October 2018 at the Melbourne Convention and Exhibition Centre, features a 4 day technical program with a wide array of technical presentations and papers, and a chance for the many fib committees to meet face to face whilst experiencing one of Australia’s most vibrant cities. The Concrete Institute of Australia is looking forward to hosting this most prestigious event, and bringing the rest of the concrete world to Melbourne in October next year. Accordingly, we invite both the fib and CIA families to join us in Melbourne for what we hope will be the biggest concrete event in Australia’s in history. For all the details please visit: www.fibcongress2018.com Professor Stephen Foster Congress Chair

Making concrete better, smarter and stronger! The Congress is focused on the theme “Better-Smarter-Stronger” and is dedicated to bringing together leaders and practitioners in the concrete industry from all over the world. The theme for the fib Congress 2018 was chosen because in an ever-changing global construction market, approaches to concrete supply, design, specification and construction are required to be better to meet new challenges and exceed the expectations of demands. In this respect our researchers, suppliers, designers, and contractors need to be smarter to be able to achieve new and innovative ways of competing with different materials, global trends, and new philosophies, to meet these requirements. This then requires us to not only be constructing stronger concrete structures, but 32

Construction Engineering Australia • Feb/March 2018

maintaining a strong belief in the importance and relevance of concrete in the ever changing and evolving worldwide construction market. There was a deluge of abstracts submitted for this erstwhile event – over 600 in total! Abstracts were submitted by authors from over 50 countries around the world, all of whom are striving for concrete to being made or used better, smarter and stronger. The final program is still being finalised and papers will be presented under the following topics: • Design and construction, including architectural and environmental design. • Updates on global codes, standards, specifications, and in particular Model Code 2020. • Modelling and design of concrete structures. • Condition assessment, deterioration mechanisms, and reinforcement corrosion. • Concrete durability, and in particular modelling, design, monitoring, and maintenance. • Sustainability, repurposing, recycling and through-life management of concrete. • Repair, rehabilitation, and structural strengthening of existing concrete structures. • Concrete materials – traditional, supplementary, and new innovations. • Alkali-activated concretes and geopolymers. • Fibre reinforced concrete. • Reinforcing and prestressing materials. • Prefabricated, precast and modular concrete. • Concrete infrastructure – bridges, tunnels, roads, ports. • Composite and hybrid structures.

CONCRETE INSTITUTE NEWS

• Underground and foundation structures. • Ultra-high performance concrete. • Concrete under extreme conditions – fire, seismic, resilience, robustness. • Shear and torsion. • Shrinkage and creep. • Historical information and learnings related to concrete. • Large and challenging projects.

Key Note Speakers The fib Congress 2018 has some outstanding key note speakers, who will each exemplify how concrete is being designed, specified, supplied and constructed “Better-Smarter-Stronger” all around the world. These include: • Dr Frank Dehn, Germany, fib Presidium Member. Commission 4 Concrete and Concrete Technology Chair. Professor for Multifunctional Construction Materials at the Institute for Mineralogy, Crystallography and Material Science at Leipzig University and head of the Institute for Materials Research and Testing, Leipzig, Germany whose main research topics are related to constitutive laws for concrete durability and mechanical concrete properties. • Professor Koichi Maekawa, Japan, Co-chair of the Organising Committee of the fib PhD Symposium 2016 in Tokyo. Distinguished Professor in School of Engineering at The University of Tokyo, Japan, whose main research work includes nonlinear mechanics and multi-scale modelling of structural concrete and developing the life-assessment of concrete based infrastructures. • Professor Campbell Middleton, UK, the Laing O’Rourke Professor of Construction Engineering at Cambridge University. Prior to Cambridge he worked for nearly 10 years in professional practice in infrastructure construction and design specialises in bridge engineering, strategic policy developments in infrastructure and smart technologies, and whose research interests cover smart sensors and structural health monitoring, advanced failure and risk analysis, asset management, non-destructive testing, additive manufacturing, applications of computer vision to civil engineering and new materials. • Professor Michael Thomas, Canada, Professor and Department Chair in the Department of Civil Engineering at the University of New Brunswick, who’s main research interests are concrete durability and the use of industrial by-products including pozzolans and slag. His studies on durability have included alkali-silica reaction, delayed ettringite formation, sulfate attack, deicer-salt scaling, carbonation, chloride ingress and embedded steel corrosion. • Dr Andy Davids, Australia, Design Director - Tall Buildings for Aurecon, who works closely with clients, creating holistic design and engineering that incorporates new developments in material sciences and construction methods to produce

optimal tall building solutions. He is one of only a handful of internationally renowned experts who designs super tall buildings.

Sponsorship and Exhibition The Congress will present the perfect forum for organisations and companies actively involved in the building and construction industry to present their products and services. There are many attractive sponsorship and advertising opportunities available to increase the visibility of any company’s brand to their key target markets ranging from small to high level packages. The comprehensive Trade Exhibition will run concurrently with the Congress. This Exhibition will showcase the latest and best in the global building and construction industry. The Exhibition will also provide delegates and exhibitors with excellent opportunities to network in a favourable environment that provides a central and energised meeting place for all participants. Further information on these opportunities can be found at: http://fibcongress2018.com/sponsorship-exhibition/

Awards for Outstanding Concrete Structures The Congress will also stage the 2018 fib Awards for Outstanding Concrete Structures to recognise the magnificent international structures that demonstrate the versatility of concrete as a structural medium. The awards program is only held every 4 years and will feature some of the greatest quality concrete work from around the world since 2014. There have been many magnificent structures that have been recognised as winners of the Outstanding Concrete Structures award, including – the Terenez Bridge, France; Centro Ovale, Switzerland; the Bella Sky Hotel, Denmark; and our National Portrait Gallery in Canberra and Scientia Building in Sydney.

National Portrait Gallery, Canberra, ACT

KEY DATES Registration for the 5th International fib Congress 2018 is NOW open! Early bird rates apply. Register at: http://fibcongress2018. com/registration/ • • • •

Full paper submission deadline Author Notifications Early Bird Registration closes Congress opens

1st March 2018 30th April 2018 7th June 2018 7th October 2018

Construction Engineering Australia • Feb/March 2018

CONCRETE INSTITUTE NEWS

eCONCRETE Continued professional development is critical to the future of all engineers in Australia. The Concrete Institute of Australia understands that in todayâ&#x20AC;&#x2122;s environment not everyone is able to get away and attend our various events and seminars. To this end the Institute is very pleased to announce the launch of our integrated online learning platform, eConcrete. Here, users will be provided opportunities for professional development at their desk, using an innovative platform to access and obtain further education. Online learning breaks down time, travel and geographical barriers that can be difficult to overcome and helps to share concrete knowledge across Australia. eConcrete will provide members and nonmembers access to well-known industry experts and academics in the field of concrete, both locally and internationally, with the push of a button. Included in eConcrete will be bitesized learning opportunities â&#x20AC;&#x201C; short 25 to 30 minute presentations delivered by industry leaders focusing on their areas of expertise. We recently launched this platform, with none other than 2017 National Engineering Bursary Award Winner, Dr Ali Amin, presenting his Award-winning thesis entry, Post Cracking Behaviour of Steel Fibre Reinforced

(R-L) Bursary Award Winner Dr Ali Amin with Concrete Institute of Australia Past President Michael van Koeverden.

Concrete: From Material to Structure, and have since added several other presentations on a variety of concrete topics. We have also rebranded the Online Learning Modules and these are now known as eConcrete Learning Modules. The content will remain the same and we recently uploaded the Cracking the Concrete Codes module (see below), based on the national seminar held in November and December last year with Professor Steve Foster and Tony Thomas.

We know that today there are a number of challenges that are presented when looking to keep up with processional and educational development. With the help of eConcrete, we can ensure members everywhere are provided with quality CPD fulfilment opportunities in the concrete field from their own desk.

CRACKING THE CONCRETE CODES Many of the Australian Standards for concrete and concrete related materials have been revised or reviewed in recent times. Further to this there have been other guidelines or codes of practice, such as the Concrete Durability Series by the

Construction Engineering Australia â&#x20AC;˘ Feb/March 2018

Concrete Institute of Australia that has been introduced. With the current review of AS 3600 taking place, and following the release of the Australia Standard for Bridge Design, AS 5100-2017, the Institute embarked on a series

of seminars in late 2017 to help the industry understand some of the important changes with respect to shear & torsion design, durability, and fibre reinforcement design. Now, the Institute has launched the seminar as an eConcrete Learning Module and this will provide industry with a practical understanding of some of these important developments that can be viewed from your desk. Delivered by two industry leaders, Professor Stephen Foster (University of NSW) and Mr Tony Thomas (Formerly Boral Concrete), this Learning Module will provide a valuable insight into relevant changes in the area of concrete.

CONCRETE INSTITUTE NEWS

CONCRETE 2019 Concrete 2019, the 29th Biennial National Conference of the Concrete Institute of Australia, will be held in Sydney from the 8th to 11th September 2019. The conference, which will focus on the theme Concrete in Practice – Progress through Knowledge, will aim attract delegates, presenters and key note speakers from all over Australia and the world! The conference as always will offer participants from all around the globe the opportunity to connect face to face, sharing innovative and interesting ideas with a wide variety of industry experts in the world class facilities of the International Convention Centre Sydney in Darling Harbour .

Being held in the harbour city of Sydney, Concrete 2019 offers delegates and partners a magnificent opportunity to not only enjoy the vibrancy of Australia’s largest city, but to also admire some of the landmark concrete structures the city has. Three of these – the Sydney Opera House, the Anzac Bridge, and the Gladesville Bridge – form part of the Concrete 2019 logo. The conference will be co-chaired by Dr Daksh Baweja and Dr Warren South, and will include an array of topics, workshops, and forums, as well as some innovative additions to the exhibition and conference over all. To keep an eye on the activity surrounding the conference, or to express interest in being involved, visit: www.concrete2019.com.au

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Construction Engineering Australia • Feb/March 2018

CONCRETE INSTITUTE NEWS

ACI PRESENTS AWARD FOR EXCELLENCE Global concrete excellence is celebrated at the American Concrete Institute Excellence in Concrete Construction Awards every year, and in 2017 the highest “Excellence” award was presented to R·torso·C located in Tokyo, Japan. Eleven additional global projects were recognized during the packed Gala event at The Concrete Convention and Exposition, in Anaheim, CA, USA. The awards were created to honour the visions of the most creative projects in the concrete industry, while providing a platform to recognize concrete innovation, technology, and excellence across the globe. To be eligible for participation in the Excellence Awards, projects needed to be winners at a local Chapter level and submitted by that Chapter, or chosen by one of ACI’s International Partners. “The Excellence in Concrete Construction Awards has become a platform for

Construction Engineering Australia • Feb/March 2018

collaboration between ACI and its chapters and global partners around the world,” said Khaled Awad, President, American Concrete Institute. “It is truly inspiring to see entries from all over the globe, showing limitless innovation and creativity in concrete design and applications, and highlighting the versatility of concrete.” The CEO of the Concrete Institute of Australia, David Millar, was one of the Excellence Award judges, and he noted “To have the opportunity to be part of the panel to review some of the most incredible concrete structures from around the world was truly a privilege.” The Institute is also pleased to announce that as an International Partner with ACI, they will enter the Kevin Cavanagh Trophy winning project, the Song School, in the 2018 Excellence in Concrete Construction Awards.

The award-winning R·torso·C located in Tokyo, Japan

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ADMIXTURES

INNOVATIVE ADMIXTURES DELIVER COSTEFFECTIVE AGGREGATE MANAGEMENT AND CONSISTENT CONCRETE QUALITY The current construction boom in Asia has caused a stark shortage of many building materials, including sand. One knock-on effect of this is that high quality aggregates are becoming harder to source, leading to a greater variance in concrete quality. However, a solution is at hand, in the form of the Clarena® group of products from GCP Applied Technologies. Sand and gravel are the most mined materials in the world, accounting for up to 85% of all materials extracted globally each year. However, the world’s concrete industry is still susceptible to shortages in supply, and this issue is particularly relevant in AsiaPacific, where many economies are enjoying economic growth of around 7% fuelled by ongoing infrastructure and commercial construction work. One popular way to cope with natural sand shortages is to partially or completely replace it with manufactured sand or quarry dust. Unfortunately, the shape, grading and presence of clay in these aggregates has a negative effect on the quality of concrete produced. This in turn can lead to poor workability, variances in performance and a loss of strength.

• Clarena® HR Series: a high range water reducer for rheology improvement • Clarena® HC Series: a high range water reducer for rheology improvement and clay mitigation • Clarena® AC Series: additives for aggregate treatment for aggregate producers. Dr Lawrence Kuo, research fellow at GCP Applied Technologies, said using Clarena® can help users improve operational efficiency in a number of areas. “For concrete producers, Clarena® admixtures offer better flexibility in the choice of materials used in a concrete mix, leading to both better consistency in quality and lower costs,” he said. “By extension, this also reduces waste, enhancing the sustainability of individual production plants.” “Similarly, for quarry operators, using Clarena® additives leads to less waste, increasing yield and productivity. Again, this enhances sustainability at individual facilities and improves profitability,” Dr Kuo added.

GCP’s Clarena® solution

One particular benefit of Clarena® additives is that they help concrete and aggregate producers address the rheology and flow of concrete to deliver optimum performance. The rheological properties of concrete are important because they determine the ease of placement, consolidation, durability and strength of the final product. Getting this balance wrong could mean that the concrete has to be replaced, increasing waste and raising production costs. Clarena® mid-range and high range water-reducing admixtures ensure better workability and a smoother finish by delivering a smooth flowing concrete with improved placement properties. The additives are ideal for use within a wide range of concrete slumps and in addition they deliver a superior finish – an increasingly important aesthetic detail, particularly in commercial and residential developments, or where precast concrete is used.

Bringing consistent quality and performance to concrete in these instances is GCP Applied Technologies, which offers its costeffective Clarena® portfolio of admixtures. This unique and patented range of products specifically addresses issues such as rheology and flow of concrete, in addition to delivering guaranteed levels of quality. Designed with ready mix and aggregate producers in mind, the Clarena® portfolio helps mitigate the negative effects of poor quality aggregates on concrete performance. It also makes production easier to manage and more cost-effective than ever. There are five products in the range, allowing concrete producers or quarry owners to select the right one for them. Some of the most popular products in Asia-Pacific are: • Clarena® MR Series: a mid-range water reducer for rheology improvement • Clarena® MC Series: a mid-range water reducer for both clay mitigation and rheology improvement 38

Construction Engineering Australia • Feb/March 2018

Improved rheology

Advanced clay mitigation method In addition to improved rheology, Clarena® additives mitigate the

ADMIXTURES

performance issues related to higher clay contents in aggregates. Their advanced design means they are able to selectively react with clay contaminants in both coarse and fine aggregates. The highly engineered, irreversible chemical reaction produced by Clarena® additives eliminates the negative effect of clays and overcomes the technical limitations of traditional mechanical processing methods. For example, with fine aggregates, beneficial fines and clay contaminates can be of similar size, yet mechanical separation cannot distinguish between them, creating unnecessary waste. Clarena® additives not only minimize this waste and reduce quality control difficulties, they also make concrete production more profitable and sustainable. The Clarena® portfolio of mid-range and high range waterreducing admixtures includes the Clarena® MC Series and HC Series, which specifically address the issue of clay mitigation. Clay minerals often expand in water and can intercalate and absorb the polyalkylenes oxide component of PC-based admixtures, reducing cement dispersion and water reduction capabilities. The MC series overcomes this by using proprietary sacrificial agents that are absorbed and intercalate with clays before the PC component of the admixture. This way, the admixture is able to retain excellent and robust water reduction as well as other desirable properties – all at low dosage rates. The result is consistent and predictable water reduction in the mix, excellent early and later age strength, near neutral set times and a superior surface finish.

Effective and efficient Clarena® patented admixtures provide greater flexibility in operations and the use of materials, while delivering consistent concrete performance. While Clarena® additives are available globally, GCP Applied Technologies understands that aggregate issues vary by region; so the portfolio offers regional customization to address specific conditions occurring in Asia-Pacific. The technical and support teams at GCP Applied Technologies have a deep understanding of admixtures and concrete production. Most importantly, local staff understand the business and operational challenges faced by customers in this region. The Clarena® aggregate management solution is supplemented by GCP’s industry-leading technical consultation and field support – Blue 360SM Field Advantage. In addition, its suite of evaluation protocol tools can assess the quality of aggregates and their impact on concrete performance. GCP’s Rapid Clay Test for instance, determines the Methylene Blue Value of the aggregate materials and can directly measure the amount of harmful clays present. GCP Applied Technologies works closely with its clients to tailor solutions to meet the needs of an individual customer or project. The company’s broad network across Asia-Pacific includes a team of dedicated specialists, with expert technical services personnel and advanced laboratory facilities which combine to help customers achieve greater construction efficiency and quality. For further information, please visit: www.gcpat.com

Construction Engineering Australia • Feb/March 2018

NATIONAL PRECAST FEATURE

NEW PRESIDENT AND DIRECTOR FOR NATIONAL PRECAST BOARD National Precast Concrete Association is pleased to announce the appointment of Kevin Crompton from Ultrafloor (Australia) as its new President and Michael Waeger from Waeger Precast as its most recent member of the Board of Directors. According to National Precast’s Chief Executive Officer, Sarah Bachmann, the appointments were made at the organisation’s Annual General Meeting in November last year. “Kevin takes over as President for a two-year term from Craig Zinn, owner of Rockhamptonbased Stresscrete,” she details. “While some big achievements were made under Craig’s presidency, we are looking forward to the next two years with Kevin at the helm.” Mr Zinn’s term saw the Association celebrate its 25-year anniversary with a celebratory dinner at one of Australia’s most famous precast structures, the Sydney Opera House. Marketing initiatives were strengthened and the rollout of AS 3850 Prefabricated concrete elements prompted a national seminar series on the new standard and its safety implications. Considerable work was also invested in developing relationships with state and national roads and workers’ compensation, and the Association had its proposal approved to extend the coverage of AS 3850 into civil construction. As Director – Operations at Ultrafloor, Mr Crompton has over 40 years’ experience in the construction industry and four years’ involvement as a National Precast Board member. “Kevin brings a wealth of knowledge and enthusiasm to his new role,” Ms Bachmann comments. The new President says he wants to further strengthen relationships with allied industry associations such as Master Builders, the Housing Industry Association and the Australian Constructors Association, with a goal of working together to achieve mutually beneficial outcomes. Also high on the agenda is to continue the Association’s good work in the area of improving safety standards for the industry. To that extent he is the Association’s representative on BD-066, the committee responsible for AS 3850. “As an association we are already heavily involved with the review and development of numerous Australian Standards,” Ms Bachmann says. “We’ve also made some fantastic inroads with the likes of Safe Work Australia, and we work with both to improve safety.” 40

Construction Engineering Australia • Feb/March 2018

(L-R): Recently appointed National Precast Concrete Association President, Kevin Crompton being congratulated on his appointment by Immediate PastPresident Craig Zinn.

The new Board term also welcomes Michael Waeger, Managing Director of Waeger Constructions, as the Board’s most recent Director. Based in the NSW Hunter Valley, Waeger Precast is one of three divisions in the innovative medium-sized construction company. The company is mainly involved in bridge construction and specialised precast concrete, with experience in other civil works such as demolition, restoration and road works. Supporting the new appointees is an experienced and fervent team of Directors from precast manufacturing companies around Australia. National Precast’s Board of Directors now consists of: Kevin Crompton Director, President Director – Operations Ultrafloor (Australia) Craig Zinn Director, Past President Owner/Manager Stresscrete Ian Coulter Director, Past President Managing Director Precast Concrete Products

Matt Perrella Director, Past President General Manager Delta Corporation Peter Healy Director, Past President Managing Director Hollow Core Concrete Graham Underwood Director National Technical & Engineering Manager Rocla Glenn Degenhardt Director National Operations Manager Humes (Holcim Australia) Andrew Nearhos Director General Manager Austral Precast Michael Waeger Director Managing Director Waeger Precast

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NATIONAL PRECAST FEATURE

the sustainability benefits that the prestressed ULTRAfloor system enables,” he explains. “The beams were predominantly our 250M and 250C beams, both of which enable the designers to develop a structurally efficient dematerialised flooring solution, resulting in significant concrete volume savings for the client and the environment.”

ULTRAFLOOR DELIVERS MORE THAN JUST A STRUCTURAL SOLUTION AT PARAMATTA DEVELOPMENT PROJECT: 105 PHILLIP STREET, PARAMATTA, NSW PRECASTER: ULTRAFLOOR BUILDER: BUILT ENGINEER: AURECON ARCHITECT: BATES SMART CLIENT: DEXUS With a growing workforce and a rising economy, the city of Paramatta currently has $6 billion-plus of new building projects in the pipeline—one of these being the construction of the multimilliondollar office development at 105 Phillip Street. Developed by Dexus and constructed by national construction group, Built, the development’s fit-for-purpose design is a 25,000m2 A-grade office tower that is set to accommodate 1,800 NSW Department of Education employees from March 2018.

HIGH SPEED AND LONG SPANS Underpinning this design are precast beams that have been manufactured and installed by longstanding National Precast member, ULTRAfloor. Extending 12 storeys high, the tower features an expansive rectangular office floor plate that shines a spotlight on the time-efficient, costeffective and dematerialisation benefits of precast concrete. 42

Construction Engineering Australia • Feb/March 2018

Selected as the project’s main structural solution for the tower levels, ULTRAfloor supplied and installed just under 2,400 individual precast concrete beams to the project from its Rutherford manufacturing facility. The ULTRAfloor scheme comprised of 250M-1270 and 250C-1270 systems for the 320mm deep slab element landing onto table-formed post-tensioned (PT) bands (1800mm x 525mm) that were also designed by ULTRAfloor’s in-house design team. Time-efficiency at every stage was at the heart of the project’s construction brief. ULTRAfloor’s Factory Manager, Neale Green, says “ULTRAfloor has a demonstrably proven capacity for producing large volumes of finished beam products in a very short time frame. To appreciate the speed of manufacture, the beam requirements for the entire project scope were produced in only an equivalent of 12 production days’ worth of casting simultaneously utilising two of our stressing beds”.

LESS CONCRETE A WINNER Designed for commercial superimposed load cases and long spans, the ULTRAfloor system not only achieved the architect’s vision of an expansive floor plate. ULTRAfloor’s Director – Operations, Kevin Crompton says their system also came with additional advantages, thanks to the inherent benefits of precast concrete. “In addition to site-based time and costrelated benefits, the other primary reason that precast concrete was chosen is because of

A SPEEDY INSTALL As well as the speed of manufacture being noteworthy, another impressive aspect of ULTRAfloor’s role in the project is undoubtedly their installation capacity. Each tower level of the development has an ULTRAfloor footprint of approximately 1,900m2, which the precaster’s installation team managed to construct at a rate that permitted an 8-day floor-tofloor cycle to be maintained.

EXCEEDING EXPECTATIONS Despite starting the installation activities later than anticipated, Built reported that site installation ran like clockwork. Mr Crompton comments, “Thanks to the resolve of our installers and that of the crane crew, we invariably made up the lost time to keep this project on track for Built and their client.” Surpassing expectations, ULTRAfloor delivered an outstanding result. “Built is a Tier 1 builder demanding superior performance from their sub-contractors,” Mr Crompton details. “We can proudly say that we believe we not only met, but exceeded their expectations time and again on this project and we look forward to the opportunity of doing so on future projects.”

NATIONAL PRECAST FEATURE

NATIONAL PRECAST LAUNCHES FLOORING SERIES VIDEO National Precast Concrete Association has released a new Flooring Series video, detailing the environmental, societal and economic benefits of precast concrete flooring. The video follows the production of several other videos that have been produced, which focus on the use of flooring in individual projects. With more than 25 years’ experience under its belt, the precast industry’s peak body has grown to become a respected and recognised voice for the Australian precast concrete industry, as it represents the industry and promotes some of the country’s leading precast manufacturers—all while highlighting the innate benefits of precast. In the new nine-minute video, the Association takes viewers through its members’ precast factories and on to construction sites where precast flooring is being used. From the factories of Delta Corporation in Perth, to ULTRAfloor in New South Wales, to Hollow Core Concrete in Victoria to Precast Concrete Products in Queensland, the video is as informative as is it widespread.

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NATIONAL PRECAST FEATURE

It shows the different types of precast flooring that are available and reveals the efficient and reliable process of taking the construction of a building’s flooring offsite and into a controlled factory environment. Showing concrete being cast, to finished flooring elements being installed on site, the Flooring series is both educational and informative. Highlighting the extensive advantages of precast flooring is National Precast’s Chief Executive Officer, Sarah Bachmann, who says, “from a sustainability perspective, precast flooring offers a lot of advantages over conventionallypoured floors. For starters, it’s much faster and makes construction sites safer, but the big benefit is that the clever flooring designs mean it can use up to 30 per cent less concrete than a traditional insitu floor.” Using ecological and economical manufacturing methods with local products, precast flooring offers improvements in

construction efficiencies and is manufactured by local communities. In the new video, hear the expert opinions of some of Australia’s top precast flooring manufacturers, engineers and builders,

and watch how precast flooring plays a significant role in Australian structures. For more information and to watch the Flooring series, please visit: www.nationalprecast.com.au

INCREASING SANDWICH PANEL R-VALUES FOR NCC DTS-COMPLIANT SOLUTIONS WITH NATIONAL PRECAST’S R-VALUE CALCULATOR As a world first, the additional thermal benefit of using an insulated high mass wall in a building design can be calculated and used as a DTS solution in the NCC. According to National Precast's Chief Executive Officer, Sarah Bachmann, a downloadable R-value Calculator is available on the Association’s website, which not only makes it easy to calculate R-values for precast walls and floors, but also quantifies the additional R-value that is afforded when using insulated precast sandwich panel walls. “In conjunction with Adjunct Professor Terry Williamson from the University of Adelaide, we’ve developed an R-value calculator tool that makes it easier to use precast to comply with the Deemed to Satisfy method in the National Construction Code,” she details. Internationally peer reviewed calculators have been created for precast sandwich panel walls, single layer panels and for precast flooring. The user is able to choose from a number of variables such as concrete thickness, insulation type and thickness, shading angle, BCA Climate Zone and building class. A printable certificate displaying both the Association’s and University of Adelaide’s logos shows the inputs and the system results and can be used as documentary evidence of compliance with the BCA. The calculator tool is supported by an Industry Standard, which provides the methodology upon 44

Construction Engineering Australia • Feb/March 2018

which the calculator is based. “What is special about the sandwich panel calculator is that for the first time ever, the Mass-Enhanced R-value of a precast sandwich panel wall can be justifiably quantified, allowing the benefit of thermal mass to be quantified and recognised in the R-value,” Ms Bachmann comments. “Previous attempts to do this – in particular the M-Factor in the USA in 1976 – had failed, but the methodology used to derive the MassEnhanced R-value overcomes the various objectives in relation to the M-Factor.”

When using a sandwich panel and seeking NCC compliance using the DTS method, designers can now achieve higher R-values. “This is very exciting. The actual R-value of a sandwich panel wall is higher than simply adding together the individual R-values of the air gaps, concrete and insulation layers. This Mass Enhanced R-value means that designers can now achieve the required R-value, often using thinner, or less costly insulation,” she explains. Both the calculators and Industry Standard are available for download on the National Precast website: www.nationalprecast.com.au

SPECIAL REPORT

Feasibility of using Alternative Composite Fibre Technology Section for Sydney Harbour Bridge Railway Track Support Structure by Dr. Olivia Mirza Timber has always been the material of choice for transoms which distribute applied rail loads to the supporting substructure of railways. Over 2.5 billion timber transoms have been installed in railways tracks around the world with over 8 million timber sleepers currently in use in Queensland alone [1]. While the mechanical properties and workability of timber are desirable, timber’s susceptibility to mechanical, biological, and chemical degradation result in a relatively short service lift of 15-20 years [2]. The Sydney Harbour Bridge’s railway network currently uses timber transoms. Its existing railway system has not been updated since the bridge was first opened in 1932. In order to improve the longterm functionality of the transoms, and provide a solid, continuous railway corridor, alternative solutions to replace timber transoms are required. While alternative materials such as concrete and steel have been researched extensively [1], no one material is ideal to replace the existing timber transoms of the Sydney Harbour Bridge. Precast steel-concrete composite panels initially proposed by Griffin [3] and later modified by Macri, Devic [4] are a possible solution that

Figure 1: Proposed Composite Fibre Panel Design Cross Section 46

Construction Engineering Australia • Feb/March 2018

utilises both concrete’s high compressive strength and steel’s high tensile strength. These panels were designed in accordance with AS3600 [5] and Kim and Jeong [6]. Whilst the steel-concrete composite panel design weighs less than the concrete alternative, they are still significantly heavy, resulting in additional dead loads that would act on the superstructure of the Sydney Harbour Bridge. Furthermore, the handling and installation of these panels is difficult due to their relatively high weight. Composite fibre material is increasing in popularity in the global market due to their excellent resistance against corrosion, moisture, insects, and is thermally and electrically insulating [7]. Wagners Composite Fibre Technology (herein referred to as WCFT) have introduced a promising relatively new material, pultruded hollow glassfibre sections. Pultrusion is the process where material, such as fibre and resin, is pulled through a shaped die. The low weight of the composite fibre material increases the ease of handling and installation, thereby reducing disruptions to the existing railway services. The material is essentially maintenance free as it is resistant against weathering and corrosion [8].

Figure 2: Bending and Shear Stress Distribution for In-Service Loading

The design for WCFT is similar to the design of steel structures where an initial design must be selected and its corresponding capacities are calculated. The proposed composite fibre panel consists of the 100mm×75mm RHS section and 100mm×100mm SHS section bonded together using the ATL Composites Techniglue-HP R26 2-part epoxy adhesive to produce a 175mm deep, 600mm wide panel as illustrated in Figure 1. The bending stresses and shear stresses of the composite fibre panel under in-service loading are presented in Figure 2. The red dotted lines represent the maximum capacity of WCFT’s pultruded hollow sections for bending and shear stress of 610MPa and 84MPa respectively. The fabrication of the composite fibre panels was conducted by Wagners in their Toowoomba workshop through the pultrusion process. Individual rectangular hollow sections (RHS) and square hollow sections (SHS) were manufactured separately through this process and cut to length. These sections were glued together through the use of the ATL Composites Techniglue-HP R26 2-part epoxy adhesive to form a 175mm×600mm×3237mm transom to be tested under railway loading. Once the panel was manufactured, holes were drilled for the shear connectors. In total, two panels were manufactured: the first panel uses AJAX ONESIDE blind bolts to connect the panel to the bridge stringer steel while the second panel uses LINDAPTER blind bolts for this connection. The two blind bolts were chosen to replicate previous experiments investigating composite steel-concrete panels for use as transoms to allow a direct comparison between all three panel types.

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Figure 3: Experimental Test Set-up of Composite Fibre Panel

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Table 1: Deflection of Both Composite Fibre Panels Under Serviceability Loads Construction Engineering Australia • Feb/March 2018

SPECIAL REPORT

To replicate the steel bridge stringers of the Sydney Harbour Bridge, two 610UB125 sections with a width of 600mm were used. To complete the assembly, the WCFT was placed onto the bridge stringers and the blind bolts were inserted into the drilled holes. M16 LINDAPTER blind bolts were tightened to a torque of 300Nm as specified by LINDAPTER while the M20 AJAX ONESIDE blind bolts were installed and tightened sufficiently. Due to the limited cavity space in the bottom 75mm×100mm RHS section in the composite fibre panel, the AJAX ONESIDE blind bolts required a non-conventional method for installation [9], and consequently, were difficult to connect. The loads 100kN, 150kN, 240kN, and 360kN correspond to the serviceability loads associated with train loading. Notably, the 240kN and 360kN correspond to the 200LA and 300LA loading as outlined in AS5100.2 [10].The final stage of loading is to determine the load that causes failure in the composite fibre panel. Load will be increased to a maximum value of 900kN. This exceeds three times the design limits. Points A and C represent the deflection beside the existing stringers whilst the deflection at the midspan corresponds to point B as shown in Figure 3. Both of the panels exhibited a greater load capacity than the maximum load possible for this experiment under the twopoint bending test. Both panels were tested to a maximum load of 900kN. Under the 900kN load, both panels did not exhibit any signs of failure or damage to the panel or fasteners. There were no visible surface cracks or deformations in the WCFT’s pultruded hollow sections. The two panels exhibited cracking noises frequently throughout the experiment. The noises were fairly consistent across the two panels. Thus, it appears the type of shear connector used to connect the composite fibre panel to the steel bridge stringers had no effect on the cracking or damage to the panel. The cracking noises can possibly be attributed to the deformation of the composite fibre panel and/ or the damage to the adhesive. Table 1 presents the average deflection under each serviceability load at points A, C, and B for the AJAX ONESIDE and LINDAPTER composite fibre panels. Table 1 reveals the variation in deflection between the AJAX ONESIDE composite fibre panel and the LINDAPTER composite fibre panel is minimal. The AJAX ONESIDE composite fibre panel had a marginally higher deflection recorded at point C and for three of the serviceability loads at the midspan (point B) while the LINDAPTER composite fibre panel recorded higher deflections at point A and under the 360kN load at the midspan. The deflection recorded at the load points, points A and C, during the LINDAPTER composite fibre panel testing appears to be marginally incorrect as they do not match closely. Consequently, the deflection at point A for the LINDAPTER composite fibre panel should be lower and is expected to be similar to the AJAX ONESIDE composite fibre panel deflection recorded at this point. Regardless, the difference between the deflection in the two panels is minimal, especially at the midspan where the maximum deflections of the panels are recorded. Therefore, it appears the type of shear connector has a minimal impact on the deflection of the composite fibre panels.

Construction Engineering Australia • Feb/March 2018

The deflections recorded in the experimental testing of the composite fibre panels are all below the serviceability limit of 7.92mm previously calculated. The maximum deflection from both composite fibre panels is 6.39mm, within the serviceability limit. While the maximum deflection is within the serviceability limit of 7.92mm, the cracking noises heard could affect the serviceability. The following findings were obtained from the study: • The two panels using WCFT’s pultruded hollow sections did not exhibit any signs of failure or damage under the maximum load of 900kN. There were no surface cracks or deformations visible on the panel. Therefore, the ultimate capacity of the composite fibre panel design exceeds 900kN. • Deflections of both composite fibre panels were below the serviceability deflection limit of 7.92mm as required by AS4100 [11]. The maximum deflection of either panel under the 300LA serviceability load of 360kN was 6.39mm, within the allowable deflection limit. Consequently, the composite fibre panel design adheres to the Australian Standard requirements for the serviceability limit state design for steel structures • The type of fastener had a minimal effect on the behaviour of the composite fibre panel in response to applied loading. The two composite fibre panels shared similar deflection, stiffness, and ductility. Furthermore, the composite fibre panel was easily connected to the steel stringers using LINDAPTER blind bolts while the panel using AJAX ONESIDE blind bolts was difficult to connect due to the limited cavity space in the pultruded hollow sections.

References [1] Manalo A, Aravinthan T, Karunasena W, Ticoalu A. A review of alternative materials for replacing existing timber sleepers. Composite Structures. 2010;92:603-11. [2] Ferdous W, Manalo A, Van Erp G, Aravinthan T, Kaewunruen S, Remennikov A. Composite railway sleepers – Recent developments, challenges and future prospects. Composite Structures. 2015;134:158-68. [3] Griffin D. Design of Precast Composite Steel-Concrete Panels for Track Support: For Use on the Sydney Harbour Bridge: University of Western Sydney; 2013. [4] Macri S, Devic A, Asmaro S. Sydney Harbour Bridge: Railway Impact Loadings on Composite Steel-Concrete Transoms: Western Sydney University; 2015. [5] AS3600. Concrete Structures. Australian Standards; 2009. [6] Kim H-Y, Jeong Y-J. Steel–concrete composite bridge deck slab with profiled sheeting. Journal of Constructional Steel Research. 2009;65:1751-62. [7] Ferdous W, Manalo A, Khennane A, Kayali O. Geopolymer concrete-filled pultruded composite beams–Concrete mix design and application. Cement and Concrete Composites. 2015;58:1-13. [8] Wagners. Composite Fibre Technologies Product Guide. 2016. [9] Fernando S. New Structural Blind Bolting Technology: An Australian Innovation. Australasian Structural Engineering Conference 2008: Engaging with Structural Engineering: Meeting Planners; 2008. p. 193. [10] AS5100.2. Bridge Design - Design Loads. Australian Standards; 2004. [11] AS4100. Steel Structures. Australian Standards; 1998.

2018 Australasian Roadmarking & Signs Conference & Exhibition

DRIVERS OF CHANGE 29th and 30th August 2018 Dubbo Convention Centre, Dubbo, NSW

CALL FOR PAPERS The Roadmarking Industry Association of Australia invites your input into the development of a highly beneficial and instructive programme for our Australasian Roadmarking & Signs Conference and Exhibition which will be held at the Dubbo Convention Centre, Dubbo, NSW on August the 29th & 30th 2018. RIAA Conferences & Exhibitions are held bi-annually and have secured a well-established reputation for successfully bringing together delegates from all aspects of the road delineation industry throughout Australasia & indeed the world.

If you are interested in presenting a paper you are invited to submit an abstract for consideration by our conference organising committee. Your abstract should detail the following: Title/Theme, Author/Presenter, an overview of the material to be covered along with any key outcomes or conclusions.

We expect over 300 local & international delegates to attend this event which includes Roadmarking & Signs Industry Contractors and Suppliers of related materials; State and Local Road Authority Personnel; Engineers and Researchers as well as Consultants and Contractors within the Traffic Engineering and Road Safety areas. Submissions of Papers & Topics relating to how road safety can be enhanced by innovative or best practice use of pavement markings, signs, roadside delineators or barriers would especially be welcome, as would papers related to improvements in processes; materials; research and development; business practices; work safety; specifications; contracts; or indeed any other topics that you feel would be of benefit to our delegates.

Please send your abstract (preferably by email) by no later than May 31 to: Roadmarking Industry Association of Australia PO Box 5070, Hallam, Victoria 3803 T: 1300 625 983 (Intâ&#x20AC;&#x2122;l 03 8679 5290) E: riaaadmin@riaa.com.au | W: www.riaa.com.au

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ACA CORROSION FEATURE

ACA CORROSION MITIGATION TRAINING: BEAT THE RUST Infrastructure owners and managers need to have an asset base that is safe and reliable, while maintaining acceptable levels of service for the duration of the expected life of the asset. Part of this management involves ensuring that organisations have effectively trained staff who understand the risks associated with corrosion and the different preventative and remediation technologies available. In the Asia Pacific region, the yearly cost of asset maintenance is estimated to be multiple billions of dollars. Avoidable corrosion damage accounts for a quarter of this and continues to have a major economic impact on industry and the wider community. The Australasian Corrosion Association (ACA) provides training to its members and others working in the corrosion management and prevention sector. Each year the Association presents a range of technical seminars and training courses designed to provide attendees with information and guidance about ways to combat and manage corrosion. Training courses and seminars cover the fundamentals of corrosion control through to more advanced techniques and procedures and professional development can count towards CPD. Participants will gain the knowledge and tools to offer the most effective solutions -extending the service life of equipment and maximising the use of a facility - to asset owners and managers. In conjunction with the Australasian Concrete Repair Association (ACRA), the ACA will be running Corrosion and Protection of Concrete Structures and Buildings training at various venues around Australia. This course provides a solid foundation of knowledge about the corrosion of both reinforcement materials and concrete and has been updated to provide an understanding of the mechanisms of corrosion, protection and repair of reinforced concrete structures and buildings. It was developed for those who have the task of resolving the problems of corrosion of steel reinforced, prestressed and post tensioned concrete elements. The training will be run between: • March 19-20 in Melbourne; • June 4-5 in Sydney; and • September 6-7 in Brisbane. This year, the ACA's delivery of the NACE Cathodic Protection (CP) 1 and 2 courses is being held in Sydney and Brisbane. The NACE CP courses are the world’s most recognised and specified cathodic protection training. The NACE CP Program is a comprehensive program for professionals in any industry including pipelines and bridges, tanks and well casings, the maritime and offshore industries, coated steel and concrete and water and wastewater systems. CP 1- Cathodic Protection Tester training provides theoretical knowledge and practical fundamentals for testing on both galvanic and impressed current CP systems. Classroom instruction is comprised of lectures and hands-on training, using equipment and instruments for CP testing. The CP 2 - Cathodic Protection Technician course gives participants both theoretical knowledge and practical techniques for

testing and evaluating data to determine the effectiveness of both galvanic and impressed current CP systems and to gather design data. Classroom instruction is comprised of lectures and hands-on training, using equipment and instruments for CP testing. CP 1 Tester courses will be conducted in Sydney between 30 April - 4 May and in Brisbane between 10 - 14 September. The CP 2 Technician courses will be held the subsequent week in each city, viz: 7 - 11 May in Sydney and 17 - 21 September in Brisbane. The CP 3 - Cathodic Protection Technologist course builds on the technology presented in the CP2 course with a strong focus on interpretation of CP data, troubleshooting and migration of problems that arise in both galvanic and impressed current systems, including design calculations for these systems. Classroom instruction is comprised of lectures and hands-on training, using equipment and instruments for CP testing. The course will be held in Brisbane between 24 - 28 September. The SSPC Concrete Coatings Inspection course will be run in Melbourne between 9 -14 April. The training has been developed in association with the U.S. Society for Protective Surfaces (SSPC) in order to thoroughly train individuals in the proper methods of inspecting surface preparation and installation of protective coatings on concrete structures and facilities. This course would benefit Inspectors, contractor managers, specifying engineers, technical representatives and material and equipment suppliers working in the concrete coating industry. Under guidelines released in 2017 by the Water Services Association of Australia (WSAA), all coatings inspectors who inspect and report on coatings applied to concrete are required to hold SSPC CCI Level 1 or 2 certification. The document—WSA-201 Guidelines for Selection and Application of Protective Coatings—is available from the WSAA website. Professional development helps you meet the corrosion challenges you face. Places on the ACA and NACE courses are still available and full details and prices can be found at the ACA website: www.corrosion.com.au/training

Construction Engineering Australia • Feb/March 2018

ACA CORROSION FEATURE Spalling concrete on a hotel wall showing exposed corroded reinforcing.

The Australasian Corrosion Association (ACA) works with industry and academia to research all aspects of corrosion in order to provide an extensive knowledge base that supports best practice in corrosion management, thereby ensuring all impacts of corrosion are responsibly managed, the environment is protected, public safety enhanced and economies improved. The ACA also conducts educational activities such as seminars and training courses to inform and guide organisations and practitioners about topics including the latest protective technologies and processes. Throughout the year, the ACA conducts training courses and hosts seminars across Australia and New Zealand. Corrosion specialists certified by the ACA, and other organisations, have the experience and understanding of corrosion causes and solutions that allow them to recommend mechanisms and procedures to consultants and asset owners.

It's not OK just because it can't be seen...

CORRECTING CONCRETE CORROSION Corrosion of the reinforcing steel in concrete is a worldwide problem that causes a range of economic, aesthetic and utilisation issues. However, if corrosion effects are considered in the design phase and the right decisions made prior to construction, buildings can be built to last and protected for as long as possible. The corrosion of steel in concrete is accelerated in harsh environments, especially coastal, tropical or desert where high salt levels or extreme temperatures can accelerate the rate of decay. Usually, the most exposed elements deteriorate first but because the active corrosion may take 5 to 15 years to initiate cracks in the concrete, much of the actual corroded reinforcement is not visible. It is important that owners of high-value assets, such as hotels and large commercial and/or residential buildings, understand the cost implications of ignoring the effects of corrosion on concrete buildings and structures. There are many advantages of planning for corrosion control and 54

Construction Engineering Australia • Feb/March 2018

mitigation. Two of the main ones are that the life of an asset is extended and maintenance time and costs are reduced. In addition, reduced maintenance requirements increase the asset’s overall utilisation and can improve its environmental sustainability.

The alkaline (high pH) conditions in concrete forms a passive film on the surface of the steel reinforcing rods, thus preventing or minimising corrosion. Reduction of the pH caused by “Carbonation” or ingress of chloride (salt) causes the passive film to degrade, allowing the reinforcement to corrode in the presence of oxygen and moisture. A voltage differential of approximately 0.5V is set up between the corroding (anodic) sites and the passive (cathodic) sites resulting in a corrosion cell where electrons move through the steel from anode to cathode. The rate of the reaction is largely controlled by the resistance or resistivity of the concrete. Acid forms at the anodic (corroding) site, which reduces the pH and promotes the corrosion of the steel.

Dangerously damaged hand rails with exposed rusting metalwork.

ACA CORROSION FEATURE

Corrosion affects all concrete buildings and structures around the world to some extent, with an estimated annual cost of billions of dollars to national economies. However, it is often more of an aesthetic issue for hotels than office buildings because they need to project a certain ambiance to provide guests with a comfortable and pleasant environment. In addition, the falling concrete from buildings, where spalling is occurring, represents a real safety risk. Hotel operators do not want scaffolding, cabling and exposed metalwork on display for extended periods of time. There are also constraints on when necessary repair or remediation work can be carried out. Commercial office buildings are usually unoccupied for several hours overnight when disruptive drilling and grinding can be done, but hotels operate 24 hours per day making it almost impossible to find convenient times to do the work. Two of the most common causes of concrete corrosion are carbonation and chloride or 'salt attack'. In broad terms, when carbonation, chlorides and other aggressive agents penetrate concrete, they initiate corrosion that results in cracking, spalling and weakening of concrete infrastructure. As the reinforcing rods rust, the volume of the rust products can increase up to six times that of the original steel, thus increasing pressure on the surrounding material which slowly cracks the concrete. Over the course of many years, the cracks eventually appear on the surface and concrete starts to flake off or spall. As the degradation of the steel and weakening of the concrete occurs from the inside and may not be seen for many years, it is often referred to as 'concrete cancer'. According to Ian Godson, Managing Director of Infracorr Consulting PL, it might take up to 15 years before any cracking is visible. “It is a hidden problem which means that, when you find it, it is often well advanced, very much like the tip of the iceberg,” Godson said. Carbonation is the result of CO2 dissolving in the concrete pore fluid and this reacts with calcium from calcium hydroxide and calcium silicate hydrate to form calcite (CaCO3). Within a relatively short space of time,

the surface of fresh concrete will have reacted with CO2 from the air. Gradually, the process penetrates deeper into the concrete and after a year or so it may typically have reached a depth of 1mm for dense concrete of low permeability, or up to 5mm for more porous and permeable concrete depending on the water/cement ratio. Chlorides, usually from seaside splash or windblown locations, migrate into the porous concrete over time, causing corrosion when the concentration of chlorides reach critical levels at the reinforcement. In addition, older structures may have utilised calcium chloride as concrete 'set accelerators' at the time of construction, again resulting in serious corrosion issues.

Elastomeric polymer membrane on a city high-rise mitigates the effects of exposure.

Concrete corrosion repair and prevention According to Justin Rigby, coatings consultant at Remedy Asset Protection, “Concrete is a great material and is generally impervious at the start, but to increase durability, a coating should be applied.” Elastomeric waterproofing membranes can be either rolled or sprayed on to a concrete surface. Flat rooftops allow membranes to be rolled on, but where there are complex geometries, spraying the coating is the most effective method of application. The traditional method of concrete repair is to remove the cracked and spalling concrete to a depth of 20-30mm behind the reinforcing bars to fully expose the rusted material and remove the contaminated concrete from the steel. All the corroded material is then removed and the steel treated or replaced, after which specialist repair concrete mortars are applied and the surface made good. A modern development is for the repair mortars to be polymer modified to improve adhesion and resist further ingress of contaminants. Coatings are commonly used in combination with patch repairs to reduce further entry of carbonation or chlorides. These “patch repairs” that remove the contaminated concrete from the deteriorating sections often do not address this hidden corrosion and result in accelerated deterioration to the surrounding areas, commonly failing again within 3-5 years. Godson added, “One of the limitations of patch repairs is that you have to remove large quantities of sound concrete to solve

Hybrid anode installation. This series of railway bridge supports for the Alvaston Freeway overpass, were successfully remediated using the DuoGuard D1000 Hybrid anodes. Photo Courtesy David Hadley, DuoGuard

the problem, causing significant noise and disruption to the building occupants.”

Cathodic Protection The main alternative to patch repair is Cathodic Protection. One type, Impressed Current Cathodic Protection (ICCP), is a technique whereby a small, permanent current is passed through the concrete to the reinforcement in order to virtually stop the corrosion of the steel. The main benefit of ICCP is that the extent of removal and repair of concrete is vastly reduced, with only the spalled and delaminated concrete required to be repaired. Once installed, the ongoing

Construction Engineering Australia • Feb/March 2018

ACA CORROSION FEATURE

corrosion can be controlled for the long term, eliminating future spalling and deterioration even in severely chloride or carbonation contaminated concrete. The selection of anode systems is the most vital design consideration for a durable and efficient ICCP system. Incorrect selection and placement of the anode system can result in poor performance and vastly reduced life of the installation. According to Godson, cathodic protection is relatively simple in theory. “Insert anodes into the concrete at set spacing attached to the positive terminal of a DC power supply and connect the negative terminal to the reinforcing steel. ICCP systems commonly operate at 2 to 5 Volts DC,” he said. “The drawback is that you need lots of cables and permanent power supplies which results in this technology being mainly restricted to civil structures such as wharves and bridges with very rare applications to buildings.” A relatively recent development has been Hybrid CP, which utilises zinc anodes

Construction Engineering Australia • Feb/March 2018

installed in drilled holes with the anodes powered for an initial period of around 10 days. The high initial CP current totally passivates the steel reinforcement, migrating chloride away from the bars and restoring an alkaline (high pH) environment in the concrete. Following the initial impressed current phase, the temporary power supply and cables are removed, with the anodes then connected to the reinforcement via locally placed junction boxes to provide ongoing galvanic protection. This relatively low galvanic current maintains the ongoing passive condition at the reinforcement and prevents further concrete damage. Hybrid CP systems are usually designed to give a 30 year or longer design life. Hybrid CP offers all the advantages of ICCP, including corrosion control and reduced concrete removal, without the high cost and maintenance of power supplies, cables and control systems. Areas and structures that were previously difficult and uneconomical to treat with ICCP can now be protected using Hybrid CP technology. This

includes small scale and remote structures including those situated in non-powered sites such as bridges, marine structures and culverts. In the case of building repairs, Hybrid CP offers significant advantages over ICCP by eliminating the need for unsightly and costly cabling and power supplies.

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

7–11 October

Congress Dates

The 5th International Federation of Structural Concrete (fib) Congress is coming to Australia in 2018.

7–11 October 2018

The Congress, focusing on the theme “Better – Smarter – Stronger”, is dedicated to bringing together leaders and practitioners in the concrete industry from all over the world. The multidisciplinary theme of the Congress provides an excellent forum to share knowledge, and to learn about advances in the concrete world. With over 580 abstracts submitted from over 50 countries and across 25 themes, there is something for everybody!

Registration Now Open

Features include: • 4 day technical program with over 350 presentations • 5 excellent key note speakers from around the globe • Exhibitors of concrete products & services from all over the world • fib Awards for Outstanding Concrete Structures Gala Dinner • Opportunities to connect with world leading concrete practitioners A Conference of this type is a once in a life time opportunity for the Australian concrete industry to show the world what we can do in our own backyard. Head to our website to secure your registration and find out more.

Professor Stephen Foster Congress Chair

www.fibcongress2018.com

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