2014 NZRMCA AWARDS CELEBRATING EXCELLENCE IN READY … · But could the ready mix and wider concrete industry be better served? As the NZRMCA Council will over coming months, I encourage

2014 NZRMCA AWARDS

CELEBRATING EXCELLENCE IN READY MIXED CONCRETE

ISSUE 7 NOVEMBER 2014

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IN THIS ISSUE• Message from the President 2

• 2014 NZ Concrete Conference 3

• 2014 Best Trade Stand 3

• New NZRMCA President 3

• Around The Regions - Northland Region 3

• NZRMCA Loses a Good Friend 4

• CCANZ Annual Report 2013-14 4

• New Holcim Import Terminal Underway In Timaru 4

• 2014 Ready Mixed Concrete Association Awards 5

• Celebrating 50 Years of Outstanding Concrete Structures 10

• Key Dates 16

• Fun (Concrete) Fact 16

MESSAGE FROM THE PRESIDENT

Kia ora readymixers,

The recent combined Concrete Industry Conference held at Wairakei was, as has become the norm, a huge success. The weather was superb, the venue picturesque, the technical programme fascinating and the range of social activities tremendous fun.

The retrospective theme of the Conference added an extra level of interest, with the various associations taking the opportunity to look back and celebrate industry milestones, notable individuals and outstanding concrete structures.

A highlight for me was the NZRMCA Awards held during the formal dinner. As has been the case in the past, the entries demonstrated that our industry is seeking continual improvement in terms of technical capability and customer service. The Awards are covered on pages 6-11 of this issue.

The conference also marked the end of my formal responsibilities as President of the NZRMCA, and I have passed the reins to Brian Godfrey of Allied Concrete. However, I will remain on Council as Immediate Past President, replacing Jon Hambling, whose invaluable contribution I would like to acknowledge.

Over recent months we have welcomed two new regional Chairs in Blair Olynsma of Allied Concrete, who replaced John Stewart in the Lower North Island Region; and Aaron Charteris of Firth Industries, who replaced Brian Godfrey in the South Island. Blair and Aaron will bring fresh enthusiasm and vigour to their roles on Council.

As I did in my AGM report I will use this column to focus on the future rather than reflecting on the past year. I would like to ask that you give some thought to the various options available to help the wider concrete industry achieve enhanced efficiency and effectiveness across its various associations.

At the Conference Rob Gaimster, CCANZ CEO, presented a paper An Aggregation of Associations, or 6 into 1 Does Go? that summarised the current association landscape and outlined the range of options for consideration.

Globally there is consolidation amongst concrete industry associations, and with New Zealand’s small population base it makes sense to investigate combining groups to maximise their value to both stakeholders and industry.

Primarily, these groups are the Cement and Concrete Association of NZ (CCANZ), Precast NZ, the NZ Concrete Masonry Association, the NZ Concrete Society, the NZ Portland Cement Association, and of course us - the NZRMCA.

Our Association is strong in its own right, with impressive member numbers and a robust Plant Audit Scheme. We also currently enjoy a synergy with CCANZ, in terms of service, administration and project support. But could the ready mix and wider concrete industry

be better served?

As the NZRMCA Council will over coming months, I encourage you to carefully weigh-up the strengths and weaknesses this opportunity presents, and decide if a new national industry body that has a strong voice, a unified industry behind it and a clear direction, is the way forward.

On behalf of the NZRMCA Council, I would like to thank Rob Gaimster and CCANZ, David Barnard and the Plant Audit Committee, the Technical Committee, and both Full and Associate Members for your contributions, participation and attendance over the last twelve months.

Personally I wish to acknowledge the work and efforts of our executive officer, Adam Leach, secretary, Angelique van Schaik, and also your councillors, Jon Hambling, Maurie Hooper, Scott Williams, Paul Donoghue, John Stewart, Brian Godfrey, Bob Officer and Andrew Moss. I believe they have represented the interests of the Association and the ready mixed concrete industry extremely well.

Finally, I wish incoming President Brian Godfrey all the very best in his leadership endeavours.

Jeff BurgessNZRMCA President

Cover image: Marsden Point Oil Refinery CCR Platformer Pour. Courtesy Refining NZ Ltd.


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NEWS

2014 NZ CONCRETE CONFERENCE

The 2014 combined industry conference has come and gone for another year, and was once again deemed a great success by all. The NZRMCA Awards were held during the formal dinner, with the selection of winners generating healthy debate. See pages 7-11 for coverage of the Awards.

The NZRMCA was fortunate to secure a range of fantastic presenters for its three con-current sessions. A particular highlight was Professor Ken Hover of Cornell University, who stood in at relatively short notice to present his paper 2700 Reasons to Confirm Tests of Fresh

or Hardened Concrete.

The NZRMCA also took the opportunity to complement the NZ Concrete Society’s 50th anniversary celebrations by taking a stand in the trade exhibitors’ area. The objective was to acknowledge the Association’s own milestone of fifty one years of existence, as well as highlight the 2014 Awards’ entries, the Plant Audit Scheme and a range of interesting old industry images (see pages 14-15).

2014 BEST TRADE STAND

For a number of years now the NZRMCA has honoured exhibitors at the combined Concrete Industry Conference who have gone the extra mile to display their product or services in an engaging manner. This year Fletcher Reinforcing took home the prize for a visually stunning and informative display.

NEW NZRMCA PRESIDENT

After three years in the role NZRMCA President, Jeff Burgess of Supacrete, has stepped down. Current Vice President, Brian Godfrey of Allied Concrete, will assume responsibilities at the next NZRMCA Council meeting on Wednesday 12 November.

On behalf of Full and Associate Members the NZRMCA would like to recognise the hard work and dedication shown by Jeff. Being NZRMCA President requires considerable time commitment and the ability to remain fully informed on industry issues. Jeff has demonstrated a willingness to attend regional meetings and in so doing has raised the value of the NZRMCA brand.

Professor Ken Hover

Outgoing NZRMCA President Jeff Burgess hands over the tokotoko to Brian Godfrey

Neil Watson of Fletcher Reinforcing with NZRMCA President Jeff Burgess

AROUND THE REGIONS

NORTHLAND REGIONBy Maurie Hooper

Over recent months the Northland region has enjoyed two well attended meetings. In late May a tour of the Busck Prestressed Concrete plant in Whangarei was conducted by Russell Benneto, who aside from walking the group through his factory also gave a

fascinating insight into the history or Busck and precast concrete in the Whangarei region.

In August the Dargaville Museum was the meeting venue. Shown around the impressive exhibits by a very knowledgeable local, the group were entertained by stories of the wild-west and outback Australia by guest speaker Alan ‘Dally’ Vuletich (brother of John Vuletich) following the meeting.

In terms of activity across Northland, volumes continue to rise steadily, with budgets generally met or exceeded. In particular, the southern part of the region is enjoying the flow on effect of Auckland’s relentless expansion. However, a degree of uncertainty remains around the Super City’s new administrative infrastructure and changing regulations.

The next issue of the NZRMCA Newsletter will contain a summary of the other NZRMCA regions.

Alan ‘Dally’ Vuletich recounts tales from his shearing days

Cameron Greig, Russell Bennetto and Maurie Hooper


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NEWS

NZRMCA LOSES A GOOD FRIEND

It was with great sadness that the NZRMCA learnt of the recent passing of Michael Watson.

Michael Watson Contracting has been a Full Member of the NZRMCA for a number of years, and supplies a range of products / services in addition to ready mixed concrete, such as boxing and laying, pre-cast panels as well as masonry and stone.

Michael had a strong passion for concrete, which was most likely instilled in him by his parents, who both worked in the industry as managers of the ready mix plant in Otorohanga.

A hardworking businessman, Michael was known for his commitment to customer satisfaction. He placed a premium on providing a complete concrete solution from a single source.

Michael was also a dedicated father of Connor and Caitlin, always enjoying time with his children. In fact, Connor had gone to work at Michael’s precast yard.

Michael’s approachable manner and genuine interest in all things ready mixed concrete will be dearly missed by everyone in our industry.

CCANZ ANNUAL REPORT 2013-14

At its recent AGM, held at the Concrete Industry Conference in Wairakei on 10 October, CCANZ presented its 2013 -14 Annual Report.

Reporting against the strategic plan, the document provides a market commentary for the 12-months in question, along with an outline of achievements within the areas of Business As

Usual and Projects - the latter grouped into the following strategic themes:• Growth• Legislative and Regulatory Framework• Education, Training, Research & Development• Sustainability• Competitive Construction Systems

As New Zealand moves more fully into recovery and growth the need for a strong and high profile industry association such as CCANZ is paramount if concrete interests are to be effectively represented. The NZRMCA recognises this fact, and has supported CCANZ projects over recent years.

The 2013-14 Annual Report can be downloaded from the CCANZ website – www.ccanz.org.nz

NEW HOLCIM IMPORT TERMINAL UNDERWAY IN TIMARU

A milestone for the Timaru economy was celebrated in mid-October with the official ground breaking for Holcim New Zealand’s new $50 million cement import terminal at the region’s port.

The Member of Parliament for Rangitata, Hon Jo Goodhew planted a tree to celebrate the groundbreaking – a symbol of the care and value Holcim places on environments in which it operates.

The old silos have already been demolished by PrimePort and the site is clear for construction to begin on the new import terminal. The company has all the approvals required and continues to work closely with PrimePort and the Timaru District Council. Holcim has invested many millions in mitigation measures.

Holcim’s Managing Director, Jeremy Smith says this investment can be taken as a sign of the global company’s confidence in the strength of the New Zealand market and in particular the opportunities with the rebuild of Christchurch post-earthquake.

“The Port of Timaru terminal provides effective access to the major market of Christchurch, utilising the new $5 million silo capacity completed in January 2014 at the Lyttelton Port of Christchurch. This terminal also provides effective distribution to the whole of the South Island market and the lower North Island as well.”

“The terminals will be a demonstration of the best in global fit-for-purpose design and port environments.’

Up to 50 people will be employed at the Timaru site during the construction phase and up to 8 once fully operational. Construction will now get underway in earnest and the timeframe for having the terminal fully operational is planned for the first quarter of 2016.

Holcim thanked the local community for its support of the company and this major project. The company also launched a local scholarship programme as a further way of thanking the community and demonstrating its investment is for the long term.

Michael Watson


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2014 READY MIXED CONCRETE ASSOCIATION AWARDSThe 2014 NZRMCA Awards were presented recently at the combined Concrete Industry Conference held at the Wairakei Resort near Taupo.

This year’s event held particular significance as the wider concrete industry came together to celebrate 50 years of activity across various associations.

The evening’s formalities, conducted by Jesse Mulligan, included the Plant Audit Scheme Supreme Award, an Outstanding Achievement Award, as well as the Technical Excellence and Extra Distance Awards.

As has become customary, the judges had to select from a range of exceptional projects and initiatives that embodied the knowledge and resolve of those who work in the ready mixed concrete industry.

PLANT AUDIT SCHEME SUPREME AWARDALLIED CONCRETE - ROTORUA PLANT

Quality control was the primary reason for the establishment of NZRMCA and the development of the Plant Audit Scheme many decades ago. The independent Scheme remains the cornerstone of the Association.

The judging criteria for this Award acknowledge consistently high performance over an extended period of time.

In producing large quantities of concrete to a reliably high quality across a number of years Allied Concrete’s Rotorua plant has demonstrated

continuing excellence in performing to NZS3104 Specification for Concrete

Production.

Judges’ Comment:

The judges highlighted the fact that this

plant had received Excellence Awards in

each of the last 5 years, which is indicative

of the attention to detail shown by the concrete production management

team. The plant is an example to all other ready mixed concrete producers

across New Zealand.

MC for the evening Jesse Mulligan warms up the crowd NZRMCA President Jeff Burgess takes to the stage with a flourish

Mark Jordan of Allied Concrete receives the Plant Audit Scheme Supreme Plant Award from NZRMCA President Jeff Burgess


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OUTSTANDING ACHIEVEMENT AWARD

ALLIED CONCRETE, ATLAS CONCRETE AND FIRTH INDUSTRIES – MARSDEN POINT OIL REFINERY CCR PLATFORMER POUR

Every so often a project is undertaken that is worthy of special recognition. The Continuous Catalyst Regeneration (or CCR) platformer pour at Marsden Point Oil Refinery, with its incredible technical and logistical challenges, is one such project.

Over a 16 hour period a convoy of 60 concrete trucks delivered 550 separate loads (2,746m3 of concrete) to form the base for Refining NZ’s $365 million CCR platformer.

The pour - believed to be one of the largest single-day off-site batched concrete pours in the country - started at 3:30am on a Saturday morning and continued through until 9:00pm at night.

Concrete truck deliveries were required from 5 batch plants owned by Allied Concrete (pour project manager), Atlas Concrete and Firth Industries across Whangarei and Ruakaka.

At any one time there were 15-20 trucks on the refinery site, with a truck delivery to the concrete pour about every 90 seconds.

United Civil Construction oversaw the undertaking with assistance from the three NZRMCA members, along with Golden Bay Cement, Winstones, Marsden Industrial Solutions (formerly MPCL), Stan Semenoff Sand Supplies, Opus Laboratories and Sika (concrete admixtures). Special assistance was provided by the NZ Police and the NZTA.

Judges’ Comment:

The judges felt that the successful delivery of this project without

quality, mechanical or health and safety incident was a tribute to the

professionalism of all those involved, as well as a demonstration to the

wider construction industry that ready mixed concrete companies can

work co-operatively to overcome technical and logistical challenges on

behalf of the client.

Craig Nisbet of Atlas Concrete, Baldev Kesha of Firth Industries and Blair Macfarlane of Allied Concrete receive the Outstanding Achievement Award from NZRMCA President Jeff Burgess


TECHNICAL EXCELLENCE AWARD - WINNER

FIRTH INDUSTRIES RIBRAFT® TC3 FOUNDATION SOLUTION

In April 2012 MBIE produced guidelines outlining the parameters and design cases that need to be allowed for when dealing with Technical Category 3 land in Christchurch. TC3 is the land identified as being susceptible to liquefaction in an earthquake, but still able to be built upon.

The solution developed by Firth Industries to satisfy MBIE requirements evolved from the existing range of Ribraft® solutions. The system is called Ribraft® TC3, which incorporates RaftJacks™ throughout the slab.

Following a settlement inducing earthquake, RaftJacks™ are activated using a hand-held tool, raising the top foundation slab and entire house to the level position.

Due to the strength and stiffness of the Ribraft® system, development to make it easy to be re-levelled was a quick process. This involved real-world trials of the crucial RaftJacks™, the construction of a near full-scale house floor/foundation slab, and the completion of a design manual.

The fast tracked development program by Firth Industries for the Ribraft® TC3 solution has ensured concrete remains an effective solution for residential floors in Christchurch.

Judges’ Comment:

The judges wanted to acknowledge Firth Industries’ ability to react swiftly in

engineering an innovative solution that met an immediate problem. From

a wider perspective Ribraft® TC3 demonstrates that the concrete industry

has the technical and design capability to quickly adapt its products and

ensure home builders, even on TC3 land, continue to enjoy the benefits of

New Zealand’s most popular residential foundation material.

Jon Hambling of Firth Industries receives the Technical Excellence Award from NZRMCA President Jeff Burgess


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TECHNICAL EXCELLENCE AWARD – HIGHLY COMMENDED

HOLCIM CONCRETE - ARCHITECTURAL FAÇADE AT 27 NUGENT STREET, AUCKLAND

Under the oversight of Dominion Constructors, the unappealing street frontage of this Auckland site is in the process of being rejuvenated through a series of polygon shaped openings in the façade, achieved through the use of the Voronoi Tessallation formwork system.

Due to the unique architectural design, it was necessary to have a concrete mix that could flow inside closed formwork, as well as have the ability to cover the congested reinforcing.

As standard concrete was not a feasible solution, Holcim Concrete developed an innovative mix to meet the unique requirements.

The specially designed concrete was placed in the formwork using two pumps, with the flow of the concrete controlled by valves at the base of the pour. These enabled the concrete to be pushed from the bottom up, to ultimately achieve the look desired by the architect (Jasmax, Auckland) and client (Aspect Furniture).

“Given the complexities and sheer design of the Voronoi Tessallation formwork, it was vital the supplier of concrete was a reliable and innovative partner, thus based on the performance and technical advice supplied by Holcim, we were able to achieve and overcome unusual challenges. We greatly appreciate Holcim Concrete’s willingness to step up and work closely to overcome significant challenges.”

Charlie Sucich, Project Manager, Dominion Constructors Ltd, 2014

Judges’ Comment:

The judges noted that the technical challenges overcome by Holcim

Concrete were complex in designing a mix that would flow easily into

the confined spaces of the elaborate formwork, without segregating, and

without requiring vibration. A willingness to “step-up” and help realise the

innovative design concept of the architect and client is a testament to

Holcim Concrete’s confidence and expertise in pushing the boundaries of

mix design.

Opinder Saggi of Holcim Concrete receives the Technical Excellence (Highly Commended) Award from NZRMCA President Jeff Burgess


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EXTRA DISTANCE AWARD - WINNER

ALLIED CONCRETE - EPD FOR READY MIXED CONCRETE USING HOLCIM MANUFACTURED CEMENT

Allied Concrete applied for an Environmental Product Declaration (or EPD) in 2014 based on analysis of its 2013 production.

Using Life Cycle Assessment tools courtesy of Holcim New Zealand’s membership of the World Business Council for Sustainable Development, a huge data collection process was undertaken across energy and material inputs for a range of concrete strengths.

The system boundary declared in the EPD includes raw material supply, transport and manufacturing up to the batching plant gate. This covered:

• Cement manufacturing • Admixture production

& delivery• Cement distribution by sea

& land transport • Water consumption

• Aggregate production• Waste volumes generated

& associated disposal costs • Aggregate delivery to the plants• Energy use at the plants

(electrical, fossil fuel)

The declared unit is 1 cubic metre of pump and standard grade concrete from 17.5 to 50 MPa produced in accordance to NZS 3104.

The data collection process took 10 months to complete, with BRANZ managing document preparation, and Studio Fieschi & Soci of Italy as EPD verifier. The completion of possibly the first EPD in Australasia for ready mixed concrete has enabled Allied Concrete to benchmark its environmental performance and examine potential efficiencies.

Judges’ Comment:

The judges were impressed by the courage shown by Allied Concrete in

obtaining an EPD and in so doing leading the way forward on behalf of the

concrete industry. Not only was the time and resource expended significant,

but the foresight in openly acknowledging the environmental impact of their

product to accurately assess efficiencies is very responsible.

Chris Munn of Allied Concrete receives the Extra Distance Award from NZRMCA President Jeff Burgess


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CELEBRATING 50 YEARS OF OUTSTANDING CONCRETE STRUCTURESAs mentioned in previous issues of the NZRMCA Newsletter, the NZ Concrete Society is marking its 50th anniversary in 2014. We have already taken a look back at “Concrete Trailblazers”, individuals who have made a lasting impression on the New Zealand concrete industry. Now it is time to explore how many notable concrete structures have been realised by the technical and collegial support offered by the Society.

NOTABLE CONCRETE STRUCTURESInformed by the work of the Society, innovation more than any other characteristic has marked the advancement of New Zealand’s concrete construction over the last 50 years.

The industry has evolved on multiple fronts and is best reflected in the diverse mix of structures built over the decades – each a unique response to pervading seismic, commercial or engineering imperatives.

These structures represent some of the most innovative solutions in the history of concrete construction, with several noteworthy examples summarised below.

THE FIRST NEWMARKET VIADUCT

With its long spans, S-curvature and the varying super-elevation of the motorway, the first Newmarket Viaduct was a truly state-of-the-art design for New Zealand.

When transport planners decided that a network of motorways was the best way to solve Auckland’s growing traffic problems, they opted for a viaduct over the inner-city suburb of Newmarket.

Designed by the Ministry of Works and opened in September 1966 after four years of construction, it was New Zealand’s largest pre-stressed concrete bridge, measuring 689m long and 27m wide. It cost $2.26 million. Towering more than 45m above Newmarket, it was

described by the New Zealand Herald as “one of the most distinctive engineering features of New Zealand.”

A steel girder structure had initially been considered, but the cost of the imported steel and ongoing maintenance persuaded the designers to go with the concrete option. The pre-stressed concrete box girder structure was favoured because it had to cross a busy urban area, major roadways and a dual track railway.

Complex for its time, the structure comprised 16 spans varying between 33.5m and 50m in length. It was designed to be constructed from each supporting column as a balanced cantilever concreted in-situ.

As each new 3.2m section was added it was tied back to previously erected units with pre-stressing cables. This process continued until finally the cantilevering spans from adjacent piers were closed at mid-span. Further pre-stressing cables were then threaded into the units to tie the whole structure together. The design included dynamic analysis for the loads to withstand a one-in-500 year earthquake.

Design Ministry of Works

Construction Wilkins & Davies


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BLUFF SMELTER

The use of precast concrete rather than steel for the pot line building and its crane beams marked a world first for the smelter industry.

Southland’s Tiwai Point was chosen (in the 1960s) as the location for the aluminium smelter due to its proximity to the soon-to-be-built Manapouri Power Station.

Beca – the project’s structural engineering consultants – costed the two 610m-long Stage 1 pot line buildings (the heart of the processing plant) in both concrete and steel. The studies showed that a pre-stressed concrete frame was marginally cheaper than a structural steel frame, offering a valuable capital saving of 8%.

New Zealand concrete was not only cheaper, its construction programme was more certain and its neutral electromagnetic properties would give better operational performance than steel.

In addition to the economic advantage, pre-stressed concrete offered excellent fire protection, low erection costs and greatly reduced maintenance costs. Furthermore, Stresscrete (the company contracted to produce the 404 columns and 202 rafters) had the resources to guarantee delivery to a very tight schedule.

The smelter began operations in April 1971, producing the world’s purest primary aluminium (refined directly from alumina ore) mostly in ingot, billet and rolling block form.

Design Beca

Construction Kaiser Engineers & Constructors Ltd

JERNINGHAM APARTMENTS – WELLINGTON

New Zealand’s first capacity design building generally goes unnoticed amongst the million dollar properties along Oriental Parade, but its value is immense.

Often described as the “father of ductile design” in New Zealand, John Hollings was the creator of capacity design. A University of Canterbury graduate, he became an earthquake engineering expert.

His address in May 1968 at the University of Canterbury introduced the concept of what came to be referred to as “capacity design” of reinforced concrete structures, a concept further developed by Professors Park and Paulay at the University of Canterbury. Wellington’s 16-storey Jerningham Apartments was New Zealand’s first building to adopt the technique.

The apartments are on a one-acre site in Wellington’s Oriental Bay. To achieve the best financial return the maximum possible number of flats had to be fitted on to the site. To meet town planning requirements, this meant a tall building with 15 floors of flats (4 and 5 flats per floor) over a ground floor of parking.

The construction company, Wilkins and Davies, favoured a slip form core with a lift slab floor system. However, compared to the capacity design it would cost approximately $100,000 more, mainly because of the extra foundation cost required to stabilise the tall, narrow tower.

The capacity design comprises beamless flat plate floors (to get the maximum number of floors within the town planning height limit) and, for the necessary earthquake resistance, a strong frame system is provided all round the building’s perimeter with all plastic deformation designed to occur in the beams not the columns.

Design Beca

Construction Wilkins & Davies Development Co Ltd


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NAC HANGAR – CHRISTCHURCH

At the time of its construction the NAC Hangar’s 124.5m pre-stressed concrete span, which holds up the doors and roof, was the country’s longest.

National Airways Corporation (NAC) was the country’s domestic airline from 1947 until 1978, when it amalgamated with Air New Zealand. The new hangar was part of an improved facility for aircraft maintenance. Its design called for an internal, column-free area of 122m by 61m to allow the simultaneous servicing of multiple aircraft.

Four separate designs were considered and costed by the designers Beca. The alternatives included structural steel, reinforced concrete arches and an internal steel box girder spine beam.

The pre-stressed concrete box girder solution – spanning 124.5m across the hangar door – was selected because it would have the best appearance and offer superior performance in the event of a fire. Given the militant trade union activity of the period, there were also concerns about the reliability of steel supplies. Furthermore, the maintenance costs for concrete would be lower than those of steel.

The concrete girder was constructed by Downer in segments on conventional ground falsework. First, the end span was constructed, with the main span progressively built out for each side of the hangar. This construction sequence is similar to that used in cantilever construction of pre-stressed box girder bridges, the girder being sequentially pre-stressed to cantilever from the main columns. After the closure of the two cantilevers, the girder was made continuous with post-tensioned cables.

The project received the NZ Concrete Society’s Award for Excellence in Prestressed Concrete at the Society’s annual conference at Wairakei in 1981.

Design Beca

Construction Downer

LOWER SHOTOVER BRIDGE

This vital piece of South Island roading infrastructure features an innovative pre-tensioned deck, and was designed to blend aesthetically with its surroundings.

Described at its 1975 opening as “mathematical precision combined with beautiful form” the bridge is a two-lane carriageway. Measuring 320m long, it’s made up of 169 precast, pre-tensioned concrete box girder sections. On the tourist route between Cromwell and Queenstown, the Remarkables mountain range forms the site’s spectacular backdrop.

It replaced the original 172m Lower Shotover Bridge (1915) which for 60 years was the main route into Queenstown from the north and east.

Governed by aesthetics, the design is a slender, curving structure that blends easily with the landscape. Opting for a precast, box girder bridge was appealing because construction crews wouldn’t have to truck aggregate from a considerable distance to a tricky site.

The bridge’s cross section is 23 per cent smaller in area than for a standard 100-foot I-beam span. Its superstructure contains 35m3 of concrete, versus the I-beam design’s 45m3. This saving in dead load on the pier foundations reduced the number of piles needed for each pier from five to four – a significant cost saving.

The shape of the piers is functional as well as aesthetic, in that the height had to be adaptable from 17 feet to 25 feet, and wide enough at the top to collect the reaction from bearings under the outer webs. The load from the middle web was transferred at the piers to the outer webs by means of transversely pre-stressed diaphragms.

The bridge received a Merit Award from what was to become the NZ Concrete Society in 1977, and its aesthetic attributes were celebrated by NZ Post with the issuing of a 35c stamp in 1985.

Design Ministry of Works and Development

Construction Fletcher Construction Company Ltd, Stresscrete New Zealand Ltd, BBR NZ Ltd


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MOTUNUI SYNTHETIC FUELS PLANT – NEW PLYMOUTH

This was the first facility of its kind – internationally – to apply seismic design in accordance with recommended criteria laid down for petrochemical plants. This included continuous dewatering of a saturated sub-strata sand layer to reduce the likelihood of site liquefaction under a severe earthquake.

Opened in 1986, the Motunui Synthetic Fuels Plant was the world’s finest commercial production facility converting natural gas to synthetic fuels. It was also the world’s largest methanol production facility, and was built in response to the OPEC oil crisis, a period when New Zealand was 85 per cent dependent on foreign oil.

The twin reformer furnace/waste heat recovery duct structures are the plant’s major components, traditionally built in steel. Beca, the structural designer, opted to replace the conventional steel structure with large, reinforced concrete cantilevers detailed to sustain post-elastic rotations near their base (“plastic hinges”).

Simple rocker bearings isolate the trusses when the columns flex under lateral load, to increase the overall stiffness of the columns. Below hearth level smaller-scale reinforced concrete cantilevers with a similar plastic hinge capability at their base have replaced the steel columns. Rocker bearings provide a pin connection to the furnace hearth.

The project – completed within budget and on schedule – received much international interest and demonstrated the capability of New Zealand’s engineering resources.

Design Davey McKee Corp, Foster Wheeler Energy Corp, Works Corp, Beca

Construction Bechtel Petroleum Inc. & New Zealand subcontractors

Other notable concrete structures that have risen to grace the New Zealand landscape over the past 50 years include the Mangaweka Viaducts, Pakuranga (Waipuna) Bridge, Eden Park’s private boxes, Wellington’s Ngauranga Interchange and Chaffers Marina, Otira Viaduct and of course the Sky Tower.

These structures, along with many more, are all indebted to the vision, foresight and courage embodied and fostered by the NZ Concrete Society.

A CELEBRATION OF 50 YEARS

The range of activities to help celebrate the Society’s 50th anniversary, including acknowledging its distinguished members, culminated with the 2014 combined Concrete Industry Conference held at the Society’s spiritual home of Wairakei, the venue of the first conference 50 years ago.

A key component of the celebrations is the publication of the commemorative book from which the text above was taken.

Image Credits:The First Newmarket Viaduct courtesy of the Fletcher Trust ArchiveBluff Smelter courtesy of NZ Aluminium Smelters LtdLower Shotover Bridge images courtesy of NZTANAC Hangar image courtesy of BecaMotunui Synthetic Fuels Plant images courtesy of Methanex Corporation

The text contribution of IPENZ is gratefully acknowledged.


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NZRMCA MIXING IT UP FOR

OVER 50 YEARS


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NZRMCA would like to thank all those who contributed old industry photographs to our 2014 conference trade stand.

A selection is displayed here.


KEY DATESNZRMCA REGIONAL MEETINGS (check local notices for confirmed dates and precise times)

MEETING DATE VENUE

Northland Thursday, 27 November 2014 Bay of Islands

Auckland Wednesday, 19 November 2014 Auckland

Lower North Island Thursday, 13 November 2014 Palmerston North

South Island Tuesday, 04 November 2014 Nelson

NZRMCA Council Wednesday, 12 November 2014 Auckland

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NZRMCA NEWS IS DISTRIBUTED THREE TIMES A YEAR IN HARDCOPY AND ELECTRONICALLY TO AROUND 500 INDIVIDUALS. EDITORIAL OR ADVERTISING ENQUIRIES CAN BE DIRECTED TO ADAM LEACH (04 915 0383 OR [email protected]).

FUN (CONCRETE) FACTCASTLE BUILT USING 3-D CONCRETE PRINTERWith just the click of some buttons, a 12-foot-tall castle has appeared in a Minnesota back yard.

Andrey Rudenko built the castle layer by layer with one of the first 3-D concrete printers in the world, an ambitious task given that most things produced by 3-D printers are much smaller, like plastic models or parts.

“Every time it’s getting bigger and more complicated,” he said of his creations. “It’s just magic for me.”

3-D printing has emerged in recent years, bringing the futuristic concepts to reality with everything from luxury cars to toy puzzles to the latest fashion. Researchers are even working to perfect printing human body parts.

While most 3-D printers produce smaller plastic objects, Rudenko wanted to create a concrete printer for large structures to be on the cusp of what he says could one day be the norm in home construction.

It took him two years of work – and one minor garage fire – tinkering with designs to make his printer, made up of rails, beams and a control box that uses computer designs, to “print” various shapes.

It’s a process less like printing paper and more like a manufacturing robot, squeezing out concrete, layer by layer.

Rudenko started producing concrete boxes – the first one, a rough rectangle. Over time, he smoothed out the lines, revised the concrete mix and designs and, with more than $1,000 in materials, started work on his first big test of the technology: the castle.

A full-scale concrete house is next on Rudenko’s agenda.

Extracts from an article by Kelly Smith in the Star Tribune (www.startribune.com). Photos: Caleb Kraft.

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2014 NZRMCA AWARDS CELEBRATING EXCELLENCE IN READY … · But could the ready mix and wider concrete industry be better served? As the NZRMCA Council will over coming months, I encourage