Search Results

Team Members Mohammed Afroz General Manager Mohammed joined Conslab in 2023 and brings 20 years of construction experience with him.... Read More Nada Sundaram Technical & Business Development Manager Nada recently joined the Conslab Team after spending his first 10 years in Christchurch since relocating... Read More Glyn Sutton Construction Manager Glyn has been a part of the Conslab team for over 12 years starting as a Site Manager on... Read More Thushani Sulochana Quantity Surveying & Estimating Manager Thushani started working for Conslab in 2017 as a Quantity Surveyor after her permanent move to New Z... Read More Mike Shackleton Operations Manager Mike started with Conslab, formerly known as Mooney concrete in 1993. He has... Read More Michael Ledbrooke Account Manager - Extend As the Account Manager for Conslab Extend, Michael, also known as Mike plays a key role in quoting, sales, relationship management, and busine... Read More

Extend Projects Food Production Hall This project involved the conversion of a space within an existing facility to a new food production line. Read More MIT Tech Pack Crane Pad For this project, the Conslab Extend team were tasked with the installation of a JIB crane foundation within an existing building at MIT Tech park. Read More New World Newton Carpark Topping The Conslab Extend team recently completed this car park repair project for BBR Contech at New World Newtown. Read More Torpedo 7 Whangarei When The Warehouse Group was converting a Warehouse Stationery store to a Torpedo7, they engaged Conslab to give the floor a fresh look. Read More Waiari WWTP A great example of the Extend team’s ability to deliver complex concrete enhancement projects throughout NZ. Read More

Flooring Projects 277 Broadway - Westfield Flagship shopping centre with over 105,000m2 of concrete floors Read More 90 Pavillion Drive This pair of new warehouses in Airport Oaks required high-performance floors to provide maximum flexibility for tenants and longevity for the owner. Read More Balance Reporoa Fertilizer storage buildings are as tough as it gets for a concrete flooring contractor Read More Bunnings DC High-performance slabs for busy Distribution Centre Read More Cardinal Logistics' Stage 1 Cardinal Logistics’ new Drury site is the country’s first fully automated facility Read More Foodstuffs North Island DC New Zealand's Biggest Warehouse! Read More James Pascoe Group Distribution Centre Award-Winning Superflat floor for VNA Racking Read More Kiwirail RD35 This project involved removing 750m of rail track from two existing sidings at the Port of Tauranga, pouring two new slabs, and then replacing the track – all within ten! Read More Sistema Massive Manufacturing Facility Read More Woolworths Palmerston North The new Woolworths Distribution Centre in Palmerston North is a mammoth building – at 38,000m2 it's large enough to fit more than five rugby fields! Read More

Construction Case Studies 277 Broadway - Westfield Flagship shopping centre with over 105,000m2 of concrete floors Read More Kiwirail RD35 This project involved removing 750m of rail track from two existing sidings at the Port of Tauranga, pouring two new slabs, and then replacing the track – all within ten! Read More Whenuapai Taxiway & Hardstand Taxiway and hardstand reconstruction project at NZDF Base Whenuapai. Read More

< Back Michael Ledbrooke Account Manager - Extend As the Account Manager for Conslab Extend, Michael, also known as Mike plays a key role in quoting, sales, relationship management, and business development, with a strong focus on driving growth for the Extend business. What excites Mike most about his role is the opportunity to learn a new trade craft while helping to expand the Extend division, with long-term aspirations of achieving nationwide growth. Despite joining Conslab only three months ago, he’s proud of how quickly he’s hit the ground running whilst rapidly upskilling his knowledge of concrete repairs to deliver technical sales with confidence. Outside of work, Mike is passionate about the outdoors and hands-on projects. He enjoys both fresh and saltwater fishing, diving, woodworking, home DIY, and all aspects of cooking and baking, particularly perfecting his sourdough. Looking ahead, Mike is focused on continuing to grow Conslab Extend’s profile and sales across the country, while also mentoring future sales team members. Guided by his personal motto, “If you can’t say it with conviction, don’t say it at all,” Mike brings a determined approach to his work and relationships. Mail To play, press and hold the enter key. To stop, release the enter key.

For this project, the Conslab Extend team were tasked with the installation of a JIB crane foundation within an existing building at MIT Tech park. < Back MIT Tech Pack Crane Pad For this project, the Conslab Extend team were tasked with the installation of a JIB crane foundation within an existing building at MIT Tech park. For this project, the Conslab Extend team were tasked with the installation of a JIB crane foundation within an existing building at MIT Tech park. This was a complex small-works project involving: • Saw-cutting a 2.7m square through the existing slab • Excavation down to 1m depth • Removal of excavated material • Supply + install reinforcing cage and hold-down bolts • Pour 8m3 of concrete with over 30m of line pumping • Vibrate, place, finish, and cure the concrete • Apply waterproof membrane to allow for epoxy coating • Apply Sikafloor-264 Epoxy coating to match the surrounding slab From the first saw-cut into the slab to the final coat of epoxy being applied was just over 2 weeks. It was great to get it done quickly and avoid any disruption to the client or MIT students. This job was a great example of the Extend team's diverse range of skills, coming together to make it easy for the customer. Key Stats 2022 Haydn & Rollett Auckland Project Gallery Previous Next

< Back Sistema Massive Manufacturing Facility THE PROJECT Conslab were engaged to design and construct the 50,000 m2 concrete floors, and 20,000 m2 heavy-duty container pavements for the Sistema Plastic Manufacturing Facility in Auckland. After close consultation with the client and principal, Conslab developed a “best in class” post-tensioned slab on grade solution for the manufacturing facility floor. The floor only required two opening joints within the main facility, dramatically reducing the expected maintenance costs over the life of the facility and allowing for flexibility for laying out production machinery in the future. The 50,000 m2facility was constructed in 14 large pours using a Somero Laser Screed to cast the floor to within +/- 10 mm of datum and EN15620 “FM2” tolerances quickly, efficiently, and with minimal labour. The 20,000 m2 heavy container pavement was designed to accommodate block stacking of 40-foot shipping containers in double-height stacks that combined to weigh nearly 50 tons each. The facility also utilized container handling equipment with 12-ton wheel loads. Conslab provided a robust 220 mm thick high strength pavement, using steel fibre reinforcement in combination with rebar to resist the heavy loads and provide a pavement without saw cuts and with minimal joints. In total Conslab utilized nearly 15,000 m3 of concrete on the project. Key Stats 2015 Haydn & Rollett Auckland 50,000m2 Post-Tensioned warehouse slab 20,000m2 Heavy Duty Combi Slab pavement, designed and built by Conslab Project Gallery Previous Next

From conception to pre-construction through to project delivery and hand over – we deliver the construction results our clients expect by combining a collaborative approach with proactive planning. Conslab are the Concrete construction experts. Concrete Construction Experts Conslab are the concrete construction experts - offering full package solutions for concrete, reinforcing and formwork.  The Conslab Process Careful planning and focus on collaboration From conception to pre-construction through to project delivery and hand over – we deliver the construction results our clients expect by combining a collaborative approach with proactive planning. Control the key inputs Concrete, reinforcing steel and formwork all supplied, coordinated, managed and installed by Conslab. This minimises delays and provides efficiency to our projects. Flexibility of Resources Conslab's expertise and resources across our construction, flooring and extend divisions provides flexibility and capabilities in all aspects of concrete construction. Managing the risks A rigorous approach to safety, quality and time management of structural concrete delivery by a team of experienced construction experts.  Retail & Mixed Use Commercial & Office Buildings Multi-Unit Residential Post-Tensioned Suspended Concrete Slabs Infrastructure - Ports, Pavements, Bridges Healthcare Airports Public / Governments RETAIL & MIXED USE Retail-mixed-use Concrete Construction for Retail & Mixed use developments Integrated concrete construction solutions for complex Retail & Mixed use developments Retail and mixed use developments can be highly program driven. They can also involve a complex mix of base build and tenant fit out specs and a diverse range of finishes. Conslabs ability to execute the full package of concrete work – from foundations, through to structural frame, a variety of structural slab solutions, and additional systems like epoxy coatings, waterproofing and polished concrete, make us well suited to the market segment. Our track record in this space speaks for itself – including delivery of the concrete work for New Zealand’s largest retail development, 277 Westfield, and being a preferred contractor for retailers like Bunning’s NZ and The Warehosue. Our ability to control key inputs like concrete, reinforcing and formwork, coupled with our collaborative and plan first approach allows us to navigate the sometimes fluid nature of design and construction priorities in retail and mixed use developments. COMMERCIAL & OFFICE BUILDINGS Commercial-office-buildings Fast, efficient, safe and reliable construction Reduce construction risk and let  Conslab turn around your project quickly and help manage change. Commercial & Office buildings can require fast delivery of the structure coupled with cost efficiency. Conslab has a proven track required of handling and excelling in the construction of commercial concrete structures. This starts from the ground up. Foundations are the most important part of any building as it provides the platform for all other works, which is why we take our quality control and delivery so seriously. Using cutting edge technology, and constant ability to upskill staff, we ensure each building is provided the best quality foundations, the first time.  Having experienced managers and engineers analysing and coordinating projects from the outset ensures success and minimizes project risk. Our abilities don’t stop in the ground – Conslab are New Zealands foremost experts in placing and finishing high tolerance floors – with well over 5 million square metres under our belts. In commercial and office buildings this translates into expert planning and delivery of floors no matter what the project throws at us – weather, high tolerances or program challenges. Conslab provide full analysis and management of the unique risks that come with each project – whether the key challenges are site access, restricted working hours, concrete supply management, formwork requirements/pressures and temporary works design, or the intricacies of mixing structural systems like pre-cast with in-situ or steel elements. We put the hard work into the analysis, co-ordination and planning to ensure we get it right first time.  POST-TENSIONED SUSPENDED CONCRETE SLABS post-tensioned-suspended Post-Tensioned concrete slab Design & build solutions  Conslab design & build suspended post-tensioned slabs offer reduced construction cost, schedule and environmental impacts. Conslab have pioneered the design and construction of suspended post-tensioned (PT) concrete slabs in New Zealand, unlocking greater efficiencies for architects, engineers and developers. Suspended PT slabs can have greater spans and reduced slab depths, resulting in fewer columns and lower floor heights. Greater flexibility of tenancy layouts, service locations, reduced construction schedules and lower environmental impacts are just some of the advantages.    Post-tensioning uses high tensile strength steel strands cast into the slab, which are tensioned to control concrete shrinkage and resist loads applied to the slab. This significantly reduces the volume of conventional reinforcing required, and allows for thinner slab profiles with flat soffits.     Conslab offers a full package solution for suspended PT slabs, managing the full design and construction process. This approach reduces complexity and risk to the client by giving Conslab full responsibility for the suspended PT slabs.  MULTI-UNIT RESIDENTIAL mulit-unit-residential Reliable concrete solutions for Multi-Unit Residential Full package concrete, steel and formwork solutions for fast and efficient Multi-Unit Residential construction With limited land availability, particularly in cities like Auckland and Wellington, the best solution can be to build upwards. Whether it’s a five or fifteen storey apartment building, highly repetitive or highly bespoke, Conslab have the ability to deliver a full concrete construction package safely, on time, and on budget. Our focus on planning and collaboration lead to organized work sequences and clean hand overs to following trades – resulting in better outcomes for the entire project team. Whether a structure uses composite steel deck floors, conventional in-situ , post-tensioned, rib and timber infill or precast flat slab, we have been there and built that – and picked up plenty of tricks along the way. By controlling reo, concrete and co-ordination of service trades, we supply a full product that checks all the boxes, as well as take the headache away from the client by providing predictability. INFRASTRUCTURE - PORTS, PAVEMENTS, BRIDGES infrastructure-ports-pavements Civil and Infrastructure concrete construction Conslab go the extra mile to get it right first try on the most challenging Civil and infrastructure projects . Civil infrastructure is often constructed in extremely demanding environments with long design life of 50+ years, requiring concrete mix designs with low permeability to ensure long-term durability. This is typically achieved by the use of Supplementary Cementitious Materials (SCMs) such as Silica Fume or Fly ash, possibly in conjunction with high cement contents and low water/cement ratios. Such mix designs can be extremely difficult to work with. Plastic shrinkage cracking, low-bleed, poor pumpability and workability are common issues. Construction in exposed or remote locations often exacerbates these issues.    Additional project requirements such as high flexural strength concrete for runways, low workability mix designs, low shrinkage mix designs etc, can add to the challenges.    Conslab are concrete construction experts who love a challenge. We've been working on some of NZ's most demanding civil and infrastructure  projects for over 20 years, and have developed a wealth of experience in the design and construction of concrete bridge decks, port pavements, runways and roads.     By developing a project specific methodology to account the unique challenges of every site, Conslab mitigate the risk of non-conformance and expensive re-work.     For heavy-duty port pavements, runways and concrete roads, Conslab can deploy our Allen Triple Tube Roller screed, which allows for the efficient accurate placement of deep concrete slabs.  AIRPORTS airports Airport pavement and structural concrete solutions Proven technical expertise and construction management for Airport concrete pavements and structures Airport projects can be complex requiring a broad depth of expertise in concrete technology and concrete construction techniques in order to deal with the mix of local and international (FAA style) standards that must be strictly adhered to. Adding to this technical complexity are the project delivery challenges such as security access, airside FOD management and the vigilance required to work alongside airport operations throughout construction activities. Conslab’s focus on planning, collaboration, supply chain optimization and risk management underpin our strong track record in the airport projects. Whether it’s delivering hangar projects airside repairs such as the AIAL hangar remedial and upgrade, or PQC pavements for taxiways and runways including Whenuapai airbase. Conslab combine our concrete technology and construction expertise with project delivery excellence to make our customers job easier. PUBLIC | GOVERNMENT public-government Concrete expertise for Public Assets and projects Full concrete construction risk management and delivery for complex public and government construction projects Public and government concrete projects can be as simple as school classrooms and footbaths, but at Conslab we are typically talking about the type of projects we cherish – the ones that pose unique challenges. Conslab have a track record delivering public buildings of significance – such as stadia (Spark Arena, TISEC, Marine Events Centre), emergency services and justice related buildings (Justice Precinct), Defence Department projects (Whenupai) and prisons (Mt Eden Prison). These projects can require the management of complex stakeholder requirements, heightened security precautions, and strict adherence to technical and contractual requirements. Conslab provide full analysis and management of the unique risks that come with each project – whether the key challenges are site access, restricted working hours, security, concrete supply risks, concrete technology requirement, thermal management or the whole other raft of challenges that unique and large scale government projects can bring to the fore. We put the hard work into the analysis, co-ordination and planning to ensure we get it right first time. HEALTHCARE healthcare Concrete construction solutions for Healthcare projects Careful planning and coordination by the Conslab experts ensures success on complex Healthcare projects Healthcare projects can create unique challenges for concrete contractors. They often involve working on-sites adjacent to an existing occupied facility and therefore create constraints on access, hours of work, noise levels and interface management that require a high level of planning. The projects can also incorporate complex specifications compared to more standardized commercial structures. Conslab use our decades of cast in-situ concrete experience to coordinate and execute healthcare projects at the highest level – brining formwork, reinforcing, large foundation raft slab and concrete technology expertise to the table to deliver exceptional results.

This project involved the conversion of a space within an existing facility to a new food production line. < Back Food Production Hall This project involved the conversion of a space within an existing facility to a new food production line. This project involved the conversion of a space within an existing facility to a new food production line. The client required a floor with a customised profile for drainage and production equipment installation, finished with a hard-wearing protective coating. The first step was to model the space in 3D to determine slab profiles and falls, allowing the client to visualise the finished product. Conslab then removed the old floor, designed and built a new slab to form the falls ready to be coated with a high-end coating fit for purpose to provide a hard-wearing base for the production line. The removal and construction of the slab was challenging - involving line pumping concrete over 80m through an operational facility and placing/finishing in a tight space. Finally, the Conslab Extend team installed a hard-wearing Sika Purcem 21 screed and epoxy system. This resulted in a hard-wearing surface which is easy to clean and will protect the slab for many years to come. This project is a great example of Conslab's broad expertise in flooring design, construction and enhancement delivering an outstanding result for our client. Key Stats 2021 Cobalt Interiors/Blue Chip FMCG Company Auckland Project Gallery Previous Next

< Back Bunnings DC High-performance slabs for busy Distribution Centre THE PROJECT Bunnings, the home-improvement retailer, will be opening a distribution centre close to the Auckland airport. Conslab has been contracted to carry out the concrete pours for the warehouse slab and external yard on this 33,775m2 site. The project utilised in total 5,576m3 of concrete. One of the key highlights of this project was the concrete pour for the warehouse slab (20,235m2 in size) which was poured over 6 back-to-back concrete pours with 3,542m3 of post-tensioning slab. The external yard (13,540m2in size) utilised a 2,031m3of combi slab as well as 50,000kg of steel fibre and a single layer of mesh with a combined weight of 77.48 tonnes. Key Stats 2018 Bunnings Auckland 20,235m2 Post-Tensioned warehouse slab 13,540m2 Heavy Duty Combi Slab pavement, designed and built by Conslab Project Gallery Previous Next

< Back Cardinal Logistics' Stage 1 Cardinal Logistics’ new Drury site is the country’s first fully automated facility Cardinal Logistics’ new Drury site is the country’s first fully automated facility with an overall capacity of 115,000 pallets. Stage 1, completed in 2023 has a capacity of managing 12,000 ASRS (Automated Storage and Retrieval System) pallets. Stage 2 will add another 48,000 pallets and the completion of stage 3 will see a further 55,000 pallets delivered from this site for the country’s’ largest privately owned 3PL provider. Haydn & Rollett invited Conslab for early design engagement to provide advice and design the right floor for the ASRS requirements. The robots and automated retrieval trucks are highly dependent not only on the levelness and flatness of the floor but also the high-quality surface finish. To ensure smooth operation of the automation, FM2 Flatness to EB15620 was required in the warehouses while the surface was mechanically trowelled to a highly burnished finish. Contracts Manager, Mark Turner from Haydn & Rollett said, “We were fortunate to have the expert assistance of Conslab deliver our slabs on Cardinal Drury Stage 1. The design needed to be unique due to the automation requirements, and the delivery faultless, and Conslab delivered on all fronts. Their team had the Clients interests at heart and no problem couldn't be resolved through hard work and collaboration”. The design team provided solutions through Dramix “Combi-Slab” option to meet the various design loads for racking, automated pallet cranes and forklifts. This solution incorporates both 400mm & 200mm thick floors with steel fibre and mesh heavy-duty reinforcement to provide a robust solution in the warehouses. The 200mm thick external yard slab was designed for 30-tonne containers stored 2 high moved by Combilift SC-3 Straddle carrier. This ~45,000m2 project (including warehouses and external yards) was delivered on time over 9 months with completion of Conslab scope in July 2023. “Conslab played a huge part in the success of this project and their contribution was very much appreciated”. Said Mark Turner from Haydn & Rollett. Key Stats 2023 Haydn & Rollett Auckland 45,000m2 overall project area 12,000m3 of Concrete 373 tons of steel fibre 670 tons of Reinforcing 21,0000m2 of Mesh Project Gallery Previous Next

New Zealand owned and operated, Conslab are a Concrete Technology company. Our team are experts in concrete materials, design, construction and maintenance, giving us a complete understanding of the concrete construction process. Get in touch today for help with your next big concrete project! 1/8 Health, Safety & Wellbeing We believe that all accidents are preventable and our long-term goal is to eliminate all serious workplace injuries across the company. Our goal is to ensure zero harm. Our number one priority is to focus on lead indicators to ensure future improvement. These include measures and initiatives that identify risks and hazards before they result in incident or injury – avoiding incidents rather than acting on them after they have happened. Our first priority includes putting in place measures to prevent risks and incidents in addition to documenting safety outcomes which remain a crucial part of our operations. Conslab are proud of our safety record with 0 serious harm incidents in over 8 years. All site staff are Sitewise certified, and the company has achieved Sitewise Green status. Our approach to safety is based on continuous improvement, with bi-annual safety days where all staff spend a full day on Health & Safety training and development. We provide all PPE for our staff and are vigilant in ensuring it's use. All staff receive annual health checks. Site specific safety plans (SSSP's) are developed for all project which we are involved in. Conslab are Mates in Construction partners, which provides support for all staff to improve mental health and prevent suicide in the construction industry. health-safety-wellbeing Sustainability Concrete production is a significant contributor to global warming and natural resource depletion. Conslab are committed to doing everything we can to reduce the environmental impact of construction work we undertake. As experts in concrete technology, Conslab advise on measures which can be used on each of our projects to reduce environmental impacts without compromising on concrete quality. Reducing the embodied carbon of concrete is often seen by project managers, engineers and architects as a challenging prospect with a lot of uncertainties. There is a perception that cost, quality and project programs will all be compromised by using concrete with reduced environmental impacts – but this doesn't have to be the case. By working with our supply partners and drawings our teams construction experience and expertise in concrete technology, Conslab can offer solutions which reduce the embodied carbon of the concrete used on our projects without any increase in risk or cost. For projects seeking Greenstar points under the Life Cycle Impacts – Concrete criteria (credit 19B.1), Conslab can provide options for achieving the most points possible with locally available materials, and take care of Greenstar reporting and compliance requirements. In addition to advising our customers on improving environmental performance on their projects – Conslab have reduced our impact in the majority of our projects through the development and promotion of efficient concrete slab designs (Post-tensioned and Steel Fibre), which can have up to 30% lower embodied carbon per m2 compared to conventional designs. Sustainability Industry Participation Conslab are committed to the advancement of the concrete construction industry. Since our inception, we have been setting the example for others to follow when it comes to professionalism in the concrete trades. We have been actively involved in a range of industry organisations for many years. Our management team are committed to sharing our knowledge and innovations through industry conferences and publications. Industry Organisations Some of the industry organisations which our company supports and are member of: ConcreteNZ NZ Concrete Contractors Association New Zealand Institute of Quantity Surveyors (NZIQS) SESOC industry-participation