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< Back Balance Reporoa Fertilizer storage buildings are as tough as it gets for a concrete flooring contractor THE PROJECT Conslab were engaged to design & build the concrete floors & pavements for a 10,000 m2 fertilizer store in Reporoa in the central North Island, the third significant project delivered for Ballance Agri-Nutrients, a leading supplier of fertilizer and feed to New Zealand farmers. Fertilizer storage warehouses pose several technical challenges. The floors are required to support large uniform distributed loads - in this case, 120 kPa - while also supporting the heavy-duty precast panels that act as storage bin dividers. On top of catering to this level of loading, the floor slabs can be subject to high levels of mechanical abrasion from front-end loaders, and chemical attacks from acidic and sulphate based fertilizers. Said Tim Walker, Conslab General Manager “Fertilizer storage buildings really are as tough as it gets for a concrete flooring contractor. The combination of heavy loading, lateral loads from the push panels, and high mechanical and chemical attack on the concrete mean that the floor is pushed to the limit every day”. Conslab utilized a Dramix “Combi-slab” solution to overcome these challenges. The solution incorporates both steel fibre, and heavy-duty mesh reinforcement to provide a very robust solution. A special concrete mix design was developed to provide durability to resist the chemical attack and high level of abrasion that the floors would face. The site location in Reporoa created an additional challenge for Conslab’s construction team. There were no local concrete plants within 45 minutes travel time of the site, and to make matters worse, the concrete plants available in the region had very low capacity and were using low-quality aggregate that wasn’t suitable for a high durability concrete floor. To overcome these challenges the team worked with the ready mixed concrete supplier to change to a higher performance aggregate, and each significant concrete pour was supplied concurrently out of two plants – in Rotorua and Taupo. “Thank you for your assistance on the Ballance Reporoa Project” Said Mick Keating, Project Manager for Haydn & Rollett, “A few of us went down for the official opening and the place is looking very sharp. Balance are very pleased with how the project went and will look to replicate this model and design in the future.” Key Stats 2019 Haydn & Rollett Reporoa 10,000m2 Seamless Combi Slab, design & built by Conslab Project Gallery Previous Next

When The Warehouse Group was converting a Warehouse Stationery store to a Torpedo7, they engaged Conslab to give the floor a fresh look. < Back 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. When The Warehouse Group was converting a Warehouse Stationery store to a Torpedo7, they engaged Conslab to give the floor a fresh look. The Conslab Extend team achieved this by: • Removing existing carpet tiles • Ground the floor to remove carpet glue • Repaired various defects in the slab, including injecting cracks, sealing joints, and patching small holes. • Ground and polished the floor to a high-end salt-and-pepper finish, blending areas that had been carpeted with those that were previously exposed and polished. A great example of giving an old floor a new life! Key Stats 2022 Retail Connection/The Warehouse Group Whangarei Project Gallery Previous Next

< Back 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! "Industrial buildings of this size are not common NZ, and are a rarity in regional construction markets. When main contractor Watts & Hughes were selected for this project, they turned to Conslab to provide a full design & build package for the floor slabs, one of the most critical elements of a distribution centre. Constructing such a large slab in a small market required careful planning of resources and coordination with our supply chain. Conslab's placing and finishing teams, site managers and engineers worked on a fly-in/fly-out basis over 5 months to deliver this project on time and on budget. The 175mm thick post-tensioned slab was constructed in 16 pours averaging 2300m2 per pour. The completed slab contains only two movement joints, between four coupled slabs of 9200m2. Conslab's patented Rhino joint system was used to accommodate the large slab movements and prevent slab curl. " Key Stats 2020-2021 Watts & Hughes Palmerston North 36,910m2 Post-tensioned slab, design & build by Conslab Project Gallery Previous Next

< Back Thushani Sulochana Quantity Surveying & Estimating Manager Thushani started working for Conslab in 2017 as a Quantity Surveyor after her permanent move to New Zealand. She then moved into a Senior Quantity Surveyor role within the team and is currently the QS manager. She manages the QS department with responsibilities for post-contract works. Having graduated with a Bachelor’s degree in Quantity Surveying from Sri Lanka, Thushani started her Quantity Surveying career first in the Middle East. Over a period of 15 years, she has accumulated experience in both contracting and consulting commercial roles while working on major developments including airports, hospitals, shopping centres, high-rise buildings, and industrial projects. Education: B.Sc. (Hons) in Quantity Surveying – University of Moratuwa, Sri Lanka Mail To play, press and hold the enter key. To stop, release the enter key.

< Back Nada Sundaram Technical & Business Development Manager Nada recently joined the Conslab Team after spending his first 10 years in Christchurch since relocating to New Zealand in 2014 following the devastating Canterbury Earthquakes in 2010 and 2011. He was heavily involved in the Canterbury Rebuilding Programme. Prior to moving to New Zealand he was working large scale projects in Singapore. He is a civil and structural engineer with over 16 years of experience in civil and structural design, project management and evaluation, design coordination and site supervision. Nada has worked for contractors and consultancy companies and been involved in residential, commercial and infrastructure development projects in Sri Lanka, Seychelles, Singapore and New Zealand. He has been involved in various stages of projects from concept design to completion. His broader experience in design, and construction supervision and project management in residential, commercial buildings and infrastructure projects will help to add value to the clients and foresee the potential risks involve in the projects and mitigate such risks. Nada enjoys solving problems and always willing to go for an extra mile to serve the clients. Over the years Nada has worked in various capacities including, Civil and Structural Engineer, Executive Engineer, Team Lead, Regional Manager and Director. Nada has worked in small to large scale projects and has good understanding of Building Codes and Standards. Nada has completed his Master of Engineering Studies in Earthquake Engineering at University of Canterbury and he is a Member of Engineering New Zealand. Mail To play, press and hold the enter key. To stop, release the enter key.

Get in Touch At our core 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. We work with the best global and local suppliers in the concrete industry, allowing us to bring the benefits of cutting-edge concrete materials and construction technology to our clients projects. Our passion for what we do sets us apart. Get in touch with one of our experts today to see how we can help with your next concrete flooring, concrete construction or repair and maintenance project. First Name Last Name Email Phone Company Message Submit Contact Info PO BOX 64360 Botany, Auckland 2163 info@conslab.co.nz Tel: 0800 4 SLABS Support Office 21 Heritage Way Otara Auckland 2019 Operations 2-12 Great South Road Takanini Auckland 2112 Thanks for submitting!

< 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

The Conslab Extend team recently completed this car park repair project for BBR Contech at New World Newtown. < Back New World Newton Carpark Topping The Conslab Extend team recently completed this car park repair project for BBR Contech at New World Newtown. The Conslab Extend team recently completed this car park repair project for BBR Contech at New World Newtown. Our works included installation of 2,600m2 of Sika Top Deck, and Dynamic Crack Bridging System which together with the FRP that BBR Contech installed, will provide the client with an upgraded car park that will last for years to come. The work was carried out in three stages by our team of approved applicators to minimise disruption as the car park remained open. A great project for the team that involved many moving parts, long hours, and a dedicated team! Key Stats 2022 BBR Contech Wellington Project Gallery Previous Next

A great example of the Extend team’s ability to deliver complex concrete enhancement projects throughout NZ. < Back Waiari WWTP A great example of the Extend team’s ability to deliver complex concrete enhancement projects throughout NZ. This project has involved a range of concrete enhancements, including over 5000m2 of epoxy coating to walls and floors, installing and coating over 500mm of coving and over 1000m of floor and precast joint sealing among many other specialized works! This work will help to protect this critical piece of water infrastructure for many years to come. A great example of the Extend team’s ability to deliver complex concrete enhancement projects throughout NZ. Key Stats 2021-2022 FH and Tauranga City Council Bay of Plenty Project Gallery Previous Next

< Back Mohammed Afroz General Manager Mohammed joined Conslab in 2023 and brings over 20 years of construction experience. Starting his career as a Quantity Surveyor, Mohammed has had commercial construction experience through involvement with projects like Westfield Albany. Following this Mohammed was instrumental in establishing and growing Composite Floor Decks Ltd as one of the country’s leading metal flooring installations businesses. Moving to Christchurch in 2014 for the Christchurch re-build program and successfully establishing the South Island branch for Composite Floor Decks Ltd has been a key achievement and milestone where Mohammed was based up till 2020. Mohammed has worked on major projects like, The Justice Precinct – Christchurch, Westfield Newmarket, NZICC, and Commercial Bay. Having been on both sides of the table, Mohammed understands the commercial and construction aspects of projects well and has a pragmatic approach to finding solutions for customers. Before joining Conslab, Mohammed was at Steel and Tube as GM - Roll Forming, where he spent 3 ½ years and gained substantial manufacturing experience. Mail To play, press and hold the enter key. To stop, release the enter key.

Flagship shopping centre with over 105,000m2 of concrete floors < Back 277 Broadway - Westfield Flagship shopping centre with over 105,000m2 of concrete floors The Project: Scentre Group (Owner and operator of Westfield in Aus & NZ) needed to create a new flagship store in New Zealand. New Market was chosen due to its high-end appeal for shopping and eateries and it’s a central location to public transport nodes. With New Market being so densely developed already, the only option was to go upwards. Many years of design and participation with the community culminated in the shopping centre that is open today. The Building The centre was to be split over two separate city blocks with a connection Airbridge for shoppers to move between. Both the 277 and 309 sites have a mixture of parking lots and retail. Before any of this could be realised, the existing historical 277 building had to be structurally strengthened before it could be detached from the portions of the building that were to be demolished. The site had historically bad ground conditions and when combined with asbestos contamination, made for hard work. Due to the inconsistent ground conditions, the entire foundation and basement slab structure was redesigned only a few weeks before the actual work started. This change included an additional 430 tonne of steel and 1,400m3 of concrete. To accommodate this unexpected tonnage, we had many re-inforcing elements made in Christchurch and shipped up to Auckland. The building is a structural steel, tray deck and concrete design. This meant multiple trades co-ordinating on a daily basis to achieve site goals. While working around other trades and over the top of each other, safety was always the number one priority. The building has 105,000m2 of concrete slab comprising 15,500m2 slab on grade with varying thicknesses and89,500m2 of suspended concrete slabs. Key Stats 2018 - 2020 Scentre Group Auckland Total concrete volume to the project: 21,000m3 Total floor area to project: 105,000m3 Total re-inforcing to project: 2,350 tonnes Man hours by Conslab: 415,000 man-hours Largest singular pour by area: 2,065m2 Largest singular pour by volume: 206m3 Project Gallery Previous Next

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