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Conslab are experts in concrete materials, design, construction and maintenance with a comprehensive understanding of the concrete construction process. We work with the best global and local suppliers in the concrete industry to produce oustanding concrete flooring and construction results. Concrete. design | build | enhance scroll down Conslab was founded in 2000 by a small team passionate about concrete technology. Conslab have been driving the New Zealand concrete construction industry forward with innovative new design and construction methods ever since, building a reputation for innovation, quality and efficiency in all that we do. 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. home-summary WHAT WE DO FLOORING From Superflat Floors to retail, agriculture to e-commerce and every application in between – Conslab designs, builds and maintains the best floors in NZ. Learn More CONSTRUCTION Conslab are the concrete construction experts - offering full package solutions for concrete, steel and formwork. Learn More EXTEND All aspects of concrete repairs, maintenance and enhancement under one roof: from coatings to polishing, crack repairs to joint filling – we've got you covered Learn More WhatWeDo

< 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.

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

< Back Glyn Sutton Construction Manager Glyn has been a part of the Conslab team for over 12 years starting as a Site Manager on the Fonterra Crawford St project in Hamilton back in 2009 – at the time the largest warehouse/DC project in New Zealand. As an Operations Manager, Glyn is responsible for all aspects of construction within our Flooring division. This includes managing QA, programming, employee safety and wellbeing. Developing the next generation of concrete flooring professionals is a key focus for Glyn to ensure that Conslab remain at the forefront of the NZ market.  Having 30+ years of experience in the building and construction industry, Glyn is one of the leading concrete construction experts in NZ, with a well-earned reputation for combining practical experience with understanding of concrete engineering and design. He has a reputation for being able to foresee possible problems on a project and then manage or mitigate those risks to keep projects on track. Mail To play, press and hold the enter key. To stop, release the enter key.

Taxiway and hardstand reconstruction project at NZDF Base Whenuapai. < Back Whenuapai Taxiway & Hardstand Taxiway and hardstand reconstruction project at NZDF Base Whenuapai. Conslab were engaged to construct the concrete pavements for a 15,000 m2 taxiway and hardstand reconstruction project at NZDF Base Whenuapai. The technical specification for the concrete pavement was very exacting to accommodate the Principals requirement for a long asset life with minimal maintenance. Conslab worked collaboratively with the client and principal consultants to develop an optimal concrete mix design and casting methodology that would meet the requirements for extremely accurate pavement finished levels, defect-free wearing surfaces, and high concrete flexural strength. Conslab supplied and placed nearly 7,000 m3 of the specially designed high flexural strength concrete to construct the pavements. The weather conditions at NZDF Base Whenuapai, with high wind speeds which can lead to plastic shrinkage cracking in concrete pavements, created additional challenges for the project team. Faced with a high risk of unacceptable surface defects from adverse weather, or alternatively delaying casting dates to avoid high wind, the team redeveloped the casting methodology to reduce weather risk and even improve program duration. Key Stats 2018 - 2019 Fulton Hogan Auckland 15,000m2 of high-performance Taxiway and Hardstand Pavement Project Gallery Previous Next

< 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

< 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.

< Back Foodstuffs North Island DC New Zealand's Biggest Warehouse! "The new Foodstuff North Island Distribution Centre at the Landing in Auckland Airport is the largest warehouse ever built in New Zealand. Completed in 2021, this building services over 100 supermarkets and stores up to 80,000 pallets at a time. The main contractor Macrennie Commercial Construction understands the importance of the floor slab in the efficiency of such buildings, and selected Conslab as Design & Build flooring contractor for the project. The safety and efficiency of warehouse operations are largely dependent on the quality of the floor slabs. The floor is the surface upon which all warehouse operations take place, and if it isn't right the building will never operate at its full potential. Conslab got involved early in the project offering advice on slab design and detailing to ensure the slab could be built efficiently within the project timeframe, without compromising on quality or performance. The final design is a 180mm thick post-tensioned slab, which was constructed over 31 pours ranging from 1670m2 to 2940m2. The slab and joint layout were developed to maximise the pour sizes and keep the number of movement joints to a minimum. Movement joints are Conslab's patented Rhino Joint to accommodate large joint openings and eliminate the risk of slab curl. The finished product is a durable, low-maintenance floor slab that will allow Foodstuff to efficiently service its stores around the country. It also happens to be the largest warehouse floor slab in the country, something that the Conslab team takes great pride in. " Key Stats 2020 Macrennie Commercial Construction Auckland 74,000m2 Post-tensioned slab, design & build by Conslab 25,753m2 Combi Slab 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 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! Working with Complete Reinforcing and several contractors, Conslab removed the rails and track, completed the formwork and placement, then poured the slab. This crucial part of the task had to be completed within six days. Adding to the difficulty, the pour began at midnight on Boxing Day. After 63 prefabricated cages measuring 12 metres long were caged into place, the Conslab team worked 24 hours a day for six consecutive days, delivering the slab, with slots for reinstalling the track, by New Year’s Eve. In total 1,598m3 of concrete was poured. Key Stats 2016 Kiwirail Tauranga 750m Track slab constructed in 10 days Project Gallery Previous Next

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! < Back 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! Working with Complete Reinforcing and several contractors, Conslab removed the rails and track, completed the formwork and placement, then poured the slab. This crucial part of the task had to be completed within six days. Adding to the difficulty, the pour began at midnight on Boxing Day. After 63 prefabricated cages measuring 12 metres long were caged into place, the Conslab team worked 24 hours a day for six consecutive days, delivering the slab, with slots for reinstalling the track, by New Year’s Eve. In total 1,598m3 of concrete was poured. Key Stats 2016 Kiwirail Tauranga 750m Track slab constructed in 10 days Project Gallery Previous Next

< Back 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. THE PROJECT The 8200m2 and 5200m2 Post tensioned slabs designed and built by Conslab provide a super-flat and highly durable surface, no movement joints and almost zero maintenance. The slabs have high load capacity and are detailed to allow for future VNA conversion, meaning successive tenants can make the most of the high-stud warehouse space (16.75m to the roof ridge) and maximise storage efficiency. The 7400m2 Yard slabs are Combi Slab designs, which utilise steel fibre and mesh to eliminate saw-cuts, greatly enhancing the durability. As a Greenstar 5 project, Conslab were tasked with providing more sustainable flooring solutions, with all slabs constructed using fly ash concrete to reduce embedded carbon. Owner: Fernbrook Property Main Contractor: Haydn & Rollett Ltd Engineer: MSC Consulting Group Architect: T Plus Architects Key Stats 2023 Haydn & Rollett Auckland 8200m2 and 5200m2 Post tensioned slabs designed and built by Conslab Project Gallery Previous Next