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< 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

< 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

Our people are the best in the business. We know concrete, in fact we've helped set the Standard. Whether it is Quantity Surveying, Project Management or Quality and Compliance, we have got the right people to get the job done. Our Team Mohammed Afroz General Manager Glyn Sutton Construction Manager Mike Shackleton Operations Manager Nada Sundaram Technical & Business Development Manager Thushani Sulochana Quantity Surveying & Estimating Manager Michael Ledbrooke Account Manager - Extend

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.

For over 20 years, Conslab have been leading the way in the New Zealand Construction industry when it comes to concrete floor slab design and construction. Based on an inherent passion for concrete technology, Conslab offers a full end-to-end solution for concrete floors. Flooring For over 20 years, Conslab have been leading the way in the New Zealand Construction industry when it comes to concrete floor slab design and construction. Conslab's approach to floor construction is unique in the New Zealand market. Based on an inherent passion for concrete technology, Conslab offers a full end-to-end solution for concrete floors. The Conslab Process Early Involvement Getting Conslab involved early in a project ensures the best possible outcome. We will provide advice on how to achieve optimal storage density, vehicle operations and minimise maintenance disruption. Decisions made at this early stage will impact the buildings performance for many years, so it is critical to a successful build. Early engagement also helps to minimise risk exposure and project cost. Design Conslab's Engineering team are experts in concrete floor design, combining the latest in design and materials technology with unrivaled experience in the construction of high-performance floors. A floor designed by Conslab will be fit-for-purpose, durable and cost effective, with each slab specifically designed for the unique demands of the project. Build Conslab's flooring construction team are the best in the business. With many decades of experience at all levels, combined with the latest in concrete placing and finishing equipment, Conslab will build your floor to spec, on time and within budget. Maintain Regular maintenance of concrete floors can increase their service life by many decades, ensuring the efficiency and longevity of your operations. Conslab's Extend division specialise in concrete floor maintenance to give your slab a long and productive life. Conslab - Commercial Concrete Flooring Experts Logistics & DC's Retail Industrial LOGISTICS & DISTRIBUTION CENTRES Logistics_DCs Cold Store | Durable flooring solutions for Cold Storage facilities Conslab's design & build solutions for cold stores provide low maintenance durable floor slabs that are built to last. Construction of cold storage facilities presents some unique challenges for designers and builders, in particular the concrete floor slab. Although often an overlooked aspect, the floor is critical to the function of cold-stores as it is the platform for all operations. The efficiency of storage, inventory movements, and the avoidance of downtime for maintenance, are critical to profitability and can be severely hampered by poor quality concrete floors. Conslab are experts in the construction of concrete floor slabs for cold storage facilities and will work with your project team to minimise risk and maximise the utility of the completed building. We will assist in working through the design and detailing required to prevent cracking and achieve a high-durability finish, minimise joints and ongoing maintenance, and ensure the slab can resist freeze-thaw damage in critical areas. Repairs and maintenance to concrete floors are always expensive, a cost which is significantly increased in cold storage environments. Repairs may require re-location of racking and stock, or in the worst case the temperature may need to be raised to allow for repairs as some products such as repair mortars or epoxies cannot be used at low temperatures. This reinforces the critical importance of getting the floor slab right first time. Super flat floors for Very Narrow Aisle (VNA) racking Maximise storage density by stacking higher and closer – minimise construction risk by using a contractor who gets it right first time. Developers and tenants of logistics buildings know that a critical measure of a buildings value is how much product can be stored in it. This has led to the continued development of storage systems with ever increasing storage density. One of the key advancements over previous decades is the introduction of Very Narrow Aisle (VNA) racking systems. VNA storage systems are a significant advancement in storage efficiency and density compared to traditional racking. Very tall racking (up to 16m) with very narrow aisles (approx 1.7m) require precise control of floor surface flatness and levelness in trafficked aisles, typically specified as DM1 to EN15620 or ConcreteNZ TS01:2021. Traditionally VNA floors have been constructed as long-strip pours that are screeded side to side. The downside of this approach is a floor which is full of joints, which are costly and lead to long-term maintenance issues. In 2014 Conslab pioneered a new approach to VNA floor construction for the James Pascoe Group Distribution Centre. Conslabs approach advanced VNA floor construction in several ways: Use of large-bay post-tensioned slabs to minimise joints and produce a much more durable and cost effective solution. Speed up slab construction by approximately 20% Mitigate risk of slab-curl by using patented Conslab Rhino-Joints Ensure VNA flatness/levelness specifications were met through advanced profiling/surveying technology and precision concrete grinding Reduced construction costs approximately 25% compared to traditional design/construction methods Since then, Conslab have refined our approach to VNA floor construction over many projects. Super Flat Floors Cold Store Heavy-Duty Container Pavements E-Commerce Super-Flat-Floors cold-storage Heavy-Duty Pavements | Heavy-duty Container pavement Design & Build solutions Conslab's heavy-duty pavements for containers, straddle carriers and reach stackers are durable, low-maintenance and built to last Heavy-duty concrete pavements are critical pieces of modern logistics and transport infrastructure. Pavements need to handle extreme loading from stacked containers, straddle carriers and reach-stackers, which often leads to slab failures and damage to slab joints and edges. Well designed and built pavements enable highly efficient storage and movement of containers - poorly designed and built pavements result in significant losses through downtime, reduced efficiency and maintenance. Conslab can design and build heavy-duty pavements designed specifically for a project's requirements. From single container set-down areas and devanning canopy's for warehouses, to 5+ high container stacks at rail and port depots. Avoiding long-term maintenance can be achieved through careful design to eliminate joints and reduce the risk of uncontrolled cracking. Conslab are experts in the design and construction of Combi Slabs which use high-performance steel fibres and conventional reinforcing to reduce/eliminate the need for movement joints. heavy-duty-pavements E-Commerce | Future-proofed slab designs unlock automation potential Optimised e-commerce floor slab design and build solutions maximise e-commerce warehouse efficiency and automation potential Demands for e-commerce fulfillment centres and warehouse space has rapidly increased over recent years. Consumer demand for fast delivery of online purchases has introduced new challenges to designers and tenants of e-commerce facilities. Project timeframes are under increasing pressure and fast-tracked construction programs are now the norm. This rapid construction is taking place on sites selected for proximity to consumers, increasing development of brownfield sites with poor or complex ground conditions, introducing additional challenges. The final layer of complexity is accommodation of automated robotics systems, which are also rapidly developing. E-commerce warehouses currently under construction must be able to accommodate current and future automation systems. Conslab understand the challenges of building e-commerce facilities, and will work with the tenant, developer and project team to build a floor specifically designed for the sites unique requirements. Some of the considerations on modern e-commerce projects: Poor ground conditions - The need for e-commerce facilities to be close to consumers requires developments of brownfield sites which often have complex ground conditions. Low sub-grade modulus, expansive soils, liquefaction potential and differential settlement are common challenges. Construction/expansion joints - To maximise the potential for automation and reduce maintenance, Conslab can design slabs with minimal or no movement joints. Joints can interfere with the movement of automated guided vehicles (AGVs) and limit changes to racking layouts. Flatness/Levelness/Stiffness - Automation systems have varying requirements for floor surface regularity. Automated Storage and Retrieval Systems (ASRS) are large racking systems with automated goods movement, these require careful control of floor slab levelness and stiffness to very tight tolerances. Small robots (AGVs) that travel on the floor generally require precise control of the floor flatness, however floor levelness and stiffness is less critical. Surface Finish - Abrasion resistance, surface reflectivity (gloss) and friction can all impact the ability of AGVs to operate on a floor. Abrasion resistance is required to ensure the floor does not degrade with high-volume of traffic. Surface reflectivity can be critical to the function of some AGVs which rely on the floor for guidance, too much or too little reflectivity can be an issue. Surface friction is critical to ensure AGVs have enough traction to move the loads they carry. Balancing requirements for future-proofing and affordability is challenging. Conslab will provide a complete floor slab solution that deals with the unique challenges of each project and achieve the balance between cost and future flexibility. e-commerce RETAIL Retail Beautiful, low-maintenance concrete floors for Retail Retailers save on operational, maintenance, cleaning and lighting costs with a beautiful concrete floor slabs by Conslab The influence of a concrete floor on retail store performance is often overlooked. Floors are the stage upon which retailors present their products to shoppers, and it plays a big role in setting the feeling of the store. Floor quality also significantly influences operational costs for large-format retailers. Lighting, maintenance and cleaning demands can be significantly reduced by a high-performance concrete floor slab. Conslab's design & build solutions for retail building are specifically designed to meet the needs of the retailer. The advantages of Conslabs approach: Superior aesthetics and colour consistency – Through careful management of the concrete mix design and construction process, and application of surface treatments, Conslab produce slabs with exceptional aesthetics to provide a great backdrop to retailer's products. In-house concrete polishing/grinding - Conslab provide a full range of concrete enhancement services, including concrete grinding/polishing. By building slabs and performing the grind/polish process we can control all variables which influence the final look. High gloss – Through specialist placing/finishing techniques and surface treatments, we can produce floors with high levels of gloss, which reduces lighting demands for retail spaces. Elimination of joints – Joints are the most common location for slab maintenance issues. By designing slabs without joints we greatly reduce the potential for ongoing maintenance costs and disruption to operations. INDUSTRIAL Industrial Food & Beverage | Hygienic, easy to clean concrete flooring solutions Conslabs Design & Build solutions for Food & Beverage facilities are easy-to-clean, hygienic and durable Food and beverage manufacturing environments require functional and durable flooring. Floors must maintain hygiene requirements, be non-slip, and easy to clean. In some instances they must also resist aggressive chemicals and regular soaking for cleaning which can damage conventional concrete floors. Meeting these requirements often involves the use of floor coatings, which pose challenges in themselves. Poorly applied coatings fail early and are costly and disruptive to reinstate. Conslab provides the full-package solution for construction of food & beverage manufacturing facilities, combining our expertise in the design & construction of concrete floors with our specialist team of floor coating applicators. We can assess the specific requirements of any food & beverage manufacturing project to determine if coatings are required, and if so which type meets the needs of the project. By using Conslab to design and construct a floor, then provide coatings, developers can be sure that the slab substrate is compatible with the applied coating, eliminating the interface risk of dealing with separate flooring and coating contractors. Food & Beverage Manufacturing Agriculture Food-and-beverage Manufacturing | Optimised concrete floors for manufacturing facilities Design & Build concrete floor slabs specifically designed for any manufacturing environment without compromising on quality Modern manufacturing facilities contain highly speclialised production equipment, which is optimised for performance. Optimised manufacturing facilities need optimised floor slabs, with specifically designed slabs for each area of the facility. Conslab work with engineers, architects, builders and tenants to provide tailor made flooring solutions in manufacturing facilities. Slabs are often required to accommodate complex plant and services layouts, pits and drainage details, withstand aggressive chemicals, be suitable for applied finishes and coatings, all while being cost effective and durable. Our team of concrete experts know that there are no one-size-fits all solutions for manufacturers, and will provide design options which balance performance and cost, so that the project team can make informed decisions about the best solution for their facilities. Manufacturing Agriculture | Durable concrete floors for Agriculture supplies Cost effective concrete flooring solutions which stand up to the tough demands of the Agricultiral industry Structures used for agriculture supply products such as fertiliser and animal feed are exposed to a range of conditions with the potential to damage concrete. Fertilisers when combined with the humidity in air forms compounds which are highly aggressive to concrete and can cause rapid deterioration of concrete slabs and storage bins. Extreme concrete cracking, spalling and reinforcing corrosion are commonly found in fertiliser storage facilities, even those built quite recently. Bulk storage of fertiliser and animal feed is also a challenge when designing concrete floors due to the heavy bulk load from the stored products, as well as a need to resist damage from loaders scraping floors to move the material. The specific requirements of any concrete floor are unique to a given site and application. Conslab designs and builds concrete floors for agricultural facilities with a focus on key performance requirements: Chemical durability to resist damage from aggressive chemicals from fertiliser, chemicals or effluent – this requires slabs which limit the ability of aggressive chemical to enter the concrete through cracks, joints and the concrete surface. This is achieved through design of seamless slabs without joints, limiting crack widths to very small diameters and using concrete mix designs with low permeability. Low maintenance through elimination of joints, high quality construction and durable design. Strength to deal with heavy bulk storage loads Resists damage from loaders scraping material off floor slab Cost effective and efficient to build As experts in concrete design and construction, Conslab work with our clients to produce the most durable and long lasting solutions possible within the clients budget. Conslab floors are long lasting and easy to maintain, ensuring minimal disruptions to operations once a new building is complete. Agriculture

< Back James Pascoe Group Distribution Centre Award-Winning Superflat floor for VNA Racking Conslab was awarded the Award of Excellence in the Slab-on-Ground Category at the 2017 Post-tensioning Institute Awards held in Atlanta, Georgia as a result of the work done on the James Pascoe Group Distribution Centre. This award is given to the top project in each category that demonstrates excellence in post-tensioning applications. The PTI Award of Excellence is an honor that serves to recognise the best in the industry and several factors are considered in selecting the awards, including creativity, innovation, ingenuity, cost-effectiveness, functionality, constructibility, and aesthetics. James Pascoe Group required a state-of-the-art national distribution centre to consolidate, warehousing for all of the groups' retail brands, which include Farmers, Whitcoulls, Stevens, and Pascoes. The long-term goal is to minimise costs and maximize value for customers. This was supported by introducing the absolute latest warehousing systems and technology including 16m high very narrow aisle (VNA) racking – the highest level installed to date in the southern hemisphere. The cutting edge VNAracking and material handling equipment (MHE) required a level of floor flatness that is considered the highest in the world, existing on the margins of what had been achieved globally. The floor was constructed as a series of large bay post-tensioned floors, coupled together so that there were only two opening joints located within the 25,000m2ground floor. Combined with the use of a new system for concrete floor jointing – the Rhino joint – this creates a surface that would require little to no maintenance during the life of the structure. The use of post-tensioning allowed for an efficient and relatively thin 240mm thick floor to cater to the 120kN back-to-back rack loading, thereby reducing the volume of concrete compared to a traditional floor system. As the key working surface in the facility, the 25,000m2 post-tensioned concrete high-performance ground floor played a pivotal role in the success of the project. A hybrid, the large-bay post-tensioned solution was developed, which minimised joints, allowed fast construction, and provided a more sustainable solution by reducing concrete volumes. The combination of faster construction time and more efficient use of materials resulted in an approximate 25% reduction in cost. This award acknowledged Conslab’s exemplary achievement in post-tensioned concrete construction. Further to this, Conslab’s efforts in the distribution centre were also acknowledged at the biennial NZ Concrete Society Awards - the project was selected for a special commendation for displaying outstanding innovation in the advancement of concrete practice. Conslab was awarded the “Technology Award”. Key Stats 2015 James Pascoe Group Auckland 25,000m2 Post-tensioned slab, design & build by Conslab Project Gallery Previous Next

< 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