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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

< 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 Mike Shackleton Operations Manager Mike started with Conslab, formerly known as Mooney concrete in 1993. He has seen the company grow in leaps and bounds. Over that time Mike has grown into one of the best concrete professionals in the industry, looking after countless flagship flooring projects, including the recent Costco Westgate. Mike now plays a big part in training our future concrete professionals and does a great job sharing his experience and knowledge. Working his way through many positions and aspects of the company, he is familiar with and competent with all things concrete. In his current role as Operations Manager allows Mike to connect and work with many great people. He enjoys seeing a project through from start to finish whether it be a 90m2 floor or a 9000m2 warehouse. Mike can help guide your project from foundation to finish and use his 30 years of experience in the industry to make sure our clients have the best flat floors possible. He is always on top of the tried, true, and tested ways, as well as keeping up with the latest innovations, enabling him to support all clients with various needs when it comes to concrete. Mail To play, press and hold the enter key. To stop, release the enter key.

< 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 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

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

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