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New Zealand owned and operated, Conslab are a Concrete Technology company. Our team are experts in concrete materials, design, construction and maintenance, giving us a complete understanding of the concrete construction process. Get in touch today for help with your next big concrete project! 1/9 Health, Safety & Wellbeing We believe that all accidents are preventable and our long-term goal is to eliminate all serious workplace injuries across the company. Our goal is to ensure zero harm. Our number one priority is to focus on lead indicators to ensure future improvement. These include measures and initiatives that identify risks and hazards before they result in incident or injury – avoiding incidents rather than acting on them after they have happened. Our first priority includes putting in place measures to prevent risks and incidents in addition to documenting safety outcomes which remain a crucial part of our operations. Conslab are proud of our safety record with 0 serious harm incidents in over 8 years. All site staff are Sitewise certified, and the company has achieved Sitewise Green status. Our approach to safety is based on continuous improvement, with bi-annual safety days where all staff spend a full day on Health & Safety training and development. We provide all PPE for our staff and are vigilant in ensuring it's use. All staff receive annual health checks. Site specific safety plans (SSSP's) are developed for all project which we are involved in. Conslab are Mates in Construction partners, which provides support for all staff to improve mental health and prevent suicide in the construction industry. health-safety-wellbeing Sustainability Concrete production is a significant contributor to global warming and natural resource depletion. Conslab are committed to doing everything we can to reduce the environmental impact of construction work we undertake. As experts in concrete technology, Conslab advise on measures which can be used on each of our projects to reduce environmental impacts without compromising on concrete quality. Reducing the embodied carbon of concrete is often seen by project managers, engineers and architects as a challenging prospect with a lot of uncertainties. There is a perception that cost, quality and project programs will all be compromised by using concrete with reduced environmental impacts – but this doesn't have to be the case. By working with our supply partners and drawings our teams construction experience and expertise in concrete technology, Conslab can offer solutions which reduce the embodied carbon of the concrete used on our projects without any increase in risk or cost. For projects seeking Greenstar points under the Life Cycle Impacts – Concrete criteria (credit 19B.1), Conslab can provide options for achieving the most points possible with locally available materials, and take care of Greenstar reporting and compliance requirements. In addition to advising our customers on improving environmental performance on their projects – Conslab have reduced our impact in the majority of our projects through the development and promotion of efficient concrete slab designs (Post-tensioned and Steel Fibre), which can have up to 30% lower embodied carbon per m2 compared to conventional designs. Sustainability Industry Participation Conslab are committed to the advancement of the concrete construction industry. Since our inception, we have been setting the example for others to follow when it comes to professionalism in the concrete trades. We have been actively involved in a range of industry organisations for many years. Our management team are committed to sharing our knowledge and innovations through industry conferences and publications. Industry Organisations Some of the industry organisations which our company supports and are member of: ConcreteNZ NZ Concrete Contractors Association New Zealand Institute of Quantity Surveyors (NZIQS) SESOC New Zealand Green Building Council (NZGBC) industry-participation

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

Conslab's Extend division provides the complete range of concrete coatings, repair, maintenance and enhancement services. Why replace old or worn out concrete when it can often be repaired or rejuvenated for a fraction of the cost. Conslab can enhance the functionality and appearance of any concrete floor or structure.   Repair | Maintain | Enhance Conslab's Extend division provides the complete range of concrete coatings, repair, maintenance and enhancement services. Why replace old or worn out concrete when it can often be repaired or rejuvenated for a fraction of the cost. Conslab can enhance the functionality and appearance of any concrete floor or structure.   Repairs & Maintenance It is often said that concrete maintenance costs increase exponentially if not taken care of regularly. Concrete assets, in particular floor slabs, are expensive to construct, but if properly taken care of should last many decades. Regular inspection and maintenance ensures this is the case. If floors and structures are left to deteriorate – minor issues can become major. Regular inspection and repair of minor issues is essential to the long-term performance of concrete assets. Conslab can manage and perform any type of concrete repairs – from patching small areas or holes, through to full rip-out and replace and seismic strengthening. Conslab's experts will recommend repair solutions that ensure repairs are long lasting and restore full functionality and durability. Enhance Aged concrete floors and structures can be difficult to replace or alter. Re purposing existing buildings for new purposes often means that a floor which was perfectly suitable for the previous use (I.e storage or a workshop) is no longer suitable for the new use (I.e retail or accomodation). There are a range of options for rejuvenating and enhancing the look of a concrete floor, from light polishing to enhance appearances and reduce maintenance, through to high-end architectural finishes with high-gloss polished concrete. Seismic strengthening of existing concrete structures is also a great option for extending the life and value of aged concrete structures. Conslab's strengthening experience and ability to manage and perform small concrete works and upgrades makes us a one-stop-shop for enhancing existing concrete assets. Expoxy & resin coatings & screeds Topping Slabs Joint Sealing Grinding & polishing Joint Repair Crack Repairs Bolt hole repairs Concrete cleaning & scrubbing Seismic Strengthening Small works projects & upgrades EPOXY & RESIN COATINGS & SCREEDS epoxy-resin-coatings Coatings and floor screeds to concrete floors are used for a wide variety of reasons. They can be used to change the appearance of a floor with coloured epoxy, enhance safety by using a non-slip coating, or protect the underlying concrete from everyday wear and tear or harsh chemicals.     The appearance and use of concrete floors can be completely transformed with an epoxy coating.     A range of epoxy and coating systems are available with various benefits and characteristics. For decorative applications epoxies can be coloured, have decorative flake or aggregate added and be applied in any pattern or shape desired. For industrial applications epoxies are used for waterproofing, anti-slip, chemical resistance, impact resistance and to allow for easy cleaning in hygiene-sensitive facilities.    Conslab's experience and expertise in coating means we can advise on appropriate systems which are cost effective and will meet your specific requirements.    In addition to selecting the correct coating for a given application, attention to detail in surface preparation and coating application are key to ensuring coatings are long-lasting and durable. Conslab's experienced team of coatings applicators will clean and prepare the surface, fill joints and repair cracks prior to applying coatings.   TOPPING SLABS topping-slabs Topping slabs are used for enhancing old floors and providing a durable hard wearing surface. Topping slabs are thin concrete slabs laid over existing concrete. The design and construction of topping slabs needs to be specific to the site's requirements and the slab's use.     Some of the uses for topping slabs include:    Provide a dense, hard-wearing surface for slabs with heavy traffic and industrial use  Provide falls for drainage purposed to level slabs  Level slabs with falls and gradients  Toppings can be designed for grinding/polishing with coloured concrete/aggregates - allowing customisation of the finished polished concrete appearance  Substrate for applied coating/tiles/carpet when the existing slab is not suitable  More cost-effective long-term option to make good a heavily damaged/worn slab   Thin topping slabs < 100mm thick should be bonded to the underlying slab. Surface preparation of the underlying slab is critical. The underlying concrete must be roughened to aid adhesion, clean and free of dust/debris. Conslab use mechanical or chemical bonding systems depending on the site-specific requirements.   Thicker topping slabs are generally constructed as an unbonded topping. Unbonded topping slabs are separated from the underlying concrete by a slip layer to allow the topping to shrink without cracking. Topping slabs must be carefully designed and detailed to control cracking, and constructed by experienced tradespeople to prevent failure and re-work. Conslab can manage the full process from design & detailing through to construction, making topping slabs stress free. CONCRETE FLOOR GRINDING & POLISHING grinding-polishing The process of grinding and polishing a concrete floor completely transforms it's appearance and texture.     Grinding floors removes the top surface of concrete, exposing the aggregate within. The depth of grinding determines how much of the underlying aggregate will be visible on the finished floor. A light grind, known as salt and pepper, exposes only a small amount of aggregate so that the floor has a speckled appearance. Grinding further exposes more aggregate, and the deepest grind taking off approximately half of the top layer of aggregate, exposing the aggregate structure and colour and giving a very unique look to the floor.    Concrete polishing smooths the concrete surface and provides a glossy finish. Floors are typically polished after grinding, but any floor can be polished to enhance it's gloss and sheen.     All concrete floors can be ground and/or polished – and the finished appearance will depend on the quality and characteristics of the concrete, and of the grinding/polishing process used.    For new concrete, Conslab can provide a full service solution including construction of the concrete floor. When building floors which are to be ground/polished, the concrete mix design can be designed for a specific appearance, with various aggregate shapes/sizes/sources and concrete colours offering endless customisation.    When existing concrete floors are ground and polished we uncover what is hidden beneath the surface. Grinding old floors reveals the story of the floor slabs construction and life. No two concrete floors are the same and the finished appearance of a ground and polished floor is always unique.  JOINT SEALING joint sealing Concrete slabs are designed with joints in them to allow for the slab to shrink and/or expand without cracking. Joints in concrete floors and pavements vary in type and size, and almost always benefit from regular maintenance and sealing.    Sealing concrete joints helps to support the joint edge and prevent damage under traffic and heavy use. It also prevents water and debris from entering the joint. Joints full of debris are more likely to be damaged and water ingress through joints can lead to premature failure of concrete slabs.    A wide range of joint sealants are available depending on the specific service conditions of the slab. Conslab can advise on joint sealant selection suitable to your site, and offer a full joint cleaning and sealing service.  JOINT REPAIR joint-repair Concrete joints are the most common point of failure in slabs and pavements. Heavy traffic, poor construction practice, design deficiencies and changes to slab use can all lead to joints being overloaded and damaged.     Often it may seem that slabs with damaged and deteriorating joints need to be ripped out and replaced, but this is often not necessary. Conslab 's team are experienced in a range of techniques and methods of stabilizing, repairing and reinstating damaged joints.    If joint damage is addressed early, when signs of joint distress first become apparent, then repairs are often minor and non-disruptive. Joints can be stabilised and strengthened to improve their durability to the working environment and ensure they still function.     When joint damage is allowed to continue to a significant amount of time, repairs become more involved and complex. This may involve cutting out areas of slab alongside joints and reinstating the slab with a new armored joint system.    Regardless of the level of concrete joint damage you may be experiencing – Conslab can advise on the best approach to repairs and maintenance so that you can get the most out of your concrete slab or pavement.   CRACK REPAIRS crack-repairs There is a saying in the concrete industry that all concrete cracks – and if it's hasn't cracked yet it's just a matter of time. This isn't necessarily the case with well-designed floors like those designed & built by Conslab, but cracking is a major cause of concern for many building owners none the less.    Cracks range in cause and severity. In many cases they are not an indication of structural or durability issues but are unsightly. In some instances cracks can be a risk to concrete elements durability as they allow ingress of moisture and contaminants which could lead to premature failure or further maintenance issues.    Conslab are experts in crack repairs, from aesthetic repairs intended to hide the appearance of cracks, to structural crack repair which restores the strength of the cracked concrete.    There is a range of crack repair products and methods, which need to be assessed for each project to determine the best repair strategy. Crack size, width, location and the type of concrete element all need to be considered when planning a repair. Conslab can provide options for any form of crack repair to ensure a long-lasting and durable solution.  BOLT HOLE REPAIRS bolt-hole-repairs Racking hold down bolts are critical to the structural stability of racking systems. When racking layouts are changed or a warehouse with racking is vacated, bolt holes are left in the floor which need to be filled.     Bolt hole repairs may seem like a simple task, but Conslab often sees cases where repairs are poorly done, messy and not done to last.    Conslab's approach to bolt hole repair is unobtrusive and leaves the surface of the slab smooth. The repair material used is very high strength and fast-setting. This means the floor can be trafficked within 12 hours of repairs, and that the repairs are strong enough to withstand heavy traffic and impacts.  CONCRETE CLEANING & SCRUBBING cleaning-scrubbing Keeping concrete slabs clean and free of dust/debris is key to maintaining industrial and logistics floors. Buildup of debris on/around slabs can cause damage to joints and products stored on the slabs. Regular cleaning reduces the risk of premature slab wear and saves repair costs over the life of the slab.    Conslab has a range of slab cleaning solutions, including ride-on scrubbing machines and specially formulated cleaning solutions. Conslab's cleaning solutions are perfect for restoring the look of old and dirty slabs, removing tyre marks, grease and oil stains.    Our ride on scrubbers allows for fast and effective cleaning of large areas and is perfect for end-on-tenancy cleaning and preparing slabs for epoxy coatings or repairs.  SEISMIC STRENGTHENING seismic-strengthening In our earthquake prone country seismic strengthening project have become a critical way to add resilience to existing structures. The Conslab team have a broad range of experience in delivering seismic strengthening projects – from the building analysis and assessment stage through to project delivery. Our broad capabilities as a concrete contractor and specialist repair and maintenance contractor allow us to deliver value in either main contractor or specialist sub-contractor roles on seismic upgrade projects. SMALL WORKS PROJECTS & UPGRADES small-works-projects-upgrades Conslab have a broad range of expertise when it comes to designing, building and maintaining concrete floors and structures and this makes us uniquely situated to deliver complex small works projects and upgrades. Whether a project is driven by seismic strengthening requirements, automation upgrades, processing/manufacturing changes or a landlord wanting to refresh a building to remarket it – Conslab have the capability to assist. Conslab can help with maintenance assessment, remediation and upgrade scoping, and project delivery – tying together our broad range of expertise in concrete for the clients benefit.

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

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

Flooring Projects 90 Pavillion Drive This pair of new warehouses in Airport Oaks required high-performance floors to provide maximum flexibility for tenants and longevity for the owner. Read More Balance Reporoa Fertilizer storage buildings are as tough as it gets for a concrete flooring contractor Read More Bunnings DC High-performance slabs for busy Distribution Centre Read More Cardinal Logistics' Stage 1 Cardinal Logistics’ new Drury site is the country’s first fully automated facility Read More Foodstuffs North Island DC New Zealand's Biggest Warehouse! Read More James Pascoe Group Distribution Centre Award-Winning Superflat floor for VNA Racking Read More Sistema Massive Manufacturing Facility Read More Woolworths Palmerston North The new Woolworths Distribution Centre in Palmerston North is a mammoth building – at 38,000m2 it's large enough to fit more than five rugby fields! Read More

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

< 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

< 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.

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