CONCRETE CONSTRUCTION

JUNE / JULY 2012

PRINT POST APPROVED - PP231335/00020
SINCE 1988
CONSTRUCTION
ENGINEERING
ARCHITECTURE
AUSTRALIAN
6 News
ACRS Launches New Certifiers Checklists,
Precast Modular Construction Coming to Australia,
Brookfield Multiplex Wins Award for Darling of a Hotel,
35 Tonne Columns at the Collins Square Tower,
The Marilyn Monroe Towers - A Challenge for Formwork,
Precast Modular Construction Coming to Australia
12 Product Focus
International Paint Introduces Intercrete
TM
14 Training Courses
2012 Concrete Repair and Waterproofing Course
16 Cover Feature
PERI Rosett Flex - Setting a new benchmark in scaffolding
18 Company Profile
The Shisham Stanley Group - An Australian success story
21 Project Focus
London 2012 Olympic Games - Squeezed on time
26 Special Report
Brutalism - concretes ugly duckling. Could it be gaining
some love at last? Could exposed concrete be returning to
favour?
30 Product Focus
Rawlinsons Construction Cost Books 20122
21
26
table of
contents
June / July 2012
Volume 25 Issue 3
Published by:
Editorial and Publishing
Consultants Pty Ltd
ABN 85 007 693 138
PO Box 224, Wallan
Victoria 3756 Australia
Phone: (03) 5781 1826
Fax: (03) 5781 1706
www.epcgroup.com
Publisher
Anthony T Schmidt
Phone: (03) 5781 1826
Mobile: 0414 788 900
Email: ats@epcgroup.com
Editor
Jack Cleaver
Email: jack@epcgroup.com
Mobile: 0438 526 620
National Advertising Sales
Phill Terry
Phone: (02) 4782 2092
Mobile: 0425 255 495
Email: phill@epcgroup.com
Business Development Manager
Greg Smith
Phone: (03) 9704 9547
Mobile: 0418 333 774
Email: greg@epcgroup.com
Production Manager
Cam Fink
CIRCULATION 10,505
Registered by Australia Post
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ISSN 1034-7860
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Copyright 2012 - EPC Media Group
UPFRONT - About the Cover
In a move that looks set to revolutionised the way scaffolding is
used across the country, PERI Australia has launched its new
Rosett Flex range of products into the Australian market.
The innovative rosette on the Rosett Flex Standard is designed
to covet the rectangular ledger component, using a gravitational
locking wedge system that again is unique in its application and
design. Once the wedge has self-centred, it is impossible to
remove the component without using dismantling force, thereby
boosting safety and stability.
Australian Concrete Construction - June / July 2012 3
CONCRETE CONSTRUCTION
JUNE / JULY 2012
PRINT POST APPROVED - PP231335/00020
SINCE 1988
CONSTRUCTION
ENGINEERING
ARCHITECTURE
AUSTRALIAN
16
8
EDI TOR S COLUMN
4 Australian Concrete Construction - June / July 2012
Tight economic conditions can call into question the cost of
essential software that powers the consultants that the Australian
Concrete Construction industry relies on. The industry leader in
CAD software Autocad and also Microsoft, have their understand-
able return-on-investment objectives but not all of us can afford to
go along for their ride.
We have all had to bite the bullet of diminishing cash-flows as we
get gripped in the bank-enabled squeeze that engineered the
Global Credit Crunch. Rest assured that the banks arent doing it too
tough like the $24 billion profit of the four majors in 2010-11.
Thats equivalent to half our nations yearly spend on infrastructure
all those roads, bridges, potholes etc.
That four-bank profit is around our total yearly defence-spend.
But, good on them - our stable banking system helped protect us
from the GFC, so we should be grateful or it could have been a lot
worse.
It must be a lot tougher for our cement companies and the
Australian steel industry who are forced to face an uncertain future
of construction down-turns, carbon taxing, and heightened
environmental questioning, with few unrelated entities giving
support apart from this magazine (the free and the good) to
promote and excite concrete construction.
Now, getting back to software
We are not suggesting that you abandon commercial software,
after all that is what our industry relies on. But, some of us are being
shaken out of the system, retrenched, or retiring, but still want to be
productive and thats good for our industry we need those skills!
Well, heres where ACC magazine can help you
Firstly, you take the risk not us if you use these links leave the
lawyers to happily circle offshore with sharks, but please leave
us alone. Virtually every type of program has a free alternative,
some good some bad. Suggest you dont use them on your
mission-critical work.
Also... be sure that you have RELIABLE, UPDATED and ACTIVE
anti-virus / anti-malware software to protect your system and
your data - regardless of the type of software you use! You should,
however, be especially vigilant if you use any type of freeware
and/or shareware!
A free offering that delivers CAD performance and real
DWG compatibility, progeCAD Smart is free for personal,
non-profit, student and learning use only. Go to:
http://www.caddit.net/progecad/smart.php
Go to Google and download SketchUp for 3D its great and
essential for all architects.
Check out Blender also which is amazing, also free. Great
Blender tutorial (do a 3D render of a building in one hour) at:
http://yorik.uncreated.net/tutorials/architecture-blender.html
BRL-CAD is a free CAD program that was developed by the US
Military (originally developed for weapons design you
never know when you might need a major bomb or two).
Its not too shabby for architectural, believe us! Best way we
know to learn 3D CAD in 30 minutes.
Microsoft Office alternatives for the poor include OpenOffice;
or use the web-based Google Documents. Online office suites
such as Google Docs, and Zoho are functional and impressive.
But you generally don't get powerful online office tools for
browser-based editing.
Want Adobe Photoshop but too poor? Try GIMP or CinePaint,
or use the web-based Picnik or Aviary.
Need to dub your video presentations, download: Avidemux
or Virtualdub.
Trouble burning DVDs (only use legit material, or its a crime).
Cdrdao or Burn, are great to burn anything.
Microsoft is also offering their WebApps suite, being a free
(yes, proof that Bill Gates cares for the poor like us) web based
version of Office. Trust Bill, it wont stay free for long!
Try www.freeSerifsoftware.com for free desktop publishing
software, free website design software, free graphic design
software and free panoramic photo stitching software.
Those of us poor, retired, rejected, or retrenched can get
almost anything we want at this website: onsalt.com surely
the webs best freeware depository.
Now, we hope weve helped you, dear readers but please
support our software majors who deserve a fair return on their
investment. Editor would like a fair return on his investment on
boxes of expensive software he has that are outdated because of
Windows and computer upgrades cause compatibility problems.
Heard the term designed-in-obsolescence?
Think the software majors will refund Editors money for now
useless software? Didnt think so!
Editor admits to being a cheapskate driving around hardware
stores to buy broken bags of cement on the cheap. Editors car boot
is not a good look, now solid concrete thanks to a boot leak in the
recent rain. Corners well though with the extra weight!
Software can be hard on your pocket heres help
Intercrete

Advanced Concrete Repair and Protection

Complete solutions for new construction and maintenance
Rapid setting properties allow fast return to service
Application on fresh concrete enables fast track construction
Solutions for construction defects low cover, slip-forming repairs
Provides long term protection from carbonation,
chloride attack and ingress of water
Waterborne cement-based technology zero VOC
Contact us for your next project:
Toll Free Australia 131 474 / Toll Free New Zealand 0800 808 807
pc-australasia@akzonobel.com www.international-pc.com
6 Australian Concrete Construction - June / July 2012
NEWS
ACRS (Australian Certification Authority
for Reinforcing Steels) is a specialist,
independent, third party product
certification body which assesses domestic
and overseas manufacturers and suppliers
of construction steels for compliance to
Australian and New Zealand Standards.
Customers need to check that the
compliance of materials they use are to the
appropriate Standards in order to meet
their duty of care.
Designers and builders assume that
the materials used will meet the design
specification. Yet, many builders, concreters,
steel fabricators, design engineers,
specifiers and site inspectors do not realise
that some construction steels sold in
Australia do not comply with Australian
Standards requirements.
When it comes time to verify on site that
the steel construction materials supplied
comply with Standards there is often only a
small window available before the steel is
encased in concrete, or erected and installed.
While visual inspection can take place
inside this brief window of opportunity,
it may be very difficult to identify at short
notice whether the material itself is
conforming or not. After all, steel products
often look alike, with little if any visual
differentiation of vital aspects of
performance such as strength, ductility,
or even the Standard of manufacture
The easiest way to check compliance against Australian Standards and reduce your risk is to review the
suppliers current ACRS certificate (viewable and downloadable from www.steelcertification.com)
and comparing it with the information on the tag attached to the product delivered.
What does site inspection need to cover? ACRS checklists can assist certifiers to ask the right
questions, and simplify the process. ACRS has developed both Reinforcing Steel and Structural Steel
Inspection Checklists in consultation with AIBS and Consult Australia. A sample copy of each of the
certificates has been included with this issue of Australian Concrete Construction magazine.
Both certificates are available free of charge from the ACRS office or by download from the ACRS
website: www.steelcertification.com
For further information, please phone ACRS on (02) 9965 7216, Email: info@steelcertification.com or
visit the website: www.steelcertification.com
ACRS makes it easy to check compliance
ACRS Launches New Certifiers Checklists
For Steels Supplied to Australian Building Standards
Global specialty contractor, Rotondo Weirich
Enterprises, Inc. (RW), the only mobile modular
precaster in the World, is proud to announce the
opening of their fourth office, RW Australia. The
US based RW is located outside of Philadelphia,
PA; RW Middle East operates out of Dubai, UAE;
and RW Antares, the Latin American branch
operates out of Mexico. RW Australia, located just
outside of Melbourne, will serve all of Australia.
"The Australian market is already familiar with
the environmental and seismic benefits and the
design flexibility that modular concrete housing
offers, so this was an easy choice for us," said
Steve Weirich, President and CEO of RW.
RW Australias focus is on modular concrete
housing facilities, which range from worker housing
accommodations, and correctional facilities to
student housing and senior care facilities. The
unique business model being brought down under
consists of setting up a mobile production facility
onsite or local to the project site, offering a
number of benefits to the owner, general
contractor, all other trades involved, and the local
communities. This model allows for drastic
reduction in program and costs, increased
communication and collaboration between teams,
and the creation of new jobs before the facilities
are even open.
Mikael Carlstrom, Director of RW Australia said:
"This unique RW modular precast construction
method uses key personnel from the RW team,
who train local labour at the site of construction,
providing RW certification and new skills which
are then transferrable to their next job. This
mobile production concept means that builders all
over Australia now have access to this superior
technology, a global network, and modular
housing expertise."
Rotondo Weirich Enterprises, Inc., a United States
business, provides precast modular construction
solutions for residential housing, military housing,
and correctional facilities. The unique onsite
manufacturing model brings the quality and
efficiency of a factory to the local project site,
eliminating any geographical limitations.
RW Australia will operate as a specialty
contractor and become involved early on from the
design phase and seeing the project through to
execution of construction. For further information,
please contact RW Australia, Ph: (03) 9824 8211
or Email: mcarlstrom@rwaustralia.com.au
Precast Modular Construction Coming to Australia
8 Australian Concrete Construction - June / July 2012
NEWS
Brookfield Multiplex has taken out the award for Best New Hotel Design
and Construction in the Asia Pacific region for The Darling Hotel at The Star
Casino in Pyrmont, Sydney.
Announced at the recent 2012 Asia Pacific Hotel Awards in Kuala Lumpur,
the accolade recognises luxury hotels built to the highest standard for
conventions, airports or resorts.
Designed by Cox Richardson, The Darling is the first 5 Star-hotel built in
Sydney in 20 years and comprises 171 deluxe rooms and suites, an infinity-
edge pool and 16-room day spa.
Brookfield Multiplex are now in the running for the International category
with winners due to be announced in London in November this year. The
international competition will comprise nine other global regions with
Brookfield Multiplex representing the Asia Pacific region.
The award recognises outstanding luxury hotels that are purpose-built for
conventions, golf, airports or resorts. Winners are selected based on a range
of variables such as green credentials, architectural merit and design.
Winning this award demonstrates our capability in designing and
constructing premier, world-class hotels, said David Ghannoum, Regional
Managing Director NSW at Brookfield Multiplex.
Featuring a slim, elegant tower with dramatic glazed facades over a
sandstone podium and entrance, the design was by Sydney architects,
Cox Richardson, with interiors designed by DBI Design.
The construction team went to extensive lengths to ensure the hotel was
built to the highest standard using the finest materials and state-of-the-art
finishes. The results speak for themselves, said Ghannoum.
The Darling forms part of The Star, recently upgraded as part of an $870
million expansion of the former Star City Casino. The Star features a range of
upmarket entertainment facilities and includes a major, high-end boutique
and restaurant precinct.
Brookfield
Multiplex
Wins Award for Darling of a Hotel
10 Australian Concrete Construction - June / July 2012
NEWS
Having your new residential development
placed in the publics mind is a dream marketing
coupe. How about Marilyn Monroe as a popular
name for a new building? All you have to do is
provide your tower with a shapely torso, then
watch your marketing take off like there is no
tomorrow. Proving this is the rapid uptake of
apartments in the shapely towers of a develop-
ment called Absolute Towers in Ontario, Canada.
The developers werent so crass as to name the
tower after the curvaceous film star, but no doubt
were pleased when the public decided to use that
nickname. If the public doesnt like a new building
it can cruel its success; vis: the Toaster in
Sydneys Circular Quay.
Due to the success of Marilyn Monroe can we
now expect that other developers will seek to
jump on the band wagon, maybe going for Lady
GaGa or Beyonce. We are in fact getting David
Bowie as Ziggy Stardust replicated on the faade
of an apartment block in Sydney, so this may be
the start of a new trend. How about Dracula or
Frankenstein quite suitable for some ugly
buildings we know.
Anyway, back to Absolute Towers - it is a
sculptural complex of five residential towers.
Construction of three of the towers was
completed three years ago, with the remaining
two towers, Absolute Word 1 and Absolute World
2, just being completed at a cost of $1.3 billion.
The two towers are also known as the 'Condo
Couple' - or for the shapely curves featured on the
southern high-rise building that has resulted in
it being given the nickname of 'Marilyn Monroe'
by the locals.
This buildings were designed in China, financed
from China, and aimed for the newly arrived
cashed-up Chinese expatriate. In describing their
design, principals of Beijing-based MAD architects
have said that for the location in a fast-developing
suburb close to Canada's largest city Toronto, they
sought a new and unique identity.
The towers have continuous curved concrete
balconies around the entire building in place of
the commonly used vertical barriers. The structure
of each tower is reinforced concrete.
To provide a fast an economical answer, PERI
designed a spectacular and extremely cost-
effective climbing formwork to handle the curves.
As the rotation of the elliptical-shaped floors is a
constant 4 in each case, the perimeter forms and
guard screening uniformly turns.
In addition, the climbing rails are inclined at an
The Marilyn Monroe Towers
A Challenge for Formwork
NEWS
angle of 26 to the vertical and connected to
the storey slabs by means of climbing shoes
and project-specific modified slab shoes.
Likewise, the formwork units are climbed
hydraulically moving with the crane would not
be possible due to the inclined climbing track.
That this unique climbing method is possible
with the rail climbing system as well as being
applicable in construction site conditions was
proven beforehand by PERI engineers with
corresponding studies along with a test set-up.
Australian Concrete Construction - June / July 2012 11
A major construction challenge has been met
on the site of Walker Corporation's Collins Square
development in Melbourne's Docklands, with
Brookfield Multiplex recently installing two 35
tonne V-shaped columns at 1 Collins Square. The
columns form a signature feature of the 19 level
office tower, and a striking entrance to the entire
Collins Square mixed use precinct.
The polished concrete columns are 15 metres
in height and were installed at a 20 degree angle.
They will form part of the support structure for the
19 Storey, 45,000 square metre tower.
The installation of the columns took place over
a weekend and required the full road closure of
Collins Street to enable the project tower crane to
install the columns.
"This is a great achievement on the site and
required meticulous planning and collaboration
with sub-contractors and authorities to ensure a
smooth process," said Ben Hawker, Project
Manager at Brookfield Multiplex who manages
the 717 Collins Street construction site.
The tower at 717 Collins Street forms part of
the $1.3 billion Collins Square project, which
comprises five commercial towers over a 10,000
square metre retail podium, and the restoration of
the historic Goods Shed South.
Brookfield Multiplex commenced construction
on the site last August and completion is
scheduled for June 2013.
35 Tonne Columns
at the Collins Square Tower
12 Australian Concrete Construction - June / July 2012
I
nternational Paint, a market leader in the
protective coatings industry, introduces
the Intercrete range for concrete repair
and protection in new construction and
maintenance projects. The products show
excellent durability, performance and
versatility and can be used in a range of
different environments such as coastal,
water and wastewater, mining, and high
value infrastructure. The ease of application
and rapid curing properties ensure fast
return to service especially beneficial in a
maintenance project. The products can be
used to coat green and damp concrete
substrates thus helping to reduce the
project timeline in new construction. The
products are water based with zero VOC
content thus minimising impact on both
health and environment whilst also making
Intercrete ideal for use in confined spaces.
A unique blend of polymers, fibres and
pozzolanic materials produce this range of
high performance repair mortars and
protective cementitious coatings. They are
Portland cement based products and totally
compatible with concrete substrates. The
high build repair mortars are easy to apply
and do not require a separate primer to go
on the substrate beforehand.
Microsilica in the products refine and
increase the density of the pore structure to
make them impermeable to water in the
most extreme of situations. The microsilica
also has high affinity for chloride ions which
enables the cementitious coatings to give
excellent resistance from chloride ingress.
For problems with low cover of concrete, which
leads to carbonation, Intercrete coatings are
ideal as 2mm of Intercrete cementitious
coating provides the equivalent to 100mm
of good quality concrete cover.
The Intercrete flooring range is based on
an epoxy, metakaolin and cementitious
modified polymer coating which forms a
dense waterproof matrix resisting up to 10
bar water pressure but allows the passage of
water vapour. These floor coatings will
prevent the risk of osmotic blistering in
subsequently applied coatings or floor
coverings by keeping water away from the
interface. The pozzolanic materials increase
the density of the matrix by reacting with
the hydrated lime, a source of salts in the
process of osmotic blistering, to form less
alkaline cement hydrates. These hydrate
then become encapsulated due to the
polymer and epoxy modification, thereby
making the surface less alkaline. As a result,
there is an improved adhesion to the surface
with other topcoats or floor coverings,
applied for aesthetics or increased protection.
The range also includes a hard alkaline
coating which protects both concrete and
steel from acidic gases, moisture and
chlorides. Another elastomeric coating is
especially designed for protecting and
waterproofing areas such as tanks, channels
and roofs where movement is anticipated.
Intercrete also has a range of specialist
products such as a tear resistant, flexible,
waterproof composite tape used with
Intercrete cementitious coatings to provide
an impermeable seal over live cracks and
expansion or construction joints.
These advanced products support our
existing range of protective coatings offer
and further extends our capability by firstly
repairing your assets and then providing
long term protection.
For further information, please contact
International Paint:
Toll Free Australia: 131474
Toll Free New Zealand: 0800 808 807
Email: pc-australasia@akzonobel.com
Web: www.internationalpc.com
PRODUCT FOCUS
International Paint
Introduces:
Intercrete
TM
TRAI NI NG COURSES
14 Australian Concrete Construction - June / July 2012
T
here is no denying that in the
construction industry today, a job well
done is very often a function of level
of training undertaken by staff in the
project. Training has become a key factor in
all aspects of the building and construction
industry in the past few years and that is
why it is imperative to know who the key
providers of this type of training in the
workplace.
Cement & Concrete Services is one of the
leading training organisations in Australia
and currently conducts 16 course topics
annually. Most of their courses and workshops
are primarily aimed at structural and civil
engineers (with topics such as Design of
Reinforced Concrete; Prestressed Concrete;
Structural Steel; Masonry; Pipelines; Precast;
Tilt Up; Residential Slabs etc).
Some of the other courses they conduct
are very suited to technical staff involved in
building and construction (as well as civil
and structural engineers). These course
headings include:
(a) Concrete Repair and Waterproofing
(b) Cement and Concrete Technology
and Practice
The Concrete Repair and Waterproofing
course has been presented by CCS over the
past 10 years and has evolved into an
informative and professional course that
has had very positive reviews from the
people who have attended.
The course features 10 speakers from
industry who specialise in their areas of
expertise. The waterproofing section of
the course features presentations on
waterproofing concrete using products
such Silanes or Pore blocking agents or
Polymer Membrane sheets.
The repair part of the course will feature
presentations on such topics as chloride
and carbonation effects on reinforced
concrete, carbon fibre strengthening of
concrete and use of galvanic protection
systems to inhibit steel corrosion.
The course also features a session on how
to repair damaged concrete masonry and
clay masonry in buildings using simple
helical stainless steel screw technology.
Another session addresses case studies
on concrete repairs, presented by a civil/
structural engineer with many years of
experience in this area.
The highlight of the course will be a
90 minute full demonstration of the various
materials used in repair (eg epoxy resins,
cementitious grouts and self levelling
compounds) and how to prepare them for
use in repair situations.
For further information on this course or
the other courses available from CCS please
visit: www.cementandconcrete.com and
download the course PDF under the Events
category.
2012 Concrete Repair
and Waterproofing Course
C
onventional scaffolding methods in
Australia have been challenged by
the introduction of the Rosett Flex
range of products by PERI Australia, a move
that has revolutionised the way scaffolding
is used across the country.
There are many points of difference with
the PERI Rosett Flex but the most prominent
distinctive visual feature is that we use solid
shaped rectangular components as a
transom and ledger (horizontal items). In
fact, we do not consider the term transom
in our inventory vocabulary, because they
are the same universal item, PERI national
scaffolding manager Gary Hexter said.
The reasoning and benefits for this
radical design has come from accepting that
many scaffolding products have not evolved
at the same pace as the industries they
work in. Many fall well short - particularly
when it comes to addressing safety as a
prerequisite in the industrial sector.
With that in mind, we set about finding
the critical compliances needed on a
scaffol d, i mproved them, and at ti mes
reinvented them, with the aim of truly
matching industry expectation and not
playing lip service to it, he said.
Not surprisingly, it has ignited strong
debate and controversy which I consider to
be a good thing. We are openly challenging
our industry peers - the mining, oil, petro-
chemical, LNG and energy communities - to
question the scaffolding they presently use,
the status quo and integrity of their
scaffolding procedures and to strive to
come up with something better, Gary
Hexter added.
The PERI Rosett Flex was introduced in
Australia to create a new scaffolding culture
in an industry that Mr Hexter said often had
little or no innovation, creativity or incentive
for improvement. He said that for many
years, end users or purchasers of scaffolding
and related products had been inundated
with generic, industry fashionable terms
such as safety, quality, value adding,
complete and total solutions that were not
necessarily genuine in sentiment or
terminology and, in some cases, could not
support what they were promoting.
Modular and system-related scaffolding
16 Australian Concrete Construction - June / July 2012
COVER FEATURE
Setting a New Benchmark in Scaffolding
PERI Rosett Flex
products permeate the industry in Australia
and, to be fair to the product ranges, they
have served the industry well for an extended
period, however, many products have
stagnated from their initial success,
Mr Hexter said.
Many products have not evolved at the
same pace that is required to keep up with
the increasing demands of heavy industry.
In any business, the arroganceof success is
to think that what you did yesterday will be
sufficient for tomorrow, he said.
Mr Hexter quoted industry heavy-weight
Rio Tinto as a company that had made
huge investments in innovation, with the
introduction of next generation technology
strategies for its mining operations - all of
which are aimed at reducing costs,
increasing efficiency, and improving health,
safety and environmental performance.
Indeed, Rio Tinito recently announced that
by the end of 2014 it would be operating the
worlds first driverless trains on the Pilbara
Iron Ore Rail Network in WA.
I believe that scaffolding suppliers, end
users and the broader community need to
aspire to the same trendsetting philoso-
phies of those of Rio Tinto - to constantly
innovate and improve, Mr Hexter said.
At PERI, we have metaphorically
introduced our rectangular train and put
it on a similar track, in that the outcomes for
our scaffolding are next generation
technologies which emulate improved
performance. The rectangular component
is just one step towards changing the shape
of things to come for our industry, he said.
By making a change to the shape of
scaffolding, Mr Hexter said PERI had been
able to reduce the handling weight of a
scaffolding bay against all of its competitors
by at least 35 per cent, while increasing
structural integrity.
This new shape allowed us to introduce
another new complimentary product to
Australia through the range of scaffolding
decks which have no industry peer. The
bespoke platforms, with an individual plank
size of 250 millimetres, give complete
surface coverage to a scaffold bay with no
gaps - even over the transom and ledger
areas, he said.
Mr Hexter explained that the decks
locked into a safe position more advanced
than any system seen previously, and had a
unique shuffling capability that allowed for
the overlapping of individual planks,
and accommodated pipes or building
structures that needed to come through
the scaffolding.
Our rosette on the Rosett Flex Standard
(the main vertical item) is designed to covet
the rectangular ledger component, using a
gravitational locking wedge system that
again is unique in its application and
design. Once the wedge has self-centred it
is impossible to remove the component
without using dismantling force, he said.
We believe that these prominent safety
features are unmatched, and that true
rosette system offers a uniquely advanced,
and much-needed scaffolding solution.
There are ring-type scaffolding systems
that use the term rosette, however, while
the ring-type cluster has an advantage over
the wedge-type and cup-type scaffolding
models, we believe that it still falls well
short of what is required from heavy
industry, Gary Hexter said.
While ring-type scaffolding has proven
to be popular throughout Australia (as did
its predecessors wedge-type and cup-type
scaffolding models) we believe that in many
instances, innovation and safety improve-
ment has stalled.
According to Mr Hexter, good
companies have good safety performance,
while better companies focus on safety
performance as a core value and strive for a
superior safety performance.
A great company, however, is one
that achieves and sustains superior
performance, and yet continues to improve
through the value of business excellence
through safety, he said.
Business excellence through safety is a
different way of considering safety. Safety
is not an icon mounted on a pedestal to
be revered, it requires a considerable
investment of time and resources, and it is
expected to deliver an average rate of
return, he added.
When business excellence is pursued
through safety, consequential benefits of
efficiency and cost savings are realised that
otherwise would not be recognised.
The PERI Rosett Flex is a German
designed and made product manufactured
by the largest maker of related products in
the world.
For further information, please visit the
website: www.periaus.com.au
COVER FEATURE
Australian Concrete Construction - June / July 2012 17
T
he Shisham Stanley Group has a
proud engineering history in
Australia that dates back to 1977.
From a simple beginning in a small shed in
a backyard, the Shisham Stanley Group has
continually expanded to its current 10 acre
site in Dandenong Victoria. The goals,
initiatives and culture of the Group have
never wavered. The company has always
believed in Australian manufacturing -
despite the growing trend to go off-shore.
The Shisham Stanley Group has gained
an enviable reputation in the steel
manufacturing industry for producing a
diverse range of products. The company
has a specialised structural steel division, as
well as being the largest producer in
Australia of Push-Pull Braces, Casting Plates,
Angles and Fixing Plates for the Precast
Concreting Industry.
Not limiting itself to these areas, the
Group also manufactures earth moving
buckets, trailers, post boxes, newspaper
distribution stands and a range of bicycle
racks. The Shisham Stanley Group proudly
maintains the skills to enable the prompt
manufacture and delivery of Australian
Standard Compliance Products.
The Groups customers are wide and
varied from local to international, and
include the likes of Australia Post in the
public sector to private companies such as
Thiess, Coates Hire, John Holland, Leighton
as well as a large group of precast concrete
manufacturers. The Shisham Stanley Group
has the flexibility to produce the one-off
jobs as well as committing to strategic
partnerships with Eastlink, the Peninsula
Upgrade Freeway Project, the Desalination
Plant (Wonthaggi) and even the manufac-
ture and relocation of Melbournes
infamous Yellow Peril sculpture.
As the dynamics of the engineering
market are continually changing and new
demands are to be met, the Shisham
Stanley Group continues to embrace the
challenges that come with change and
thrive on adapting its plant and systems
to meet the specific needs of the steel
manufacturing industry.
Many could confess that in any business
challenges are frequent. The true test is
having the ability to overcome these
effortlessly with a minimum of fuss. This is
what the Shisham Stanley Group takes
enormous pride in. Looking to the future
beyond 2012, the Shisham Stanley Group
will maintain a strong-hold in the steel
manufacturing market by welcoming and
embracing change.
For further information, please visit the
website: www.shisham.com.au
The Shisham Stanley Group
An Australian Success Story
18 Australian Concrete Construction - June / July 2012
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L
ondon will become the first city to
officially host the modern Olympic
Games three times, having previously
done so in 1908 and in 1948. But its not all
joy Contractors have been hustling to
complete the estimated $760 million
construction project that was delayed in
the excavation stages of new 200 hectare
Olympic Park by unexploded German
WW2 bombs buried in the mud. And this
low-lying site has plenty of mud!
Some 7,000 people have been working
on the site for four years. At the height of
construction, up to 24 trains per week were
delivering aggregate products and cement
for over 400,000 cubic metres of concrete
batched on site for the London Olympic
Park, each train carrying 1,200 tonnes.
The construction is squeezed on time. As
recently as last month (May) there were still
11 temporary sites to construct - and the
site teams have to create five venues that
will have 143 sessions and 900,000 tickets
that don't start there until the middle of
June 2012. Thirty-four venues are under
construction or renovation and the cost
blowout to the British public is reported to
have reached AU$16.87 billion, way above
the original estimate.
Every permanent venue must have an
established after use no white elephants
was the mandate. But along the way they
seem to have lost their nerve, perhaps due
to the parlous state of the British economy,
and gone for the cheapest result.
The redevelopment of the area to build
the Olympic Park required compulsory
purchase orders of dozens of properties
as businesses fought eviction adding to the
delays - 206 companies had to relocate.
The result is mostly an uninspiring
collection of dreary prefabs with a London
Olympic stadium that has little visual
appeal (it was stripped of its fancities due to
budgetary constraints). Critics have
questioned both its aesthetic value and
suitability as a national icon - especially
when compared to the Beijing National
Stadium or Sydneys Olympic stadium for
that matter. The few permanent venues are
in place but the temporary ones are just
being built, which means the Olympic Park
still looks more like a building site than a
completed facility. No doubt it will come
good by the time the games commence,
and if not, it will likely be obscured by a
media blitz focussing on celebrities.
While the tight financial picture and
temporary nature of the games has
generated criticism, they have also been
welcomed as having prompted a
redevelopment of many of the areas of
London in which events are to be held the
site was a decrepit 200 hectare industrial
area in the east of London. Nearby,
Australias Westfield has constructed
Europes biggest shopping centre.
London 2012
Olympic Games
SQUEEZED
Australian Concrete Construction - June / July 2012 21
ON TIME
Some 7,000 people have been
working on the site for four years.
PROJECT FOCUS
The Olympic Stadium will have a capacity of 80,000 during the
Games: 25,000 permanent seats in its permanent lower tier, and a
temporary lightweight steel and concrete upper tier holding a
further 55,000 spectators that can be removed after the Games.
The organisers are hoping to sell this component after the games.
The concrete contains 40 percent less embodied carbon than
conventional concrete and was delivered to the onsite batching
plant by rail to limit the need for road transport.
Facilities for athletes within the Stadium include changing rooms,
medical support facilities and an 80 metre warm-up track. Spectator
services, refreshments and merchandise outlets are located outside
the venue on a podium that surrounds the Stadium, rather than being
located within the Stadium itself. To save money, the organisers are
believed to be using shipping containers as toilets this is something
you wont know about unless you have the experience of being there!
The stadium's track and field arena has been excavated out of the
soft clay found on the site, around which permanent seating for 25,000
as a sunken elliptical bowl, using concrete rakers. The natural slope of
the land is incorporated into the design, with warm-up and changing
areas being dug into a semi-basement position at the lower end.
The foundation of the base level uses concrete 5,000 piles up to
20 metres deep. From there, there is a mixture of driven cast in situ
piles, continuous flight auger piles, and vibro concrete columns. The
second tier, which allows for the addition 55,000 seats, is 315 metres
long, 256 metres wide; and 60 metres high. The stadium is built
using only 25 percent of the steel, 10,700-tonnes, in the structure
compared to that of the Olympic Stadium in Beijing. The designers
are proud of the minimal use of steel, which makes it 75 percent
lighter than Beijings, the stadium also reuses large pipes from a
previous gas pipe project, recycled granite, and all building
products were transported using trains and barges. While being no
doubt structurally efficient, the stadium simply fails to excite.
22 Australian Concrete Construction - June / July 2012
The games aim at sustainability
with low-carbon-dioxide concrete
PROJECT FOCUS
In the euphoria of the games the public will be treated to a
handball arena coated in recycled copper, to a foldaway basketball
stadium - and an artful sewage pumping station with its walls
lovingly adorned with designs of a Victorian sewage system which
runs nearby. Now, thats going to impress!
Best not to mention the massive sewage farm near the Olympics
site, or that recycling of sewage delivers drinking water to
Londoners, such that it is said that the water you drink has been
through seven other people!
The Basketball Arena, by architects Wilkinson Eyre, is one of two
venues that can be taken apart into kit form and transported. This one,
which seats 12,000, consists of a tent-like membrane stretched over
Australian Concrete Construction - June / July 2012 23
a random arrangement of curved forms. Rio gets the next games in
2016 so the Brits are hoping that they can be persuaded to buy it.
The other reusable building, Magma Architecture's Shooting
Range, consists of three separate structures located in the grounds
of the Royal Artillery Barracks in Woolwich. Their walls are covered
in octopus-like fabric 'suckers' that act as ventilation shafts and, at
ground level, doorways.
The Central Park Bridge, spanning the river Lea between the
Olympic Stadium and the Aquatics Centre, is really three bridges in
a Z-shape. During the Games this will be the main pedestrian route,
so the gaps between the bridges have been filled in with a temporary
rubber surface that looks like a paint factory explosion.
The Handball Arena nicknamed the Copper Box looks like the
generic sports centre it will become post-Games, but the unassuming
design holds several surprises: a rainwater harvesting system,
retractable seating and 88 'light pipes' in the roof which reduce
lighting bills by 40 percent.
Another of the Olympic Park's set pieces,
the Aquatics Centre, is one of the few
permanent buildings intended for use by
the local community and elite swimmers
afterwards. The Centre is an indoor facility
with two 50 metre swimming pools and a
25 metre diving pool. It was designed by
Pritzker Prize winning female
architect Zaha Hadid in 2004
before London even won the bid.
The centre is located opposite the
Olympic Stadium on the opposite
bank of the Waterworks River. With
its distinctive architecture and
curved roof, it is the first venue
visitors see upon entering the
Olympic Park. The curvaceous
building is 45 metres high, 160 metres long;
and 80 metres wide. In direct contrast to all
the temporary lightweight structures, at least
the Aquatic Centre satisfies the concrete lover,
with prominent shapely concrete elements.
Unfortunately, it was reported that the centre
would cost about three times as much as was
originally estimated, totalling about 242m.
The six-board dive tower is made from 462 tonnes of concrete.
The steel roof weighs 3,200 tonnes. The three pools hold around 10
million litres of water. During the Games the venue will have a
capacity of 17,500. The two temporary 'wings' will be removed
post-games reducing the capacity to a regular 2,500, with an
additional 1,000 seats available for major events.
PROJECT FOCUS
24 Australian Concrete Construction - June / July 2012
Over one million tonnes of aggregate fill materials were
delivered to the Olympic Park, in addition to the aggregates
required for over 400,000 cubic metres of concrete production.
Carbon measurement and reduction is something that has
been very important on this project, and there has been a
strong commitment to reduce the embodied carbon in the
concrete destined for the Olympic Park.
The ability to deliver products to the site by rail had a
significant impact on the embodied carbon of the aggregate
materials. For example, the embodied CO
2
of the aggregate
from Cornwall was reduced by 73 percent by using rail
transportation compared to the equivalent road journey.
This rail transportation of raw materials and sustainable mix
design has reduced carbon emissions by a significant amount,
representing a 42 percent reduction against the UK industry
average for ready-mixed concrete.
The Olympics Development Authority specified at the
outset that 25 percent by weight of all materials used on the
Olympic Park venues and infrastructure should be recycled or
secondary products. The supply of concrete supported the
ODA and the Olympic Park contractors in a number of ways to
achieve this challenging objective.
The concrete supplier identified and selected a range of
secondary and recycled aggregate fill and single sized
materials for inclusion in the supply frameworks. These
materials complemented the primary products, and included:
Secondary aggregates arising from the production of
China Clay
Recycled rail ballast
Recycled construction and demolition waste
Glass sand manufactured from recycled bottles
The secondary and recycled materials were all delivered
to the Olympic Park by rail and offered as an alternative to
primary aggregate materials.
The Concrete
Should Win a Medal
B
rutalism is an architectural style that
was spawned in the modernist
architectural movement and which
flourished from the 1950s to the 1970s.
Buildings where the raw concrete is exposed
have the rare ability to remind people of
graffiti covered tunnels or industrial buildings
regardless of how well they are designed or
carefully constructed. They dont fit into the
streets and city centres where they appear
but their strength and power speak of a
time when people had a belief in architecture
as a force for civic good. These structures
were solid spaces to create a solid and
strong world emerging from the austerity
of the Second World War.
The original inspiration for the brutalist
style came from the designs of Swiss
architect Le Corbusier as well as those of his
followers, like Australias Harry Seidler.
The name originates from the French term
bton brut, or ' raw concrete' , although
concrete was not the only material these
buildings were constructed from, but it was
grey concrete that always dominated. It is
the label retrospectively given to a style of
architecture that flourished in the 1960s
and 1970s. It is perhaps most characterised
by heavy expanses of exposed concrete,
virtually no decoration and generally exposed
service pipes and brightly painted ducting.
At its worst it conjures up rows of soulless
grey Soviet apartment blocks or bleak
British housing estates that we see in
English cop dramas. No wonder it attracted
the name brutalism. It found its home in
Australia at many of our universities, with
blocky shapes that contrived to oppress the
spirits of generations of students.
Australia has taken the demolition hammer
to many of these unloved buildings. Sydneys
Macquarie University is a powerful expression
of the brutalist style, contrasting dramatically
with surrounding native greenery. The
University of Melbourne has several too,
these being the Engineering Building, the
Education Resource Centre Library and the
McCoy Building. But, Sydneys UTS tower on
Broadway tops the list of Australias ugliest
buildings for sure.
Brutalist buildings generally demonstrate
an aggressive largeness of scale with a
dominating, unfriendly, character. The style
aimed to be honest with structural materials,
with concrete walls, columns, beams, and
services such as lift and stair shafts expressed
as design features. This can be seen today in
Canberras High Court and the National
Gallery Precinct, particularly in the internal
support columns and the patterns of the
supporting beams as well as in the external
architectural elements. You will even see
concrete ceilings as a major feature in these
buildings.
Conflicts have raged over brutalist
buildings such as the landmark Cameron
Offices in Canberra. Built in 1975, these
offices are recognised as being so
significant that they were placed on the
Register of the National Estate. Yet
amazingly the Commonwealth overrode its
own heritage laws and demolished more
than two-thirds of the complex in 2003. And
26 Australian Concrete Construction - June 2012
BRUTALISM
SPECI AL REPORT
Concretes Ugly Duckling
26 Australian Concrete Construction - June / July 2012
Brutalist buildings generally demonstrate
an aggressive largeness of scale with a
dominating, unfriendly, character.
Boston City Hall
Building: UTS Lindfield
in Sydney there was much discussion about
the monolithic Sydney Masonic Centre and
the Sydney Entertainment Centre, both
now significantly altered to completely
cover up their raw concrete structures.
Architect Harry Seidler must be turning
over in his grave, because his prized
exercise in brutalism at North Sydney
Council offices has been painted over to
relieve the grey concrete appearance.
But he still has his Blues Point Tower (a
concrete monster that blights Sydney
Harbour unloved by many Sydneysiders).
One concrete building that encapsulates
all that is wrong with brutalism in a city
environment is the grimy grey Sydney Police
Centre in Surry Hills. Its heavy concrete
appearance is justifiable to some extent as
the building was designed to be bomb and
bazooka proof - if only New Yorks World
Trade Centre had similar concrete robust-
ness! Concrete can be cleaned to look
attractive as has the Sydney Opera House,
so there is no reason why the Sydney Police
Centre should continue to look so grimy.
It's not just that brutalist buildings often
don't interact with the surroundings and
appear hostile to human scale - it's also the
over-use of exposed concrete as a facade
material. Some of these buildings looked
OK when first completed, but invariably end
up looking post-apocalyptic when they are
stained with dark streaks. When brutalist
buildings have been well situated and well
looked after, they have been a success.
When set in rural surroundings the sheer
contrast of concrete against greenery can
be striking. Those lesser architects who
copied Le Corbusier houses in their verdant
surroundings forgot the need to do
likewise. Le Corbusier forgot it himself and
turned out a succession of overbearing
concrete buildings later in his career.
Australias best efforts in ugliness pale
beside the worst examples of brutalism
elsewhere.
If you were to heed what the inhabitants
of Boston in the US say, then you would no
doubt hear them wanting to tear down
their brutalist City Hall, which weighs
90,000 tonnes. In Americas oldest metropolis,
where traditional brownstones set the tone
and civic outlook is closely linked to
America's colonial past, the City Hall is one
major monstrosity. In 1976, the American
Institute of Architecture voted Boston City
Hall among the six most important buildings
in the United States. Today it picks up no
awards. Today, the opposition to this building
is a popular sport: Many find it hard to
imagine anything as ugly. Boston City Hall
opened in 1969. It has since climbed to the
top of the list of World's Top 10 Ugliest
Buildings and Monuments.' Unfortunately,
concrete also figures in the remaining nine
on the ugly list.
The new city hall, based on a master plan
by architect I.M. Pei, was to be the flagship
of an idealistic Government Centre.
Although it is now hard to imagine, the
Boston City Hall was a signal for a new
beginning, as a vital hub for education and
innovation.
SPECI AL REPORT
Australian Concrete Construction - June / July 2012 27
Could it be gaining
some love at last?
Could exposed concrete
be returning to favour?
Sydney Police Centre
Robin Hood Gardens London
Today we have wonderful plastic coated plywood formwork and
excellent formwork systems that ensure great appearances. Low
range water reducers and self-compacting concretes have helped
enormously. Dont even think about off-form unless you have the
budget to do it well (Parliament House Canberra
shows how). You need 40 Mpa off-white
concrete for a creamy mix dont do it with less
for large areas. Just remember that there is no
colour control in ordinary blended cements,
each pour can look different.
So off-form concrete is due for a revival but only
under new thinking and techniques, dont try to
replicate what was done 40 years ago! Why it didnt
work before was due to the variable absorbency of
rough-sawn timber formwork and poor curing control. Architects
complained that the concrete came out runny at the start of the pour
and finished as a stiff porridge. It was common for agitator drivers
to add lots of water to the concrete. Concrete has the property of
the wetter mix areas to look darker when cured,
most unfortunate! Absorbent areas of timber
formwork showed up as a patchy lighter colour.
If you want a rough sawn today use a quality
boarded-patterned form liner from companies
like Rekli - dont go with timber boards over
large areas. Consider this in factory precast
panels for a quality result. But over small areas -
remember keep it to small areas - old-fashioned
timber boarded can look great.
Does their unpopularity mean we destroy all the brutalism style
buildings, much the same as we tore down so many of our beautiful
Victorian and Georgian buildings that were seen as harbouring
disease and classed as slums at one time. Now, we see that as
vandalism, and a great mistake, to rip the Victorian heart out of our
cities. Will the next generation vilify us because we seem to favour
the demolition of brutalist buildings?
''If you look at fashion, it comes back with a trend after everybody
has forgotten about it. Seventies is trendy now - all the 70s colours
are back now. Could the same happen with brutalism?
There are an increasing number of people who now are seeing
some brutalist buildings in a new light. As our cities build more and
more faceless glass shoe-boxes, there are those who are starting to
appreciate the honesty of the few remaining brutalist buildings.
Many have had heritage orders placed on
them, like the unfortunately named Harold
Holt Swimming Pool in Melbourne.
With a global economy that has managed to
homogenise everything from architectural,
fashion and graphic design, historians in the
future will have a difficult task in determining
what was happening in Shanghai or Sydney,
simply because the same buildings are built,
the same clothes are worn, the same music is listened to, and the
same movies are seen.
Brutalism was one of the last architectural styles that pre-dated
globalism. It was a time when society thought the future of science-
fiction was upon us. Le Corbusier and the new modernist movement
sought to eradicate the past, and its irrelevant cosy urban lifestyle.
28 Australian Concrete Construction - June 2012 28 Australian Concrete Construction - June / July 2012
SPECI AL REPORT
People are only now seeing
Brutalist buildings in a new light
New Brutalist-revival
buildings are about to
be built in our cities
How were those brutalist boarded concrete finishes done?
UTS Tower Sydney
University library in California -
at least its earthquake resistant!
Vitra fire station by Zaha Hadid
The National Gallery in Canberra is a good example of a
brutalist concrete building coming good with age. Canberra
spiders love the rough bush-hammered concrete walls, perfect
for their webs. The silky sheen of spiders webs adds a softening
to the rawness of the concrete walls. The Sydney Opera House
is displaying a lovely patina as the skin oils from thousands of
visitors touching the concrete have added a polish where
they have touched. Unfortunately for curtain-wall and painted
panels, the opposite is true unlike concrete, lightweight
construction can look pretty dire after just a few short years!
Today, the worlds most famous female architect Zaha Hadid
is an unabashed brutalist - single-mindedly, she has placed
raw concrete on a pedestal of public approval. In 2004 Hadid
became the first female recipient of the Pritzker Architecture
Prize, architecture's equivalent of the Nobel Prize.
Her Phaeno Science Centre in Wolfsburg, Germany, is a
floating concrete megalith that stands on stilts. It embodies
the same materials and design philosophies that signified
brutalism. Her MAXXI - National Museum of the 21st Century
Arts in Rome similarly revels in its exposure of raw concrete.
Showing that concrete has arrived again is the RIBA Stirling
Prize for architecture awarded to this building as the best
building built in Europe for that year.
Brutalism can look good just wait!
30 Australian Concrete Construction - June / July 2012
PRODUCT FOCUS
Rawlinsons has been producing building price
books since 1983 and is the leading source of
construction cost information in Australia.
The company first published the Rawlinsons
Australian Construction Handbook after conducting
a survey that revealed that such a manual was
much needed within the construction
industry and it was subsequently
received with great enthusiasm. Users
can be confident that each and every
price in both books has been
reviewed, researched and updated as
necessary, in each new edition.
Rawlinsons publications have an
extensive circulation and are highly
respected by all involved in construc-
tion, from all three levels of government; bankers;
developers; builders; risk assessors; architects;
engineers; quantity surveyors; building owners;
hospitals and health sectors; insurers; etc. and our
publications have areas of interest covering the
requirements of these and many other disciplines.
This year, in keeping with the companys
philosophy of constantly developing its publications,
Rawlinsons has enhanced and increased the data
on green and sustainable construction issues
including green design; energy management and
auditing and; environmental management. Other
sections covered in this book include:
building price indices;
building costs per
square metre;
elemental costs;
comparative costs;
detailed prices;
refurbishing and
recycling;
labour and plant
constants;
building planning, administration and
management and;
international costs for selected countries.
The Handbook is a 950-page, hard-covered book
and is targeted at commercial projects.
Rawlinsons Construction Cost Guide was
formulated particularly for the small commercial
and domestic market, and has been specifically
developed to meet the need for costing informa-
tion for the smaller project. Now, in 2012, in its
twentieth edition, this publication covers building
price indices; building costs per square metre;
elemental costs; comparative costs; detailed
prices; renovations; labour constants
and; property insurance.
The Cost Guide is a 275-page book
that is not designed to compete
with the Handbook, but rather to
complement it.
Rawlinsons has not increased its
prices for the 2012 editions, with the
cost of Rawlinsons Australian
Construction Handbook remaining at
$375.00 per book, whilst Rawlinsons Construction
Cost Guide is $248.00. These figures include GST,
quarterly updates for April, July and October 2012
and, courier delivery to your street address.
For further information please Email:
info@rawlhouse.com or to place an order, please
visit the website: www.rawlinsons.com
Rawlinsons Construction Cost Books 2012
Australian Concrete Construction - June / July 2012 31
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