NATIONAL

NATIONAL PRECAST
CONCRETE ASSOCIATION AUSTRALIA NUMBER 67 • February 2013

PRECASTER
ACN 051 987 181 • ISSN 1037-9908 www.nationalprecast.com.au

An inspired reinterpretation of the traditional church

The Anglican Parish of Dapto was looking to create a building that The faceted precast entry points funnel users into the building, and
would complement the existing church hall, welcome visitors and the striking black and white colour scheme highlights the differences
re-connect with the public. By cleverly re-organizing the site, the between these entry points and the remaining external mass. A bright,
architect has created an open and welcoming face to the public white, smooth finish was used for the entry areas, while in contrast the
with a commercial café and forecourt, which on first impressions bulk of the building features an earthy, black rough-textured finish.
does not reveal that the building is a church.
Silvester Fuller’s bold, civic design links the old church hall on one side
and the existing pre-school on the other. The central hub is in the form
of a foyer and 500 seat auditorium. Used not only for Sunday worship,
Award winner
the auditorium now accommodates a broad range of events seven days The project has won a Commendation
a week, catering to the wider community and blurring the line between
religious and community space.
in the 2012 RAIA National Architecture
The tight budget required a simple and cost-effective construction. The
awards and the Blacket Prize and
solution was to use load bearing precast concrete panels supporting Public Architecture award in the 2012
steel trusses and a single pitch roof. The use of precast was also the AIA NSW awards.
perfect solution for an economical and efficient method of achieving the
impressive, large spaces that were integral to the church’s functionality.
Story continued on page 2...

Photographer : Martin van der Wal

IN THIS
ISSUE

Page 1 Dapto Anglican Church Page 3 Shell Cove noise walls Page 5 Atherton Gardens
Page 2 New Standard & Code on the way Page 4 Rowland Apartments Page 6 Admixtures, Exposed Aggregates

National Precast... making precast first choice

NATIONAL PRECASTER NUMBER 67 • February 2013

...story continued from page 1

The architect and client team visited Austral Precast’s Wetherill Park plant in
NSW to help find a solution to achieve the texture and finishes desired. They
accidently stumbled upon some ‘unfinished’ panels that had been discarded
prior to the final smoothing process. The resultant rough, lumpy, irregular
exposed aggregate surface was exactly what they were looking for. It took
some convincing of the manufacturer that the architect would be happy with
‘unfinished’ panels, and that they would not be rejected on site. The fact
that custom form liners were not required was an added bonus to an already
restricted budget.
The builder, Premier Building Group finished the project on time and to budget.
Frank Tropea from Premier comments “The restricted site and necessity to
keep the adjacent buildings fully operational made this a challenging project.

Photographer : Martin van der Wal

The use of precast meant the structure could go up quickly and efficiently
in the restricted area. The loadbearing precast panels were the first to go up
as they were essential to support the roof structure and critical to the time
frame.“
Location: Dapto, Wollongong, NSW
Client: Anglican Parish of Dapto & Anglican Church Property Trust
Architect: Silvester Fuller
Builder: Premier Building Group
Precast manufacturer: Austral Precast

Photographer : Martin van der Wal

New Standard and Code on the way

Over the last 2 years National Precast members have been being constructed today.
active in a detailed review of AS3850-2013 Prefabricated The review of the National Code of Practice brings the 2008 issue
Concrete Elements and the National Code of Practice for of the Code in line with the national harmonisation of WHS laws. Its
Tilt-up and Precast Concrete in Building Construction. The release for public comment will follow the release of the Standard.
reviews were crucial for our members as the documents will
govern all aspects of the manufacture and safe erection of National Precast congratulates Safe Work Australia and Standards
precast concrete and will provide clear direction to everyone Australia for their joint decision to co-ordinate both the review and
in the building industry. release of both documents. With the precast industry continuing
to grow its share of building construction around Australia, it is
The draft of the new AS3850 will be released for public comment important that this unique opportunity for public comment is widely
first and will be in 2 parts. It will cover all precast concrete considered as an enhancement of the safe incorporation of precast
elements in building construction, expanding on the current concrete elements in building construction. an enhancement of
Standard which mainly covers single storey industrial buildings and the safe incorporation of precast concrete elements in building
which is now often not relevant to many of the precast buildings construction.
PAGE 2
NATIONAL PRECASTER NUMBER 67 • February 2013

The art of noise

Shell Cove is a large residential mixed-use project being jointly
developed by Australand and Shellharbour City Council. Located
on the coast 20 kilometres south of Wollongong, it is the largest
coastal tourist/residential development ever initiated by a local
government authority in Australia. When completed, the $1.5 billion
development will create around 3,000 prime residential lots, a
300 berth marina constructed within an in-shore boat harbour, an
18-hole championship-standard golf course, community parks and
playgrounds, cycleways, and a range of quality commercial, retail,
tourist, community and recreational facilities.
As the development grew towards the existing Bass Point Quarry -
that provides crushed basalt for concrete production to the Sydney
construction market - the need to address road noise became
paramount. The main access road to the quarry required a noise
wall to be constructed, in stages, over its 2.5 km length to create the
necessary quiet locale for the nearby residences. The most recent housing, either as the rear fence of a dwelling or as a side boundary to
stage was supplied by Hanson Precast. a residential access road.
From the RTA Noise Wall Design Guideline, the concept of adding ‘art’ The latest stage of the Shell Cove noise wall comprised 1569m2 in
to the practical design considerations for a noise wall is encouraged. area and had two different heights of 6.5m and 4.5m, as specified by
Local communities benefit from the visually pleasing designs that can an acoustic engineer. 94 panels were supplied to the project with 6
be incorporated into noise walls – adding to their obvious acoustic different panel sizes. The typical larger panels, 6m long by 3.5m high,
functionality. This can be done by introducing texture and colour to the weighed 8.9 tonne with the smallest panel weighing 1.2 tonne.
precast panel. A black pigment was added to the concrete mix, 4% of cement weight,
In this case, a Reckli mould liner was selected for the noise walls, to provide an integral and low maintenance colour to the panels.
using an Andalucia profile - the first time the design had been The pigment was selected from an aesthetic perspective to provide
used in Australia. The random block pattern of the liner has reference to the local basaltic rock, which is also used extensively
a variable profile of 30mm. Normally, liners are made in throughout the project in feature stone walls in landscape areas.
1.2m widths so the decision was taken by Reckli to According to Keith McComasky from builder Trade West “We
create a master mould that would ‘join’ five liners recognised the benefits of using precast concrete panels over smaller
as one to eliminate all vertical joints. This made lightweight panels early on.
the setup of the liner for casting the panels
an easier task for Hanson and resulted “Precast panels offer fast installation and we were able to lift fewer
in an improved quality of finish for panels as opposed to many. They are durable in the long term, as well
all panels. as being less susceptible to damage during transport and installation.
And they are supplied as the finished product. In terms of finishing,
All panels with the the coloured panels don’t require any messy finishing trades after
texture facing have installation”.
been positioned
towards the Client: Australand Corporation (NSW)
Builder: Trade West
Engineer: MYD Consulting Engineers
Precast manufacturer: Hanson Precast

PAGE 3
NATIONAL PRECASTER NUMBER 67 • February 2013

Dress circle living

Sophisticated urban living has arrived in the heart of
Adelaide’s CBD with this landmark apartment block.
The $51 million, 15-storey Rowland Apartments complex consists of
87 apartments in South Australia’s first 8.1 star Nationwide House
Energy Rating Scheme (NatHERS) building.
Situated close to Adelaide’s historic Her Majesty’s Theatre in the
popular Central Market precinct, the project provides local students,
professionals and others who crave an urban lifestyle with the latest
in high rise living – and also sits at ease with its historic, lower-rise Once the decision to use the acid washed panels was made,
neighbours. another challenge arose: ensuring that the majority of paler panels
As well as environmental performance – enhanced by features such were constructed to the required two-storey height while remaining
as solar-powered hot water systems, water retention tanks and under the maximum engineering weight requirements. At close to
double glazing – the project is characterised by attention to finishes 22 square metres per panel, this meant thin – therefore relatively
and details designed to appeal to discerning residents. fragile – panels. Combined with the acid washing requirement, this
These include fully tiled balconies and generous 920mm-wide solid called for extra care in the treatment and handling process so as not
timber apartment entry doors with natural wood finishes, while that to damage the panels. To address the issue, hydraulic tilt-up frames
bugbear of apartment living, excessive noise, is eliminated by double were used for casting and washing.
corridor and party walls with a 55mm air gap: totalling a privacy- The decision to increase the building height from 14 to 15
assured 160mm thickness. storeys mid-build posed another challenge. This required the swift
Similar standards applied when it came to the exterior finish, with design and supply of an additional 20 subtly-different panels that
precast the first and only choice. It offered the winning combination retained the building’s design integrity, without hampering the tight
of aesthetics, durability, speed and ease of construction, value and construction program.
safety that the developers desired. Happily, construction proceeded smoothly, aided by another precast
The 2,510 square metres of precast panels that make up the advantage: the panels were delivered on walkway frames, eliminating
building’s façade were supplied by the SA Precast team, which the risk, time and cost associated with the alternative: ladders and
worked closely with the designer and builder prior to the project’s boom lifts.
commencement. Involvement at this early stage enabled a level The final result is a structure that’s ideal for 21st century living,
of planning and preparation that helped streamline construction, enabling residents to enjoy both the heritage and history that
despite a number of challenges. Adelaide has to offer as well as its growing range of thoroughly
“The original plan called for off-form colour panels with polished modern delights.
panels at the ground and fifth level. However, the designer then Client: MANDALA Developments Pty Ltd
requested a trial of an acid washed panel for a different look. The Builder: Brookfield Multiplex
ultimate decision was to finish the majority of panels in a paler acid Designer: D’Andrea & Associates
wash with a darker, contrasting acid washed panel, along with some Structural engineer: Lelio Bibbo
polished panels,” explains Claude Pincin, from SA Precast. Precast manufacturer: SA Precast

PAGE 4
NATIONAL PRECASTER NUMBER 67 • February 2013

Estate planning
Extensive additions to an existing Melbourne housing estate have changed the game when it comes to public housing.
This $43.4 million project comprises a seven-storey, 152-unit block The largest challenge on this project was the coordination of
built on the site of a former carpark - an upgrade to the existing the brick pattern in the façade panels. Because the shape of the
Atherton Gardens housing estate in Fitzroy, Victoria. In addition to building did not allow for a modular panel system, every panel had
its accommodation, the new facility includes a community space, to be detailed individually to ensure the pattern was maintained. In
kindergarten, office and parking facilities. addition, bands of highlight bricks ran across multiple panels. Great
A key requirement was to avoid a grim, monolithic example of early care had to be taken with the shop drawings and manufacture to
public housing and instead create a space on a more intimate make sure these bricks, in particular, were in the correct position.
scale. Cost was an issue: with a tight budget and an ambitious plan, Assisting construction speed and safety was the fact that the
some creative thinking was required. façade work took place offsite and was craned into position with
With much of the suburb’s architectural history associated with no need for the added risk and cost of scaffolding, hoists and so on.
local brickworks and brickform warehousing and factories, a The final result more than fits the brief: an accessible and human
masonry building was a clear first choice, however the cost and scale structure with a warm and welcoming façade that’s in
time required to construct this were prohibitive. keeping with the history of its surroundings.
That’s where the precast solution came in. Use of precast panels Client: Victorian Government
specially cast with a brick inlay facing delivered the best of both Architects: Bird de la Coeur/McCabe Architects
worlds: a highly durable and cost effective construction material Builder: ABI Group
that also met the aesthetic requirements of the job. Accordingly, Engineer: Robert Bird Group
a complex and highly distinctive brickwork basketweave design, Precast manufacturer: Westkon Precast
interspersed with bands of bright colour, was developed for the
project.
When a brick is cast into concrete, the bond of the brick and the
concrete is permanent and structurally superior to masonry alone
and offers a number of advantages in addition to its structural and
aesthetic value. These include many of the distinct advantages of
precast in general, including reduced construction time, simplified
engineering, no requirement for flashing, lintels or weep cavities
and no need for concern about efflorescence or having sand,
mortars or mixers on site.
Westkon Precast, which has experience working with brick
inlay panels, was selected to supply the precast, which required
numerous highly specialised reusable moulds to create the brick
pattern and ensure that it repeated accurately, panel after panel.
The brickwork on the panels was created in conjunction with a
specialist company that makes fully-fired brick facings some 10
to 15mm thick. These were positioned face down in a mould and
the concrete poured to create the panel – a method that allows for
dimensionally stable placement of the bricks. The brick face panels
equated to 2,200 square metres of conventional brickwork.

PAGE 5
NATIONAL PRECASTER NUMBER 67 • February 2013

Admixtures in precast concrete NATIONAL PRECAST

CONCRETE ASSOCIATION AUSTRALIA

Concrete additives have been used since Roman and Egyptian times, when it was discovered
that adding volcanic ash allowed concrete to set underwater. The Romans knew that adding
horse hair reduced cracking, whilst blood made concrete more frost-resistant. CORP ORATE MEMBERS
Asurco Contracting n [08] 8240 0999
Modern admixtures can improve the durability, strength and workability of concrete whilst Austral Precast n [03] 9794 5185 (VIC) or [02] 9604 9444 (NSW)
accelerating the production of precast components and speed of on-site construction. Today’s or [08] 9261 9880 (WA) or [07] 3265 1999 (QLD)
admixtures can also be used to improve frost resistance and thermal properties, minimize Delta Corporation n [08] 9296 5000 (WA)
Duggans Concrete n [03] 6266 3204
shrinkage cracks, improve stability during placement and transport, reduce corrosion in steel
Hanson Precast n [02] 9627 2666
reinforcement, or inhibit the surface mortar to expose the aggregate. Hicrete Precast n [08] 8260 1577 (SA)
Admixtures can assist the precast manufacturer to increase productivity, reduce power, and use Hollow Core Concrete n [03] 9369 4944
Humes n 1300 361 601
resources more efficiently. Polymer chemical admixtures accelerate the curing process without
MJB Industries n [08] 9797 0999 (WA)
the need for external heat, thus reducing energy consumption. During manufacture, other PERMAcast n [08] 9525 1380 (WA)
admixtures reduce the energy to run concrete mixers and vibrators, improve the flowability Precast Concrete Products n [07] 3271 2766
of concrete to allow more slender forms, and enable moulds to be removed quickly for fast Quatro Design n [07] 5525 0775
turnaround and reduced cycle times. Reinforced Earth n [02] 9910 9910
Rocla n [07] 3331 3515
Many admixtures are highly active chemicals and if two or more are being used in a mix design, SA Precast n [08] 8346 1771 (SA)
they should be checked for compatibility. They should not be used without the approval of the Stresscrete n [07] 4936 1766
design engineer nor should they be regarded as a substitute for good concreting practice. Ultrafloor (aust) n [02] 4015 2222 (NSW) or [03] 9614 1787 (VIC)
Waeger Precast n [02] 4932 4900
Admixtures should conform with AS 1478.1-2000 and should be sampled and tested in
Westkon Precast Concrete n [03] 9312 3688
accordance with AS 1478.2-2005.
AS S OCIATE MEMBERS
Actech International n [03] 9357 3366
Active Minerals International n [07] 4059 0648
Ancon Building Products n [02] 8808 1111
Aspedia n 1800 677 656

Exposed aggregates in precast Barossa Quarries n [08] 8564 2227 (SA)

BASF Australia n [03] 8855 6600
Bennett Equipment n [08] 8268 1199 (SA)

concrete Building Products News n [02] 9422 2929

Cement Australia n [03] 9688 1943
DesignBuild Source n [03] 8844 5822
Aggregates are comprised of coarse gravel or crushed rocks such as limestone or granite, Everwilling Cranes n [02] 9892 3377
together with fine aggregates such as sand. The size, shape and proportions of the Grace Construction Products n 1800 855 525
aggregates in the mix will affect the workability, placement, cohesiveness, strength and Lanxess n [02] 8748 3910
Nawkaw Australia n 1300 629 529
durability of the finished precast concrete product.
OneSteel Reinforcing n [02] 8424 9802
The aggregates remain hidden by a thin layer of cement paste; they can be exposed by the Pacific Computing (Australia) n 1300 769 723
use of retarders, or by grinding, water washing, sand (grit) blasting, acid etching or bush Parchem Construction Supplies n 1800 624 322
Reckli Form-Liners & Moulds n 0418 17 6044
hammering.
Reid Construction Systems n 1300 780 250
If the mix isn’t coloured with pigments, the fine aggregates, namely sand, will determine the RJB Industries n [03] 9794 0802
final colour. On the other hand if coarse, exposed aggregates are used proud of the surface, Sanwa n [02] 9362 4088
Shore Hire n [02] 8708 1200
they will dominate the colour and appearance of the final product. Sharper, more angular
Sika Aust n [02] 9725 1145
exposed aggregates will produce more shadow and trap dirt, whereas rounded, smoother Sunstate Cement n [07] 3895 1199
shapes will give a softer appearance and be easier to clean. Aggregates can also be honed P ROFES S ION AL AS S OCIATE MEMBERS
or polished to achieve a more prestigious look that reflects light, and the use of decorative or Aurecon Australia n [02] 9465 5751
different coloured stones can add interest to the final product. Grant Thornton n [02] 9286 5850
Inhabit Group n [02] 8003 6333
The best way of getting a good result is to meet with the engineer and precast manufacturer, Moray & Agnew Lawyers n [02] 4911 5400
order some trial samples before deciding on one you like (with the engineer’s approval) that Sellick Consultants n [02] 6201 0200
the precaster can produce and finish for the price. The precaster can then record the details Tekdraw Drafting n [08] 8342 0500 (SA)
of the mix design which means avoiding the need to specify aggregate sizes and proportions. AFFILIATE MEMBERS
Baseline Constructions n [02] 9080 2222
British Precast n +44 (0) 116 254 6161
Precast New Zealand n [64] 09 638 9416
OV ERS EAS MEMBERS
The architectural market is spoiled for choice when it comes to Golik Precast Ltd (Hong Kong) n 852-2634 1818
the selection of aggregate that can be used in precast. According OCV Reinforcements n [66 2] 745 6960
to Steve Falland from Barossa Quarries, over 20 unique colours
of marble or granite are available and only sound, clean stone
The information provided in this publication is of a general nature and should not be
is selected before being crushed and screened to exact sizes as regarded as specific advice. Readers are cautioned to seek appropriate professional
advice pertinent to the specific nature of their interest.
specified. The crushing plants are carefully cleaned to ensure
cross-contamination is avoided between different colours of stone. Published by
National Precast Concrete
Association Australia
6/186 Main Road Blackwood SA 5051
Tel [08] 8178 0255 Fax [08] 8178 0355
Email: info@npcaa.com.au
PAGE 6 Executive Officer – Sarah Bachmann
www.nationalprecast.com.au