WHAT'S HAPPENING AT MONARK

July 2021 - Structure takes shape!

75% of Monark's structure is now complete with the structural steel and precast panels along Adelaide Road installed up to roof level! We have started placing level 4 floors and in some areas level 5. The next major structural milestone will be the installation of rood steel followed by framing for the roof.

Timber framing for the facade is underway with teams to install the cladding and windows ready to commence on site in August. For the past 2-3 weeks the plumbers have been running pipes from the ground floor to level 1, simultaneously we have been preparing for the sprinkler contractor to begin fixing their pipes.

Another key contractor on site at the moment are the intumescent painters, making their way through painting the fire protection onto the structural steel.

As we work towards completing the main structure over the next 3-4 months we will commence partitioning on the lower floors as our focus turns to progressing the internal works.

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The last level 3 slab pour area, pre-pour!

Monark from a distance! The tower crane is holding up a panel up whilst the props are connected to take over and hold it up.

Scaffold stairs next to precast stairs. Eventually a curtain wall will go in place in front of the precast stairs forming a fancy facade.

The last level 3 slab pour area, post-pour! The structural steel and panel starter bars (that the precast panels slot into) protrude out of the slab.

Apr 2021 - Well Underway...

It has been full steam ahead on site over the past few months, charging through the installation of our precast panels. We are now nearing completion of our lower level panels (those that span from the ground floor up to level 3) with only 9 out of the 86 lower level panels remaining. These will be installed over the next 2-3 weeks. 

 

Pouring of the level 1 and 2 slabs in the apartments is also progressing well and we expect to complete this in the next 4 weeks. Next our attention will turn to infill the level 1 and 2 floor slabs in the lift, stair, and corridor areas.

As we complete installation of the lower panels, we will soon start forming the level 3 slab, which will allow us to begin installing the upper level panels (level 3 to the roof, 79 panels in total). This level 3 slab is different in that it is formed across the top of the lower panels, as opposed to the level 1 and 2 slabs which were formed in between the 3-storey high panels.

With the splice in our structural steel columns being located above level 2 we are now installing the next lift of structural steel which takes us up to roof level. This will allow for the installation of the level 3 precast ribs and formation of slab as mentioned above before the upper levels are installed.

The formation of our stitch joins are now running like a well oiled machine - we are nearing completion of all joins up to Level 2 now with pours occurring twice weekly. We have now poured over 1500m3 of concrete on site! 

And to top things off our first set of precast stairs arrived on site today and will be installed over the next two days.

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A concrete pour in action!

Concrete placers at work forming a slab area/cell on Level 1.

Our first precast stair delivery, 2 flights of stairs and a panel sitting on the truck soon to be crane lifted into the building.

The crane holding a structural steel beam in place while Pinnacle connect it to the steel frame.

Jan 2021 - Joining the Pieces Together

After an energising break over Christmas we're right back into action. This month we have begun working on the stitch joins that join the precast concrete panels together, putting in and tying the reinforcing steel, then boxing up the framework before filling with concrete.

The final big section of raft slab is being poured today (28th Jan!) with the concrete team starting on site at 5:40am this morning! 

We've also achieved the first of the upper floor slab pours, a cell/room on level 1.  The reason for pouring the upper levels in cells is the precast panel temporary propping system. The panels are supported by large steel props bolted into and between the panel and raft slab until the rest of the structure (stitch joins, floor slabs) are in place, enabling the props to be removed. There are roughly 15 cells to pour per level, and planning the sequencing of these pours around installing and removing the temporary propping, as well as coordinating timing for production and delivery of other structural elements has proved an interesting challenge for the Aoraki site management team.

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Propping underneath the first floor to support the weight of the concrete until it is set and stable.

The first apartment/cell finished slab.

The order of precast panels and slab pours may seem a little illogical but is designed around propping and forming slabs in the most efficient manner.

Reinforcing prepared and ready for the first floor slab to be poured.

Dec 2020 - Up, Up, Up!

There's been another step change on site over the last few weeks - we're building up!

The formation of the raft slabs has been quite an undertaking, involving careful coordination to ensure the large concrete pours go smoothly. This included starting the concrete pour early on a Saturday morning to ensure we could get consistent flow of concrete delivery trucks to site without hitting traffic congestion. Two out of three of the ground floor raft slabs have now been poured. When finished, the ground floor will contain 1,100 cubic meters of concrete!!!

While preparing to pour the final section of raft slab we are also standing our large precast panels on site. These large upright structures are once again dramatically transforming the look of the site as we build vertically 3 floors at a time.  

 

Formation of the Level 1 and Level 2 suspended floor slabs are scheduled to commence early next year so that will be the next major change to look out for!

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First area of raft slab being poured, 400m3

of concrete in this particular pour.

After pouring, concrete is first vibrated and then floated to smooth the surface. Curing compound is applied and it is left to set.

Precast panels installed and temporarily propped ahead of the suspended floor slabs and in-situ stitch joints being formed. Each panel is 3-storeys high, a further 3-storey high panel will be stacked on top of these panels at a later date, taking this structure up to roof level. 

Precast panel being lifted from the truck and rotated using both the tower crane and mobile crane, before the tower crane guides this panel into its final position.

Preparation for installation of precast panels on the newly formed raft slab is underway, including setup of the mobile crane that will assist our tower crane with rotating the precast panels once lifted from the delivery trucks.

Nov 2020 - New Crane on the Block!

There's a buzz of excitement on the site now that our crane is up and fully operational! It signals another new phase of construction, and we can now concentrate on getting ready to pour the ground floor raft slab.  

The ground floor raft slab will be poured in three sections. The first is scheduled to be poured by the end of the month. In preparation for this we have been focusing on completing the inground services, with our reinforcing steel fixers following close behind tying the mammoth volume of steel in the raft slab. The second section is due to be poured in December, and the third and final section is due to be poured in the New Year.

While preparing for our first section raft slab to be formed we are also working on forming the lift pit on site, as well as completing services infrastructure work out on both King Street and Adelaide road.

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Crane - hand drawn-website.jpg

Oct 2020 - Preparing for our Crane

One of our first major milestones has now been met - the piling is complete! Brian Perry Civil did a great job and have now de-camped, leaving the site looking quite different to before they arrived.

 

Out on Adelaide Road,  G.P. Friel have been busy installing the underground services to service the new apartment building, including new storm water manholes on Adelaide Road - quite a challenge on such a high volume traffic area.

 

The next major will be getting our crane up, and to that end we have been busily preparing the crane base. The crane base makes clever use of the building's foundations and will therefore remain in place once the crane has been removed. Our crane will have the capacity to lift up to 24 tonnes so that it be able to handle the large precast panels on our project, and will stand approximately 10 storeys high in order for our 3 storey precast panels to be lifted over the top of the building as we progress through construction. 

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Installation of reinforcing steel for the formation of our crane base is underway.

Completed crane base being stripped of form work.

Installation of the cast in crane anchors complete with jig to ensure the position of the anchors suits the soon to be installed crane tower sections.

Tying the reinforcing steel for the crane base.

Sept 2020 - Piles, piles, and more piles!

The focus over the last few weeks has been piling, and with ~160 piles to get in this is no small job. There is quite a high variability in how easy/hard each pile is to drill, and so far they have ranged from taking about 8 minutes to 2 hours to drill a single pile. In brief, for each pile a 13m deep hole is drilled, filled with concrete, and then reinforcing set into it. Check out the reinforcing being driven into the concrete (click here!) - its quite mesmerising!

Despite some  obstructions being encountered, Brian Perry Civil are putting in a great effort and progressing well - we're on track to have piling completed in early October. 

Towards the end of last week, GP Friel were working on Adelaide Road excavating for and installing storm water manholes and we started preparing the ground for the crane base/slab, which will soon have reinforcement put in and tied between 6 piles.

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Pile cages are laid out/stored between drilled/completed piles (the plastic caps are there for safety reasons).

Excavating around the 6 crane base piles to make room for reo and concrete, which will form the crane base slab.

Scaffold has been erected in the crane base area to allow for breaking out of concrete.

Fully excavated crane base area, which has reached the water table!

Freddy's Concrete Cutters breaking out concrete from the lower area of piles for the crane base.

Freddy's Concrete Cutters breaking out the top of the crane base piles, so that reinforcement for the crane base slab can be tied to the pile cages.

Aug 2020 - We are GO!

It's been a busy two months since we signed on to deliver the Monark Apartment development in June; the building that was on site has come down and been removed, our team have moved onto site, extensive groundworks have been completed to prepare the ground, services are in the process of being re-routed, and piling has commenced (3 completed, ~157 to go!) 

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The team have arrived! Site office is in place and the the site has been cleared ready for the next stage.

It's getting busier on site now as Brian Perry Civil get stuck into work on the piling.

For each pile, a hole must be drilled, filled with concrete, and reinforcing driven down to a depth of 13m.

Preparing the ground before the team even moved onto site.

The view from Adelaide Rd prior to work commencing! 

The old building at King St prior to demolition.