Honestone takes concreting expertise sky high
Flooring, Concrete Products, Concrete Floors
The rebuild of a superior university complex (Faculty for Engineering Technology at University of Technology, Sydney, Australia) was a contest in itself, in the cost-base range of $200 million AU. Specialists were brought on board to make sure the finite touches were perfect.
Renowned flooring and wall solution specialist, Honestone, was selected to re-level the existing concrete of the 14-storey unique building and install a 6mm superior designer floor finish.
Working alongside Lend Lease, Australia’s largest construction company, in conjunction with architects Denton Corker Marshall (DCM), the team worked meticulously to create an incredibly aesthetic and functional studious environment.
Honestone director, Rick Hendriks, said “The theme of the fit out was industrial - a lot of concrete walls and floors, rusty look wall panels.
“For us the job involved installing over 5500sqm of 2-6mm cement overlay (panDOMO FloorPlus and Loft) to 14 levels of lift lobbies and promenades/walkways.”
Mr Hendriks said installing floors to the main access ways at the final stages of a construction site was very challenging.
Internally the building design consisted of 4 lower levels (ranging 300sqm to 800sqm) with various entry points to the street, so these remained accessible, but the remaining 10 levels (each 300sqm) were in the remaining levels of the high rise tower with central crevasses extending up 12 stories.
Due to significant irregularities in the structural concrete substrate, Honestone had to firstly correct finish floor heights +-75mm.
Commencing onsite in December 2013, the Honestone team had to survey each and every square metre of flooring, not necessarily to make level, but to make Honestone’s floor finish flush with adjacent floor finishes.
Next was concrete grinding and shaving to remove up to 25mm structural slab. A second crew followed with crack repairs and grouting balustrade posts which were fixed to the structural slab. Finally, a third crew came through installing up to 45mm levelling compound to the lower points.
Commencing works on level 4, the Honestone team worked its way up the tower. This meant the crew were able not to shut down the whole level, and to meet the builder’s tight deadline.
Honestone was operating on 3 levels at any one time and various stages of the works involved. After completing the tower the Honestone team moved into the larger lower level floors.
With the preparatory works complete mid-February, Honestone then proceeded with the final floor finish in the same sequence. The company commenced on level 4 and started a new level every 2 days - 3 levels at any one time.
At this stage of the project, some levels had all trade works complete on the lower levels ready for handover, whilst the upper levels were still having utilities installed.
Containing dust was an issue, access was an issue, flooding was an issue, however the skilled crew at Honestone was able to overcome them and ensure a flawless finish.
“At times we had wind driven, horizontal rain travelling 30m to flood our floors,” Mr Hendriks said.
“Other times we had water flood on level 1 from a water leak in the roof on level 13.
“We had 20mm water flood floors that were only laid 6 hours earlier and we also had rags, masking tape, render dropped down the crevasse onto our freshly laid floors.
“By the end of April we had the majority of floors installed having also completed additional works requested by the builder.”
Mr Hendriks said this was the first job in Australia where a continuous pump was used to install panDOMO.
“Importing a specialised pump from Germany allowed us to meet the very tight schedule Lend Lease had, to complete the project,” he said.
“We were able to install 500sqm panDOMO in 2 hours.”
The overall project took Honestone 6 months.
“Our customers challenge us on a regular basis to push the envelope on quality, delivery and price,” Mr Hendriks said.
“We’ve put together quite a team to meet these challenges. Clients are never let down, and overly satisfied with the results.”
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