The Liveable Streets team is tasked with general maintenance, emergency management, renewals, rehabilitation, road rails, kerbs, crossing, and spill response.
Early in 2022 heavy rains resulted in landslides in Whitford, Auckland. Just 7m from the slippage site on Whitford Road, was housing. With further heavy rains expected, there was an immediate threat to property. There was also the added potential risk of damage to nearby power/utility lines which needed to be considered in the solution’s design. To keep the residents and community safe, a protection wall needed to be erected, fast.
Interbloc to the Rescue
Envirocon’s high productivity, quick reaction Interbloc Precast Concrete Wall System was chosen. When compared to the other options - timber and gabion baskets - it was a no brainer. Both legacy construction systems were too slow to install.
In contrast Interbloc allowed for rapid deployment, with trucks rolling in one after the other offloading blocks which were installed in real time. In just 4 days, 337 blocks were installed to build a wall 2.4m wide, 2.4m high, and 20.4m long.
Wall being installed by the TWC Contracting team
The wall will be in place for an uncertain amount of time and subject to high loads and hydrostatic pressures. Interbloc’s inherent flexibility added additional benefits. A unique block stacking configuration was required, eliminating the need for vertical reinforcing. This aided the speed of installation without compromising structural integrity. Interbloc mortarless interlocking system also allows for water to drain through the wall.
Another key benefit for Liveable Streets is the ability to non-destructively dismantle the wall with ease at any stage in the future and reuse the blocks for another structure or take advantage of Interbloc’s industry leading Buyback Guarantee.
Liveable Streets is an excellent example of the suitability of Interbloc for emergency slip management - a common problem faced by road maintenance contract holders across New Zealand. Similar solutions have been provided throughout the Waikato and Marlborough.
Interested to know more? Get in touch today.
“At Daltons we are the best in our field and we like to deal with the best and that’s why we chose Interbloc” - Kerryn, Auckland Area Manager
Daltons is one of New Zealand’s largest landscape supplies businesses. Their products range from fertiliser and compost to aggregate and mulch. Key to Dalton’s success has been their investment in state-of-the-art manufacturing systems and commitment to quality. Tidy, flexible, and efficient bulk materials storage plays a small, but important role as well. Since 2008, Daltons have chosen the Interbloc precast wall system to build their storage bins.
(Interbloc Bin for Daltons Landscape Supplies' Christchurch Yard)
One of the most common solutions that Daltons has used is Interbloc bins. A natural benefit of the bins is it separates their product, making it easier to pick out what’s needed. That’s not the only reason why they chose Interbloc, though. A key plus for them has been the flexibility in the system. Giving them the ability to grow (or shrink) their bins as needed.
“ We can change it. If our bins are too small, we can make them wider, it’s just putting in another footing, putting the rods back in, and restacking them” - Kerryn Gibson, Dalton Landscape Supplies Auckland Area Manager.
Daltons has used the Interbloc solution time and time again. So when it comes to designing or redesigning their yards, it’s easy. This is largely thanks to Interbloc’s intuitive and simple modular design. With the blocks’ interlocking shear key, it is quick and easy to build structures.
Cleanliness is also an important factor for landscape yards. Landscaping is all about creating a space where aesthetics are important. To fit this concept, storage solutions need to create a clean and organised environment. Interbloc fits the brief largely because of its modular design.
“The tidy aspect is something for a landscaped yard. You want to stand out and look good”
If you’re wanting a well-organized landscape yard that suits your current and future needs, get in touch:
Fulton Hogan is one of New Zealand’s leading civil contractors. They have a deep commitment to building the infrastructure that powers economic growth. Most recently, this has meant they’ve expanded asphalt production at their Silverdale plant in the rapidly expanding area of North Auckland. Key to asphalt production is aggregate storage. Envirocon’s Interbloc wall system was used to build flexible, durable, and safe storage bunkers.
When additional aggregate storage was required at Fulton Hogan’s asphalt manufacturing plant in Silverdale, the company specified Interbloc. It was a no-brainer - Fulton Hogan has extensive experience utilising the Interbloc system throughout the country for similar purposes.
12 bins of varying sizes were constructed from the Interbloc precast wall system, giving an additional capacity of 1,750m3 of aggregate storage, equal to 2,750 tonnes of material.
(Looking straight onto the finished Fulton Hogan Silverdale aggregate bins)
To complicate matters, the bins had to be built at the top of a 3m high retaining wall on three sides. The combined weight of the filled bins and the backfill material meant that engineers needed to be satisfied that the retaining walls would be able to handle such loads, especially since unsuitable base soil meant retaining walls had failed in the past. Interbloc showed its unique versatility by allowing high surcharge capacity reinforced earth walls to be built by simply casting geogrid into the blocks during the manufacturing process.
“Due to the steep topography of the landscape, a retaining wall was constructed out of Interblocs to provide a level surface for the aggregate bins to be built on,” explained Fulton Hogan's Project Engineer Oli Brooks. “Geogrid was used in the backfill behind the retaining wall, and tied into the blocks. Granular backfill (DQ65 which has a compacted dry density of 2.14tonnes/m3 )was then placed and compacted in 150-200mm layers, with geogrid installed at each Interbloc row ", explains Envirocon’s Peter Fowler.
(Fulton Hogan employees installing geogrid reinforcing for the retaining wall)
The asphalt plant had to remain in production throughout the expansion process. As a result, the 20-year-old storage yard had to be deconstructed in stages. This meant temporary bins were built using Interblocs, in a different area of the yard, to accommodate some of the material while the full operation of the plant continued. These blocks were then re-used at the final bin sites.
This project was the first to use the new Interbloc base block for the storage bins. The combined forces of the product, the height required to store materials in the footprint available - and to provide support for a fixed roof – meant base blocks could spread the wall load over a bigger footprint, delivering greater design efficiency.
(Holding the aggregate bins (with the new Interbloc Base Block) up is a 3m long retaining wall)
All bins were assembled on-site, and Brooks felt the process was “pretty straightforward - the 3D drawings helped significantly,” he said. This was critical as the density of stored aggregates varied between 1.4 to 2.3 tonnes/m3.
“The new layout and storage volumes have removed the safety and storage problems, and future-proofed it for many years to come,” said Peter Fowler proudly.
(The finished aggregate bins at Fulton Hogan Silverdale)
The Interbloc system easily absorbed the loadings required of such a structure, and the team found its construction very straightforward.
The number of 3D drawings of the block layouts supplied by Envirocon really helped the team visualise what they were building, said Brooks. “This made the whole process go a lot more smoothly.”
Brooks particularly praised the support received from Envirocon during the build. “The Interbloc team, specifically Peter and Cole, have been very responsive and accommodating to design changes and last-minute requests,” said Brooks. “And the 3D drawings of the block layouts were very helpful for the site team to visualise what they were building.”
Wyatt Landscape Supplies is the latest addition to the Wyatts Haulage group based in Warkworth, north of Auckland. Key to setting up and running a landscape supplies yard is a well organised site for you and your clients to navigate easily, and the flexibility to rearrange bins as demand for materials change.
Traditionally, building bulk storage solutions is expensive, time consuming and inflexible. Interbloc offers an antidote. Faster to install and easier to rearrange whenever a change is required.
Wyatt Landscape Supplies had used the Interbloc system before, and knew it would be right for the aggregate bins at their new landscape yard. The company stores a range of aggregates including metals and scoria, sand and lime, and landscaping pebbles, mulches and mixes - some of which are also under cover. Each bin measures between 5000mm wide x 4500mm deep x 1800mm high and 3500mm x 3500mm x 1800mm, depending on the product being stored.
Dave Wyatt, Managing Director of Wyatt Landscape Supplies, knew that whenever he needed to re-configure the site it would always be quick and easy, because of how easy it is to assemble and rearrange the bays. A ‘nice’ added extra was the sustainability credentials entrenched in every Interbloc block – made from 100 percent recycled wet concrete, every block contains zero embedded carbon.
At the heart of the Interbloc precast concrete wall system is a unique interlocking concrete block. The block delivers a high productivity system, meaning Interbloc customers can build faster, stronger, safer. The certified, central lifting anchors built into each Interbloc block help with moving them safely, and also serve as anchor points for ropes and strops. The blocks have excellent horizontal shear strength in both directions, which helps them withstand any knocks and bumps from forklifts or other mechanical machinery.
No specialist heavy-lifting cranes are required when constructing the bins - the right forklift is capable of constructing Interbloc walls like this, and the blocks “pull apart” like LEGO so that no destructive dismantling is ever required, and the blocks can be reconfigured endlessly.
“We’re so confident in our system and blocks we offer a unique buyback guarantee,” explains Envirocon’s Sales Director Jack Bright. “This buyback guarantee means when you no longer require the blocks, you’ll be able to trade them in for cash.
Lex Norton owns and operates the lime prill storage facility for the far north located in Kaikohe. The bin has a capacity of 500 tonne and was constructed in February 2008 using Interbloc in combination with a simple externally supplied shelter roof.
Although the Interbloc solution is able to keep gods dry in combination with a suitable roofing structure, it is imperative that Lime prills be kept dry so the Interbloc team sealed all joints between the blocks for added comfort for the client. Jack Bright said, “Our solution can be customised to meet the clients needs and the ability to seal for added product protection is a good example of being able to meet the customers need correctly and without additional complexity”
Lex Norton said that he chose Interbloc for many reasons, they included,
● Strength of the blocks to withstand the odd hit from the loader, ● They where free standing ● Assembly could be carried out with their fork lift, ● The product was competitively priced compared to other solutions ● The ability to expand and or relocate the bin at a future date.
When asked to summarise the process and his dealings with Interbloc, Lex stated “I was very happy with the Interbloc fertiliser bin and would recommend Interbloc structures for smaller farm storage requirements”.
Situation
Errol Watts is a typical Te Puke farmer. Born and bred in the region, Errol farms a total of 295 hectares across two sites. Milking 1200 cows means Errol requires supplementary feed to ensure maximum productivity throughout the year. One of the supplementary feeds utilised by Errol is Palm Kernel Expeller (PKE). PKE’s a bit like fertiliser, in that it is highly susceptible to moisture damage. When you’re dealing with a product that costs around $300 a tonne, reducing waste is important. Achieving cost effectiveness and weather tightness weren’t the only concerns of Errol’s. A company which could handle the project from start to finish was also important, “Service matters, and with Interbloc you get good service” says Errol.
Solution
Errol had previously contracted Interbloc, so when he went looking for a new PKE bin he took the time to look into Interbloc’s standard PKE bin package. As Errol puts it “They did some work for me a couple of years ago so when I found I needed a PKE bin and saw Interbloc’s PKE bin all in one package I gave them a call”. The standard PKE bin was designed by Interbloc in conjunction with farmers. It is a 48m³ bin made from Interbloc interlocking concrete blocks. The the walls are 600mm wide for strength and stability. The price tag includes a concrete slab with a 2m apron to ensure any spillage out the front doesn’t go to waste. The bin utilises a heavy duty canvas cover which five removable galvanised steel hoops to keep it taunt. The hoops slide into hole locates on the top of the bin. The canvas cover is attached for the bin at the back and is easily pulled back and forth. All this can be installed quickly – one day once the concrete slab has been laid.
If you ask Errol, the features of the standardised bin weren’t the deal maker, “it was a no brainer. Firstly the blocks are a brilliant idea. They’re convenient, durable, and flexible. When I am not using the PKE bin for feed storage, I can use it to store fertiliser or something else. It’s not just a bin, you see, because of the modular design of the blocks we can use the blocks to build other structures any time”.
Errol’s story is typical of the farmers who have purchase Interbloc PKE bins. Modern farming means Interbloc solutions need to cater to a variety of on farm requirements. The standardised design means Interbloc can offer a competitively priced product and this shows in sales to day.
Benefits
Zero waste
Turn key construction – Errol was able to focus on running his farm while Interbloc handled the whole process.
Competitively priced
When Ruawai pedigree Holstein breeders and dairy farmers Blair and Neil Sidwell needed to build a new maize silage bin they called on Interbloc for the solution. With 35 years farming experience the Sidwells know what they want when it comes to their business, and Neil was quite precise. “Build us a silage bin, forty by twenty, by one point two metres high!” he said.
Once the floor was poured, and the required number of blocks had been transported to the site, the Interbloc team had built their bin within two days, and it was full of good maize silage, safe and sound, two weeks later. Before committing themselves to building an Interbloc maize silage bin, the Sidwell brothers went through an extensive cost comparison process, from which Interbloc emerged to beat the nearest competitor’s price by 50%.
Combining this factor with the flexibility and durability of its products, and the speed of the Interbloc operation was, as the Sidwells’ said, “… a no-brainer!” Like the Sidwells’, more and more farmers now recognize the advantages of the Interbloc silage bins over the alternative in-ground pits.
“No more mud contaminating the precious resource, which on a bin this size (1000M3) can lead to silage losses of up to 30%, or $23000,” said Interbloc’s Jack Bright. “The approaches to the new bin are clean and tidy, and with a more even compaction of the silage, its quality is maintained.
And the Sidwells are better able to more efficiently and economically deliver it to the Stock.” Blair Sidwell was also very pleased with the Interbloc solution and noted that when the planned increase in herd size takes place they will be able to easily increase the bin’s capacity with the simple addition of another row of Interblocs.
Good silage stack management is essential if best results are to be achieved. A poorly designed pit or bunker not only adds to wastage but also increased the workload involved with feeding out. “The objective must be to do it right first time,” says Jack Bright, who has been in the industry for over 15 years and shares some of his experience here.
The Sales Director, Bright says, “farming has become big business, farmers have to maximise the return they get from every dollar. If they don’t adapt” he says, “they’ll be left in the wake of those who do!” “Good farming is all about maximising potential for quality production and consequent profit, and minimising factors that could adversely affect those goals!” says Bright.
A properly specified and constructed silage bunker ensures greater and more even compaction so, in the case of maize silage, farmers can achieve an average density of 225kg DM/m³ compared with less than 200kg DM/³ when stacked Otherwise. Positioning the bin handy to where the silage will be fed out is important, and so is its orientation to prevailing wind, rain and sun. And it’s also important that the site is able to be easily accessed by large truck and trailer units and that the surrounding ground is firm. And while harvesting maize at the right time will minimise any leeching to almost nil, it’s also important to make provision for the water to be drained away from the site. *Based on a tractor bucket reach of 2.5m high and a twin U bin structure – the most economical and easiest to build. Actual bunker size will be determined by each individual farmer’s herd management practices but ideally 15 – 20cm of the face should be removed each day and the whole face every 24 hours.
These factors will also determine the optimum stack height for efficient operation of the facility, with maximum height also being affected by the loader’s bucket reach. Oxygen is the number one enemy of good silage making and so, to ensure its access is controlled, a good quality 150mm micron thick polythene is essential. Choosing black or white polythene will pay dividends and better enable the farmer to keep temperatures in the stack below 30° Celsius, the point where the silage is over cooked and the food value can start to drop off rapidly.
Some things never change and old car tyres are still one of the best ways of ensuring the stack is kept properly wrapped and sealed and it’s always a good idea to lay baits for rats, mice and possums, making sure the bait is secure from other farm animals.
Interbloc is an MSE wall system.
When Industrial Processors faced an urgent requirement to build a high surcharge retaining wall fast, they turned to Interbloc. Our one tonne interlocking precast concrete wall system combined with geogrid for a faster, stronger, safer wall.
Background: The South Waikato operation had an existing timber retaining wall which was failing, leading to a requirement to replace the wall. Time was of the essence, as an extended shutdown impacts on operations.
Industrial Processors canvassed all the possible retaining wall options, and choose Interbloc due to the cost efficiency, speed of construction, and ability to move the wall as the business grew and the site configuration changed.
The end result was a retaining wall up to 5.4m high, installed in a 7 days and on a compacted gravel foundation.
Mechanically Stabilised Earth (MSE) Walls: What is a MSE wall?
MSE is a method of reinforcing a wall to withstand high loads. It’s common with bridge culverts and high retaining walls. Essentially it ties the wall elements (in our case Interbloc blocks), to the retained soil using a matt like material. In the case of Industrial Processors geogrid was used. The matting it layered, and the backfill and soil is compacted as the wall is built. The matt is also sandwiched between the blocks to create one complete and strong structure.
MSE is a faster, more cost effective, and stronger solution when building retaining walls with large loadings. There’s numerous different MSE systems out on the market, however its only when MSE and Interbloc are combined that you truly get the unique benefits of speed, durability, and flexibility.
Situation
Fulton Hogan has a long history of operations as one of the founding contracting businesses in New Zealand. More recently, Fulton Hogan has extended its operations into Australia and is rapidly growing a presence and reputation as a major contractor who delivers what they promise. Fulton Hogan sets high standards and in return looks for suppliers who match their organisational attributes and culture for success.
In 2012 Fulton Hogan undertook a substantial redevelopment of their Auckland Regional HQ based in Mt Wellington. A key part of the redevelopment was to improve the sites water management system as the aggregate would sit in puddles of water which led to wet aggregate being used in the production of bitumen.
In addition, during the redevelopment of the site, the Project Manager of the site redevelopment saw an opportunity to improve the overall efficiency of the yards operations by upgrading the existing aggregate storage facilities. The existing system used old mass concrete blocks that didn’t interlock creating potential safety issues.
Solution
Fulton Hogan invited Interbloc to submit a storage solution for the yard, specifying six key criteria to be met:
Obtain easier access to bunkers for the truck drivers to allow fast delivery of aggregate
Health & Safety is paramount so the containment solution has to be highly stable
Cost effective and engineered to high standards
Flexibility as the volume of aggregate varies throughout the year
Supports the company’s corporate sustainability mission statement
Interbloc designed 2 x 6 bay bunkers 40m long and 20 m deep with a total cubic capacity of 2,500m³. The designs allowed for free flow of water from site. The solution was fully engineered and met Fulton Hogan’s high health and safety standards. The feedback since the opening of the redeveloped site has been excellent.
Benefits
Alwyn van der Linde, FH’s Auckland Regional Manufacturing Manager, says Interbloc won the job because it is a fully engineered solution. The goal was to provide more efficient truck flows across the yard and improve health and safety. “Bunkers were custom designed and engineered to meet our strict standards. We also know that if our requirements change in the future that we can reuse parts of the solution again” explains Alwyn, “Interbloc is a company with a proven record of doing things correctly, they have formed many significant partnerships in the construction industry and we are happy to be included in that group.” Truck drivers are finding it easier and quicker to complete deliveries, and appreciate the sites cleaner and more organised layout. Fulton Hogan have achieved their goal of improving the sites water management, at the same time as reinforcing their commitment to creating a healthy and safe working environment.
Situation
Well Connected Alliance has been tasked with constructing an infrastructure development that ranks as the largest roading project ever seen in the country.
This immense development, known as the Waterview Connection, is a $1.4 billion project that includes the construction of 4.8km of six-lane motorway. Even more ambitious is the fact half of this motorway link will be underground, making it the largest road tunnel in Australasia.
The extensive tunnelling process creates plenty of excess water and it is essential that this liquid is stored and treated. This is where Interbloc plays a crucial part.
Solution
Interbloc was contracted to supply blocks for the project and build a two-bay settling pond owing to a few key factors.
McConnell Dowell – a partner to Well Connected Alliance – chose Interbloc to provide the settlement ponds because its blocks were engineered and could be removed with ease at the end of the project.
As Interbloc Account Manager Dion Rout explains, Interbloc provides options that save customers time, money and hassle.
“Because the project was only over two years, Well Connected Alliance needed something that could be dismantled when the project was finished,” he says.
“The flexibility of Interbloc made this an easy option for them. With these short time frames, Interbloc was the quickest and most cost-effective option.
“Installing an alternative system – which would have been solid concrete – would have taken a lot longer.”
Interbloc’s unique Buyback Guarantee also played its part in having the company on board. The scheme provided the customer with a level of security and assurance about the end result that only Interbloc could deliver.
“The added benefit is that because of the unique Interbloc Buyback Scheme, at the end of the project Interbloc will take care of the blocks,” Dion says.
“This is what got them over the line, because they only needed the blocks for a specific timeframe.
“We are happy to take the blocks back because we trust their quality so much.”
A total of 369 x 1200mm blocks and 9 x 1800mm blocks were used to create 130 lineal metres of wall that reached 1.8m high. It was sealed using shotcreate, which provides a watertight solution.
Benefits
The blocks were versatile and flexible.
Installing Interbloc blocks saved time compared to alternative options.
The Interbloc Buyback Guarantee means this was the most cost-effective option for the customer.
Situation
Viterra has operations in North America, Australia, New Zealand and China. The Regina, Saskatchewan-based company is organised as three business units including an agri-products business that, among other things, makes and sells fertilizer.
Storing bulk fertilizer isn’t straightforward. Left unchecked, the weight is enough to push out the sides of the large tin sheds normally used to house the agricultural nutrients. To avoid this, fertilizer suppliers build strong internal retaining walls to take the strain around the edges of the building and separate the different types of fertilizer.
Agri-business giant Viterra already had retaining walls installed at its Geelong and Adelaide fertilizer stores, but ran into health and safety problems with conventional building techniques. An additional complication was the landlord of its 150 by 70 metre Geelong store insisted Viterra could only use removable materials to build retaining walls and not cause permanent damage to the building’s concrete slab floor.
Solution
Rohan Pollard of Blueprint Consulting Engineers said: “Viterra was considering a number of solutions. They needed an engineer-designed system and the walls had to be removable. Interbloc provided them with what they needed at a price they were comfortable with. The solution exceeded Viterra’s requirements in every way.”
The health and safety requirement was paramount. Pollard said: “The Interbloc approach doubled the factor of safety at the stores. That was important to Viterra; it’s a large company and needs surety in its health and safety systems. The company wanted a solution compliant with the code; its existing walls were under strength and under capacity”.
Overall there is now a total of 1.2 kilometres of Interbloc walls split between the two sites. This mean shipping some 3000 tonnes of blocks from New Zealand along with 45 tonnes of reinforcing steel and pouring 1,700 cubic metres of concrete.
Benefits
Pollard said the beauty of the Interbloc approach is that Viterra came decommission an entire wall and re-erect in another location: “It’s just a matter of unbolting and moving. Putting a wall elsewhere might take a couple of days”.
This level of flexibility and speed was essential to the overall project. Viterra needed the work done with the minimum amount of disruption. Pollard said the company was never going to be able to shut down its facilities for six months to allow for building work: “Interbloc managed to work with the minimum disruption on the existing sites”.
