The increasing demand for sustainable and resource-efficient construction processes presents significant opportunities for specifiers, suppliers, and contractors to transform their business practices for the better. This demand is fueled by several factors, including the government’s desire to reduce carbon emissions. The ultimate goal of sustainability is to ensure that we do things today in a way that can be sustained for the future. At Envirocon, we understand that these changes can be painless, practical, and cost-effective, as we have successfully implemented them for the past 18 years.

A Practical Approach to Sustainable Construction

Implementing sustainability doesn't have to be a daunting task, but it often requires partnering with experts in the field. This is where Envirocon comes in. Approximately 300,000 tonnes of high-quality, certified, wet concrete - equivalent to seven Sky Towers worth - would go to waste because it cannot be used before it cures. Envirocon was established to eliminate this waste. We work closely with some of New Zealand's largest concrete companies to permanently close the loop on concrete waste by transforming excess high-quality concrete into precast concrete products that can be reused repeatedly. Our expertise lies in matching insecure and volatile supply with mass market demand. We do the hard work on sustainability so our customers can unlock exceptional benefits.

Accreditation Matters, Avoid Greenwashing

When there is a demand for a solution that is not readily available, there may be a temptation to offer an inadequate response, which is known as greenwashing in the sustainability world. Greenwashing occurs when a proposed solution may sound good but ultimately fails to make a significant impact. Specifiers, contractors, and asset owners need to feel reassured that their sustainability initiatives are genuinely effective.

Envirocon serves as an example of how to achieve this. Our company operates New Zealand's only construction-related Product Stewardship Scheme, which has been accredited by the Minister for the Environment under the Waste Minimisation Act 2008, demonstrating our zero-waste approach to handling excess concrete. Additionally, we have a registered Environmental Product Declaration that establishes the ultra low embodied carbon profile of our blocks. These two independently verified accreditations provide a comprehensive sustainability solution for contractors striving to fulfill complex and ambitious sustainability objectives.

It’s Only Going to Get More Important

By putting carbon reduction plans into action, we can help mitigate further impacts including slowing down global warming. The average global temperature is projected to increase by 1.5°C above pre-industrial levels by 2040, and without immediate and significant action, the impacts of climate change will only become more severe (Intergovernmental Panel on Climate Change).

Creating more resource-efficient practices also supports a more sustainable planet. By shifting focus to resource efficiency, it’s estimated we can reduce the use of raw materials by 60% and the costs of waste management by up to 90% (European Commission). Choosing solutions that enable the ability for resource efficiency will help achieve these estimates.

Sustainable construction is a topic of growing importance, and the New Zealand government has enacted two critical pieces of legislation regarding carbon reduction and resource efficiency: the Zero Carbon Act and the Waste Minimisation Act.

Enacted in 2019, the Zero Carbon Act sets a target for New Zealand to achieve net-zero carbon emissions by 2050 and establishes an independent climate commission to provide guidance on accomplishing this goal. The Waste Minimisation Act, enacted in 2008, promotes waste reduction, reuse, and recycling, with the goal of conserving resources.

Envirocon and its product ranges demonstrate how compliance with these Act’s can be achieved without needing to reinvent the wheel;

• Reusing wet excess concrete that would otherwise be sent to landfills, resulting in low-carbon, zero-waste Interbloc as the carbon cost has already been assigned to the project from which it originated.
• Creating Interbloc and Stonebloc to be dismantled with fewer new materials needed, thereby producing less carbon.
• Reusing wet excess concrete and preventing it from being sent to landfills.
• Offering modular concrete blocks that can be used repeatedly without being discarded, minimizing waste. This create a circular economy. 

Practical Sustainable Construction Case Studies

CITY RAIL LINK

The City Rail Link - a huge infrastructure project - aim’s set the benchmark for developing sustainable infrastructure in New Zealand. Following the ISCA framework, carbon reduction and resource efficiency are some of the projects’ highest priorities.

Envirocon and the Link Alliance started working together as soon as construction commenced in 2019. Link Alliance was able to get certainty excess concrete was diverted from landfill - helping to achieve the zero waste goals of the project, and at the same time reuse low embodied carbon blocks on the project.

Nick Braxton is the Principal Sustainability Advisor for the Link Alliance. He explains that the Alliance has a “zero waste to landfill” policy that makes Envirocon a perfect partner for them. “Our non- linear approach to waste management means we’re using excess concrete for a wide range of purposes instead of sending it to landfill,” he says.

As the project comes to an end, the intention is to take the blocks back off the project and repurpose them for other structures.

WATERVIEW TUNNEL

The $1.4 billion project, the Waterview Connection, includes the construction of 4.8km of six-lane motorway. To achieve this, extensive tunnelling needed to be conducted resulting in plenty of excess water.

Interbloc was contracted to form the settlement ponds for this project, largely due to the engineering capacity of the concrete blocks and that they could be removed easily after the project finished via the buyback guarantee. 

By using Interbloc for their settlement pounds, the Waterview Connection was able to be resource efficient.

Key Lesson - Sustainability Doesn't Have to be Hard

Envirocon demonstrates how partnering with the right suppliers can deliver innovative and comprehensive sustainable construction solutions which don’t necessarily need to be difficult, expensive, or lower quality.

We are excited to announce that we have developed a new program to recognize and reward contractors who have demonstrated exceptional skill and expertise in the installation of our Stonebloc range. Our program has four levels: Bronze, Silver, Gold, and Platinum.

As a contractor, becoming a Stonebloc Accredited Contractor is a great way to differentiate yourself from other contractors in the industry. By completing the training and meeting the required criteria, you will be demonstrating to your clients that you are fully qualified to install Stonebloc to the highest standards. Additionally, by having a proven track record of delivering outstanding results, you will be showing your clients that you are committed to providing the best possible service.

(Dan, Tex, and Louesito from Ground and Pound with their certificates after completing their Stonebloc Accredited Contractor's training)

But the benefits don't stop there, as an Accredited Contractor, you will also benefit from a range of exclusive perks and support, such as:

• Discount on the wholesale price of our products
• Easy-to-use design software
• Personalized service and support from a dedicated support person
• Free technical support
• Installation plans and detailed instructions

It's important to note that Stonebloc isn't the best fit for every retaining wall contractor. We also have ambitious growth plans so we want to partner with contractors that share our ambition. Below is a list of what we're looking for in a Stonebloc Contractor:

• A commitment to delivering exceptional customer service
• A proven track record of delivering high-quality retaining walls
• A desire to continuously improve and stay up-to-date with the latest industry trends and techniques
• A willingness to collaborate and work closely with our team
• A desire to grow your business and take advantage of the opportunities that our Accredited Contractors program provides

If you are interested in becoming a Stonebloc Accredited Contractor, please visit contact us for more information on the requirements.

We look forward to working with you and helping you to grow your business.

Waterproofing an Interbloc system, made up of precast concrete blocks, is a crucial step in ensuring the longevity and durability of the structure. Interbloc systems are widely used in settlement ponds, retaining walls, bins, and bunkers, among other applications.In this blog, we'll discuss how to properly waterproof an Interbloc system, why it is important, and why we recommend using sealants for most Interbloc structures.

How to seal an Interbloc structure

1. Use a suitable sealant: The first step in waterproofing an Interbloc system is to apply a sealant to the interlocking layers of the blocks. The sealant should be applied in layers to ensure complete coverage before proceeding to the next step.
2. Seal the joints: The joints between the precast concrete blocks in an Interbloc system are a common point of water ingress. To prevent water from entering through these joints, they should be sealed with the same sealant. The sealant should be applied to the joint in a continuous bead before the structure is put into use. It is important not to apply too much sealant to the joint as it can cause the precast concrete blocks to shift and move, leading to structural issues.
3. Regular maintenance: Waterproofing an Interbloc system is not a one-time process. It is important to conduct regular inspections and maintenance on the system to ensure that the waterproofing remains effective. This includes checking for any cracks or damage to the sealant.

(The highlighted are shows an example of where you'd add sealant if you wanted to waterproof your Interbloc structure)

Why it’s important to waterproof

Waterproofing an Interbloc system is vital because it helps to protect the structure from water damage. Water ingress can cause the system to weaken and deteriorate over time, leading to costly repairs or even complete failure. Waterproofing also prevents structural damage such as rusting of steel reinforcement.

Why we recommend sealants for most Interbloc structures:

Sealants are an excellent choice for waterproofing Interbloc systems because they are easy to apply and can provide long-lasting protection. Sealants are flexible and can move with the structure, which helps to prevent cracking and damage to the waterproofing. Finally, sealants are a cost-effective solution for waterproofing Interbloc systems, making it an attractive option for those on a budget.

Waterproofing the Waterview Tunnel’s Settlement Pond

A well-known Auckland roading project, the Waterview Connection, needed settlement ponds to store and treat liquid from the tunnelling process. Interbloc was chosen for it's combination of engineering and modularity. 

In order provide a watertight solution, sealant was added to the joints of the 1.8m high walls. It was sealed using shotcreate, allowing for a temporary solution to hold the liquid. When the settlment ponds were no longer needed, the sealant was removed and the blocks sold back to us via the buyback guarantee. 

By taking the steps to waterproof an Interbloc system using a waterproofing sealant, and not applying too much of it, you can ensure that the Interbloc system will remain in good condition for many years to come.

Are you in the events industry and looking for a way to add brand identity and functionality to your concrete blocks? Our new 'brand your block' service is here to help.

We can customise the look of a block so suit your brand by sticking decals to the side of the blocks. These high-quality decals are perfect for branding and customizing all of our counterweight and bollard ranges, from 10kgs to 1500kgs. They're great for a variety of events, including weddings, parties, and corporate events. With our decals, you can transform your blocks into unique and personalized pieces that will make your event stand out.

(BollardBloc on the left and a decal for Tomo's Saws and Mowers on the right)

Here are a few ways you can use our 'brand your block' service:

• Use them as counterweights for marquees and tents, ensuring stability and safety
• Use them as weights for signage and banners, keeping them in place even in windy conditions
• Use them as bollards to create barriers and define spaces
• Use them as hoardings to create a backdrop or partition
• Use them as seating, adding a pop of color and personality to your event

The decals are made with a special adhesive that ensures they'll stay put with a 12 month warranty. They are easy to apply and remove. 

We offer both hire and buy options for the concrete blocks. If you're wanting to hire, any decals will be yours and are not part of the hiring process. Buying online will be offered soon but for now contact us, we will be able to help you to buy bundles of blocks with customised decals that fit their brand.

So why settle for plain, boring blocks when you can add some style and functionality with our decal service? Contact us today to start branding your blocks, elevating your space with unique and personalized concrete blocks for any occasion.

Stonebloc retaining walls are a versatile and durable landscaping solution that can enhance the aesthetic appeal of any property while also providing functional benefits. They are particularly popular in New Zealand due to their natural-looking finish and ability to withstand the elements. Not only do they improve the overall appearance of a property, but they also increase its value.

When it comes to housing in New Zealand, there are a few different types to consider. Terrace housing, for example, is a type of housing where a row of houses is built closely together, sharing one or more walls. These houses are typically smaller in size and are a popular option for urban areas where space is limited. Stand-alone houses, on the other hand, are individual houses that are not attached to any other property. These houses are typically larger in size and are popular in suburban and rural areas. Multi-unit housing refers to buildings that contain multiple dwelling units, usually apartments. These are usually popular for high-density housing.

Standalone House
Terrace House
Multi-Unit House

Regardless of the type of housing, Stonebloc retaining walls are an ideal solution for creating functional outdoor spaces. For terrace houses, they can be used to create a sense of privacy and separation between properties while also providing functional benefits such as retaining soil or creating level terraces. For stand-alone houses, they can be used to create raised garden beds, level out uneven areas and enhance the aesthetic appeal of the property. Multi-unit housing buildings can also benefit from Stonebloc retaining walls, they can be used to create more outdoor spaces for the residents, and also can be used as a sound barrier.

(The Standard Stonebloc Block)

One of the best things about Stonebloc retaining walls is that they are easy to install, no matter the type of housing. Whether you have a terrace, stand-alone or multi-unit house, a Stonebloc wall can be installed quickly and efficiently. The standard size of the blocks is 800 x 400 x 400mm and they weigh 300kgs, making them easy to handle and maneuver during the installation process. The minimal foundations required for installing the wall makes it easy to set up and it can be done with minimal disruption to the surrounding area.

(Installing with Stonebloc)

Many existing homeowners often switch to Stonebloc retaining walls as they have experienced issues with their timber retaining walls. Timber retaining walls are prone to rotting, warping and insect infestation, which can cause them to fail over time. Stonebloc retaining walls, on the other hand, are made of concrete and are not susceptible to these issues. They are also more durable and can withstand the elements better, making them a more reliable option for retaining walls.

(Stonebloc retaining wall on the left, timber retaining wall on the right)

Installing a Stonebloc retaining wall not only improves the aesthetics of the property but also adds value to it. The functional outdoor spaces created by the wall can be used for entertaining, relaxing, and even for additional housing. It increases the overall appeal of the property and makes it more attractive to potential buyers. By adding a Stonebloc retaining wall, homeowners can increase the value of their property, making it more desirable and potentially increasing the sale price. Additionally, the durability and longevity of Stonebloc retaining walls make them a smart investment for homeowners looking to improve their property and add value over time.

In conclusion, Stonebloc retaining walls are a great addition to any property in New Zealand, regardless of the type of housing. They are easy to install, durable, versatile, and customizable. With the ability to transform a house's outdoor space and add value to the property, it's no wonder that they are a popular choice among homeowners. If you're looking to enhance your property and create functional outdoor spaces, consider installing a Stonebloc retaining wall with the help of a Stonebloc Accredited Contractor.

The Paris Climate Agreement, also known as the Paris Agreement or COP21, is a legally binding international treaty adopted by almost every country in the world in 2015. Its goal is to limit global warming to below 2 degrees Celsius above pre-industrial levels and to pursue efforts to limit the temperature increase to 1.5 degrees Celsius. In order to achieve this, countries have committed to regularly reporting their greenhouse gas emissions and implementing measures to reduce them.

As the world shifts towards a more sustainable future, there is an increasing demand for products and services that can help reduce carbon emissions and create climate resilient economies. Products like Interbloc and Stonebloc are leading the way in this regard by providing innovative building solutions that can help to meet the needs of the Paris Climate Agreement while following the principles of circular economy.

Interbloc, with its precast concrete blocks using wet excess concrete, is an excellent example of circular economy in action. By repurposing excess concrete, Interbloc is not only reducing the environmental impact of concrete production but also saving costs and resources. They are keeping the resources in use for as long as possible and extracting the maximum value from them before recovering and regenerating the products. Interbloc also offers a buyback guarantee, which means they will repurchase any used blocks at the end of their useful life, ensuring that the blocks will be repurposed, completing the loop of the circular economy.

Not only that, but Interbloc blocks are energy-efficient, durable and modular. This means that they can be easily assembled and disassembled, making them ideal for construction projects that are subject to change, such as temporary structures or phased developments. This is particularly useful for reducing waste and minimizing construction time, and it can help to create climate resilient economies by providing durable and sustainable building solutions that can withstand the effects of climate change.

Stonebloc is another range in the the Envirocon catalogue, with a focus on timeless aesthtics. It’s designed to be used in a modular system, which allows for flexibility and adaptability in construction projects, helping reduce waste and minimize construction time. By offering durable and sustainable building solutions, Stonebloc plays a role in creating economies that can withstand the effects of climate change

Both Interbloc and Stonebloc are examples of how businesses can play a role in meeting the needs of the Paris Climate Agreement by providing innovative solutions that can help to reduce carbon emissions, repurpose waste materials, and follow the principles of circular economy. They also help to create climate resilient economies by providing durable and sustainable building solutions that can withstand the effects of climate change. They show that it is possible to have a thriving economy and a healthy environment, and that businesses have a responsibility to contribute to the global effort to combat climate change and to promote a more sustainable future.

As we kick into 2023, we thought it'd be a great opportunity to look back at the challenges and achievements of 2022 and highlight our focus for 2023.

In many ways, 2022 was a year of preparation. From manufacturing to sales and marketing, significant investment was undertaken to prepare Envirocon for future growth.

On the operations side of our business we continued to expand our engineering capacity, doubling the mould-making team in preparation for new collection points and manufacturing locations to be opened. Late 2022 saw the opening of East Tamaki, and as we return to work January sees the opening of Timaru and Cromwell. We’ll target to open an additional three locations over 2023, bringing manufacturing closer to our customers and lowering the cost and environmental impact of freight.

We also put a big emphasis on product development and R&D , as a result 2023 will see Envirocon launch three new Stonebloc products to round out the range and offer a complete solution. We’ll continue to launch new and improved counterweight block designs in larger weights. Finally, we’ll be launching an improved version of the Stonebloc standard block, incorporating more tolerance into the block, improving the installation experience.

Ram raiding across the country provided the opportunity to showcase the flexibility of our concrete blocks. We combined the strength of our 1000KG concrete block with a timber seat to help Kiwi businesses protect their assets, creating BollardBloc.

A core focus for the company is continuing to improve the ease of design and use of our Interbloc and Stonebloc construction systems. 2022 saw the launch of Envirobuild, a custom built, cloud based 3D design software system that dramatically speeds up the design of Interbloc and Stonebloc structures. Envirobuild quantifies the blocks required for the design and creates high quality 3D visualisations of structures that can be explored by third parties via our Envirobuild Viewer functionality. As we move into quarter one of 2023 we’ll be launching Envirobuild for public use.

As foreshadowed at the beginning of 2022, sustainability continues to sit at the core of our business. We completed and registered NZ’s first precast concrete Environmental Product Declaration (EPD) which demonstrates the very low embodied carbon footprint of our precast construction systems.

The registration of our EPD rounds out our CarbonSmart® sustainability story - arguably the most comprehensive approach to sustainability in NZ today. Our focus for 2023 will be to spread this message to larger audiences, bringing the benefits of fast, efficient, durable construction with impeccable sustainability credentials to organisations facing increasing demands from government and asset owners.

We’re excited to announce the launch of our first Environmental Product Declaration (EPD) for our Interbloc precast construction system.

Our EPD is unique in a number of ways;

• It’s the first EPD in NZ to cover precast concrete products
• It demonstrates low embodied carbon footprint for our precast elements
• It demonstrates the impact of zero waste design, and benefits of recarbonation at end of life

In April 2022, we approached thinkstep-anz - leaders in product life cycle assessment and sustainability- to produce an EPD for Interbloc. This would focus on manufacturing with Envirocon’s CarbonSmart® sustainability system.

"Congratulations to our client EnviroconNZ for rounding off the year with a published EPD for their pre-cast concrete blocks. [Envirocon] design these blocks to reduce construction waste and make them from quality concrete that would otherwise be wasted. Less waste. Tick. Low embodied carbon. Tick. CO2 reabsorbed over their life. Tick. Lots of things to love! It’s been a great project to be part of."

thinkstep-ANZ, December 2022

The launch of the EPD shows our unique and unrivaled combination of sustainable features & benefits;

• Product Stewardship - we’re NZ’s only construction related accredited product stewardship scheme diverting high quality concrete from landfill.
• Low Carbon Construction - our CarbonSmart construction systems provide a very low embodied carbon footprint for concrete construction as demonstrated by the EPD.
• Recarbonation - our blocks reabsorb carbon throughout the structure’s life
• Zero Waste through Deconstruction - our structures can be non-destructively dismantled and reused via our unique buyback offer.

Our systems also delivers;

• Fast, Easy Installation - two people can build up to 160m2 of wall per day using standard equipment.
• Code Compliant Engineering - orthodox engineering design allows simple design and consenting processes.
• Safety and Durability - our precast elements are manufactured from high quality certified concrete, incorporating standard certified precast lifting anchors with a FoS >5 for multiple lifting.
• Proven System - in market since 2004 with over 4000 structures built throughout NZ and Australia.

About Environmental Product Declarations

EPD’s are a recipe for the environmental footprint of a product. It is not an endorsement, but provides a level playing field for the comparison of products. In addition EPD’s can make the process of reporting on products and projects through sustainability rating schemes such as the Infrastructure Sustainability Council’s IS Rating Scheme easier.

“An Environmental Product Declaration (EPD) is an independently verified and registered document that communicates transparent and comparable data and other relevant environmental information about the life-cycle environmental impact of a product.

Multiple datasets are included in an EPD: resource consumption of energy, water and renewable resources, and emissions to air, water and soil. This data is aggregated using multiple environmental impacts including contributions to climate change (carbon footprint), air, water and soil pollution and resource depletion.

Other relevant impacts and environmental information may also be included. This may include data on product performance, the company’s environmental management system or other environmental certifications.”

(EPD Australasia, 2023)

About Envirocon

Envirocon is a sustainability-driven precast concrete company that supplies easy to use, fast and flexible construction systems.

We work with NZ’s leading companies to close the loop on concrete waste for good.

We do this through our Interbloc and Stonebloc precast wall systems. At the core of the systems are proprietary block designs. The block designs look simple enough, but when you dive deeper they deliver a powerful combination of benefits.

(Interbloc pre-cast concrete blocks on the left, and Stonebloc retaining wall blocks on the right)

They start life with ultra low embodied carbon, and continue to reabsorb carbon over their life.

They reduce time, labour, and materials waste during installation.

They deliver unparalleled durability, increasing the life of the structure.

They can be non-destructively dismantled and reused at the end of life.

We call this approach the CarbonSmart - Low Carbon, Zero Waste sustainability system.

Envirocon’s delivery service is a great option for those looking for a convenient way to get our blocks to the site. Envirocon freight can be delivered with flexible dates and can help reduce costs.

We have put together a list of our top tips for a smooth delivery of blocks. Applying these tips will help reduce the time of unloading blocks while ensuring everyone’s health and safety. These tips will also help make the dispatch process as easy as possible, even when sites are trickier to access.

Check the Truck

Before we organise dispatch of the blocks, ensure your contractor has checked that an average- width truck (about 2.55 metres) can access the site. You can do this by requesting your contractor to visit the site and by providing them with accurate information. This is important as the contractor then informs the Envirocon Sales and Dispatch Teams. Doing this check will help the ensure the most efficient and timely delivery. You don’t want to find the truck cannot fit into the site after we have sent the blocks!

However, if you find the truck cannot access the site, you will need to request a small vehicle, such as a forklift or excavator, to bring the blocks from the truck to the location.

The Type of Truck Matters

Take the time to plan the type of truck you will need, considering the size, your order tonnage, and accessibility of the site. This will help reduce back and forth of communication between you and us. For example, if you have limited space, you would want to avoid using a curtain sider. Different trucks will be able to carry different max tonnage and it is important to understand not every truck will suit every project, order, or site.

Some of the common truck tonnages are 10, 14, and 28T. Our Envirocon trucks allow for a tonnage capacity of between 10 and 14 tonnes. 

(Envirocon trucks ready to start dispatch)

The Gradient is Important

The gradient, or the steepness of the site, is important because it may inhibit the delivery and construction of the structures. A site that is too steep will make it difficult for a truck to access. It also risks safety of the drivers and those on site, given the heavy weight of blocks. Furthermore, if a gradient is too steep, there is a risk of the truck tipping, creating another safety concern. We do not want to risk any accidents or someone getting hurt. So if you do have a steep gradient on your site, let us know. We'll work with you to find a solution.

(

Check for Other Factors that Could Affect Site Access

Remember, an entire truck must be able to access the site for the delivery of the blocks to proceed and be successful. Before the truck dispatches, “sweep” the site and check to see if anything else could make the site inaccessible to a truck. For example, narrow access and overgrown trees.

Also, make sure your driveway has been completely sealed. Unsealed driveways make delivery difficult, of course, since a truck needs to drive onto the site. You don't want the truck to sink into the soft concrete.

Following from this, make sure you unload the blocks onto solid ground. Do not place the blocks on soft, wet soil or ground.

Sufficient Storage Space

Stonebloc pallets are large and can take up a lot of space at an area of 1m2 per pallet. Before you unload the pallets, make sure you have selected and organised a large enough space to store the blocks between the installation process.

Pallet Placement

Speedy and efficient installation is one of our primary goals as it reduces labour and makes the process more cost-effective. If you can place the pallets along the length of the planned wall, this will reduce the time to construct the wall. This is because it reduces double handling and the additional manual labour of moving blocks more than necessary.

Consider Delivery Time

When you place a delivery order with Envirocon, your Envirocon representative and Envirocon’s freight supplier will help you organise your delivery date. Try to book your delivery date as soon as possible. This will ensure you can avoid any unnecessary delays, helping you construct the wall sooner.

Dispatch, delivery and unloading of Envirocon’s concrete blocks can be a simple, stress-free procedure so long as you're prepared. It is important to ensure the site is accessible and meets the requirements to avoid any delays and extra costs.

In the wake of the pandemic, the cost of materials, freight, and resources have been a concern for many in the construction industry. With the ever-growing demand coming from the South Island, Envirocon came up with a solution that would meet the growing demand for concrete blocks in the area and decrease freight costs.

Our Christchurch yard has its own manufacturing facilities; it is a self-sufficient plant which allows us to minimise the costs, time and simplify processes. This positively impacts our South Island partners and their growing businesses.

We have put together a list of the benefits.

Freight Cost

This yard is a great solution for cost and time efficiency. An important point of our regional strategy is to begin manufacturing closer to customers to reduce freight costs.

The Christchurch yard can even serve lower North Island orders if the process is feasible and more cost effective than North Island freight.

More Stock

With the new yard, we can produce and expand our stock of concrete blocks to meet the demand and needs of more customers and contractors. Many have expressed their concern about our stock in the North Island yards “flying out the door” because of the high demand. The development of our yard in Christchurch will ensure everyone has access to our concrete blocks when you require them, we have increased the production of our concrete blocks. You will not have to wait as long for more to concrete blocks to be manufactured before dispatch.

(Blocks stacked, ready for delivery in the Christchurch Yard)

Both Interbloc and Stonebloc

The Christchurch yard has the capacity and resources to manufacture both the Interbloc and Stonebloc ranges. However, the majority of Stonebloc stock currently still comes from Auckland. We use moulds to produce our interlocking concrete blocks by pouring in high-quality wet, excess concrete. Once the blocks are set within the moulds, we take them out, and leave them for several
days to continue setting before they are ready for dispatch. The yard has a large roof cover, perfect for pouring concrete into the moulds when it’s raining. 

(Concrete being poured into Interbloc moulds)

The expansion of the self-sufficient Christchurch yard offers those in the South Island and lower North Island the chance to acquire their Interbloc and Stonebloc faster while not compromising on the cost. Envirocon is also developing yards of matching capacity in Timaru and Cromwell. So, keep an eye out for updates on this exciting news!

As a homeowner, building a retaining wall can be an intimidating endeavour if you don’t know where to start. It’s important to seek simple, cost-effective solutions while being able to bypass the construction industry jargon. Understanding the overall process, from quoting, to installation, and maintenance, can help ease any confusion and ensure a successful outcome.

We have put together a guide for homeowners who are investigating solutions for retaining walls. If you are needing a standard or conventional retaining wall, this guide will serve as an easy-to-follow checklist to get you started and prepared.

Remember, the homeowner assumes responsibility to check this list and ensure their designed retaining wall meets the requirements and regulations for installation.

Council Consent

While most types of walls do need consent from the council for safety, some do not. However, retaining wall requirements may vary between different councils. So, it’s important to check with your local council, and make a note of what you need.

Walls that are less than 1.5 metres high, and support nothing such as a garden, often don’t need consent. If you're in Auckland, use this tool to give you a rough idea of if you need consent or not.

(Auckland Council's Retaining Wall Tool)

Buildability

There are many external factors to a retaining wall to consider, therefore, construction of the wall needs to be realistic and designed thoughtfully.

For example, consider: 

• Consider how trucks and other large machinery will access the site. Is the space large enough for them?
• Can the blocks get to the planned retaining wall location?
• Is there adequate drainage for rain and water?
• If you have a sloped property, consider how the slope, surrounding buildings, and structures might be affected in the event of storms, heavy rain, or even natural disasters such as earthquakes.
• Heavy rainfall or natural disasters can put pressure on retaining walls if they’re constructed on a slope. They are at risk of cracking, moving, or even collapsing, which is, of course, a safety concern. There are several factors that can put slopes at a higher risk. For example, if the surface material is soft or loose, comprises of mostly soil, has a gradient of over 35 degrees, or if the slope has been cut into. Take the time to research signs and other risk factors for slopes before going ahead with a design.
• Make sure you consider any other restrictions to the site. Check for blockages such as trees. Also, make sure the ground you are planning to build upon is solid and not soft.

• Retaining walls are a structure and therefore, need to be designed with expert engineering. Getting the help of a contractor, such as a Stonebloc Accredited Contractor, will help avoid any headaches. Stonebloc Accredited Contractors are professionals who will understand how your project will work best with Stonebloc.

Tip: Take some photos of where you want your retaining wall to be constructed. Send them to your Envirocon representative who will help determine what you need.

Engineering Consent

Specific engineering is used mostly for consent purposes. Be sure to consider the following:

•  If you need council consent, you do need a site-specific design.
• If your site conditions lay within a number of Stonebloc ready-made designs, you will only require an engineer’s short review.
• Allow time to issue design calculations for a PS1 document, which is a producer statement used for specialist work such as engineering. A producer statement such as a PS1 helps the council determine whether the building work meets the Building Code regulations.
• Geotech report and pass it on to a consultancy for the design and consent process. Geotechnical engineers are important as they help calculate factors that will influence how the retaining wall will be designed and built, such as considering how much weight the site and wall itself can hold.

While designing and building a retaining wall for your home can seem daunting, it doesn’t have to be. Nor does it have to break the bank. This checklist should breakdown the tasks you need to do and provide a place for even newbies to begin. Following this checklist will reduce delays, unnecessary costs, and ensure your retaining wall is safe, durable, and aesthetically pleasing.

Steve and Sopa are a Pokeno based couple who recently chose to work with Stonebloc to build their retaining wall. They wanted to create a retaining wall where their fruit trees could grow above, while doubling as an entertainment area for their home. The couple were meticulous and heavily researched the design and buildability of their retaining wall plan. This helped ensure a successful construction of their retaining wall and will make sure it stands the test of time.

(Steve & Sopa's Stonebloc retaining wall, with their fruit trees sitting on top)

After reviewing the checklist, we’d recommend reaching out to our Stonebloc representative to see how Stonebloc would work for you and your home.

In the face of rapid climate change, the construction industry has environmental and sustainability responsibility it must follow. Businesses in the industry must adhere to government regulations like  the Zero Carbon Act and the Waste Minimisation Act.

Embodied carbon is the amount of carbon produced to create a structure or infrastructure. Concrete “consumes” most of the embodied carbon produced. The concrete industry must respect the energy expenditure -  the amount of energy a material produces over its lifetime.

We offer a solution to sustainability responsibility that pays homage to legal, and governmental requirements, while creating a product that withstands the test of time. We have engineered a product that adheres to government regulations such as the Zero Carbon Act by pouring high-quality, certified excess wet concrete to moulds to form our concrete blocks.

The carbon is associated with the project the concrete it initially came from prior to being added to our moulds. By doing this, we incorporate a circular economy by keeping our resources in use for as long as possible. Closing the loop on concrete waste is our greatest value. We understand that high-quality, excess concrete is a valuable material and we must decrease our carbon footprint by considering the product’s end of life.

We capture the excess concrete while it is still in its wet form, and pour it into our moulds, creating Interbloc precast wall systems. These blocks have powerful benefits as they start life with low embodied carbon and continue to reabsorb carbon over their life. The blocks reduce time, labour, and materials, are durable and have an extended structural lifetime. Structures can be broken down and the blocks reused, creating a circular economy system. We call this approach our CarbonSmart® sustainability system. This system is also financially beneficial with the reuse of resources, instead of having to source new materials. Our systems are designed to make the transition to our products, seamless, low labour, and time efficient.

(Interbloc Landscape Supply Bins for Wyatt's Landscape Supplies)

Interbloc is part of our product stewardship scheme, which is an approach to managing the environmental impacts of materials throughout their life cycle. Striving to utilise all useable wet concrete, we divert it into our Interbloc moulds. This reduces the carbon use and subsequent waste of valuable materials.

Stonebloc is also sustainable because the blocks allow for non-destructive dismantling. Over time, all the carbon produced will be reabsorbed through re-carbonation. Stonebloc was selected by the South Taranaki District Council to build the sea wall at Opunake Beach. Given the previous 1995 wall was prone to disintegration and erosion from the sea water and elements, the council wanted to build a new wall that was durable and able to withstand a coastal environment, increasing the lifetime of the product and the structure overall.

(Stonebloc seawall for Opunake Beach)

A more sustainable solution such as the ones we offer ensure minimal process changes and reduces delays and cost. Our concrete blocks can be used for a range of applications like aggregate bins, retaining walls (Interbloc and Stonebloc), fertilizer bins , and PKE Bins .

Our Interbloc precast wall system is a low carbon, zero waste construction solution that meets government sustainability regulations. It is an environmentally friendly, cost-effective alternative to other concrete designs.

Our precast wall system is a low carbon, zero waste construction solution that is financially efficient in the long run. It also doesn’t require any changes in behaviour when making the switch. The transition is seamless.