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Concrete In Australia : September 2008
PROJECTS New Zealand dairy company Fonterra’s milk powder storehouse incorporates New Zealand’s largest post-tensioned concrete slab, with a combined area of 50,000m2 . New Zealand’s largest post-tensioned slab The Fonterra Cooperative Group Ltd’s milk powder storehouse in Te Rapa, constructed a few years ago, incorporates New Zealand’s largest post-tensioned concrete slab, with a combined area of 50,000m2 . Using a post- tensioned concrete slab on grade provided several key advantages to the project including large joint free bays, enhanced durability and the ability to cater for very high loads. The post-tensioned slabs included: • a 35,000m2 storehouse • a 15,000m2 post-tensioned fl oor internally for the dry goods external pavement/container stand. The project also incorporated a steel fi bre reinforced slab used for unloading material directly from trains and a heavily reinforced slab for supporting a rail track. All of the slabs were constructed using Somero laser screeds. The 75m by 460m internal post-tensioned floor provided the main storage/operating surface for the storehouse. The building is divided into three separate storage areas by internal walls. The fl oor is 165mm thick, and is designed to cater for forklifts with axle loads of up to 24.6t. It was constructed 22 Concrete in Australia Vol 34 No 3 in 12 pours, with the size of individual pours ranging from 2,300m2 to 3,345m2 . The post-tensioning tendons in each pour were crossed over with the adjacent stage across the building, tensioning the pours together and holding the joint between them tightly closed. This resulted in bay sizes of up to 6000m2 that did not contain any joints. The joints between each 6000m2 bay were armoured using LESA Systems Type G steel joint armour, which incorporates a “sliding plate” type design to keep the joint opening covered after the joint opens. The armour protects the joint edge from spalling, and reduces fatigue/damage to forklift traffic crossing the joint. These measures also helped to meet the hygiene requirements for the storehouse which required that there were no entry points for rodents or other animals into the building. The joints were doweled to allow load transfer across the joint. The design ensures that any joint opening is kept covered. A paper describing this project, written by personnel from contractor Conslab and concrete supplier Allied Concrete and design engineer BBR Contech, was delivered at last year’s New Zealand Concrete Conference.