PRECAST CASE STUDY: MODA THE HILLS

Forming part of an overall effort to improve the neighbourhoods of Sydney’s North West by bringing vibrant green spaces, cycling and walking trails and shopping districts to multiple communities, the Moda The Hills project is designed to target young professionals, familieas or downsizing purchasers.

Located alongside the lush grounds of the Castle Hill Country Club and International Golf Course, the development is characterised by contemporary design features, natural surroundings and proximity to public facilities and transport, with key features including rooftop gardens, high-speed internet and a range of leisure facilities.

TOWERS STRENGTHENED BY PRECAST
Arden Group, a respected developer, has undertaken and completed a variety of residential projects in Sydney and Brisbane. To develop Moda The Hills, Arden assembled a distinguished team of artists, landscape designers and builders. National Precast member Alpha Precast is a prominent member of this team, having been awarded the contract for the manufacture and installation of prefabricated concrete walls for the project, in March 2019.

One of Sydney’s more recent manufacturers of precast, the company is run by owner Daniel Nassar, who has over 20 years’ precast manufacturing experience. Nassar confirms Alpha’s approach is to put together a team of highly skilled people to encourage confidence in the design, manufacturing and installation of precast concrete on every project contracted. With a guaranteed priority of quality and service, Alpha designs and manufactures precast in one of the biggest facilities under one roof in Australia.

“In Moda’s case, we manufactured 999 Class 2 off-form wall panels for a total of 48 levels of four mid-rise towers,” he says. Of the four residential towers, three are 12 storeys high, and one is six storeys. Panels measured between one and six metres wide and between 2.8 and 3.6 metres high and were cast between June and September 2019.

SHORT INSTALLATION TIME
“One of the reasons precast was chosen was its speed of construction,” says Nassar. “We managed to install all 999 panels on the four towers in under 16 weeks.”

“One of the reasons precast was chosen was its speed of construction. We managed to install all 999 panels on the four towers in under 16 weeks.” Daniel Nassar, proprietor, Alpha Precast.

STRUCTURAL RELIABILITY
As the precast for this project was loadbearing, both flat and ship-lapped joints were part of the panel design, with ship-lapped joints used to prevent water entry. In order to connect to flooring slabs, recesses and starter bars were integrated into the panels, increasing efficiency and accuracy during the installation.

ONSITE BENEFITS FOR BUILDER AND SITE WORKERS
A factory-controlled manufacturing process is highly beneficial for a large-scale project such as Moda The Hills. As well as significantly shortening the construction program, there was also a priority to create a safer and tidier work site. The preference for precast meant fewer onsite trades, less shipping, less waste and a better and more productive work environment. With Alpha working as an extension of the builder’s team, high standards were maintained across all works completed, both in the factory and onsite.

A WIN FOR SOON-TO-BE RESIDENTS
The modern architecture and high building efficiency of the four mid-level towers promises to create a highend feel for the 200 families that will soon inhabit the residences, while also meeting key functional benchmarks, says Nassar.

“We are proud that we can be part of delivering beautiful homes for so many families, homes that will stand the test of time, while at the same time being thermally efficient, termite proof and boasting a four hour fire rating.”

The project is expected to be completed in December 2020. ■

Project: Moda The Hills – Residential Towers
Precaster: Alpha Precast
Location: Kellyville, NSW
Client: Aland
Builder: Aland
Architect: Aland
Engineer: Mance Arraj