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Managing vertical construction across a large healthcare build.
Case study supplied by the National Precast Concrete Association Australia
At the new Toowoomba Hospital in regional Queensland, precast structural systems supplied by Novus Precast were used to reduce site labour, accelerate installation and maintain construction sequencing across one of the state’s largest healthcare projects. (main image: Precast stair core installation underway at the new Toowoomba Hospital using large-format concrete elements supplied by Novus Precast.)
Delivered on a large greenfield site, the development included a multi-storey hospital structure with extensive vertical elements, including columns and stair cores extending up to 10 storeys. From the outset, the project team faced the challenge of maintaining programme continuity across a repetitive structure while operating within a constrained labour market.
Traditional in situ construction methods would have increased deck congestion, extended floor cycle times and placed greater pressure on site-based labour resources. Installation of vertical elements at height also required a repeatable and controlled process capable of maintaining consistency across multiple levels without disrupting parallel trades.
To address this, the project adopted a precast approach designed to shift labour into manufacturing while simplifying installation sequencing onsite.
Approximately 1,500 precast columns were manufactured and supplied by Novus Precast across nine levels using the APTUS column connection system. The system incorporated threaded reinforcement bars, couplers and anchor heads to connect stacked precast elements while maintaining both temporary stability during installation and long-term structural performance.
Each column was designed to be lifted directly from delivery vehicles into position, reducing onsite handling requirements and simplifying logistics across the structure.
Alongside the columns, Novus Precast also manufactured six large precast stair cores comprising 51 individual units. The tallest structures reached approximately 45 metres, with individual units weighing up to 92 tonnes.
Precast columns and stair cores supplied by Novus Precast were installed across the new Toowoomba Hospital project to accelerate structural sequencing and reduce onsite labour requirements.
Standardisation supported manufacturing repeatability
A key aspect of the project was the use of standardised layouts and reinforcement detailing to improve manufacturing consistency across repeated elements.
Steel jigs were used during fabrication to improve dimensional accuracy and reduce variability between units. This supported alignment between design, production and installation while assisting with tolerance management across repeated structural components.
The approach also enabled more predictable installation onsite.
Columns were installed immediately following completion of each formwork deck, allowing structural works to progress without interruption. Average installation times were approximately seven minutes per column, reducing floor cycle durations and limiting disruption to adjacent trades.
The APTUS system also reduced reliance on temporary propping during installation. By maintaining structural continuity between stacked elements during construction-stage loading conditions, including wind and self-weight, the system improved access across decks and reduced congestion for concurrent works.
“On a project of this scale, consistency and predictability are critical,” said Steven Prowse, Managing Director at Novus Precast.
“Using a connection system such as APTUS that provides both temporary stability during installation and long-term structural performance allowed us to install efficiently at height while maintaining programme certainty.”
For the stair cores, connection detailing including grouted joints and recessed coupler pockets was developed to reduce reinforcement congestion and improve constructability during installation.
The ability to install large structural elements without interrupting surrounding works also reduced exposure to external delays, including weather impacts and labour availability pressures.
Precast reduced pressure on site labour
The Toowoomba Hospital project reflected a broader shift towards manufacturing-led construction systems on large healthcare and institutional developments, particularly where labour constraints and programme pressures were affecting delivery.
By relocating a significant portion of structural work into controlled manufacturing environments, the project reduced dependence on onsite labour while enabling faster and more predictable sequencing during construction.
The project also demonstrated how connection systems are increasingly becoming central to the performance of precast construction, particularly where installation speed, temporary stability and repeatability across multiple levels are critical to programme delivery.
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