Monier Limited - Company Profile - Papua New Guineamonier.com.pg/Monier-Company-Profile.pdfMonier...

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Monier Limited - Company Profile Background: Monier Limited was established in Papua New Guinea in 1958 and was purchased in 2005 by Sir Theo Constantinou. Since 2005 the proprietor of Monier has made significant investment in growing capacity and capability in the production of construction materials and manufacture of building products. Monier directly employs in excess of 350 people in Port Moresby and has established strong brand recognition and a reputation for quality of products and services throughout Papua New Guinea. Monier is a significant contributor to the local communities and proudly supports local groups who demonstrate a commitment to improving the standards of education and health in Papua New Guinea. Executive Summary: Monier is the single largest producer, supplier and distributor of construction materials and building products in Papua New Guinea. Monier makes every attempt to perform to its creed of “the mark of quality” Monier’s standard range of products includes;

• Quarry Products o Roadbase – base coarse 80 CBR, sub base 60 CBR o Rock-spalls / Gabion Rock o Concrete Aggregates - 10mm and 20mm o Asphalt and Sealing Aggregates - 7mm, 10mm, 14mm, 20mm o Manufactured Sand o Washed River Sand o Builders Mix graded premixed coarse and fine concrete aggregate o Filter Rock o Diorite – general fill

• Concrete Products o Standard Grades (N) of Readymix Concrete - ranging from 5MPa to

40MPa, 10mm or 20mm maximum size aggregates, 80mm or 100mm “slump” water content.

o High Strength Grades and Speciality Grades (S) of Readymix Concrete - up to 65MPa structural mixes and/or high “slump” water content - low shrinkage concrete <600microstrains

o Readymix Design Services – mix designs developed trialled and tested to comply with relevant local and international standards and engineering specifications.

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• Precast Concrete Products o Stahlton Beams – engineer certified flooring system o Manhole and Drainage Components – MH surrounds, MH lids, lintel

beams, box culverts, gully pits, barriers o Step Treads – various sizes o Architectural and/or Engineered Elements – made to design precast

elements with architectural finishes and/or engineer certified structural properties.

• Reinforced Concrete Pipe Products o Flush Joint Pipe – 225mm to 1800mm diameter, Classes X,Y & Z,

1.22m or 2.44m long o Recessed Rubber Ring Joint Pipe – 300mm to 1800mm diameter,

Classes X,Y & Z, 2.44m long o House Stumps – termite proof

• Masonry Products o 100mm (4”) Blocks – standard, ¾, ½, ¼, solid, split rib o 150mm (6”) Blocks - standard, ¾, ½, ¼, lintel, channel, clean out split

rib o 200mm (8”) Blocks - standard, ¾, ½, ¼, bond beam, deep lintel, knock

out, full & ½ height sill, channel, clean out, knock out - clean out, biscuitless clean out, hollow, split rib, H block, ½ height standard, inspection cap, capping stone, livestock block – piggery grate

o 300mm (10”) Blocks – channel, square (cube), ½. o Unipave Paving – coloured and plain o Square Pavers – coloured and plain

Production and manufacturing operations are supported by:

• Highly experienced and dedicated line management team

• Monier’s quality control system and an independently accredited, PNGLAS, testing laboratory.

• Papua New Guinea’s largest fleet of truck mounted concrete mixers

• Fleet of tipper trucks

• Fleet of crane and side-lifter trucks The following information provides greater detail of Monier’ capacity and capability;

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Monier’s Operations:

• Quarrying Monier operates a high capacity hard rock quarry, Nebiri Quarry, producing varying size aggregates for readymix concrete, asphalt and road sealing and various grades of high quality roadbase materials

Ideally located in the National Capital District close to Port Moresby Monier’s Nebiri Quarry has a proven capacity to produce in excess of 1millon tonnes of quarry products per annum. With 3 high volume capacity crushing plants the Monier Nebiri Quarry operations provides the flexibility to produce high volumes of standard products in conjunction with manufacturing products to customer specifications. Monier regularly produces and supplies:

• 20mm CBR 80 & 40mm CBR 60 Roadbase to DoW or NAC specifications

• 10mm, 14mm, 20mm asphalt, sealing and concrete aggregates to DoW or NZ / AS standards

• 10mm, 14mm, 20mm builders mix

• Manufactured sands for asphalt and concrete fine aggregates to DoW or NZ / AS standards

• Rock spalls Monier generally holds stock of standard products to provide some buffer against urgent customers’ orders and/or unexpected demand. As well as the 3 crushing and screening trains Monier operates a Nirox Trommel for high capacity production of rock spalls, gabion and armour rock. A large fleet of mobile plant and equipment including a power screen aids production flexibility providing for supply of a large range of product types. The power screen is used to process “non standard” or alternative specified sands, aggregates and filter rock, All specified quarry products are quality controlled to ensure products meet relevant standards and codes, such as Australian Standards (AS) for concrete and asphalt aggregates and Department of Works (DoW) specifications for roadbase materials and sealing aggregates. Regular sampling and testing is undertaken across the product range and test results certified to provide customers with confidence that the quarry products are compliant with the relevant specification and standards.

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Average production rate per crushing and screening plant depend on the materials being processed, proven average production rates are;

• Plant 1 – 100 tonnes per hour

• Plant 2 – 70 tonnes per hour

• Plant 3 – 80 tonnes per hour The standard operating shift at Monier’s Nebiri Quarry is 10 hours per weekday providing for an average output of all standard processed materials of 2,500 tonnes per day. Flexible hours of operation allow Monier management to flex operations to increase daily production rates during periods of high demand. In August 2013 Monier executive management announced that a contract had been signed with Metso Minerals Australia as part of a PGK45million capacity and capability upgrade of the Monier Nebiri Quarry. The plant design was developed around the scope of a minimum total production rate of 450 tonnes per hour. Build up of the mobile fleet to support a quarry upgrade had commenced in 2012, civil works will commence in 2013 and the upgrade is scheduled to be completed in late 2014.

Aerial view of Monier’s Nebiri Quarry, NCD

Materials stockpiles and the 3 crushing and screening plants to bottom of image

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“Load and haul” of raw feed to the crushing plant at Nebiri Quarry

• Readymix Concrete Monier operates two computer controlled readymix concrete batch plants producing quality certified readymix concrete including high strength concrete for structural applications. Located at Saraga Street 6 Mile Port Moresby the Monier readymix concrete operations are ideally located to service the construction and building industry in the National Capital District. A fleet of 22 x 6m3 and 7.4m3 truck mounted agitators (concrete mixers) provide for high capacity of delivery of readymix concrete to customers sites. The 2 Monier concrete batch plants have a manufacturers (plated) capacity rating of 70m3 per hour each and have proven capacity in excess of this in short bursts. The 2 batch plants are completely independent of each other providing for 100% obsolescence in the unlikely event of a plant breakdown during a continuous concrete pour. Plant 1, a D&L Forbes Batching Plant, has a proven production rate of over 400m3 per day of readymix concrete. Plant 2, a newly erected Con E Co Lo Pro, has not yet run to the limit of capacity but experience with similar plants indicates that it will achieve the same or higher daily capacity. Onsite cement and aggregates storage and Monier’s fleet of trucks for cement and aggregates cartage provide mitigation against stock-outs that would otherwise interrupt readymix concrete production and continued delivery.

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Monier produces all standard readymix concrete (“N” grades) to Australian Standard 1379 and special grades of readymix concrete (“S” grades e.g. low shrinkage, temperature controlled and/or high strength) to Australian Standards and/or engineers / designers nominated specifications. Monier has installed a high capacity water chilling plant to allow temperature controlled concrete to be produced. Monier’s industry best practice concrete batch computers allows measurable and traceable addition of admixtures that contribute to control of setting times, pump-ability, workability, minimising water content and minimising shrinkage as and when required. Monier operations are integrated allowing control of the supply chain and quality control of raw materials ensuring appropriate standards of quality are maintained. Monier’s PNGLAS independently certified concrete, aggregates and soils testing laboratory provides the capability for the rapid adjustment of readymix concrete designs in response to naturally occurring and unavoidable variations in raw materials. Plastic concrete is sampled and tested in accordance with the requirements of Australian Standard 1012. A disciplined sampling and testing regime is undertaken to determine trends in concrete characteristics and to ensure target strengths and other specified minimum requirements are achieved.

Monier’s D&L Forbes 70m

3 an hour readymix concrete batch plant located at 6 Mile, Port Moresby

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Monier’s new Con E Co 70m

3 an hour readymix concrete batch plant located at 6 Mile, Port Moresby

• Precast Concrete Monier has the capability to manufacture an ever expanding range of structural and architectural precast concrete elements including;

o Prestress “Stahlton” beams engineered suspended flooring system o Large flat structural panels o Profiled and coloured architectural cladding panels o Prestressed structural elements o Manhole components o Pit Covers o Paving slabs and o Wash tubs

Much of the Monier precast concrete elements are manufactured to customers’ specific engineered designs with Monier managing the process from development of shop drawings, fabrications of moulds and casting beds, development of mix designs to prestressing and casting. As necessary engineering certification of designs are obtained to ensure the structural integrity of manufactured elements. All reinforcing steel used is certified to meet appropriate standards by the manufacturer and all concrete is sampled and tested in accordance with Monier’s QC system and relevant Australian Standards. Many smaller standard precast products are held in stock allowing “off the shelf” purchases.

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• Masonry Monier operates a “Columbia” masonry machine manufacturing a range of concrete blocks and pavers. The “Columbia” masonry machine provides flexibility of production allowing a wide range of standard as well as made to order products to be manufactured. The “Columbia” manufacturing process ensures consistency of appearance, dimension and quality of the masonry products providing for faster and more accurate block laying. The standard Monier masonry range includes all those products generally used in construction of residential, commercial and industrial buildings. Monier has the capability to manufacture masonry blocks and pavers with a range of textured faces in a variety of colours. Similar to the other manufacturing operations Monier’s masonry products are sampled from production runs and tested in compliance with the Monier QC system. Unless otherwise requested all masonry products are palletised and customers can prearrange delivery utilising Monier’s fleet of delivery vehicles. Refunds are offered for pallets returned in good condition

Display of masonry products at Monier’s 6 Mile Sales Office

• Reinforced Spun Concrete Pipes Monier manufactures a range of reinforced spun pipes for use in drainage and sewerage applications. Reinforced spun concrete pipes, flush joint and rubber ring joint, in sizes range from 225mm to 1,800mm diameter, in lengths of either 1.22m or 2.44m. Reinforcing steel used in the reinforced spun concrete pipes is certified by the manufacturer and the concrete used is sampled and tested in accordance with Monier’s QC system.

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Stock of reinforced concrete pipes at Monier’s 6 Mile compound

• Sand Processing Sands (fine aggregates) are a critical raw material used in the manufacture of readymix concrete and concrete products. Having a secure supply of suitable sand is critical for the manufacture of quality concrete products. This is especially true for Port Moresby where naturally occurring sands of suitable quality for use in certified concrete products is relatively rare. Monier has invested in and operates a state of the art CDE Global sand processing plant that provides the functionality to wash and “size” the sand to meet design requirements. Naturally occurring deleterious materials are washed out while simultaneously screening to size the sand and to remove any organics and coarse particles. Monier also sells washed, screened sand into the Port Moresby construction and building industries and to home handymen. As well as concrete products sand is used for under-slab bedding, pipe bedding and backfill, landscaping etc.

Monier’s sand processing plant at Nebiri

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• Laboratory & Testing Services The Monier production and manufacturing facilities are supported with a PNGLAS accredited quality control laboratory. The Monier laboratory manages the quality control system undertaking regular sampling on raw materials, during processing and on finished products to confirm appropriate quality of finished products. The Monier laboratory regularly undertakes concrete trials to ensure that customers’ specifications are achievable, to confirm performance of concrete mix designs, and to confirm compatibility of customer’s nominated additives. Sampling and/or testing can be undertaken on concrete, aggregates, roadbase and soils at customers’ request and test results reported on PNGLAS accredited certificates provided after completion of testing.

Example of a Monier Laboratory PNGLAS accredited test certificate

The Monier laboratory is supported by a team of qualified concrete technologists able to develop concrete mix designs to meet customers’ and designers’ specific requirements.

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• Customer Service Monier provides solutions to customers with specific construction materials or and/or building products needs or requiring “non-standard products”. The Monier technical and management team undertake specification and contract reviews prior to quoting to ensure that the customers’ requirements are understood and catered for. Monier invests significantly in technical research and development to design products that meet customers’ expectations, specifications and/or relevant standards and codes. The range of materials and products manufactured in combination with the end to end quality control and high capacity delivery capability have ensured that Monier is the supplier of choice for contractors, constructors and builders involved in the more technically complex projects and when quality is critical. In recent times Monier has been a construction materials and/or building products supplier of choice for the following prestigious projects in Port Moresby or NCD;

• PNG LNG Project

• Vision City Shopping Mall

• Grand Papua Hotel

• Residency Apartments

• Windward Apartments

• Holiday Inn Express and All-Suites Buildings

• Grand Papua Hotel

• Avara Annex Building

• Old Parliament House Redevelopment

• Hubert Murray Highway up grade (5 Mile to 6 Mile)

• Steamships Harbour Offices

• Exxon POH Management National Managers: Fred Oa (precast), Gaspar (RMC), Gabriel (pipes), Philip (Quarry) BC, LN, MMcL, GB, TK, Bio; Relevant experience in industry, high profile projects worked on.

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• Community: Monier is a significant contributor to the communities that it operates in and provides

significant funding for the “Buk bilong pikinini” early childhood library and reading

program, Sir Theophilus Foundation PoM General Hospital Charity, Dave Cavil’s

self funded Laloki community life skills school and the Caritas School in Port

Moresby. Monier is the premier sponsor of PNG Rugby Football Union

Thank you for your interest in Monier (PNG) Limited and we look forward to assisting

you with supply of construction materials and building products for your project no

matter the scale or complexity.

Monier (PNG) Limited

Saraga St, Port Moresby NCD, Papua New Guinea

Phone: +675 3253389

Email: [email protected]

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