Professional engineer with over 25 years’ experience in Australian precast industry, Igor Vavilov has practical and in-depth knowledge in all aspects of precast operations and project management, including concept development, tendering, vendor engagement, design, design management, planning, production, operations improvement, technical and engineering support, quality control, logistics, erection, site temporary works, budgeting, cost and variation control, contract management, dispute resolution, staff and stakeholders management.
During his eventful career, Igor held several pivotal and challenging positions such as Chief Design Engineer, Design Manager, Technical Manager, Operations Manager, National Project Manager and Senior Advisor. He has worked across numerous challenging precast projects, including landmark buildings like DRAF offices in Canberra, Sydney Star City Casino, Western Hotel in Martin Place, Homebush Olympic Stadium, National Museum in Canberra, Jane Foss Russell precinct for USYD, Regency apartments in Chatswood, and Westfield shopping complexes. As a National Project Manager for Heidelberg Cement Igor also participated in many capital material-handling projects such as batching plants, crushing & screening installations, and associated infrastructure. He is past member of the BD02 Australian Standard Committee; NPCAA Precast Handbook Committee (second edition); and the External Advisory Committee of Western Sydney University. |
Some Notable Projects
There were many other projects not mentioned here, including structural and civil applications with wide range of precast products. All of them required hard work and collaboration among dedicated professionals.
It is always fascinating to see how an architectural vision is transformed into a concept and then into drawings and specifications and finally takes shape and becomes part of our vibrant built environment. |
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Star Casino, Sydney
Builder: Leightons Architect: Cox / Hillier Engineer: Ove Arup Precast: Rescrete, Precast Concrete
Description: This Landmark Sydney development was one of the largest building projects in Australia at the time. The Star features two gaming floors, eight bars, seven restaurants, 351 hotel rooms and 130 apartments, as well as the 2,000 seat Sydney Lyric Theatre. Due to large project scale precast was supplied by two companies. Curved building façades were formed by intricate cladding precast panels of 160 mm thick. The panels had a medium sandblast finish and a consistent sandstone colour resulting from a tailored concrete mix with added oxide pigment. There were many elaborate three-dimensional units with vertical and horizontal returns and integrated parapets. Façade waterproofing required an open drain joint system and punched window panels. Involvement: Project management: program, coordination, variation control. Engineering: panels and brackets design and calculations, design for stripping and handling, drawings review. Production: scheduling, technical supervision, quality control. Logistics and erection: delivery program, erection concept. |
No 1 Martin Place - Western Hotel Builder: Grocon Architect: Buchan Group Engineer: Bonnaci Winward Precast: Rescrete
Description: A landmark multi-storey development adjacent to the historical GPO building, No 1 Martin Place is a fusion of history and modern architecture offering a vibrant multifunctional urban space. The load-bearing polished precast façade has cast-in bands of natural dark green granite, black granite disks, and stainless steel elements. More than 1300 precast elements with seven different panel thicknesses and variable concrete strength with 6700 sq. m. of polished area. Three-dimensional elements required double and triple-cast technique. Some polished precast soffit elements acted as permanent formwork. Involvement: Project management: program, coordination, claims, cost and variation control, contract, stakeholder engagement, etc. Engineering: concept, mix design, design optimisation, connections and panels design and calculations, drawing review, design management, NCRs. Production: production concept for 3D elements, scheduling, technical supervision, quality control. Logistics and erection: delivery and erection sequence, temporary works. |
35 Clarence Street, Sydney
Builder: Barclay Mowlem Architect: Crone Associates Engineer: Arup Precast: Rescrete
Description: A sixteen-storey office tower in the Sydney CBD has a total lettable floor area of about 23,000 sq. m. Polished three-dimensional precast cladding panels form intricate façade, complemented by curved curtain walling. A typical precast panel on this project had four polished surfaces and a deep polished windowsill attached to panels before delivery. To overcome the challenge of waterproofing the complex façade geometry, an open drain joint system with elaborate half-lap profiles, flashing and drip groove arrangement was adopted. Involvement: Project management: program, coordination, claims, cost and variation control, contract, stakeholder engagement, etc. Engineering: mix design, panel sizing and splitting, waterproofing concept, design optimisation, connections and brackets design, drawing review, design management, NCRs. Production: production concept and moulding, scheduling, technical supervision, quality control. Logistics and erection: delivery and erection sequence. |
National Museum, Canberra
Builder: Bovis Land Lease Architect: Ashton Raggatt McDougall Hartel Precast: Rescrete
Description: This unique landmark project and major cultural attraction combines the National Museum of Australia and the Australian Institute of Aboriginal Studies. Stunning façade panels with computer generated profiled surface. Initially a plastic pattern was produced by CAD/CAM enable technology using supplied electronic file. From that single pattern, a concrete master mould was produced which followed by fabrication of several concrete production moulds. The final units were cast face-down on concrete moulds. Some panels were simultaneously leaning outwards and tilting sideways, and the structure had no square angles. Involvement: Project management: program, coordination, claims, cost and variation control, contract, stakeholder engagement, etc. Engineering: connections and brackets design, panel design for stripping and handling, special lifting bracket design, drawing review, design management, NCRs. Production: production concept and mould design, scheduling, technical supervision, quality control. Logistics and erection: delivery and erection sequence. |
Jane Foss Russell building, USYD
Builder: Abigroup Architect: John Wardle Engineer: GHD and Arup Precast: Hanson
Description: This bold and innovative five Green Star rated eight-storey development for the University of Sydney includes elevated public plaza, 3850 sq. m. library, retail space and student services. Precast package included polished feldspar curved, bladed and flat wall panels, off-form profiled ceiling elements, three-dimensional polished roof units, and patterned precast panels using Reckli formliners. The precast polished roof with highly complex geometry was the standout feature. Some of the units have up to five polished surfaces at different angles, which created challenges for design, production and erection. Involvement: Project management: program, coordination, claims, cost and variation control, contract, stakeholder engagement, etc. Engineering: layout concepts, design optimisation, connection details, drawing review, design management, site inspections, NCRs. Production: production concept for 3D elements, technical supervision, quality control. Erection: erection sequence, handling design, site rectifications. |
IGS Kerrie Murphy building, Ultimo
Builder: Baseline Architect: AJ+C Engineer: Taylor Thomson Whitting Precast: Hanson
Description: The five-level iconic school building for IGS is a prime example of a total precast structure. Precast elements included off-form external walls, lift shaft units, off-form off-white curved stairwell walls, 300 mm thick 13 m long hollowcore floor planks and massive 16-tonne external load-bearing sandwich panels. The sandwich panels consisted of 50mm of high-density polystyrene with a 65mm outer skin, and a 165mm inner skin of structural concrete and were Nawkaw-stained in precast yard. Erection of the precast elements required heavy lifts using a 300-tonne crane and careful planning as a result of the small and congested site. The erection sequence and temporary bracing of the precast were critical during erection and required meticulous design and coordination of all personnel. Involvement: Project management: temporary works coordination, claims, contract, dispute resolution, stakeholder engagement, etc. Engineering: temporary works design and approval, erection concept and sequence Production: overall operations management Erection: erection and temporary works supervision, site rectifications. |