Strategic thinking keeps food manufacturer's project on target.

We constructed extensions to Leader Products’ Otahuhu plant for additional fully cooked plant. This entailed building a food hygiene environment adjoining an existing plant while the rest of the processing factory kept operating normally, manufacturing frozen convenience foods for retail, food service, industrial and quick service restaurant clients.

In the early stages of the construction project, changes needed to be made to the already approved design with multiple applications to Auckland Council to amend the building consent. Motivated to keep the construction project progressing while the consents were partially reviewed, we proactively worked with the project’s consultants and key tradespeople to make significant changes to the project programme and sequencing of works.

This proactive approach minimised delays during the construction phase and enabled the project to meet critical installation dates for equipment at the new facility.

How we made a difference

• Proactively modified the construction programme to mitigate the impact of building consent delays on critical completion dates ahead of equipment installation.
• Consistently complied with the client’s rigorous food safety regulations and health and safety requirements throughout construction.
• Applied extensive knowledge of robust requirements for constructing food processing lines and for working around operational food lines.

The details

• Supported by a structural steel frame, the new plant was about 41m by 55m, or approximately 2200sqm.
• The slab-on-grade foundation was designed to use lightweight Polyrock instead of basecourse. Suitable for sites with difficult or restricted access, this method provided long-term stability, reduced costs, and lowered ongoing maintenance.
• Numerous internal slab pours were programmed so the falls to point drains in each of the multiple rooms could be incorporated accurately. The building envelope itself was a combination of insulation panels with sheet metal cladding and precast concrete panels.
• 2500sqm food processing building.
• 6000m2 new yard.
• Site Contaminated – appropriate contam site procedures implemented.
• Fire separated new Plantroom.
• Special Floor Finishes.
• Temperature Controlled individual rooms.
• Attached 2 storey Offices/Amentities including fit-out – approx 400m2 total.
• Facilitate equipment install programmed install dates.
• Coordinate and work in conjunction with several separate contractors.
• Design/Build Fire Protection.
• Dynamic approach to meet the client's constant changes to design.
• Accommodate ongoing site access for continued operation of adjacent processing plant.