Dryer Building Remediation

When FPC was engaged to investigate weather issues and the impact it was having on manufacturing at this Waikato food processing facility, FPC’s assessment quickly highlighted that the works would require a considered and specialist response rather than routine maintenance.

A dryer building is a critical piece of infrastructure within a dairy manufacturing facility. Long term exposure had led to moisture ingress, concrete deterioration and coating performance issues.

The challenge was twofold. Firstly, diagnosing and repairing complex defects at height on a large, ageing structure. Secondly, delivering the works within a fully operational, hygiene‑critical environment where production needed to continue without interruption.

Access added further complexity, with much of the remediation undertaken via rope access with crew suspended, while the plant operated below. As works progressed throughout the building, additional areas requiring remediation were identified beyond those noted during the initial inspections. Internally, access was above sensitive production areas with strict hygiene controls in place.

For these maintenance works, FPC began with a detailed assessment of the dryer building. Cracks were measured and referenced against historic drawings, areas of interest were mapped, and the structure was assessed with structural engineers and suppliers to identify a long-term and robust solution.

This detailed upfront approach enabled FPC to identify targeted, durable remediation solutions. Works ranged from specialised crack injection products matched precisely to crack width, through to concrete repairs and the reinstatement of welds.

Externally, specialist abseiling subcontractors worked alongside FPC to safely and efficiently access the structure at height. Internally, full scaffold towers were erected and completely enclosed, creating a sealed barrier between construction activities and live production areas. This ensured food‑grade hygiene standards were maintained at all times.

Throughout the project, works were carefully sequenced and continuously reassessed. Higher‑risk areas were prioritised first, allowing risks to be actively managed while keeping the plant fully operational for the duration of the remediation programme.