The Challenge

It was a high-risk, high-stakes project that demanded precision, innovation, and a deep understanding of their operational environment.

The real challenge came with access. The façade was completely unreachable from the ground, and surrounding structures couldn’t support traditional scaffolding.

The Solution

We started with a five-month pre-construction phase, working closely with Fonterra to explore the best possible solutions that met Engineering Standards, food, safety & quality and buildability. This optioneering process was critical to ensure we designed a new façade fit for purpose.

It also allowed us to assess the risks, understand the constraints, and ultimately recommend Fire Resistant Panels (FRIP) as the safest and most effective replacement to the existing glass façade.

With the access complexities at hand, FPC’s Small Works team engineered a suspended scaffold system — 15 storeys high — which was attached and constructed directly to the building for the duration of the project.

Every panel, both glass and FRIP, had to be manually handled from the loading bay to the workface. It was a logistical puzzle, but our team managed it with care and precision.

Maintaining hygiene was non-negotiable. Client operations could not be compromised, so we wrapped both scaffolds hygienically to maintain a two-layer defence system to keep out weather and contaminants — the size of the scaffolds and barrier systems were 650m2 each.

The Value

  • Weather & Hygiene Protection: Understanding the importance to Fonterra’s need to maintain their high hygiene food processing environment, our innovative two-layer scaffolding construction provided the defence to protect this throughout the construction duration delivering the project with no hygiene breaches.
  • Innovative Planning: This wasn’t just about replacing a façade — it was about solving a complex problem. During the pre-construction phase, meticulous planning focused on accessibility issues, a suitable replacement to the glass façade and temporary weather and hygiene protection to ensure a solution was delivered that met the needs of our client and did not disturb their operations.
  • Delivering Under Pressure: the successful completion of the project on time, with zero defects demonstrates our ability to undertake complex and fast paced projects and to a high quality.