Fonterra Te Rapa – D4 Wall Replacement

The root of the problem was a failing existing façade — where an undersized and corroding structure had led to significant deflection and cracking compromising the weathertightness of the structure.

One of the biggest challenges was the location. The façade sat in the middle of an ongoing site upgrade, which meant space for laydown and movement was extremely limited. On top of that, the wall faced the region’s prevailing winds, and the work had to be done during winter.

We approached this as a full design and build project. To begin, we erected a 16-storey scaffold using prefabricated sections lifted into place by a 100-tonne crane. By fabricating the scaffold on the ground, away from the active construction zone, we were able to install the top half of the scaffold in just one day.

Once the scaffold was in place, we installed a weatherproof barrier to protect the internal wall lining after the façade was removed. Our team dismantled the existing façade by hand in under a week, using a pulley system to lower materials into waste bins at ground level.

As soon as the wall was exposed, we discovered extensive corrosion. Working quickly with our structural consultant, we carried out an engineering assessment and developed a remediation plan to restore the structure and prepare it for the new façade.

The replacement system involved installing a RAB board barrier system, followed by battens and metal cladding to match the aesthetic of the existing building. We used 50m and 23m knuckle booms to install the cladding and flashings all while managing frequent stand-downs due to strong winter winds.