Project Overview
The DPP2 HVAC plant building, which had reached the end of its operational lifespan, was replaced to maintain consistent reliability. This involved dismantling the existing EPS panel structure and installing a new Kingspan panel building complete with Ardex membrane roofing. Additional improvements included a new duct system and filter banks, an external staircase, a Redline boot exchange, a new exterior door for HVAC access, conveyor covers in the packing room, and enhanced access via a new P5 staircase.
The Challenge
Weather posed a significant challenge during this project, as the work was carried out within a 3-month winter shutdown window in Hawera. The constrained footprint necessitated extensive scaffolding to protect the plant from water ingress, adding complexity to the scheduling and coordination. Additionally, overlapping contractor scopes required meticulous project planning to ensure smooth execution, and the location required specialised trades from out of town. Internal plant upgrades also demanded adherence to stringent hygiene protocols across multiple levels of the processing plant.
The Solution
The refurbished DPP2 HVAC now includes an external staircase, significantly improving accessibility for maintenance tasks without breaching the redline area, which is crucial for operational safety. Additionally, the Ardex membrane roofing provides enhanced weather protection, offering superior durability compared to the original roofing materials. The newly installed P5 staircase, which was pre-fabricated off-site, has been integrated to improve staff movement efficiency throughout the plant, ultimately reducing transit times and enhancing workflow.
The Value
Weather Protection: Effective scaffold weather-proofing minimised weather breaches.
Accessibility: Enhanced external access allows out-of-redline servicing and cleaning.
Efficiency: Internal pressure and temperature were optimised by duct re-routing and blanking redundant lines.
Safety: Roof safety improvements and the new external staircase enhance maintenance accessibility.
Performance: HVAC performance was improved, and all works were successfully completed within the winter shutdown timeframe.