Roof Strengthening and Weatherproofing

The roof strengthening and weatherproofing project was initiated to address critical structural and hygiene issues at a Takanini manufacturing plant, a facility that operates 24/7.

The existing roof required straightening and weatherproofing, and the steel installation demanded precise access in a sensitive operational environment.

The most complex aspect of this project was the proximity of the site to the Huntly–Auckland 220kV transmission line. This high-voltage environment necessitated strict compliance with national electrical safety standards, including a formal stand-over requirement issued by Transpower and managed in conjunction with Omexon. This added an extra layer of regulatory oversight and planning to ensure all works were executed safely.

Another challenge our team encountered was the scaffolding that would be required for internal access was visually intrusive and logistically complex.

FPC Small Works had to get extremely creative with scaffold design to ensure the internal birdcage worked within the constraints of the live site. A hygiene barrier was integrated to protect ongoing operations while still allowing safe access for steel installation – a task we completed a full week ahead of schedule.

Collaboration was central to the success of this project, especially given the red line environment. The team worked closely with the client to manage site measures, pre-start meetings, and the permitting process – navigating both the host facility’s operational requirements and FPC construction activities.

Early preparation paid off. Steel shop drawings were finalised ahead of time, enabling fabrication and galvanising to progress smoothly. Once on site, the roof was straightened to a flat plane, thoroughly cleaned and water blasted, before being sealed with a TPO membrane.

Flashings and pressure bars were installed to complete the weatherproofing and ensure long-term durability.

Weather was another factor. We planned around rain days to use contractor time effectively – laying membrane on dry days and welding seams when conditions didn’t allow for gluing to the substrate.

• Partnerships: Strong collaboration with the client and external partners like Transpower and Omexom ensured safety, compliance, and alignment throughout the project.
• Planning: Early expectation management, detailed sequencing, and flexible scheduling around weather conditions kept the programme on track and stakeholders fully engaged.
• Resilience: The team adapted to a high-voltage environment, hygiene constraints, and unpredictable weather, delivering ahead of schedule with minimal disruption to operations.