Fonterra Head Office

Our team completed the replacement of Intumescent fire protective coatings for steel in the Fonterra Head Office. The project spanned six levels, and our primary challenge was to deliver the completed project within a tight 27-workday deadline while ensuring minimal disruption to the building’s daily operations.

Key Challenges We Faced:

🔹 Strict Time Constraints – We had only 27 nights to complete the project, requiring meticulous planning and execution to minimize disruption for fonterra and their staff.
🔹 Working in an Operational Building – This involved:

• Ensuring the safety of employees and visitors.

• Isolating work areas to prevent interference with daily activities.

• Containing and protecting work areas to ensure no damage to the office and equipment.

• Maintaining the organization’s business operations without interruption.
  🔹 Complex Access – Many areas were difficult to reach, demanding innovative solutions.
  🔹 No Power Tools – The restriction on using power tools added complexity, forcing us to rely on manual labor and creative approaches.

Solutions We Implemented:

✔ Overcoming Difficult Access:
We utilized mobile scaffolding with a cantilever structure, enabling safe and efficient work in hard-to-reach areas.

✔ Enhancing Worker Safety:
All workers were equipped with personal fall protection systems (harnesses), especially when working on step ladders and scaffolding near the atrium.

✔ Working Without Power Tools:

• Specialized hand tools with carbide inserts were employed.

• A step-by-step manual cleaning process was implemented, with continuous quality control at each stage.

• Chemical solutions were used to soften and facilitate the removal of the old coating.

• A team-based work method was organized, with alternating tools and worker positions to maintain efficiency.

✔ Ensuring Safety and Minimizing Disruption:

• Protective barriers and warning signs were installed.

• Regular safety briefings were conducted for the team.

• Plastic sheeting partitions were set up to isolate work areas.

• Flooring and surfaces were protected using specialized materials to prevent damage.

• Cleanliness and order were maintained in work areas at all times.

• Work was carried out outside business hours to minimize disruption.

How We Succeeded:

The project was successfully completed thanks to thorough planning during the preparation phase and daily monitoring of tasks. Our team of 12 worked seamlessly, adjusting schedules and prioritizing tasks as needed. This approach not only allowed us to meet the deadline but also ensured the highest quality of work.

Acknowledgments:

A huge thank you to Bayleys Property Services for entrusting us with resolving such a critical coating failure at the Fonterra Head Office. 

We’d also like to thank Fonterra for their cooperation and support throughout the project. Your understanding and flexibility were invaluable in helping us carry out such extensive work within your Head Office.

Finally, thank you to Coating Inspection Services for providing our client with the assurance that the project was completed to specification, ensuring they won’t face this issue again in the future.

Key Takeaway:

This project underscores the importance of not cutting corners during the coating application process. Quality and precision are critical to avoiding costly and disruptive issues down the line.