250 metres of roof seismic jointing and 80 metres of exterior vertical seismic jointing used.

The Dairy Goat Cooperative in Hamilton undertook a major expansion of its milk processing plant in order to meet a dramatic increase in export orders for its niche goat milk products.  Foster Construction contracted Interior Components to install its internationally proven jointing systems and roofing products, crucial for the overall structural integrity and weather-tightness of the very large complex.

Speed, efficiency, and strict hygiene were key requirements of the contract as the plant had to remain in full production for the duration of the construction project.

Interior Components has considerable expertise in installing its products in a range of settings with similar requirements; particularly hospitals, residential care facilities, and hotels. Its employees were therefore able to quickly identify systems to ensure compliance.

All cutting of flashing and seismic jointing for example, was done off site, or in designated areas, to ensure no airborne dust could contaminate the production line; thorough pre- and post-installation cleaning checks were made of all equipment; and all lunches were checked at the gate to ensure no nut products were brought onto the site.

“New Zealand’s first pandemic response lockdowns added another point of interest,” John Hutchings, Interior Components, wryly comments. “Both companies easily met the new operating requirements however, so the project was completed to plan – albeit with twice-daily temperature and health checks for all staff, plus intensive on-site hygiene.”

The contract’s physical requirements were impressive.

More than 250 metres of customised flashing had to be installed on two sloped pitch roofs that spanned the new tilt slab build, and also abutted the existing plant on three sides.

“The resulting expanse of fully integrated roofs forms a huge rain catchment area so all flashing, gutter and joint systems had to use proven products capable of rapidly directing large volumes of water off the complex roof,” added John Hutchings.

The integration of new and existing buildings which were 15 metres high also required over 80 metres of vertical seismic jointing and expansion joint covers. Seismic joints protect against natural shifting and movement, and are engineered for earthquake proofing.

“We often use expansion joint covers to neatly blend the expansion joints into the surface of a building,’ says Hutchings, “but the vertical lines of the grey seismic joints in this project actually add interest to what would otherwise be large expanses of plain wall.”

Congratulations to Dairy Goat Cooperative and its members on their new-look plant – a solid commitment to the future of their niche export products.