APL Hautapu
Working alongside Foster Construction Group, Feisst Electrical provided a full supply and install for APL’s 50,000m² state-of-the-art glass manufacturing plant at Hautapu in 2021.
Works within the factory included six very large main switchboards, each supplied from their own dedicated transformer, plus installation of a high current 400V Bus Duct for power reticulation throughout the factory, and powering the specialised, largely automated, double-glazing equipment.
Included in the build were three attached two-storey office spaces. Two were fitted out, with the third earmarked for future development. These areas required an impressive level of finishing, right down to the colour of any visible fixings used.
The project achieved a 5-star Green Star industrial design rating. Accordingly, the Fosters team influenced every part of the supply chain and every material selected.
Special features included:
- Factory lighting using 806 LED high bay light fittings. All fittings equipped with daylight harvesting technology, so that on a bright day where plenty of sun was available via the large skylights, the surrounding lights dim and consume less energy.
- Precision measuring and installation of the Bus Duct system. Prior to being manufactured and shipped from overseas, this had to be site measured with millimetre precision - ensuring it wouldn’t clash with equipment, openings, and service trenches as it weaved around the factory. In most cases, clash detection was achieved using 3-D modelling.
- To achieve the 5-star Green Star rating, meticulous attention to detail and record-keeping was a must; product amounts brought on site were recorded, all wastage was measured and recorded as it left site.
Built 2019-2021, project delivery was significantly challenged by Covid-19 lockdowns and additional protocol. The team had to be constantly ready to ‘hit the ground running’ when allowed back on site.
The sheer size of the site pushed the team in terms of project and self-management.
An interesting fact about this project:The largest construction project in New Zealand at the time (2019-2021), APL Hautapu measures 437m long, 144m wide, and 17m high. Each of the skylights within the factory is larger than the size of an average house.
