Project Sistema Hayden & Rollett has helped Sistema Plastics consolidate its operations in a new purpose-built facility in Auckland. INSIDE »
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New facility has the scale
Design with ‘wow’ factor
Global success story Sistema Plastics’ impressive new facility on the outskirts of Auckland finally brings all the company’s operations under one roof.
Outline Design has delivered an inspiring new environment to take the Sistema brand to the next level in terms of design, production and distribution.
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HAYDN & ROLLETT » Sistema Plastics
Volume 15 | Issue 6
Business North
Haydn & Rollett has been closely involved in every aspect of consolidating Sistema Plastic’s Auckland buildings into the one integrated facility
Sistema project a real success Karen Phelps The 55,000sqm Sistema Plastic project in Auckland has been nothing out of the ordinary for Haydn & Rollett, which is well versed in such industrial builds. The main difference has been the sheer size of the facility and in particular procuring materials and labour in the extremely busy Auckland market, says Haydn & Rollett project manager Sam McPhee. “For example usually we close the building in to enable the floors to be poured. “Due to the size of the building, in this case, we erected temporary walls using shipping containers. “Otherwise if we waited until the building
was enclosed the building programme would be too lineal and extend the duration,” he explains. The facility incorporates a 50,000sqm manufacturing, storage and distribution area, 3500qm of office and ancillary rooms and 17,000qsm of car park and yard area. Haydn & Rollett has been closely involved in every aspect of consolidating Sistema Plastic’s Auckland buildings into the one
integrated facility assisting from an early design stage. By accepting the design and ground risks, Haydn & Rollett has allowed cost certainty for the client, says Sam. Situated on a 10ha site in Mangere next to Auckland Airport, Sam says that the project competes with not only the most prestigious manufacturing facilities in New Zealand but internationally.
“Haydn & Rollett has built its reputation on consistently delivering exceptional quality construction. We plan meticulously, consult and pay attention to the detail. That way, we maintain the highest standards.”
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The project, designed by Woodhams Meikle Zhan, was a negotiated tender contract and construction commenced on August 3, 2015. Sam says that by the time construction commenced the months of planning and sequencing Haydn & Rollett had invested in the project came together. Detailing and manufacturing of materials such as roofing, structural steel and precast concrete panels had already taken place months in advance. An enabling works package had already been undertaken by the owners of the subdivision and Haydn & Rollett has completed excavation of the site and installation reinforcing steel and concrete.
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Steel Roofing helps streamline design Getting Steel Roofing involved in a project at the outset means that the company can offer clients valuable advice often resulting in cost and time savings, says company managing director Brent Botha. A case in point is the company’s recent involvement in the new Sistema Plastics 50,000 m² manufacturing and warehouse facility at the Auckland International Business Park. Brent says that Steel Roofing assisted construction company Haydn + Rollett to streamline the roof design before the project went to the final design stage, resulting in cost savings and project time savings, ensuring that the programme ran smoothly and the client received best value. The fact that Steel Roofing, which supplies and installs long run metal roofing, metal wall cladding and membrane roofing, had worked with Haydn + Rollett for several decades on numerous projects was beneficial for all involved, says Brent. Using materials sourced from Roofing Industries Ltd, the project used Maxispan and Colorcote ZRX, products specifically suited to industrial and commercial applications. Because Roofing Industries is New Zealand’s only 100% nationally New Zealand owned and operated metal roof and cladding manufacturing business the result is a close-knit passionate team delivering superior roll-formed solutions, says Brent. The company manufactures and supplies tailor-made innovative and visually appealing metal roofing, cladding and rainwater goods for commercial, industrial, rural and residential projects. Paul Ross from Roofing Industries says that the Maxispan high rib roofing and cladding profile, used on the Sistema Plastics project, incorporates a number of innovative practical design features and provides significant spanning advantages with
superior spanning at low pitch and wide cover which reduces installation time. He says that Colorcote ZRX has outstanding colour and gloss retention and is ideal for industrial sites where there is a high risk of deterioration from corrosive elements in the environment. The combination of the two products resulted in a roof and cladding system that combines strength and longevity with good looks. Steel Roofing started the massive roofing project in October last year and will complete it by mid September. The company will install not only the roof and associated gutters and downpipes but also Roofing Industries Multirib metal wall cladding for large portions of the building. The medium height, long run roofing and cladding profile is quite possibly New Zealand’s most popular commercial and industrial roofing and cladding profile, providing numerous benefits for the building designer including clean lines and innovative design features offering superior strength and spanning capability over similar profiles. Steel Roofing had its beginnings over four decades ago and brings a lot of expertise to each project. Brent says that thanks to product and expertise from Roofing Industries, along with working as a team with Haydn + Rollett and other contractors, the result is a track record of successful projects completed on time and on budget:
“Haydn + Rollett operate with a key group of contractors and suppliers they know and trust. We develop long term partnerships with our clients. We have a proven track record of completing these types of commercial projects, which is why people choose to partner with us - they can rely on us to get the job done.”
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Volume 15 | Issue 6
HAYDN & ROLLETT » Sistema Plastics
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Sistema scales up with new facility • from page 2 Sam says the construction of the premises - which was completed in October - was relatively straightforward aside from the immense size of the project. Maintaining quality was typically challenging on such a large project, which is where Haydn & Rollett’s systems and processes have really come to the fore with a firm focus on regular site meetings, health and safety, management plans and auditing to ensure the project kept on track and a quality result was achieved for the client. “Haydn & Rollett has built its reputation on consistently delivering exceptional quality construction. We plan meticulously, consult and pay attention to the detail. “That way, we maintain the highest standards,” explains Sam. He says the project tracked ahead of programme with Sistema gaining early access to key areas to commence fit-out works of plant. It was a key requirement to ensure the build programme was designed to help Sistema with its own processes to fast track the development with the goal being to get Sistema operational in the building. “Value engineering by Haydn & Rollett at the beginning helped to tweak the project to save clients time and money through smart material selection, how the project was staged,” he said. “We changed our build methodology to ensure the client had early access to begin and integrate their own fit-out sooner.”
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The construction involved 50,000sqm of manufacturing, storage and distribution area, over 3500qm of office and ancillary rooms and 17,000qsm of car park and yard area.
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HAYDN & ROLLETT » Sistema Plastics
Volume 15 | Issue 6
The new Sistema Plastics manufacturing facility is situated on a 10 hectare site in Mangere next to Auckland Airport.
Dempsey Wood Civil has the expertise Before construction of the new Sistema Plastics facility could begin Dempsey Wood Civil was on the job. The company undertook all the enabling works for the project - trimming subgrade, ground improvement works, drainage works and laying sub-base metal for the foundations - in preparation for the building. They also completed the final floor preparation, laying a fine metal layer within the building and concrete yard. “This aspect of the project required considerable attention to detail and expertise as this had to be completed to a tolerance of just 3mm,” says Dempsey Wood Civil Area Manager, Daniel Taylor. “We used a tractor box grader with lasers to ensure this kind of detailed accuracy. A fine layer of metal was applied and the laser grader automatically lifted the grader up and down to the required levels to ensure the extremely fine tolerances.” To finish its part of the contract Dempsey Wood Civil also constructed the retaining walls, carpark and concrete footpaths around the building and installed service ducts. Dempsey Wood Civil’s early involvement in this development project combined with their expertise enabled the building construction works to commence ahead of schedule. This Sistema Plastics project is an example of how Dempsey Wood Civil has established its reputation in problem solving, providing innovative solutions.
“Our approach to our projects,” explains Daniel, “is that Dempsey Wood Civil aims to provide proactive, innovative and integrated delivery methodologies coupled with customer-focused project management and going the extra mile to give our customers what they want.” Dempsey Wood Civil is an established Auckland-based civil contracting company with a sound reputation for providing a high-quality service to public and private sector clients. The company’s proven contract management expertise combined with its in-house capabilities enables it to successfully undertake a variety of civil infrastructure and land development projects. Daniel considers that the Sistema Plastics project demonstrates Dempsey Wood Civil’s adaptability and ability to successfully complete multi-faceted projects leveraging its vast industry experience. “By offering a complete enabling works package we provide our clients with one point of contact, which enhances quality control and makes the process easier and faster. “Our track record for innovation and collaborating with our clients as well as all other involved parties to devise best for project solutions has seen us successfully achieve a diverse range of project targets, meaning that Dempsey Wood Civil will continue to be an important partner in growing Auckland.”
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HAYDN & ROLLETT » Sistema Plastics
Volume 15 | Issue 6
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New facility reflects firm’s innovation • from page 5 “It’s an example of our partnership approach, which focuses on solutions and involves taking personal responsibility, being adaptable and always looking to make a constructive contribution to assist the client.” He says that the Sistema Plastics manufacturing facility has resulted in a highly prestigious and celebrated project epitomising the Haydn & Rollett motto of ‘excellence together’. Sam says that the significant manufacturing facility reflects the innovative nature of Sistema, which was started from a garage in New Zealand. Taking a simple premise - well made, beautifully designed, stackable food safe storage containers - the Sistema range was born. The Klip It collection with its distinctive blue clips launched the company into the Australian and New Zealand markets. That range has now been added to with the release of the Microwave and To Go family of products which are designed for added convenience. Sistema now exports products to 82 countries around the world with customers
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Sistema now exports products to 82 countries around the world with customers numbering in the millions.
numbering in the millions making it a true Kiwi success story, says Sam. “This project reinforces what Haydn & Rollett is very good at – turnkey delivery from
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HAYDN & ROLLETT » Sistema Plastics
Volume 15 | Issue 6
Business North
The new Sistema Plastics manufacturing facility has resulted in a highly prestigious and celebrated project epitomising the Haydn & Rollett motto of ‘excellence together’.
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With 50,000m2 of manufacturing, storage and distribution area, over 3,500m2 of office and ancillary rooms and 17,000 m2 of car park and yard area the new Sistema Plastics facility will be one of the largest in Australasia. An essential component of the on-going maintenance of the facility will be the Monkey Toe Group products installed on the building, which provide an easy way for Sistema to protect the building and people needing to access it for maintenance purposes, says Monkey Toe Group marketing manager Jeff Poole. Monkey Toe Group has provided internal ladders, plant platforms and walkways. Jeff says that Monkey Toe walkways provide safe and secure access without damaging the roof. The unique beam design allows walkways to span up to three metres between supports and still maintain a massive live load of 2.5kPa/m. (That is about three people per square metre.) Jeff says that this provides greater flexibility for installations and means there are fewer contact points with the roof. The company offers aluminium walkways for longer spans and more extreme conditions or SkyWalk fibre reinforced plastic for a more lightweight option.
A hatch provided by Monkey Toe Group to complement Sistema’s service doors will help provide service access. Jeff says that most of the external components have already been installed on the roof with work progressing on the internal aspects of the contract. A New Zealand owned and operated company, Monkey Toe Group was started in 2006 and offers a range of roof access systems (walkways, ladders, hatches, aluminium handrails, steps and stiles, gutter guards and snow guards); roof mounting (plant platforms, condenser mounts, solar mounts); handrails and glass balustrades and stairways (steps and stiles, external fire stairs and accessories). Jeff says the company aims to always be at the forefront of industry changes with a key focus on safety combined with ease of use. All products are made from high-grade materials and are easily installed - simply clipped and screwed together but able to bear loads that rival costly structural installations. The company’s unique clip fixture, which clings to buildings like a monkey's toe, safely gripping the roof without compromising its structural integrity, is a key aspect
of its product range. All Monkey Toe Group products are fully compliant with AS/NZS industry standards and many come with a lifetime warranty. Products are manufactured in New Zealand at the Monkey Toe Group factory in Hawera. Jeff says that because Monkey Toe Group has an engineer and design team as well as a nationwide network of installers, the company can assist customers from concept to installation. The company is already a favourite with many significant construction companies such as Naylor Love, Fletcher, Hawkins Construction and Cape Limited. Due to company growth Monkey Toe Group offers offices in Auckland and Christchurch and has a presence in Wellington. The company can supply and install product nationwide. Jeff says that Monkey Toe Group has relished the opportunity to be part of the significant Sistema Plastics build: “Monkey Toe, like Sistema, began from a small concept and has now grown to a national business. It’s an honour to be involved with such a great New Zealand success story like Sistema.”
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HAYDN & ROLLETT » Sistema Plastics
Volume 15 | Issue 6
Business North
A custom designed wood wall wraps around the central lift core and main stair within the reception area incorporating the Sistema logo in a creative working of lineal plywood.
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OUTLINE DESIGN » Sistema Plastics
Volume 15 | Issue 6
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Global reach: A feature wall graphic lists the 90-plus countries to which Sistema Plastics distributes its products.
Internal design with the wow factor Karen Phelps Outline Design worked in close collaboration with Sistema to design and deliver an inspiring new environment to take the Sistema brand to the next level in terms of design, production and distribution, says Outline Design director Victoria Wilkes. The company was engaged to create a working environment for the new Sistema head office and global production facility in Mangere, Auckland. It wasn’t the first time Outline Design had worked with Sistema – it had previously
completed the Sistema Penrose office as well as Sistema fit-outs in France, Australia and the United Kingdom. In the Mangere project innovative design elements sit alongside a vibrant base palette that strongly references the key Sistema blue Klip colour that features throughout the extensive product range. Victoria says that one of the key aspects of the design was the carpet layout, a strong geometric pattern utilising the Sistema blue alongside complementary tones of greys and blues. “This dynamic element serves as an anchor within the space, setting the tone for the many
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“This dynamic element serves as an anchor within the space, setting the tone for the many other feature components such as feature walls, pendants, pinboards and screens.” other feature components such as feature walls, pendants, pinboards and screens,” she explains. Timber is another strong design statement that introduces warmth while maintaining the graphic aesthetic. A custom designed wood wall wraps around the central lift core and main stair
within the reception area incorporating the Sistema logo in a creative working of lineal plywood. Victoria says that the client wanted to inspire staff and visitors alike with the Sistema success story.
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Volume 15 | Issue 6
OUTLINE DESIGN » Sistema Plastics
Business North
Internal design has the “wow” factor • from page 11 To that end a world map highlighting the extent of the brand’s global reach sits among work stations within the main office area. Another wall lists the countries to which Sistema distributes - over 90 countries globally - which makes for an impressively long feature wall graphic. Not only did the Outline Design team create the colour palette for the new office spaces it also documented all of the working environments within the new facility which included the two level main office as well as the production facilities satellite offices that are scattered across the 54000sqm production floor. Outline Design specified and procured all furniture and fittings. The office layouts were another key element that Outline Design worked closely on alongside the client. The open plan environment is divided into specific zones and is punctuated with plenty of communal areas that cater to formal, informal and collaborative meetings, as well as break out zones for staff interaction and lunch time away from their desks. “Each component of the Sistema business has its own defined zone within the larger office environment. “Any specifics required for each team have been thoroughly considered, from the large art and design department with its ample storage and display areas for prototype and concept product review, through to the carefully considered mail robot stations scattered throughout, facilitating the distribution and
Looking good: feature components of the interior design include pendants, pinboards and screens. Global reach; A feature wall graphic lists the 90-plus countries to which Sistema Plastics distributes its products.
collection of mail via state of the art robotics technology,” explains Victoria. Outline Design brought over a decade of experience in commercial interiors across numerous sectors globally to the Sistema project. Victoria says that is why it was able to deliver a bespoke solution with a high degree of personalized service, remaining responsive to the client’s requirements as the project progressed. She says this personal and responsive approach is core to the company’s point of difference.
“Each component of the Sistema business has its own defined zone within the larger office environment.”
Companies such as Cubicon and Damen combined their expertise with Outline’s to bring an excellent result to the client. “With relationships at the heart of the success of the business, Outline’s long standing working history with key suppliers
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meant clear and efficient communications and a guarantee of quality. “This brought an excellent result to the client on budget and on time with the wow factor Sistema are very proud of,” Victoria says.
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OUTLINE DESIGN Âť Sistema Plastics
Volume 15 | Issue 6
Business North
Dynamic element: one of the key aspects of the design was the carpet layout, a strong geometric pattern utilising the Sistema blue alongside complementary tones of greys and blues.
house
Business North
Volume 15 | Issue 6
OUTLINE DESIGN Âť Sistema Plastics
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The open plan environment is divided into specific zones and is punctuated with plenty of communal areas that cater to formal, informal and collaborative meetings, as well as break out zones for staff interaction and lunch time away from their desks.
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