As part of a $14.3m expansion for Mars Petcare in Whanganui, Stevensons Structural provided over 80 tonnes of structural steel, to both a local principle building contractor and the end client.

This was used in both the new building erected over the existing factory, and also within the factory to provide new electrical switchboard mezzanine floors and connections to the new building services tunnel. Before the new building construction was commenced Stevensons Structural, had to provide temporary steel work above the existing roof to support a scaffold structure for all contractors to work off during the new build process.  

The temporary steel consisted of almost 100 weather tight penetrations above a working factory and connections to the existing building structural steel.

All up over 16 tons of temporary steel provided the platform that allowed the project to safety proceed over the existing building, all whilst production continued below. The new building consisted of five single apex portal frames free spanning just over 50m, both the columns and rafters where constructed of tapered beams, and the building was finished with a tapered end wall and complex connection to the existing building.

The entire steel erection was completed whilst the existing factory continued to produce excepting two major lift days when the main rafters were positioned. In addition to the main building build, Stevensons Structural supplied and erected 15 tons of mezzanine floors within the factory. The mezzanine floor was supplied in large prefabricated sections that were negotiated through the factory in and around critical and expensive production equipment, to minimize erection time within the factory.The initial sections where erected immediately adjacent to expensive production equipment and completed during the annual Christmas shutdown period.

The remaining sections were fabricated together, rolled and erected all within a specially created fabrication enclosure created by Stevensons Structural to meet the expected high standards of HSE and production hygiene requirements required by Mars.

This effective and cost effective enclosure design created by Stevensons Structural has been adopted by the team at Mars for isolating various sections of the factory whilst demolition and eventual commissioning of sections of the new factory. This is testament to the innovation of finding solutions that ensure all parties ‘win’ whilst having very different objectives.

This project typifies the team approach to problem solving that the team at Stevensons Structural prides itself, working effectively with the principle contractor on a difficult site and also with the end client, with extremely high standards required for not only health and safety, but also strict hygiene standards typical of a working factory providing food stuffs for some of our most cared for and adored citizens… Our pets.

"Stevenson’s are a professional and highly competent organisation. We were impressed with their ability to deliver, design under ambiguity and preparation. The installation occurred with virtually no rework or error. Well done to this team. I would highly recommend to others."

Mark Agnew
Engineering Manager
Mars Petcare New Zealand