Project Overview
Fonterra’s Project Hoiho at the Whareroa site was a major undertaking focused on constructing Energy Centre 6 (EC6), a new facility housing the country’s largest heat pumps as part of a comprehensive ammonia processing plant upgrade. Excavat was contracted by Apollo Projects to deliver foundation and civil construction services for this project.
The Challenge
The primary objectives of Fonterra’s Project Hoiho were twofold: significantly reducing Fonterra’s carbon footprint through advanced energy solutions and eliminating operational risks associated with the existing reticulated ammonia refrigeration system. The new EC6 plant would house multiple ammonia water chillers and heat pumps, requiring robust foundations capable of supporting heavy industrial equipment while maintaining the highest safety standards.
The complexity of the project stemmed from the need to construct foundations that could accommodate New Zealand’s largest heat pumps while ensuring the containment of all ammonia within the EC6 facility. This transition from a distributed ammonia system to a centralised chilled water distribution network required strong foundation preparation to support the substantial mechanical loads and vibration requirements of the new equipment.
Excavat’s Scope of Work
Excavat delivered foundation preparation and civil construction work for the EC6 energy centre. The scope included four main components:
Footing Excavation: The team excavated and prepared footings to support the heavy heat pump and chiller equipment. This work required precise excavation to engineering specifications and proper soil preparation for long-term structural stability.
Floor Slab Preparation: Base surfaces were prepared with proper compaction and levelling to meet the requirements of the ammonia processing equipment. This preparation work prevents settlement issues and ensures facility longevity.
Damp Proof Membrane Installation: The team installed protective membranes to prevent moisture ingress that could compromise equipment performance or structural integrity.
Formwork Installation: Formwork systems were constructed to shape the concrete foundations with the dimensional accuracy required for the heat pump and chiller installation.
Roof-slab Prep and Pour: The team prepared and poured the concrete roof slab system, including surface preparation, reinforcement placement, and formwork setup to achieve the specified structural requirements
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