Excavat completed a comprehensive commercial shed pad project for Global Stainless, a specialist fabrication company requiring precision-engineered infrastructure to support their expanding operations. The project involved the construction of an 812 square meter engineered concrete floor pad, designed to accommodate heavy industrial equipment and manufacturing processes.
Client Background
Global Stainless are a company at the forefront of stainless steel fabrication. Specialising in manufacturing pressed dished ends (domes), stainless steel spheres, tube rolling, pressure vessel heads, long radius bends, and knuckling/flanging tank ends for industries including dairy, transport, food production, and beverages. Their products are distributed throughout New Zealand and Australia, with mirror-polished spheres designed by artists and architects shipped globally.
Global Stainless has a great amount of specialised equipment, including extra-wide hydraulic presses and heavy knuckling machines, to produce high-quality hemispherical domes and long radius bends that exceed previous industry diameter limitations.
Project Scope
The project required creating a substantial industrial foundation capable of supporting Global Stainless’s heavy manufacturing equipment and operations. The 812 square meter engineered floor pad needed to meet stringent engineering specifications while accommodating the specific operational requirements of a precision fabrication facility.
Key aspects of the project included:
• Achieving precise subgrade preparation 250mm below existing floor level
• Ensuring proper drainage and moisture protection for industrial equipment
• Meeting exact leveling tolerances required for heavy machinery installation
• Coordinating complex formwork and reinforcement installation
• Managing the phased concrete pour to maintain structural integrity
Project Execution
Excavat’s comprehensive package began with precision site preparation using cut-to-fill methodology, excavating to the correct subgrade level 250mm below existing floor level. The team installed and compacted 120 cubic meters of fines hardfill in a 100mm layer, followed by 40 cubic meters of blinding sand leveled to ±10mm tolerances using skidsteer and box blade techniques.
The formwork phase required sophisticated planning to accommodate the complex engineered requirements. Excavat established comprehensive formwork systems, excavated perimeter footings and footing pads, and installed damp-proof membrane with properly taped joins. Steel reinforcing and SE82 mesh were installed according to engineering specifications, with door rebates formed and a sophisticated slab free joint system installed using 600mm HD16 starters with densotape detailing.
Following STDC inspection approval, the team executed a carefully planned phased concrete pour. The 150mm thick, 30 MPa concrete slab and footings were strategically poured beginning with the western end to the free joint, then completing the eastern section. This approach ensured optimal structural performance while managing the logistics of the large-scale pour. Final finishing included stripping formwork, cutting construction cuts per engineering plans, and preparing perimeter areas to enable safe scaffolding and scissor lift access for Global Stainless’s subsequent facility construction.
Ready to Start Your Commercial Construction Project?
Excavat specialises in delivering precision-engineered foundations and commercial infrastructure solutions for businesses across diverse industries. Whether you need an industrial floor pad for heavy machinery, site preparation for expansion, or complex concrete work for specialised operations, our experienced team brings the technical expertise and attention to detail that your project demands.
Contact Excavat today to discuss your commercial construction requirements. Let us help you build the solid foundation your business needs to thrive.
