Real Steel Hautapu Facility

Real Steel needed a new facility to lift production capacity and operational efficiency for its steel plate manufacturing and processing business. The project was delivered on a greenfield site at Hautapu, Cambridge, through early contractor involvement and a design and build model.

The main structure covers 7,700 square metres, with 4,000 square metres of yard, 1,750 square metres of carpark and 750 square metres of two storey office. Precast concrete panels and structural steel carry a building tailored to heavy industrial machinery, specialised processing equipment and six gantry cranes. The press foundations required excavation around three metres below ground level, incorporating suspended 3.5 tonne steel plates within the concrete to support high load machinery.

The main structure was consented while the fitout was still being finalised. Pit walls were designed and cast offsite as precast units, then lifted into place as they became ready, with Real Steel fabricating anchor plates in house. The client gained access eight weeks ahead of schedule.