New Zealand Steel Electric Arc Furnace Project
Project Overview:
Nikau Contractors was engaged by New Zealand Steel to undertake the specialist demolition of legacy steelmaking infrastructure at their Waiuku facility. The project focused on the safe and efficient deconstruction of the former Bird House and associated steel structures to make way for a state-of-the-art Electric Arc Furnace (EAF) – a major investment in cleaner, more sustainable steel production in New Zealand.
The works were completed in a live industrial environment, requiring exceptional planning, safety oversight, and environmental control to meet the strict operational standards of the client and New Zealand regulatory frameworks.
Scope of Work
Environmental Remediation
As part of the enabling works, Nikau completed a full environmental clean under Class A containment conditions, targeting hazardous residues accumulated over decades of operation. This included:
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Removal of asbestos-contaminated dust from internal surfaces
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Treatment and disposal of extensive bird guano contamination
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Independent air monitoring and third-party clearance inspections to ensure compliance
These tasks were critical for preparing the structures for safe demolition and future redevelopment.
Asbestos Removal
Nikau deployed its specialist asbestos removal teams and proprietary crane systems to safely remove deteriorated asbestos cladding. Key measures included:
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Controlled removal and handling procedures
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Sealed waste transport and EPA-compliant disposal
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Use of custom-engineered access via Nikau’s own demolition cranes, minimising worker exposure and improving efficiency
All works were undertaken in accordance with New Zealand’s Health and Safety at Work (Asbestos) Regulations 2016.
Health and Safety Excellence
Operating within a live steel production facility demanded strict safety coordination. Nikau implemented:
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A dedicated Permit to Work (PTW) system with a full-time site permit receiver
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Comprehensive task risk assessments and daily pre-start meetings
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Coordination with NZ Steel’s operational teams to ensure safe integration of demolition activities
Zero harm and regulatory compliance were achieved throughout the project.
Structural Deconstruction
Demolition of the former Bird House and adjacent structures involved complex methodologies due to the height, steel composition, and interconnected nature of the buildings. Nikau’s approach featured:
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Precision cut and crane techniques for high-level dismantling
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Use of engineered rigging plans and lift studies to control heavy steel elements
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Progressive, sequenced removal to maintain structural integrity and site safety
Steel Recovery and Recycling
In alignment with New Zealand Steel’s commitment to sustainability, Nikau ensured that all recovered steel was:
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Washed and decontaminated on-site
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Segregated and processed for recycling
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Sent to approved facilities to be reintegrated into future steel production
This closed-loop material handling approach significantly reduced waste to landfill.
Traffic and Site Management
The demolition zone was positioned adjacent to major internal haul routes and public access areas. Nikau developed a detailed site traffic management plan, ensuring:
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Safe pedestrian and vehicle movement within the industrial precinct
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Coordination of heavy vehicle logistics to prevent congestion
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Minimal disruption to ongoing plant operations and surrounding communities
Project Outcome
The New Zealand Steel Electric Arc Furnace project highlights Nikau’s capability to deliver technically complex demolition in sensitive environments. Our team successfully enabled a major upgrade of New Zealand’s steelmaking infrastructure while upholding our core values of safety, sustainability, and precision.
