Firth opens state-of-the art, $30 million masonry plant

Firth opens state-of-the art, $30 million masonry plant

November 29, 2017: Firth Concrete, New Zealand’s leading supplier of ready mix concrete and masonry products, has opened the country’s most technologically-advanced masonry block plant at Hunua in South Auckland.

The plant was officially opened today by the Honourable Judith Collins, member for Papakura. It will bring 24 new jobs to the Papakura and Franklin regions, with some employees transferring from the former East Tamaki plant, and a number of new employees involved in the plant’s construction also joining the business.

Building Products Chief Executive Matt Crockett, of parent company Fletcher Building, said the $30m investment was a significant commitment.

“This is the first major investment in masonry manufacturing in New Zealand for many years. We have installed world-class automated systems that mix aggregates from our nearby GBC Winstone quarry with cement from our Golden Bay Cement plant, producing a range of high quality blocks, bricks, pavers and retaining wall products.

“Fletcher Building has invested over $400 million into local manufacturing over the past five years. This investment is critical at a time when there is significant and growing demand for housing and infrastructure in Auckland as well as within the regions. We are proud to continue supporting local industry and local jobs here today.”

The plant will have a fast turnaround on changing moulds and products. What once took 4.5 hours to change, will take less than 30 minutes.

Using high-tech moulding equipment and curing kilns sourced from the United States, UK and Europe, the Hunua Masonry Block plant can produce 50,000 blocks per day – four times the capacity of the previous East Tamaki plant.

Mr Crockett said that increasing production was a key driver of the decision to seek a new site.

“Masonry products have the unique ability to add strength, structure, and design as well as sound-proofing and insulating properties to commercial and residential buildings and associated structures. Masonry has become increasingly popular, and increasing the capacity and flexibility of our product output is an important step in ensuring we are delivering for our customers.”

After a property search, Firth decided to build the new 4,900m2 plant on a former quarry site adjacent to a working quarry, operated by Winstone Aggregates, west of Papakura. Both companies are within the Building Products division of Fletcher Building.

More info:

Firth’s Masonry business has had a major project underway in Auckland over the past two years to replace its aging East Tamaki facility - with the first blocks produced at the new, state-of-the-art Hunua based block manufacturing plant in September.

Firth’s 44 year old East Tamaki site had become surrounded by residential and light industrial properties over the years, making it unfit for heavy industrial use in the long term. The decision was made to move the Masonry manufacturing to Winstone Aggregates’ Hunua quarry, 20km from East Tamaki at Papakura.

Construction of the new plant on a hilly site has involved the cut and fill of approximately 170,000m3 of earth to produce a flat site for the foundations.

Two years on the new plant features two new, state-of-the-art, five block machines (CPM50s) which enable a significant increase in production capacity, faster mould change times, a more consistent product output and less repair and maintenance downtime.

“This is a very exciting time for Firth as we make this new facility fully operational,” explains Cameron Lee, General Manager for Firth. “Hunua allows us to better cater to our customers needs in the Northern region. To put this into perspective; just one of the two new lines at Hunua can easily cope with the production both lines were producing at the old East Tamaki plant.”

Better distribution

With the new Hunua plant located 45kms south of Auckland’s CBD and, taking into account Auckland’s worsening traffic congestion, the Firth Masonry team were keen to avoid causing delays getting product across the bridge to customers. The solution was to create a North Shore distribution centre in Silverdale which opened in June. The new yard is stocked overnight by the Firth team, avoiding any traffic congestion and allowing more frequent deliveries to customers - from three to five per day - with reduced delivery times.

“I want to thank the Firth Masonry team, particularly Anthony Sheddan, National Masonry Manufacturing Manager, for seeing this major project through to fruition and ensuring Firth’s ability to support our customers requirements in the best possible way now and into the future,” says Cameron Lee, General Manager for Firth.

© Scoop Media