The New Zealand International Convention Centre has been one of New Zealand’s preeminent and high-profile vertical construction projects of the last decade. With multiple contractors working within an extremely busy 32,500m2 site, spanning four levels in the heart of Auckland’s CBD, the scale and complexity of the project was increased by a significant fire during what would have been the final stages of our work on-site. InterGroup displayed flexibility and stamina in responding to this unforeseen event, working with the client to assess the rework required and delivery. We worked on the NZICC from 2019 to late 2024

What We Did 

InterGroup was initially engaged by Fletcher Construction to complete fireproofing and corrosion protection from Level 3 (ground floor) to the roof. When the fire occurred, our team was on track in accordance with the prescribed programme, having completed 99% of the scope of work and progressing to the final stages of our work on site. Post-fire, our scope was increased to include remediation works as well as the rework of our additional scope

Onsite supervision, route audits and real-time data capture underpin quality. All completed works are GPS-verified, with regular joint audits conducted alongside Council to ensure standards are met. 

Delivered over seven years on the NZICC, this complex coatings project required tight coordination, strict HSQE controls, and safe delivery across a challenging city site with works at height and at grade.

Overall Performance 

Project results included the successful completion of 20,000m² of works, utilising Altex Coatings Ltd fireproofing systems (Carboline and Nullifire), along with advanced coatings application and abrasive blasting techniques.

After seven years at the New Zealand International Convention Centre (NZICC), InterGroup Northern Coatings had completed its scope on one of the most complex coating projects I have been involved in. The initial phase involved applying intumescent fire protection coatings in the middle of Auckland CBD, within a live construction environment with no roof or walls and up to ten other trades operating simultaneously. 

 At around 90% completion, a fire event significantly changed the project’s scope. InterGroup was then re-engaged for the rebuild phase, which included full removal of coatings by abrasive blasting followed by a four-coat paint system. All works require total encapsulation, dehumidification, and dust and fume extraction across multiple work areas. I would like to thank the team for their hard work and dedication throughout this challenging project.

Regional Manager Fabric Maintenance & Coatings /InterGroup  

Meeting Complex Operational Challenges

This was a highly complex project with multiple contractors on site and hundreds of personnel at any one time. Our expert coatings personnel delivered extensive work at grade, at heights, working from mobile platforms, and from complex scaffolding setups. Significant challenges were posed by the central city location, meaning access had to be highly coordinated to avoid delays. In addition, robust environmental controls were required to encapsulate contaminants, and health and safety protocols had to be stringently implemented and strictly adhered to. 

InterGroup’s thorough and ISO accredited HSQE systems were employed and have underpinned our exceptional health, safety, quality, and environmental performance. After seven years on the New Zealand International Convention Centre project, InterGroup Northern Coatings completed what was the most complex coatings project I’ve personally been involved in.

Adding value and expediting Work 

As part of the remediation process, 98% of the steel work in the building was required to be replaced or recoated. In conjunction with the client and other key subcontractors, InterGroup developed and constructed five on-site blast-and-paint booths to expedite completion of the work.

We managed all aspects of the booths – from HSE and containment to providing dedicated spotters to ensure the integrity of the blast booth environment and effectively creating mini blast yard facilities. These on-site facilities provided the capacity and flexibility required to complete the steel rework in and around the other trades working on site, delivering time and cost efficiencies to an already compromised construction budget. We also drew on our wider organisational capability, using our offsite blast and paint booths in Kawerau and Taranaki to assist with delivering the high volume of work required to be completed under significant time pressures.  

Innovative approach to quality management and programme expedition

Quality control and assurance are always integral to intumescent coatings projects, and InterGroup invested heavily in quality management on this project. The client’s requirements for extended durability and aesthetics meant some coating systems comprised of up to five coats, and the coating system employed required a robust QA/QC process with rigorous Inspections and Auditing provided by InterGroup’s Internal QA and QC team, as well as third-party inspectors. There were Hold Points at all critical elements of coating application, including surface preparation to ISO Sa 2.5 Blast Standard, Chlorides, Surface Profile, and Dust Levels.  

From implementing a Quality Assurance system, Conqa, to manage the digital capture of all quality information, to working closely alongside manufacturer representatives on site, we ensured optimal productivity and quality outcomes. We further minimised the costs associated with remediation works by delivering targeted spot repairs. We took control of the environment by partitioning large areas of the project with encapsulation and ensuring steady progression across varying external climate conditions through the use of industrial dehumidification units and extraction systems, creating optimal application conditions in line with product and manufacturer requirements.