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Max Projects

Max Projects - Carpentry subcontracting for the civil, commercial and residential construction sectors throughout Christchurch.

Christchurch Nurses Memorial Chapel

Client: Christchurch City Council/Insight
Project: The deconstruction and restoration of the Nurses Memorial Chapel
Timeline: Sept '17 - Sept '18

Christchurch Town Hall

Client: Hawkins Construction
Package(s): Formwork and concrete
Timeline: Jan '16 - Mar '17

Christchurch Cathedral Junction

Client: Fortis Construction
Project: Repair and fit-out of all Quest Apartments, Hotel and retail units
Timeline: Oct '12 - Oct '13

Christchurch Art Gallery

Client: Fulton Hogan
Package(s): All Carpentry, paint and plaster works
Timeline: Feb '15 - Dec '16

Christchurch Victoria Park Restoration

Client: City Care/John Fillmore construction Joint Venture
Package(s): Formwork and concrete
Timeline: Apr '17 - Dec '17

Christchurch Acute Services Building

Client: CPB Contractors
Package(s): Formwork and external carpentry
Timeline: July '16 - ongoing

Spark Building

Client: Naylor Love
Package: Carpentry package on new five-story commercial building
Timeline: Oct '18 - ongoing

Tommy Taylor Courts Restoration

Client: Fulton Hogan
Project: Restoration of Tommy Taylor App Blocks
Timeline: Sept '17 - July '18

Lyttelton Tunnel Deluge System

Client: McConnell Dowell
Package(s): Formwork and concrete
Timeline: July '17 - Mar '18

ARA Institute of Technology - U Block

Client: Pace Project Management
Project: Repair and refurbishment of ARA U Block
Timeline: Dec '14 - June '16

Burke Street Apartments

Client: Orange Homes
Project: Demolition and rebuild of four two-story apartments
Timeline: June '15 - Feb '16

Focus Technology Group Ltd Fit-out

Client: Focus Technology Group
Project: Internal office fit-out
August 2017 - October 2017

Northcote School - HD Unit

Client: Ministry of Education
Project: Strip-out and refurbishment of a school high dependency unit
Timeline: Jan '17 - Apr '17

Christchurch Nurses Memorial Chapel

Client: Christchurch City Council/Insight
Project: The deconstruction and restoration of the Nurses Memorial Chapel
Timeline: Sept '17 - Sept '18

This heritage project required deconstruction of the historic Nurses’ Memorial Chapel by hand, with each piece being documented and labelled, in preparation for reconstruction. The original parquet flooring was retained and new elements constructed, including a new slate roof ordered from the UK. Some complexities were encountered, such as the discovery of asbestos in the main entrance subfloor. This required containment of the area, with no access permitted for eight weeks while removal was completed. The delay impacted the entire site, but the Max team worked to proactively address programme slippage. For example, they removed a large window to create a second access point and adjusted methods and programme, so workstreams could be undertaken concurrently rather than via a slower, sequential approach. As a result, there were four teams working at the same time, on the east-west, north-south, basement and roof areas. While the original plan was to complete each face and structural element in sequence over six months, the same work was achieved in four months to successfully claw back time lost by the asbestos removal.

The team fielded by Max was highly skilled tradespeople, with expertise in the techniques and care essential to limit damage to heritage features. The timber work was fragile but highly significant to the project, and some damage was expected. However, all timber panelling work was completed without damage or need for replacement of visible timbers. Our strong identification of risks and implementation of a site-specific plan to minimise and manage these, ensured we completed the project safely, on time, to the satisfaction of our client. This was supported by our use of a consistent dynamic scaffolding system which could be altered at short notice and certified as safe to proceed with minimal lag time. Subcontractor buy-in to Max heritage project requirements, and strict processing obligations ensured the motto ‘measure twice-cut once’ with no unforeseen surprises underpinned our execution of all works. Despite a 13-week delay to programme caused by asbestos, the Max team’s expertise and access to additional resources enabled resequencing and acceleration of works to achieve completion within programme and to budget. The technical skill of the tradespeople fielded by Max meant significant elements of this historic structure could be preserved and beautifully restored for future generations to enjoy.

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Christchurch Town Hall

Client: Hawkins Construction
Project: Formwork and concrete
Timeline: Jan '16 - Mar '17

On this project, we undertook installation of formwork systems for replacement of the earthquake-damaged foundations, walls, stairs and slabs of the Christchurch Town Hall. The project also required concrete repairs to the earthquake-damaged elements of the building which were retained.

The programme was challenged by delays caused by ground water, and significant additional works. However, the Max team kept the formwork package on track through proactive planning and by forming some works ahead of time, when there were opportunities to stay ahead of the production curve. On a project which was significantly delayed, the Max team’s ability to innovate resulted in a six week ‘gain’ in programme. This was achieved by combining three separate concrete pours into one large pour of >350m3 of concrete. As a result, the internal auditorium of the main building was progressed much faster than originally planned.

As well as playing a key role in the overall critical path for the project, the Max crew’s performance was strong. Works were completed without safety or environmental incident, to fully meet quality, time and budget requirements.

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Christchurch Cathedral Junction

Client: Fortis Construction
Project: Repair and fit-out of all Quest Apartments, Hotel and retail units
Timeline: Oct '12 - Oct '13

Cathedral Junction was one of the first post-earthquake projects to get off the ground in Christchurch, and involved repair and complete fit-out of Quest Apartments, Hotel 115 and fit-out of 18 retail units. It is significant as being the very first project undertaken by Max. Managing Director, Dave McSorley, was the project’s Site Manager, overseeing more than 170 staff and up to ten contractors, at any given time.

This use of a managed labour model to deliver a project was extremely innovative… and successful. All works were completed on budget and on time, to a standard of quality which the client described as ‘going above and beyond to deliver to the highest of standards’. The Cathedral Junction project, delivered successfully via a managed labour model, has provided the foundations on which the Max Group has been built.

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Christchurch Art Gallery

Client: Fulton Hogan
Package(s): All Carpentry, paint and plaster works
Timeline: Feb '15 - Dec '16

We undertook earthquake repairs to the Christchurch Art Gallery during, and following, its base isolation retrofit. The scope of works included new timber flooring, plastering and paint works, door works and installation of a new suspended ceiling.

With tight timeframes, our ability to innovate was key to project success. For example, for repair of existing wooden floors we developed a simple system for working through and grading flooring. With inspections required after flooring was lifted, and an immovable deadline for the reopening of the gallery, it was essential to lay the retrofitted flooring extremely fast and join it seamlessly to existing floors. Planning and preparation was essential to a high quality finish and maintaining programme. To ensure readiness to install the moment we got the ‘green light’; as floors were lifted, we de-nailed, cleaned and stacked components according to thickness and straightness. This attention to detail was essential, there had been up to six sandings completed in parts of the Gallery, so thickness of the component floor boards varied by up to 4mm.

Other challenges included the demands of working under an NEC3 form of contract. Project administration demands were stringent and included protocols such as ‘before and after’ photographs for all works, and clear articulation of quantities/rates. However, Max’s contract administration was diligent. Our delivery met or exceeded contract requirements for quality, and was achieved on budget and on time, to support the Gallery reopening on the scheduled date.

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Christchurch Victoria Park Restoration

Client: City Care/John Fillmore construction Joint Venture
Package(s): Formwork and concrete
Timeline: Apr '17 - Dec '17

The Victoria Park contract was awarded to Max Projects as a continuation of the package of works delivered for the Christchurch Town Hall (refer below), and our strong performance on that contract. Our crew was tasked with the removal and replacement of curved walls, as part of the post-quake restoration of Victoria Park.

The project benefited from an innovative approach to source and use specialised re-usable formwork. This created a significantly more efficient method for curved wall construction. After researching and sourcing a suitable proprietary formwork product called ToughForm, our Project Manager undertook testing, ahead of onsite deployment. This approach was highly successful, both in speed to deliver and the cost savings (i.e. reduced labour costs and a 75% reduction in materials).

Despite the intricacy of construction required, Max delivered this project to fully meet quality specifications. There was a 5mm tolerance for the curved walls which was checked using GPS. All our work was completed on time, with zero remedial works due to location errors. Given the worksite was close to the Avon River, our team also adhered to strict environmental protocols, to ensure works were completed without incident. All aspects of delivery by the Max team were strong, with the
result that ongoing work was awarded to us, by our client.

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Christchurch Acute Services Building

Client: CPB Contractors
Package(s): Formwork and external carpentry
Timeline: July '16 - ongoing

Max Projects provided formwork systems for in-ground foundations and the installation of feature precast concrete panels throughout the new Acute Services Building, located at Christchurch Hospital. The specialist precast concrete works which our team delivered included installing up to nine floors of architecturally finished units. The complexity of installation for the IL Level 4 building was to ensure the structure fully met requirements for superb seismic performance.

Foundations for the project were provided in accordance with a demanding programme. Supply and installation of all foundational concrete formwork was achieved, while coordinating with revised structural design requirements.

All aspects of this project were completed to specification and programme, and within budget. In particular, the quality of the final product was noted as being ‘high’. Our client benefited from Max Projects ability to undertake the formwork package, working flexibly, and in a way which accommodated events and delays which impacted the critical programme.

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Spark Building

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Tommy Taylor Courts Restoration

Client: Fulton Hogan
Project: Restoration of Tommy Taylor App Blocks
Timeline: Sept '17 - July '18

This earthquake remedial project was for a community housing complex. Max group staff undertook an extensive range of work which included internal and external structural timber works, as well as internal linings, re-painting, plumbing and electrical services, external cladding systems and floor linings. Our brief was to undertake repairs to the earthquakestrengthened building, sympathetically, so as to minimise repair costs but still provide the best result for our client.

With the combination of renovation, new build and EQ repair expertise we had onsite, the Max team was key to on time, on budget completion. For example, they identified the cladding system specified could not be warrantied for 16 of the 20 ranch sliders, without replacement of the doors and reconfiguration of openings. Their approach was to design and retro-fit bespoke flashings which, once waterproofed, were fully warrantable. The Max team’s ingenuity and expertise eliminated programme delays and the budget blow-out which replacement of doors would have caused.

The main challenge was a strict completion deadline – this was necessary to give tenants certainty for moving back into their homes. When unforeseen issues (related to physical conditions and mould) added works to the programme, these all had to be completed within the original deadline. Despite this, all aspects of the project were completed on time and on budget based on the Max team’s ability to interpret the brief and provide our client with certainty of budget and assurance time constraints would be met. We achieved strong health, safety and environmental outcomes (there were no lost time injuries or environmental issues), and quality was specifically remarked upon as being ‘impressive’ by the Christchurch City Council.

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Lyttelton Tunnel Deluge System

Client: McConnell Dowell
Package(s): Formwork and concrete
Timeline: July '17 - Mar '18

Max constructed a new pump station with concrete foundation and floor. Service ducts were cast in place, we plastered and painted the exterior solid-fill concrete block walls, and constructed timber roofing with corrugated iron cladding.

A key challenge of this project was the restricted work site. Our crews were working in a space-constrained/fully isolated work area, adjacent to a services road, with limited space for storage. Given the location, a key consideration was to carefully sequence and co-ordinate deliveries of materials to site, and to minimise traffic management issues.

Our quality assurance and procedures ensured a quality project was completed with only one minor painting defect. The project was also brought in on budget with some client-directed variations to contract. There were no accidents or incidents, with only one near miss reported. This was closed out in a Tool Box talk and measures put in place to prevent recurrence.

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ARA Institute of Technology - U Block

Client: Pace Project Management
Project: Repair and refurbishment of ARA U Block
Timeline: Dec '14 - June '16

Max Projects was contracted to undertake repairs and refurbishment to U Block in Christchurch Polytechnic’s hospitality precinct. The scope of works was for removal of plant/equipment in hospitality department kitchens, soft demolition including removal and replacement of concrete floors, internal and external carpentry repairs, painting/plastering and decorative repairs, reinstatement of kitchen facilities and plant.

The project was extremely time-bound. Works were programmed to begin during the 2014 Christmas holiday period, with a firm deadline to ensure the project was completed in time for return of hospitality students in Semester One, 2015. Facilities in the U Block included multiple commercial kitchens. A major challenge was removal and then later reinstatement of equipment in the hospitality campus kitchens. This demanded care to ensure equipment was not damaged on removal; and attention to detail to ensure everything was returned accurately into original locations.

With careful planning, and the ability to rapidly mobilise additional manpower through our Max Contracts labour pool, U Block reopened on-time for the new academic year. We achieved this by fielding multiple ‘managed teams’ of skilled tradesmen to accelerate programme. This included resourcing and rostering night shift operations to fastrack delivery of works. At the project’s peak, we had more than 30 tradesmen, foremen, carpenters, plasterers, labourers and hammer hands on site.

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Burke Street Apartments

Client: Orange Homes
Project: Demolition and rebuild of four two-story apartments
Timeline: June '15 - Feb '16

Max assumed the role of main contractor for this project, immediately following construction of the foundation slab. The scope of works included the rebuild of six existing units (i.e. four 2-storey and two 3-storey apartments) and construction of new 2-storey block. Within scope was demolition, framing and flooring for first and second levels, construction of roof and exterior joinery, first and second fix works; snagging and cleaning prior to handover.

Following handover at foundation stage, internal audit by the Max team identified levels were out by 20mm and the slab was ‘off square’. Re-cutting and grinding was undertaken to ensure all subsequent phases of construction could be completed to specification. This was crucial to overall project quality, and is an excellent example of Max’s Quality Management Systems.

Other challenges included a very short time frame caused by initial consenting issues. These had pushed out the commencement date by three months, but without a corresponding extension in the delivery date. Despite this, Max delivered the project within agreed extended timeframes. To achieve this feat, we increased work crew numbers so programme milestones could be met, something we were able to do by drawing on the large pool of labour available to us through Max Contracts.

Project success was driven by our project leadership’s involvement in weekly and bi-weekly meetings with the client. These provided a forum for early identification of issues, so scope, programme and financial creep could be addressed. Our approach, based on open communication and ‘no surprises’ delivery, resulted in strong project outcomes for our client.

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Focus Technology Group Ltd Fit-out

Client: Focus Technology Group
Project: Internal office fit-out
Timeline: August 2017 - October 2017

The interior fit-out of this new office space, was complicated by the need for a Building Act exemption. This was necessary so first fit-out of the new tenancy could proceed. This was identified early by the Max project management team who engaged specialist Architects and Fire Engineers to collate and submit the documentation required for the exemption to be granted.

Our proactive approach saved our client time and money – submission to Christchurch City Council was seamless and the exemption was obtained without delay to programmed works. Strong project management was key to the successful delivery of the project. This included conducting a thorough risk management process to identify and develop a detailed programme of works. Expert planning and resourcing also meant all materials were ordered, and subcontractors procured and scheduled to achieve timely completion of works. Our good pre-planning minimised waste products. What waste there was, was correctly recycled and disposed of in accordance with the Max Projects’ site specific Environmental Policy and procedures. On this contract, we were able to provide our client with certainty of completion date, ensuring they could move into their new premises on time, without incurring additional rental costs. Quality Management procedures specifically put in place ensured the project was delivered to specification and within budget, to the full satisfaction of our client.

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Northcote School - HD Unit

Client: Ministry of Education
Project: Strip-out and refurbishment of a school high dependency unit
Timeline: Jan '17 - Apr '17

This project entailed the strip-out of an existing toilet block, followed by construction of a High Dependency Unit within the existing structure. Included within the works package was construction of a new timber ramp, decking, doors and frames.

Carried out in the January school holidays, the project was extremely timebound - all work had to be completed prior to the school reopening for the new academic year. This was substantially achieved, despite the short three-week programme, with some minor works being completed after school hours.

Our contract performance was strong – all work was completed with zero harm and on budget. The standard of quality achieved, and MOE’s high satisfaction levels, has resulted in Max being awarded further MOE contracts.

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