One New Zealand Stadium (Te Kaha) is Christchurch’s new multi-purpose venue designed to host major sporting events and concerts. The development represents a significant investment in the city’s future, creating a modern enclosed stadium capable of accommodating thousands of visitors while providing facilities for athletes, staff, and patrons.

The scale and diversity of the project required drainage solutions across a variety of environments, including commercial kitchens, player changing rooms, public amenities, and external pedestrian areas. Each location presented different hydraulic and operational requirements, requiring a combination of standard and project-specific drainage systems.

One of the more unique challenges involved the player changing room facilities. The design incorporated large communal shower areas where multiple shower heads could operate simultaneously. While the anticipated flow rates were high, only a single waste connection was allocated within the plumbing design. This required a drainage solution capable of handling large volumes of water without compromising performance.

Working alongside David Browne Contractors (DBC), Allproof Industries developed a custom Vision Shower Channel system. By increasing the channel width, depth, and outlet size, the hydraulic capacity of the system was significantly improved. This ensured the system could comfortably manage the hydraulic demand through the single waste connection while maintaining compliance with AS/NZS 3500.2 (Sanitary Plumbing and Drainage) and NZBC Clause G13 (Foul Water). Wedge Wire and Equator grates were selected to provide a durable architectural finish suited to the changing facilities.

Beyond the standard changing amenities, the recovery and performance zones required specialised attention, particularly the cool-down areas featuring large built-in cold plunge pools. Due to the significant water displacement and splash associated with these pools, a high-capacity drainage solution was required. Allproof manufactured custom 5-metre vinyl clamping channels designed to accommodate large volumes of water while maintaining a secure watertight connection with the specified commercial safety vinyl flooring. The channel incorporated a stainless steel wedge wire grate, providing a durable architectural finish and slip resistance suited to wet barefoot traffic areas.

Managing surface water across tiled spaces such as communal ablutions and the team coach’s shower facilities required a reliable point drainage solution. Allproof tile floor wastes were installed throughout these wet areas and integrated with precise envelope cuts to achieve compliant floor falls and efficient water removal. The systems also provided a secure connection to the sub-tile waterproofing membrane, supporting long-term watertight performance while delivering a hygienic and durable finish suited to both high-traffic public amenities and private team facilities.

To address point drainage requirements across the stadium’s commercial vinyl flooring areas, a tailored approach was implemented to suit the operational demands of different spaces. In the player changing rooms and public toilets throughout the facility, Allproof’s Vinylrite was selected. Finished with a chrome-plated grate, the system uses a clamping mechanism designed to maintain a watertight seal with the vinyl floor covering, providing a flush finish suited to high-traffic public and athlete areas.

Back-of-house hospitality zones, including food preparation areas, cold storage rooms, and bar areas, required a more heavy-duty drainage solution. These spaces utilised cast bronze vinyl drain systems paired with stainless steel grates and internal strainer baskets. The removable baskets assist in capturing food and organic debris before it enters the sanitary drainage system, supporting ongoing maintenance and efficient washdown procedures.

Commercial kitchen areas also required hygienic drainage systems capable of withstanding demanding operating conditions and regular cleaning. Vinyl Clamping Channels and sumps were supplied to integrate with commercial vinyl flooring finishes while maintaining efficient drainage performance and ease of maintenance.

Externally, the stadium required effective management of surface water across extensive pedestrian circulation areas and loading bays. Polymer concrete channels fitted with stainless steel wedge wire and heelproof cast iron grates were selected to provide the required hydraulic capacity and load performance. The systems were selected to suit both pedestrian areas and service zones subject to vehicle loading in accordance with AS 3996.

The project incorporated a combination of off-the-shelf and custom-manufactured drainage products, allowing each area of the stadium to be serviced by a solution tailored to its specific requirements. Throughout construction, close collaboration between DBC, BESIX Watpac, and Allproof ensured products were supplied as required and technical support was available whenever needed.

In total, the project utilised a broad range of drainage solutions across internal and external applications, demonstrating the importance of selecting systems appropriate to each environment. Through a combination of project-specific hydraulic design, durable materials, and coordination between contractor and manufacturer, the completed stadium now benefits from drainage infrastructure designed to perform reliably during major events for many years to come.

As one of Christchurch’s most significant recent developments, One New Zealand Stadium stands as an important asset for the Canterbury region, showcasing how collaboration between contractors, designers, and local manufacturers can contribute to the successful delivery of complex projects.

Project Team

Main Contractor: BESIX Watpac
Plumbing Contractor: David Browne Contractors Ltd

Products Supplied

Vinyl Clamping Channels & Sumps
Vinylrite
Cast-Bronze Vinyl Waste
Custom Vision Shower Channels with Equator Grates
Tile Floor Waste
PC125 Polymer Concrete Channels with Stainless Steel Wedge Wire Grates
PC125 Polymer Concrete Channels with Heelproof Cast Iron Grates
GPO Tundish
Finishing Collar

New Zealand drainage solution manufacturer Allproof Industries has taken a significant leap forward in its growth strategy, officially opening a purpose-built facility in Pōkeno dedicated to PVC pipe production for DWV systems. NZ Plumber takes a tour. >>>

WORDS: JE T’AIME HAYR

<Read the original article on NZ Plumber>

The launch of the new Allproof PVC pipe manufacturing facility marks a natural evolution for the family owned and operated company, which has spent more than two decades manufacturing injection-moulded drainage components. Adding pipe extrusion to its capabilities positions Allproof to offer more complete system solutions to the market.
“This is a logical expansion for the growth of our business,” says General Manager Adam Jackson. “Our company has been around for nearly 40 years and we’ve been involved in the PVC fittings category for about 20 years, but we didn’t offer pipe, so this has been a consideration for a long time.”

From concept to commissioning

The new 2,500m² facility on a 12,000m² site took four years from concept to completion and represents the largest single investment in Allproof’s history. Purpose-built for pipe manufacturing, the plant houses a 30-metre-long extrusion line capable of producing PVC pipe in standard six-metre lengths.
Rather than relying on external expertise, the company upskilled their staff for complete in-house capability. That process has included sourcing machinery globally and working closely with material suppliers, giving staff exposure to international manufacturing practices while building local capability.
“We’ve done this 100% internally with our existing production and engineering teams,” Adam says. “Naturally there’s been a bit of trial and error and a lot of learning along the way, but we’re really happy with how things are shaping up.”
Production output and the number of products offered to the market is currently growing, with capacity expected to scale over time.

Building toward complete system supply

The addition of PVC pipe manufacturing allows Allproof to move closer to becoming a full-system provider in the DWV space—a shift that has clear benefits for customers.

“By offering more complete systems, we simplify procurement for plumbers and merchants and introduce more choice into the market.” — Adam Jackson, General Manager, Allproof

“By offering more complete systems, we simplify procurement for plumbers and merchants and introduce more choice into the market—particularly for those seeking locally made products,” says Adam.
“Plumbers are running businesses as well, so they’re making decisions based on price, quality and lead times, so our goal is to be competitive across all those factors. We want Allproof pipe to represent our existing brand and values. And by providing our customers with more choice that makes the industry more robust.”
Another benefit? Controlling both pipe and fittings gives Allproof greater oversight of quality and consistency across its offering.

Navigating a changing supply environment

The facility comes online at a time when global supply chains—particularly for petrochemical-based materials—are under pressure. Like others in the industry, Allproof is feeling the impact.
“We’re tackling the same resin issues as the wider market,” Adam says. “Supply is constrained, but demand is still there, and that’s pushing prices up.”
The company is working with suppliers to secure material from a broader range of sources, such as the United States instead of Asia where necessary.
“All suppliers are scrambling to ensure security of supply, so it’s an industry-wide challenge.”
Despite these pressures, Allproof’s strategy remains unchanged and Adam is optimistic.
“This has been a long time in the making. Our position here is long-term, so while the current environment is challenging, it doesn’t alter our strategy.”

Local manufacturing and sustainability considerations

While the raw materials used in PVC production are largely imported, Allproof sees clear environmental and logistical advantages in manufacturing pipe locally.
“If you’re shipping finished product, you’re essentially shipping a lot of air,” Adam explains. “Bringing in raw materials uses container space far more efficiently.”
The PVC pipe itself is technically 100% recyclable, although reprocessing comes with limitations around how the material can be reused. And recycled content is already being considered where appropriate, though it is not viable across the full product range.
The new operation aligns with Allproof’s existing environmental certifications and manufacturing practices, extending them into the pipe category.

Strengthening local capability

The Pōkeno facility has created eight new roles to date, spanning production, quality and warehousing, with further growth expected as operations scale.
Taking a measured approach, the company is focused on building capability sustainably rather than expanding too quickly.
“We’re still in the early stages,” says Adam. “Right now, it’s about building that customer base and then growing from there.”
More broadly, the move reflects a view that local manufacturing has an important role to play in New Zealand’s construction sector.
“There are some products that make sense to manufacture locally. In a global market, not everything will be made here, but there are opportunities where it stacks up.”

A milestone moment

The facility was officially opened by New Zealand’s Prime Minister Christopher Luxon in front of around 120 guests, including customers and industry partners—a milestone moment for the company.
“We were incredibly proud to host the Prime Minister and showcase what we’ve built,” Adam says. “It was a great recognition of what local manufacturing can achieve.”
Looking ahead, Allproof’s ambitions are clear. “As a business, we measure success through market share, customer experience and ultimately sales growth. This is about continuing to build on that and expanding our presence in the market.”

Factory tours are available for customers, offering plumbers and merchants the opportunity to see the production process and gain a deeper understanding of how locally manufactured systems are made.

Explore the Range

Learn more about Allproof’s locally manufactured uPVC product range HERE.

Located in Christchurch, the Lancaster Park War Memorial Entrance Gate was built in 1924 to remember athletes who lost their lives during World War One. The gates are considered significantly important to the local community as a distinctive and memorable part that remained in place through the park’s evolution into one of New Zealand’s largest stadiums.

Following the 2011 Christchurch earthquake the stadium was demolished, transforming Lancaster Park into a recreational park with facilities for community sport and was re-opened in June 2022. The Memorial Gates were mostly undamaged in the earthquake and were restored and opened to the public in 2023.

As an historic site of community value, the landscaping design needed to be considerate but also reflect a new forward-looking city evolving from the 2011 earthquake.

Allproof’s 200mm clear opening Commercial Channel drain was installed to capture and remove surface water from the Arc of History that was installed around the gates looking into the park.

The Heelproof Cast Iron (HCI) grate was selected, the material is sympathetic of the historical design of the Memorial Entrance Gate. The HCI grate features allow for large volumes of pedestrian traffic and a long service life as it’s a highly durable solution with an impressive P5 slip resistance (AS4586) rating.

The channel is made in New Zealand from 100% recycled material predominantly collected from single-use post-consumer streams. The recycled material provides a lightweight channel that improves installation by reducing install time, breakages, costs, and embodied carbon through logistics, all without compromising on strength. The Commercial Channel has been designed to utilise the strength of the surrounding concrete to create a strong durable solution.

The Commercial Channel was set off the foundations of the memorial Memorial Entrance Gate; this avoided any disturbance to a historical structure while also allowing for a full concrete encasement and the ability to create a fall towards the channel. The channel works as a visual separation between an exposed concrete finished surface and pavers.

Allproof’s production facility generates its own clean energy on site from 450 solar panels. Toitū have acknowledged Allproof’s sustainability commitments at its manufacturing facility by awarding an enviromark bronze certification. This provides confidence that Allproof understands and values sustainable business practices while being a forward-looking New Zealand business.

Understanding the applicable NZBC clauses for a durable, functional and compliant drainage system at the garage door.

Servicing surface water at a garage door is often complicated by incorrect detailing or by referencing the wrong acceptable solution. To design a compliant and durable system, it is crucial to understand how the relevant NZBC clauses apply specifically to garage entries.

Understanding the Applicable Acceptable Solutions

E2/AS1, section 9.1.3.4 outlines the requirements for meeting the acceptable solution at a garage door opening. Key elements include:

• • A 50 millimetre set-down from the internal slab to the exterior surface
  • The formation of a rebate at the doorway
  • A ramped fall to the external paving
  • A sealed base beneath the garage door

These elements form the foundation of a compliant detail that prevents internal moisture ingress.

The clause also states that there must be provision to drain water away at the opening. This part is often misunderstood. Designers sometimes reference E2/AS1 section 7.3.2.1, which applies to ground floor level access at pedestrian doors, not garages. This section calls for 150 x 200 millimetre channels, minimum lengths, and falls, requirements that do not apply to garage entrances.

Garage entries are addressed separately in E2/AS1 section 9.1.3.4, and the drainage requirements are significantly different.

Compliant Ways to Drain Water Away at the Garage Opening

1. Falls in Paving

Creating falls in the concrete or paving so water flows away from the garage is the most common solution. Water is then collected in a sump further down the driveway.
This method eliminates the need for drainage directly at the door and combines:

• • E2 (Internal Moisture) compliance
  • E1 (Surface Water) management

A plastic stormwater pit with a cast iron grate will typically meet vehicle-loading expectations for residential driveways.

2. Installing a Surface Water Drain (Channel Drain)

Where falls cannot be achieved, for example, when the driveway slopes toward the garage, drainage can be provided via a three-sided channel drain positioned at the doorway.

This channel must comply with E1 surface water requirements, which in turn satisfies the E2 requirement that water be drained away.

Key installation considerations include:

Offset the channel from the slab edge, allowing it to be fully encased in freshly poured concrete

• This ensures vehicle loadings are distributed through the concrete encasement
• Butting a channel against a dry slab edge will not achieve the required strength or durability

Provide a sump before connection to stormwater

• This can be an inline sump for minimal visual impact
• Or a sump placed elsewhere along the driveway

Select a channel sized to meet rainfall demand

• Rainfall events are typically calculated using a 1:50-year design storm
• Channel size, grate selection, outlet size and flow tests must align to ensure adequate capacity

Channel drains provide an effective solution where direct collection at the garage door is necessary, and various grate materials and load ratings are available to suit the environment.

Selecting the Correct System

The selection of any surface water drain should be based on:

• • Calculated rainfall demand
  • Required outlet capacity
  • Load rating requirements (e.g., vehicle traffic)
  • Material selection for durability
  • Compatibility with sump and stormwater connections

Allproof designs and manufactures surface water drainage solutions for a wide range of residential and commercial applications. Supported by flow rate testing and demand calculations, Allproof can assist in selecting and specifying the correct system for each project. This reduces RFI requests, simplifies compliance with acceptable solutions, and ensures a durable, functional outcome at the garage door.

Related Products

Allproof’s 300 millimetre clear opening commercial channel was selected for its sustainability, performance, and long-term durability.

Designed by +MAP Architects, 22 Karori is a luxury apartment development situated on the Auckland city fringe, overlooking the Waitematā Harbour towards Devonport. With sustainability and energy efficiency at the centre of +MAP’s design philosophy, the building has been developed to be lived in, and loved, by generations to come.

Drainage Requirements for a Basement Car Park Ramp

Basement and semi-basement car parks often present unique hydraulic challenges. As rainwater travels down a ramp, it increases in velocity and can hydraulically bridge narrow drainage openings. This makes the width of the catchment area critical to ensure effective surface water removal during peak rainfall.

For 22 Karori, Allproof’s CC300 commercial channel was selected for its 300 millimetre clear opening, providing a wide and reliable catchment to prevent water from bypassing the drain during high-flow events. The system was installed both on the ramp and within the car park itself to ensure consistent performance across all trafficable areas.

Product Selection for Performance, Safety, and Durability

Ramp Drainage – Heelproof Cast Iron (HCI) Grating

The ramp required a grate that could withstand vehicle loads, weather exposure, and continuous water flow. The HCI heelproof grate was selected due to its:

• • Class D load rating for wheel loads up to 8,000 kilograms (AS 3996)
  • Slip resistance rating of P5 (AS 4586), suitable for steep and wet surfaces
  • High durability and resistance to long-term wear
  • Suitability for environments with accelerated run-off and sudden load impact

These attributes make HCI an ideal choice for vehicle ramps where water management and surface safety are both critical.

Internal Car Park Drainage – 316 Stainless Steel Wedge Wire Grating

Inside the car park, the design team selected Allproof’s 316 grade stainless steel Wedge Wire grate, providing:

• • A clean architectural appearance in line with the building’s premium aesthetic
  • Excellent corrosion resistance in enclosed or partially ventilated spaces
  • Smooth top finish for improved pedestrian and vehicle comfort
  • Structural performance that complements the CC300 channel body

Wedge Wire is a preferred choice for premium developments due to its durability, low maintenance requirements, and high-end finish.

A Sustainable, Locally Manufactured Solution

The CC300 system is manufactured locally in Allproof’s Toitū enviromark® bronze certified facility, supporting the project’s sustainability objectives. Using a New Zealand-made product reduces transport emissions and supports the circular economy through Allproof’s established recycling programmes.

Allproof works with designers to provide drainage solutions that meet the hygiene, cleaning, and maintenance requirements of food processing facilities.

When it comes to food processing and packaging, hygiene is critical. These areas operate under strict cleaning and maintenance regimes to maintain compliance. A major part of this performance is the effective management of trade waste. A well designed drainage system ensures hygiene standards are upheld throughout the process and that flooring remains clean and dry, supporting a safe working environment for staff.

A recent project where Allproof was engaged to assist was at The Pure Food Co. production facility in Auckland. The base build fit-out had included an imported stainless steel floor drain system that was not suitable for the demands of fortified food processing. The gratings were slippery and the components were not fit for purpose. The customer was experiencing frequent blockages caused by strainers filling too quickly, which left product on the floor instead of draining into the channels. This resulted in regular shutdowns of the production lines for maintenance and cleaning.

Allproof worked alongside the team to provide a replacement solution that matched the process requirements of this innovative New Zealand business. Close interaction between the customer, their staff, and the manufacturer resulted in a system supplied to site in a timely manner and suited to the application. The replacement system, manufactured in Allproof’s Toitu enviromark® bronze certified facility, included channel drains with wide openings and R13 slip rated gratings to provide a safer and more durable working environment. The strainer baskets within the sumps were increased in size and designed for easier servicing, reducing downtime during cleaning and sterilisation. The solution was specified, designed, and delivered on time so the changeover caused minimal disruption to production.

Another example is the Ziwi meat processing facility, where the original channel supplier was replaced with Allproof after it became clear that their generic system did not meet the site’s specific needs. With Allproof, the customer was able to customise sizing and slopes for slot drains, and specify sumps and channels to suit the application rather than accept standard off-the-shelf limitations. A key development was the redesign of the strainer baskets to incorporate larger openings that allowed meat particles up to 20mm to pass through effectively. Allproof also recommended adding a T-bar riser to assist staff in locating sumps during washdown procedures. The overall design has resulted in a system that is easier to clean and maintain, supporting a consistently high hygiene standard.

In high hygiene environments, the design and in-service demands on a drainage system must be prioritised from the outset. A local manufacturer with proven experience can advise on the most suitable product for each application, provide both standard and custom solutions, and deliver within the required timeframes. Whether the facility is a food processing plant, a healthcare or aged care site, or a secure unit requiring anti-ligature design, engaging Allproof at the early design stage helps ensure that safety, hygiene requirements, and internal processes are fully supported.

Related Products:

New Zealand projects are increasingly being delivered in challenging exposure zones, and Allproof has been working closely with designers to ensure hydraulic systems align with durability requirements across a wide range of environmental conditions.

Drainage systems must first be designed for function. Their primary role is to collect and convey water from the surrounding environment, whether that environment is a roof, patio, courtyard or driveway. Once the hydraulic performance requirements are confirmed, material selection and surface finish are determined by the environmental exposure of the installation. Conditions such as coastal air, sheltered locations that do not receive natural rinsing, or thermally active ground can all influence long-term durability and product performance.

Several high-profile projects in Rotorua illustrate this challenge. Located in the geothermal zone, these developments face intense corrosive conditions caused by sulphur-rich steam and high-temperature ground emissions. Some existing building elements have failed well before their intended design life. As part of remediation work, products are now being specified in ABS plastic, which provides a high level of corrosion resistance in thermally aggressive environments.

Another ongoing project involving a secure health facility is located above localised fumaroles. These thermal steam vents expose materials to continuous corrosive vapour and elevated temperatures. To maintain durability and compliance, all stainless steel components have been specified as grade 316. Grate selections include recycled GFP, a glass-filled recycled polypropylene that offers consistent performance, slip resistance and long-term durability in both corrosive and thermally volatile environments.

Threshold channels and surface water drains also require careful consideration. These products may be installed in high-exposure zones or in sheltered areas under soffits or overhangs. In these protected locations cast iron can oxidise heavily because it is not regularly washed by rain or cleaned by pedestrian traffic. Although this oxidation does not reduce structural integrity, it can have a noticeable aesthetic impact on the finished project. To address this, Allproof provides stainless steel grates in grades 304 and 316, as well as engineered plastic grates that are frequently manufactured from 100 percent recycled material. Plastic grates also offer improved resistance to corrosive environments, including coastal exposure and geothermal conditions. Modern black plastic grates are increasingly specified because they align well with contemporary design palettes and provide a durable, consistent finish.

Allproof grates are load tested to AS 3996, which is the recognised standard for determining load class suitability for both pedestrian and vehicular traffic environments. In addition, a selection of Allproof grates are slip rated to AS 4586, which supports safe specification in areas where slip resistance is required by design or regulation.

Ongoing communication between designers, installers and manufacturers remains essential. Allproof works closely with architects, hydraulic consultants and contractors to ensure correct material specification for each environment and to confirm that the installed products meet both performance expectations and aesthetic requirements. This collaborative approach helps deliver drainage solutions that remain durable, compliant and visually consistent across a wide range of New Zealand exposure conditions.

Considered one of the country’s most innovative and sustainable projects in its category, the recently built Kings Plant Barn in Stonefields, Auckland has looked to connect people and plants with a focus on sustainability.

Energy is generated on site from solar panels with water collected, filtered and reused from their irrigation system. The building itself has been built with sustainable products such as a timber frame as well as products made from recycled materials (such as the playground).

Allproof’s 200mm clear opening Commercial Channel has been installed throughout the garden centre to capture and remove surface water. The Commercial Channel is made in New Zealand from 100% recycled material predominantly collected from single use post-consumer streams.

Regular watering within a garden centre places increased importance on designing and installing an effective surface water drainage solution. Organic debris is often washed onto the floor and into the channel drain. Product selection needs to consider the ability to remove hazards as customers regularly walk across the drainage channel, any chemicals the system could be exposed to, and ongoing maintenance.

The Heelproof Cast Iron (HCI) grate was selected, this grate has a class D (AS3996) load rating allowing for heavy duty equipment to travel over the system, such as large trolleys and forklifts. The grate also removes hazards from pedestrians as the openings resist heels as well as being P5 slip resistance rated (AS4586). The slip resistance features reduce risk to staff and customers in wet conditions, especially young children who will be present as Kings plant Barn has a playground.

Grates are 500mm in length and secured with lockdowns at the centre. This allows for the easy removal and maintenance while stopping movement or unauthorised access.

The Channels are made at Allproof’s main production facility on the North Shore of Auckland which generates its own energy on site through 450 solar panels installed on the roof. The production facility has been given a Toitū enviromark bronze certification providing confidence that Allproof understands and values sustainable business practices.

Related Products

Allproof has published two years’ worth of new passive fire tests for plumbing and electrical services in the online technical manuals. This substantial update has introduced new products to complement Allproof’s existing range. These include a 200 mm Fire Collar for large plumbing pipe systems, and 50 mm and 100 mm Fire Plates tested to cover large voids in floor slabs, used in conjunction with 50 mm and 100 mm Fire Collars for FWG positions in floor slabs.

Additionally, a newly designed multi-service transit box, constructed from stainless steel and called the Wallthrough, caters to multi-service entry points into hotel rooms or apartments at the fire-rated corridor wall. Allproof has recently undertaken an acoustics test on the Wallthrough so that performance can be assessed by an acoustics engineering team when adopting the solution for a project.

These products utilise Allproof’s advanced intumescent formulation, which provides a fast-activating penetration closure for various systems and services. The new testing encompasses these devices as well as plumbing and electrical services using other Allproof collar types such as ALLFC, DIFC, and CIFC, on the following substrates: concrete floor slabs, CLT floors and walls, plasterboard walls and ceilings, and composite floors.

Continued research and development, as well as improvements to fire test results through design and installation changes, keep Allproof Industries at the forefront of New Zealand passive fire product development and testing.

Pact Group processes and supplies high quality locally recycled material. “Completely closing the loop, guarantees consistent supply and integration of food-grade and non-food grade recycled local resin across all industry sectors.” – pactgroup.com

Pact Group have recently upgraded their hard plastics wash line which cleans and fragments a range of plastic materials. Pact Group process around 1000 tonnes of recycled Polypropylene (PP) resin per year, the upgraded wash line provides the ability to increase this. The material comes from various streams such as post-consumer.

Roadside recycling is collected, sorted and bundled at an Auckland Material Recovery Facility (MRF). Pact Group purchase bundles of PP from this facility to be processed back into 100% recycled material. This is then supplied to Allproof to manufacture a range of drainage and passive fire protection products, such as the Commercial Channel drain range. The whole process, from recycle bin to new product, takes place in Auckland.

The upgraded wash line facility uses large volumes of water for the cleaning process, this water is recycled on site to reduce usage. With any commercial activity involving water a reliable and high performing drainage system is essential. The drainage system must be able to accommodate for any spills to remove hazards and efficiently remove large volumes of water in the unlikely event of an equipment malfunction.

Allproof’s 200mm clear opening Commercial Channel was selected as the drainage solution. A total of 63 metres of channel has been installed around the internal perimeter of the facility. At the entrance, 10 metres of the Heelproof Cast Iron (HCI) grate were installed to accommodate forklifts carrying bales of recycling in, and then transferring bags of cleaned and ‘chipped’ material out to the next facility to complete the process. The HCI grate has a Class D load rating (AS3996) and P5 slip resistance (AS4586) providing the ideal solution for high traffic and heavy commercial applications exposed to wet conditions.

The Glass Filled Polypropylene (GFP) grate was selected for the drainage channels around the rest of the facility where only class A pedestrian traffic occurs. This grate also has a P5 slip resistance, reducing workplace risk, an important consideration for Pact Group, who state “safety is first” among their corporate values.

Both the channel and GFP grate are manufactured at Allproof’s bronze enviromark® certified facility using solar energy and 100% recycled PP processed in the facility where the product is now installed. This closes the loop, delivering a high performing, sustainable drainage solution through the collaboration of two innovation-driven companies.