As a supplier to the plumbing industry since the 1980s, Ian Jackson promoted the introduction to New Zealand of the AS 3500 Australian Plumbing Code, now known as AS/NZ 3500. NZ Plumber talked to Ian about his family run Allproof Industries business and his significant contribution to the industry over many years, which was recognised in the 2022 New Year’s Honours.

This article has been taken from NZ Plumber April-May 2022 issue, written by Matthew Lowe.

Work has always been a family affair for Ian Jackson, from joining his father’s plumbing business in 1953, to running successful ventures with his wife Maureen and seeing his children help him grow Allproof Industries.

The 85-year-old remains a shareholder and Director of the Auckland-based company and says he is happy to contribute where possible. His efforts over the years were recognised in the 2022 New Year Honours when he received the MNZM for services to the plumbing industry and the community.

Apprenticeship Beginnings

It all began after Ian finished his secondary education at Wellington College and started working with his father Jim Jackson at JP Jackson Ltd in Taihape in January 1953. Ian says it was a unique plumbing and drainage business in the North Island’s Central Plateau that serviced an area from Taupo to Hunterville.

“Before World War II this area was relatively isolated with the roads mainly metal, which meant Jim Jackson had very little opposition as a plumbing and drainlaying company serving the district’s rich farmlands, central mountain area, ski fields, Waiouru Military Camp and the Taupo area,” explains Ian.

“My father’s business quickly flourished at the start of World War II with the building of Waiouru Military Camp half an hour north of Taihape.”

He adds that the company went on to obtain the first significant equipment in the area, such as diggers, compressors and rock-blasting equipment for major drainage and sewage treatment constructions.

“Jim Jackson was much more than a plumber,” says Ian. “I remember my father having the conversation in our house with his good friends Jim and Rolly Shand about starting a plumbing supply business owned by plumbers.

“This was, of course, the idea that led to the Shand Brothers becoming Plumbing World in Palmerston North and the commencement of a successful major national plumbing supply chain.”

Australia to Auckland

After Ian completed his apprenticeship, he decided to move to Auckland in 1958 to gain experience in commercial plumbing before then heading across the Tasman. “I was employed by WA Chenery, at the time New Zealand’s largest plumbing company. I gained further experience in Australia working as a plumber at Tooths Brewery, Sydney.”

It was in Sydney that Ian got married to Maureen in 1962 and three years later the couple moved back to Auckland and he started his own company, Jackson Plumbing Ltd. It soon became prominent as an inner-city maintenance company, with a sheet metal shop making the Asta brand of hot water cylinders, and lead edge barge and ridge products for Alex Harvey decramastic roofing.

“We operated Auckland-wide for the next 30 years,” says Ian. “In the ’80s, Maureen and I purchased Barry Wilkie’s plumbing business on the  Whangaparaoa Peninsula and that company became Wilkie Plumbing, servicing the Hibiscus Coast area.”

Growth of Allproof Industries

In 1986, Ian became a shareholder in Allproof Industries, an Australian company supplying waterproofing products to the construction industry, and over the next few years, he and Maureen gained the total shareholding of its New Zealand and Australian arms. “As a supplier to the plumbing industry, I saw the opportunity to introduce to New Zealand a different more efficient and cost-effective way of plumbing, particularly to the commercial and apartment construction sector,” he explains. “This was the Australian Plumbing system AS 3500 Plumbing Code, later to become known as AS/NZ 3500. With this design layout of the standard, materials and labour costs were greatly reduced.”

Allproof Industries commenced manufacture of products required for the AS/NZS 3500 standards and over the past 35 years has designed and manufactured a large number of products, including many new ones created by its design team.

Ian is proud of how the company has grown to now employ about 130 staff. Its head office and main manufacturing factories are based at Beach Haven on Auckland’s North Shore, and it has a warehouse and team in Christchurch and representatives in Tauranga and Wellington. In Australia, the company has a warehouse facility and representatives in Melbourne and Brisbane.

Ian and Maureen’s children are also involved in the industry with one of their sons, Adam, now General Manager at Allproof, their daughter Jacinta the Administration Manager and their other son, Jared, spent 24 years with the company.

“It’s been a great privilege working so closely with my wife and children. I have enjoyed watching them learn about the business and it has been an enjoyable experience working alongside them to grow the business to what it is today.” Maureen passed away in December 2020 but Ian notes her legacy to the industry lives on as Master Plumbers introduced the Jackson Women in Plumbing Trophy, awarded at its annual conference.

Community Involvement

Through Allproof, Ian has also supported a number of charities, schools, sporting and local music organisations and he has been a member and president of the Auckland West Rotary Club. “My family has always been philanthropic. We usually have a discussion amongst ourselves when we get requests and tend to support relevant groups or organisations that we may have a connection with, or feel they warrant and would benefit from our support.” Ian lists his interests away from plumbing as sport, rugby, swimming, surf lifesaving and music. “I have played as a drummer and pianist in many bands,” he says.

NZ Plumber Magazine | April-May 2022

NZ Plumber is the award winning, bi-monthly magazine for New Zealand’s plumbers, gasfitters and drainlayers.

Read it here

Using NZ-made provided a premium system and finish to the 5-star Cordis Hotel in Auckland while navigating challenges through the construction process.

One of Auckland’s premier hotel and conference destinations, Cordis, opened its landmark 17-story Pinnacle tower in late 2021, increasing the hotel’s capacity to 640 rooms. This makes Cordis the largest hotel in New Zealand in terms of room count. The Pinnacle Tower, designed by New Zealand architects Jasmax, cost $170 million and offered Auckland’s central city a new level of 5-star accommodation. Behind the flashy exterior, various processes brought together the best in NZ design, construction, manufacturing, and commercial plumbing.

When designing the hotel, durability and trusted systems were prioritised by the designer, Philip Rutkiewicz, to ensure the longest lifespan of the fittings. Even with a concrete and steel structure, Jasmax was mindful of the impact of building movement and the potential risks of defects within such a large project. Philip considered the security that an Allproof shower tray provides, aiming to assure clients that their investment and revenue stream were well protected, aligning with the 5-star hotel’s goal of setting “a new benchmark for modern luxury in Auckland“. Based on this decision, the architectural team specified the Allproof Tile Over Shower Tray system for all 235 rooms of the extension.

Stainless steel shower trays offer excellent waterproofing features with a fully welded stainless steel impermeable layer falling to a flood-tested channel and spigot connected to PVC waste, virtually eliminating any risk of failures or leaks in this high-risk area. Other impervious solutions such as exposed stainless or acrylic trays have durability limitations in a high-use environment and often do not meet the interior design style demanded by a 5-star destination.

The Allproof stainless steel tray is installed over the flooring structure and below the tiles, with the selected waterproofing membrane running down the walls and lapped into the tray. This results in a fully watertight base below the tiles and behind the wall linings, while providing the aesthetic of a fully tiled shower.

Allproof was engaged in the design process early on, allowing time to plan the project. Although Allproof’s Tile Over Stainless Tray is usually custom fabricated to measure, given the scale of the project, another approach was required. Allproof developed 13 tray designs after several site meetings with the designer, main contractor, and plumber to find solutions and specifications to meet the very tight construction timeline. To accommodate the tight timeline, Allproof laser-cut in-house templates of the trays to suit all room layouts, ensuring a perfect fit once the trays arrived, with no installation delays. The template also included the ability to mark the outlet, allowing concrete cutters to make the floor waste penetrations and plumbing services to be brought to the point of the wastes.

Allproof helped develop a sample room for signoff from the overseas owner, Langham Hospitality Group, based in Hong Kong. Through this procedure, Allproof had the opportunity to refine the process and plan full-scale production. Hanlon Plumbing was contracted for the installation of the plumbing systems, emphasising the importance of the schedule and deadlines. To meet the project’s demands, Allproof dedicated 5 staff members of their 35-strong stainless fabrication team to the production of the trays, with their own in-house production timeline set to meet the one on site. Their workshop, comprising, among other plant and machinery, a laser cutter, several CNC press brakes, and a dedicated gluing room for the bases, meant that 235 tile-over-shower trays were fabricated over a 9-month period and completed ahead of schedule. Notably, not a single tray was rejected, a contractor’s dream!

This project demonstrates that with correct planning and selection, the use of trusted suppliers and proven contractors can ensure a project is completed ahead of time and delivered perfectly.

The process is just as important as the product.

This is an underscoring principal that has driven Allproof’s local manufacturing focus in recent years. As a manufacturer of market leading plumbing and drainage products, Allproof understands its environmental responsibility and takes it seriously. Allproof is striving to be an environmentally conscious manufacturer whilst continuing to produce premium products for the plumbing industry. Allproof firmly believes that the production process is just as important as the quality of the products that it produces. This has led to a targeted investment in its North Shore manufacturing facility, which includes new energy efficient injection moulding machines and clean renewable solar energy to power them.

Allproof have recently completed the installation of 449 solar panels through solar installation company Solarcraft. The installation took 6 months of initial planning followed by a team of five tradesmen completing 900 man-hours over a four-and-a-half-week period. This marks a key milestone for the company and underscores Allproof’s desire to be an industry leading manufacturer with an environmental conscience.

The projected daily average of 750kWh of clean renewable energy (in excess of 1,000kWh per day during summer months) generated from the 1700m² solar panel installation is used to power Allproof’s North Shore head office. This building includes its injection moulding, product assembly and outward goods departments. This will provide Allproof’s main facility with nearly 50% of its energy needs sourced from self-generated, clean solar energy. To give context, this is enough power to supply approximately 34 average New Zealand homes (www.ea.govt.nz/consumers/what-is-electricity). Excess power generated through peak production times is supplied back into the grid for local homes and businesses to benefit from clean energy. This impressive solar panel installation saves 50 tonnes of CO₂ from entering the atmosphere every year.

Another benefit to the onsite production of clean energy is the ability to charge Allproof’s plug-in Electric Vehicles (EV’s). By charging the EV’s onsite, Allproof can utilise the clean renewable energy generated onsite to significantly reduce the emissions of vehicle kilometres driven. Accompanying the plug-in EV’s, Allproof is also upgrading its fleet of sales vehicles to hybrid electric vehicles. These vehicles have improved fuel efficiency, reducing CO₂ emissions whilst allowing the sales team to continue to offer the high level of service required by our customers nationwide.

In addition to these developments at Allproof’s manufacturing hub, the company continues to increase its range of drainage and passive fire protection products made from 100% recycled plastic. These recycled materials are locally sourced from kerbside collections and allow Allproof to provide a large range of secondary recycled products, enhancing the lifecycle of these plastics, produced with a focus on sustainability and an overall reduction in environmental impact.  Furthermore, Allproof also holds the Best Environmental Practice (BEP) Certification for the production of PVC products, as part of its wider AS/NZS1260 product certification.

Allproof is committed to supplying high quality NZ made products with a goal of reducing its emissions and wider environmental impact. This is being achieved in a multitude of ways primarily including:

• • Local manufacturing
  • Focus on renewable energy and energy efficiency
  • Environmentally conscious material selection

The ongoing focus on the manufacturing process, will ensure that Allproof continues to provide the high quality products the company is known for with the environmental focus that is critical for generations to come.

In the realm of New Zealand’s plumbing and construction industry, Allproof Industries stands as a stalwart advocate for local ingenuity and environmentally conscious production methods. Pioneering the intersection of sustainability and innovation, we proudly present our latest offering: the 200mm clear opening drainage channel meticulously designed and crafted in-house, manufactured from 100% kerbside recycled plastic.

In-House Mastery of Design and Production

At Allproof, our commitment to quality extends to every facet of our operations. Embracing a design philosophy that “The Process is Just as Important as the Product”, Allproof champions in-house production. Our journey begins with a collaborative effort—from product design to tool making and the precise manufacture and assembly of the final product, all orchestrated from our Beach Haven manufacturing plant. This approach empowers us to not only maintain robust stock levels but also diminish reliance on offshore manufacturing, ensuring a consistent supply to meet market demand.

The Evolution of a Medium-Duty Drain

Driven by a dedication to meeting market needs, our dedicated team invested over 12 months in meticulously designing and crafting the 200mm drainage channel. After recognising a gap in the market, this locally produced channel made from 100% kerbside recycled material fills the need for a medium-duty, high-capacity drain. It promises excellent hydraulic performance while being easy to install, even in challenging hard-paved areas.

This drainage system boasts a variety of grates including the heelproof black plastic (GFP) grate, designed to withstand New Zealand conditions. Our cast iron (HCI) drainage grate boasts a class D load rating for commercial traffic under AS3996. Additionally, a 316 stainless steel wedge wire grate, with a class B load rating and R11 slip resistance (AS4586), caters to streetscape pedestrian areas and light vehicles.

An integrated inline sump fulfills sediment catchment requirements without disrupting the channel’s visual continuity, seamlessly connecting to the stormwater mains system.

A Seamless Installation Experience

In response to market demands for user-friendly solutions, our click-together straight channels eliminate the need for additional components, ensuring a fast and easy installation. Alternatively, our unique channel levelling clip system speeds up installation by utilising rebar to adjust channels to the desired height, eliminating the necessity for concrete haunching.

As stewards of New Zealand’s environment, Allproof recognises the pivotal role of responsible production practices. Steering clear of offshore manufacturing not only mitigates the environmental costs associated with external control but also minimises the ecological impact of shipping and transporting pre-made items. Embracing locally sourced 100% NZ recycled polypropene, including the plastic from your everyday shampoo bottles, our products embody a commitment to sustainability, transforming recycled materials into durable drainage channels designed to withstand the test of time.

Explore more about our extensive range of products crafted from recycled plastic, our ongoing environmental initiatives, and our commitment to product certification.

Commercial Channel 200mm

Mitigating risk is important when considering what components will be installed in your shower or wet room.

Tile Over Stainless Tray in Cordis Hotel Penthouse Suite, Auckland.

A lot of home owners have experienced leaks in a tiled area and the associated repairs and removal of mouldy or rotten framing, carpet and the like. This is one of the reasons for the popularity of Allproof’s offering of custom stainless steel shower trays. Allproof, an Auckland based family-owned manufacturing company is leading the way with a wide offering of tile over, exposed and commercial shower trays for a wide market application. All aspects of their NZ Manufacturing focusses on best environmental practice using solar power, rain water harvesting and manufacturing as much as possible with locally sourced recycled products.

The tile over shower tray is a game changer when it comes to modern bathroom design. It sits well in residential timber floor construction as well at high rise intensive properties where the shower may boundary other tenancies and properties which could be affected by a failure in the waterproofing system. Allproof have designed an engineered XPS base that will provide the required falls to meet NZBC E3 by having a base that provides the falls so the tiles are directly fixed to the stainless-steel tray. This removes the requirement for a screed or membrane in the high-risk area, with linings and waterproofing coming over the shower tray and terminating on the base. The trays are laser cut and CNC folded in house to specific design ensuring accuracy and efficiency in turnaround for one off projects.

Most Kiwis grew up in a house with an exposed stainless tray. This is a testament to the durability and simplicity of this design that these still exist and now are being specified for Kianga Ora projects, gyms and the seaside batch. These trays have a pressed fall that aids drainage to a point drain outlet and the tray is supported on a CNC cut Poly base for ease of installation. A floor waste gulley and a range of grate options finish the system with a no maintenance drain by removing any easy clean basket type waste which can be problematic, particularly in a public washroom. This system also aligns with Allproof’s fully tested passive fire range which is crucial when penetrating a fire cell between tenancies.

Design trends can be accommodated with Allproof tiled shower trays allowing a wide range of grate options in the tile over system, to being able to have an exposed tray with a channel drain or battened over for the nautical look. Call Allproof today to discuss your project and the advantages of a stainless steel shower tray in your next bathroom project and support New Zealand made.

Allproof Shower Trays:

When considering a shower area in a room, there are factors of the build that need to be considered. These considerations will affect the selection of the outlet, location of the channel drain and also if a shower tray under the tiles would be a prudent choice to guarantee the longevity of the install.

The main limitation on shower area design is the subfloor. Design and engineering factors relating to the joist selection or concrete slab depth will have an effect on the depth that can be taken out of the subfloor to allow for required falls towards the channel or outlet. As a rule of thumb, to achieve a 1:50 fall (NZBC E3 3.3.5) towards a shower channel you will allow 20mm for the channel and then 20mm/metre for falls. So, a one metre long shower will require a 40mm set down in the floor to allow level entry to be realised.

The goal of a flush entry into the shower area can sometimes be limited by these factors. If there is not sufficient capability to drop the floor in this area then there are other options to reach a level entry.

The location of the shower channel affects the length of fall required and therefore the depth. The channel can be moved to another wall to reduce the run to it, or even placed at the entry so that the build-up of the fall is against the wall and won’t have an impact on the interaction with flooring outside the shower area. Another option is a point drain in the middle of the shower area that will also reduce the fall or run length to the outlet. The aesthetic compromise is diagonal cross cuts to create a fall from four directions whereas a channel only requires a fall from one direction.

If the available depth is still not acceptable then the use of a hob, or step over, will allow the build-up to be on top of the floor or slab, completely removing any interference with the construction of the floor. Arguably a hob also contains the water better inside the cubicle, reducing splashing or tracking of water into the main bathroom area.

Often when there is a restriction in the sub floor, this will also affect the selection of the waste system. In the past the go-to has been the easy clean waste due to its squat design which is normally shallow enough to fit in a 140mm joist space. However, this selection can be problematic due to the restriction and maintenance required of the bucket in the waste. As time goes on, the end user has often found it easier to remove the bucket from the waste, removing the water lock and generating a bad smell. Passive fire rating of the easy clean wastes is very difficult too.

The floor waste gulley is the most up to date way to deal with the waste, it has excellent flow rates, accepts passive fire solutions well and is maintenance free. Modern mains pressure systems provide good flow to flush any debris in the trap to sewer system.

Another consideration is the subfloor may also be part of an inter tenancy, or be over living areas. The inclusion of a tile over stainless steel tray with threaded BSP fittings to glued PVC allows designers and installers the comfort of a durable enclosure with risks of leaks eliminated.

An early examination of the subfloor in the design phase will make final selections easier for the shower finishes, rather than having to go back and redesign structure to accept the shower solution that is desired. From there, the choice is easy for an Allproof Vision shower channel or Allproof custom tile over tray to the required specification.

Related Products

We have recently published the most considerable update to our passive fire testing literature to date. This update includes the expansion of our scope in fire testing into electrical penetrations as well as a comprehensive assessment of composite flooring. This advancement in Allproof’s tested installations increases the capability of its industry leading NZ made passive fire protection products.

The most noticeable evolution from the latest PFP literature update is the creation of an electrical testing document. This document solely focuses on a range of electrical and A/C mixed service penetrations. Tested solutions include paircoil, data cable bundles, optic fibre, TPS cables along with other common electrical services that require fire rating. The Allproof flush box intumescent pad (FBINT) has also been included within this document giving a clear overview of all fire rated electrical services. This development means that installers and engineers can now use the same supplier and product across a wider range of services while benefiting from Allproofs New Zealand made advanced intumescent technology. This refines the selection of passive fire products and aids the ordering and installation process whilst supporting local business.

Since its arrival in the market, composite floor systems had proven challenging to fire rate. Allproof lead the market and developed the Drop-In Fire Collar (DIFC) that overcomes installation challenges associated with the undulating profile on the underside of the floor slab and varying depths of concrete cover. This 100% New Zealand made product changed the industry, however as these flooring systems have advanced new profiles and depths have been released. There is a broad range of composite tray profiles that use different topping thickness depending on the span and structural engineering. Along with the different types of plumbing services, pipe material and dimensions it has been a challenge to achieve testing in each possible scenario. Allproof has now added an assessment to their literature allowing the application of DIFC’s on composite floor profile changes of 60, 80 and 210mm, the DIFC’s FRL is equal to that of the composite floor tray up to 120 minutes.

Allproof’s passive fire range is also BRANZ appraised. This provides confidence that the range has been rigorously examined by BRANZ, a trusted independent organisation. As part of this process, Branz methodically reviews Allproof’s test reports verifying the results and audits the technical manual to ensure compliance and technical accuracy. To provide additional assurance, Allproof’s quality system and manufacturing process are also evaluated to ensure ongoing product quality. The resulting BRANZ appraisal [No.1088] provides assurance to the passive fire industry that Allproof’s products provide outstanding performance and compliance.

Allproof manufactures and tests products with a clear objective in mind; to create systems that streamline specification and installation while achieving the highest result possible. This ultimately improves the cost by removing additional components or products and saving time. Allproof’s intumescent is known for its excellent performance, this means that Allproof don’t need to over-engineer their systems. Often a simple collar and a little sealant will provide ample protection. Allproof also publishes all their spec sheets, install information and test results on their website with no access restrictions. Allproof believes in removing barriers and making it as easy as possible for customers to research, select and install their products. There is a passive fire newsletter database that is optional; this provides notifications on new developments across this fast moving product range. Click here to sign up.

Passive Fire Products

Level threshold on the face of things sounds simple: a level entry where the external surface is the same height as the internal surface. However, when studying the New Zealand Building Code, specifically E2/AS1 External Moisture 7.4 Level Thresholds, it becomes apparent there are some complex details if the external surface is created with a concrete slab. In this scenario, a channel drain is required that complies to specific specifications. To illustrate this I have summarised some key details from E2/AS1 7.4.2.1 Concrete Slab:

A channel with a 150mm minimum depth and a 200mm minimum width,

• • 1:200 minimum fall to an outlet,
  • Outlets discharging to an E1 compliant drainage system,
  • Maximum 3.7 meter channel length,
  • Paving Falling away from Channel, 1:40 for first meter,
  • Paving drainage to meet requirements of NZBC Clause E1, and
  • Grating that is;
    • Supported independently of the building
    • Removable for maintenance and cleaning
    • Has a continuous 12mm gap from building line
    • Refer to figure 17b for a sectional detail.

There are many channel drain products on the market that offer solutions to the above clause. It is worth doing a little research on these products prior to specifying as some may have complex install methods and/or be non-customisable on site. Both of these factors can result in a poor install appearance, performance and/or increased labour costs and install time. Products will often come in 1m or 2m straight lengths with a fixed width grate, however, the building line rarely follows a straight line and can step in and out around joinery. Products that don’t provide the ability to adjust the grate width will result in an increased gap where the joinery steps back. This increased gap is unsightly and may not meet client approval (for example, a daycare centre).

Whilst in the past a three sided channel may have been accepted at a threshold situation, council is becoming more and more cautious about moisture transfer and the designed operation of the glazing suite. It isn’t possible to use a three sided channel for level threshold as the building side of the channel will interfere with the intended free drainage path to the compliant channel.

Joinery is designed to direct moisture away from the building, this will be impeded by closing off this drainage path, hence the requirement for the 12mm separation and L shaped channel required by code. Some suppliers may encourage the use of three sided channel products as an alternative solution, this can lead to unnecessary admin and design complexities with the risk of not being granted. When designing an alternative solution councils will require additional hydraulic performance calculations and structural details. It may be worth considering this extra effort when off-the-shelf solutions are available. Trying for an alternative solution may delay the consent process and extend construction timelines.

There are off-the-shelf systems that can be customised to suit each varying application. These can reduce onsite labour, and minimise design time with published details and compliance documentation. An example is Allproof Industries Perimeter Drain, an L shaped channel that can be installed directly against the foundation slab. The Perimeter Drain provides the required width with additional depth for screeding a fall inside the channel towards the outlets. This system is an off-the-shelf product that can easily be customised on site. The 1m long channels can be cut to desired lengths and angles as they follow the building slab and the NZ made system of adjustable brackets and grates can also be cut on site to follow the joinery line. The use of this system will allow you to maintain a clean, consistent and “continuous gap of 12mm minimum from door frame and wall cladding”. The grate and bracket system is secure, self supporting and bolted into the channel whilst being completely removable to allow channel servicing and maintenance as required by code. The Perimeter drains L shaped channel creates the boxing for a single concrete pour, grates can be immediately installed once the finished surface is cured reducing labour and overall contractor time on site. There is also the option for custom NZ fabricated stainless grates to follow the unique building line.

Some aesthetic features may require other systems that need to be cast into or fixed to the external slab. For instance, if a reduced grate width is desired on a high-end residential property, a Cantilever Bracket or Cast-in Cantilever Bracket will provide the ideal solution to suit various external slab finishes. A Cast-in Cantilever Bracket is ideal for an exterior concrete finish while a Cantilever Bracket provides an excellent system for tiles or pavers. This system also offers the option for a tile insert grate, minimising the impact of the threshold transition by removing the visible grate. These systems are made to measure providing a fully customised solution to facilitate your vision with no compromise on the finished appearance, performance and compliance.

Allproof level threshold systems are designed and made in New Zealand. With a national support network, the offering of onsite customisable systems and custom fabrication level threshold doesn’t need to be challenging. Allproof provides a dedicated nationwide specification support team to develop the perfect solution for your project from design to install.

Level Threshold Products

Co-written with Andrew Smith, Specifications Manager at Allproof Industries.

Resources: E2 External moisture, Building Performance Systems, MBIE

Drainage systems designed and tailored to provide hygienic solutions for facilities that care for New Zealand’s most vulnerable.

According to Stats NZ, building consents issued in the preceding 12 months to May 2021 for hospitals and nursing homes increased in value by 44.5% to $711 million (an increase of $219M NZD). Educational facilities increased by over 60%, an additional $561 million. All these facilities cater to the most vulnerable members of our society. Each facility most likely contains an area for the preparation and/or serving of food; the world health organisation states “unsafe food containing harmful bacteria, viruses, parasites or chemical substances can cause more than 200 different diseases — ranging from diarrhoea to cancers. Around the world, an estimated 600 million — almost 1 in 10 people — fall ill after eating contaminated food each year, resulting in 420,000 deaths.”

A kitchen or food preparation facility therefore must perform at the highest hygienic level possible to safeguard the health of the occupants using these buildings. The success of a commercial kitchen or food and beverage production facility is made or broken on its design. Drainage design is of special importance but is often an afterthought behind aesthetics and functionality. A good drainage system contributes to food safety and hygiene, conversely, insufficient drainage can result in food contamination.

When designing commercial kitchens, off-the-shelf drainage products may not provide the best solution for the very specific needs of each application. A better approach is to understand the installation environment and assembling tried-and-tested systems with the appropriate capabilities, designed into a customised, optimal layout. This will maximise performance and economy by not under or over-engineering while benefiting from systems with proven quality and reliability.

Commercial kitchens are spaces that are subject to regular occurrences of spillage of liquid used during cooking and cleaning, as well as grease, fat and food waste. Without an appropriate drainage system, wastewater can cause pipe blockages, and major disruptions to service. Kitchens must be designed so that any liquids present on the floor or discharged from equipment are quickly and safely removed.

In a commercial kitchen, drainage can impact major aspects of the operation with food safety among the highest concerns. Food can become contaminated if wastewater is not safely drained away during food preparation and when cleaning surfaces. Good drainage systems prevent bacteria from entering into the premises, and reduce the incidence of contaminated water pooling and stagnating.

Allproof manufactures commercial drainage systems from high grade stainless steel with a variety of designs that can be tailored to suit each application. Stainless steel makes an excellent hygienic material for kitchen and food processing facilities because it contains no pores, cracks or open spaces for bacteria, including odour to embed itself in, as it is a self-contained piece of material. Its great mechanical properties mean it’s also resistant to dents and surface defects ensuring the surface remains sealed for hygienic purposes. It is also easy to maintain/clean ensuring that bacteria doesn’t have an opportunity to grow or spread.

Drainage is an important factor to consider when designing a kitchen or food preparation facility, it can be difficult if not impossible to remediate work should the installed drainage system not be sufficient for the intended purpose. It is advisable you engage the assistance of a hydraulic engineer and Allproof — a specialised drainage supplier — at an early stage to get the right customised solution.

Recent updates to NZBC E3/AS1 (Amendment 7 Nov 2020-21) have refined various requirements for containment of water in the case of accidental overflow from a sanitary fixture. These requirements are applicable if the “accidental overflow could damage an adjoining household unit or other property” and the fixture does not have an integrated overflow with a flow rate greater than the inlet/tap (and minimum flow rate of 0.25 l/s).

In the case of creating a containment area with floor waste an “impervious floor covering” is required to be:

1. 1. 1. “Continuous and covered or joints sealed where they meet the wall, and
      2. Extend to the doorway and all walls of the room, or to at least 1.5m from all sanitary fixtures and sanitary appliances in open-plan rooms.”

The floor waste shall comply with NZBC Clause G13 however a graded floor is not essential in this situation.

A scenario for this may look like an open plan kitchen in a townhouse, the kitchen floor could be vinyl or tiled with the rest of the open planned living space carpeted. If the kitchen sink is unable to satisfy overflow requirements, the kitchen floor would need to be impermeable and to span at least 1.5 metres from the sink or follow details set out for junctions with walls. A floor waste would need to be situated within this area to enable the drainage of surface water should an accidental overflow occur.

A tiled floor will require a waterproof membrane applied to a leak control flange, a floor waste gully, spigot and grate will complete the system allowing the grate to finish flush with the tiled surface. In this situation a four-way riser junction could be utilised allowing other waste systems to integrate with the drain. In an apartment or multi-storey tenancy a compact junction and gully system could be utilised such as Allproof’s Boss Gully allowing the system to sit within the available floor/ceiling cavity.

Bathrooms with sinks that don’t fit overflow specifications also require a floor waste, this practice has been well used and it is very common to see a tile insert grate under a vanity in recent projects. The same compact Boss Gully junction could be used to connect the shower waste and sink outlets into one system. For showers with limited joist space of 150mm an Easy Clean Revolver could be utilised, this is ideal for residential projects that don’t require passive fire protection. However, if you are under no space constraints a traditional floor waste gully would be recommended as less maintenance is required.

Another area for consideration would be a laundry, E3/AS1 2.1.1 b) refers to appliances and fixtures, meaning even without a sink the laundry may need to comply to containment specifications.

It is advisable to locate the floor waste in an accessible location to ensure it is maintained and primed. If the floor waste isn’t connected to other drainage systems as suggested above, the water trap/seal could dry out allowing odours to escape into the room (unless a dry floor waste is used that discharges directly outside, this is applicable only for accidental overflows and must comply to G13 3.4.3). Also, any maintenance required would become difficult to conduct, ‘out of sight, out of mind’ would be an appropriate term. Allproof have a wide range of high performing floor waste systems that are visually discreet with custom finishes to provide these spaces with an aesthetic appeal while applying to code and protecting the property (and adjoining) from moisture damage.