DATE OF PROJECT 2025
LOCATION Auckland Airport
MAIN CONTRACTOR Hawkins
This project at Auckland Airport featured a substantial 3,000m² warm roof installation and was complex due to the massive insulation build-up, ranging from 700mm to 1400mm in height.
It required careful coordination within the airport environment, managing flight zone restrictions, wind conditions, and intensive health and safety requirements while delivering a critical path roofing system on a demanding programme.
Sansom secured this project based on previous experience with Hawkins in successfully delivering complex warm roof projects, our reputation in the market, and existing relationships with the project team.
We used 7-10 of our specialist team to deliver the warm roof installation. The scope included a straight fall design with extraordinary insulation depth and complex post detailing, requiring flood testing across all gutters, and EFVM ILD testing to all membrane areas, executed in four distinct stages.
Massive Insulation Build-Up: The unique scale of the insulation system created significant labour intensity and the sheer volume of materials required careful planning and installation sequencing. We implemented a staged approach, dividing the roof into four sections to manage the complexity and maintain quality control throughout.
Shrink Wrap Implementation: Learning from similar significant-sized projects, we convinced the client to implement comprehensive shrink wrap protection. The roof was divided into four sections, with each stage shrink-wrapped, completed, and then relocated to the next section. We installed timber battens at shrink wrap entrances with temporary sealing to prevent water ingress even during rain, allowing work to continue without risk and maintain the critical programme.
Material Storage and Crane Access: With materials stored one level below the working area, every pallet required crane lifting to the roof level. Airport operations – including flight schedules, wind conditions, and weather windows – affected crane access. We factored this into our planning and maintained open communication with Hawkins about programme impacts.
Plant Installation Coordination: The plant equipment and steel frames were ordered only after our warm roof installation was substantially complete, as the client understood the difficulty of working beneath installed equipment. We detailed around all base plates and posts, then the plant was brought in after membrane completion. This pre-planning avoided the challenging scenario of working in extremely confined spaces.
Temporary Protection Management: Following completion, two layers of temporary protection were installed by the main contractor. Despite this, some materials were inappropriately stored on the completed warm roof. We maintained vigilant monitoring and addressed issues promptly through collaborative discussions.
The architect remained highly proactive with constant site visits, ensuring quality standards and addressing any unknowns in the design or installation promptly. Their involvement helped maintain momentum throughout the project.
The warm roof membrane was successfully completed in 2025, meeting all programme requirements and quality standards. Flood testing validated the installation across all four stages. The project received outstanding feedback from both Hawkins and the architect.
“The Sansom team lead by Paul and Mel, have been doing excellent work at Auckland Airport WP1 project in a challenging and demanding environment. Their attention to detail in the planning and sub-contractor input has allowed the Hawkins team to collaboratively develop methodologies for warm roof installation, airfield waterproofing works, plant room waterproofing to complete the works successfully with excellent quality.
Health Safety for Sansom is paramount and there has been great buy in from the Sansom team to execute hot works in live environment. The onsite team led by Mel has developed an excellent positive culture toward health and safety and team wellbeing.
Excellent work team Sansom!”
– Quintus Slabber, Project Director
The project’s success on a critical path programme demonstrated Sansom’s capacity to scale resources effectively while maintaining quality under demanding conditions. Hawkins’ trust in our capabilities – requesting our early involvement – validated our reputation and the value we bring beyond just numbers.
We continue work at Auckland Airport on related packages, including membrane installation to gutters, extensive coating works through plant rooms, and tanking, with some work packages scheduled to continue for the next two years as part of the broader airport development.
