Specialist Steel for Extreme Environments

Blog

Specialist Steel for Extreme Environments

Blog/news

The Coolpak Rolleston development is not your typical storage warehouse. It is one of the most technically demanding projects CM-NZ has project managed.

From the outset, this project required expert design, careful coordination, and quality materials capable of performing in conditions far more extreme than most buildings in New Zealand will ever face.

About the Project

Coolpak is one of New Zealand’s leading providers of temperature-controlled logistics and cold storage services. building a new automated cold storage facility in Rolleston. Once complete, it will play a central role in supporting large-scale frozen food logistics across the region.

This new facility will feature seven levels of automated pallet racking and capacity for around 15,000 pallets. The main cold store will be approximately 120 metres long, 45 metres wide, and 20 metres high. It will operate in complete darkness and in a reduced-oxygen environment, removing the need for sprinkler systems and improving fire safety. In some areas, internal temperatures will remain at minus 25 degrees all year-round.

From the earliest design stages, it was clear that this project would require more than standard construction solutions. Nowhere was that more evident than in the selection of the steel.

Why Steel Was a Critical Design Decision

The cold storage facilities will place huge demand on the building structure. For example, internal temperatures would sit at minus 25 degrees, while summer temperatures outside can exceed 30 degrees. This creates a temperature difference of more than 55 degrees across the building envelope.

Under these conditions, standard structural steel is simply not enough. If the wrong grade is used, steel can become brittle and lose toughness, increasing the risk of cracking and failure under load.

For this project, the structure required steel that was rated for the -20 to -40 degree range. New Zealand and Australian standards were not suitable and required the higher European standards. Local manufactures couldn’t meet our technical and volume requirements meaning that offshore sourcing became a necessity rather than an option.

Why Chinese Steel Was the Right Choice

The Coolpak structure requires approximately 814 tonnes of steel. For many local fabricators, this represents more than a year’s production capacity.

To meet demand, CM-NZ partnered with Chinese manufacturer Jingong, who were able to manufacture the full package in around six weeks and ship it progressively to New Zealand.

Paul’s Visit to the Factory in China

CM-NZ Director Paul Belcher had the opportunity to travel to China and visit one of Jingong’s large manufacturing plants in Hangzhou.

Paul was impressed by the scale, organisation, and cleanliness of the factory. The site was highly structured and supported by mature systems and processes. It operated at a level well beyond anything available locally.

Designing for Efficiency and Long-Term Value

Working closely with our structural engineering partner, BG&E, the CM-NZ team explored how specialist steel could improve overall building performance.

This has a direct impact on the building’s operating efficiency. It reduces the amount of air that needs to be cooled, lowers refrigeration plant requirements, and cuts long-term energy use.

These design choices will deliver ongoing savings for Coolpak over the life of the facility.

Progress on Site and Delivery Programme

Today, the steel installation is progressing well. Large sections are assembled on the ground, bolted and welded, then lifted into position and fully braced.

Although high winds and weather conditions have caused occasional delays to the crane operations, overall progress remains strong. Around 65% of the steel has now been delivered and erected.

The project remains on track for completion in November 2026. CM-NZ is proud to be part of this development and looks forward to seeing it support Coolpak’s operations for many years to come.