Overview
Designed for optimum workflow and efficiency, Real Steel Hautapu is a purpose-built steel plate manufacturing plant.
The building is constructed to house some of the largest and latest steel processing machinery in New Zealand, supporting both the expansion of the business and the centralisation of Real Steel's operations in Cambridge.
About the project
Delivered through an Early Contractor Involvement and design and build model, the project involved construction of a new facility on a greenfield site at Hautapu, Cambridge.
The main structure being 7,700 m², the project includes 4,000m² yard space, 1,750m² carpark and 750m² two-storey office space.
Featuring extensive foundations, precast concrete panels and structural steel construction, the building is tailored to accommodate heavy industrial machinery and specialised processing equipment, along with six gantry cranes.
Real Steel are industry-leading steel plate manufacturers and processors, and the new Hautapu facility was designed to support increased production capacity and operational efficiency for the business.
A key feature of the build was the construction of significant press foundations, requiring deep excavations of approximately three metres below ground level. These foundations incorporate suspended 3.5-tonne steel plates within the concrete structure to support high-load machinery and operational performance, alongside the coordination of specialist industrial services and heavy equipment requirements within the wider building design.
One of the standout innovations on this project was consenting the main structure while the fitout was still being finalised. The fitout involved significant foundations and press pits that were still in design while construction was already under way. To keep the build on track, the team designed and cast all pit walls as precast units offsite, then lifted them into place once ready. Real Steel fabricated the anchor plates in house, and Fosters' design team worked closely with them to ensure the plates and precast elements fitted together seamlessly, all while construction continued at pace.
This close collaboration between design and construction teams was central to delivering the project well ahead of schedule. The project was delivered in ten months; the client gaining access to the building eight weeks ahead of schedule.
2026
14,000m2
$14M
Client testimonial
Real Steel Managing Director Luke Mathieson said that Fosters was initially chosen as the lead contractor on the design and build project because of an “upfront approach” alongside a competitive offer.
“I also liked the fact that I was working with Fosters shareholders,” said Luke. “That gave me confidence.”
He notes that Fosters lived up to reputation – offering plenty of extra value throughout the duration of the build.
“Our factory required significant foundation works for our machinery, and Fosters engineered highly efficient solutions. In fact, they made several recommendations on construction methods to create better outcomes.”
Begun in late-June 2025, the completed building and yard was handed over to Real Steel in April 2026.
“Fosters’ site management, communication and delivery were top notch,” said Luke. “They delivered the project in nine months – from digging dirt. It was exactly on time and on budget, and the quality of the build is amazing.
“Fosters handling of this project, from start to finish, was impressive.”
“Fosters’ site management, communication and delivery were top notch. They delivered the project in nine months – from digging dirt. It was exactly on time and on budget, and the quality of the build is amazing.”
Luke Mathieson, Managing Director Real Steel
