AIAL East Baggage Hall Demolition

Location: Ray Emery Drive, Māngere, Auckland
Duration: August 2022 – August 2023
Project Value: Over $1 million

Project Overview

Henderson Demolition was tasked with the comprehensive deconstruction and demolition of the East Baggage Hall at Auckland International Airport, alongside the removal of linking bridges. The project involved demolishing structures down to the concrete slab level, removing footings and foundations, grubbing out piles to a depth of 2 metres, and removing redundant services and fuel lines. Additionally, the site was track rolled to match the surrounding ground contours.

Key Site-Specific Risks and Mitigations

1. Foreign Object Debris (FOD)
Given the proximity of the demolition site to active airplanes—less than 20 metres away—managing FOD was a critical concern. Strict controls were implemented to prevent debris from interfering with airfield operations. To mitigate this risk, Henderson Demolition kept the building structure intact during internal demolition, with scrim and fencing placed around airside baggage door openings to contain debris. The team also ensured that all material was removed directly into hooker bins placed within the building.

2. Structural Collapse of Connected Walk Bridge
The demolition of a suspended walk bridge connected to an active portion of the airport posed significant risks. To prevent structural collapse, Hawkins Construction installed temporary propping to the underside of the walk bridge. This provided stability during the demolition process and allowed for the safe separation and removal of the bridge structure without compromising adjacent buildings.

3. Services Strike
The risk of striking critical services, which could potentially shut down airport operations or endanger personnel, was another major challenge. To address this, Hawkins Construction identified and rerouted both above and below-ground services before demolition began. This precaution ensured that no vital infrastructure was accidentally damaged during the works.

Unique Challenges

The project presented several unique challenges, including working in a space-restricted environment with multiple contractors on site and operating less than 20 metres from active airplanes. Hot works prohibitions, accelerated crane schedules, and the presence of polystyrene and plastic embedded in the concrete slabs added further complexity. Delays in the project start date required numerous methodology adjustments to ensure the project remained on schedule.

Methodology

To ensure safe and efficient completion of the works, Henderson Demolition employed the following methodologies:

• Internal Deconstruction: The building shell remained intact during internal demolition, serving as a barrier to control FOD. Internal auxiliary equipment and conveyors were removed, followed by the breaking of concrete plinths. Materials were placed directly into covered bins, and the site was regularly dampened with water to manage dust.

• Structural Demolition: After completing internal deconstruction, external cladding, roof purlins, and steel structures were carefully removed. Heavy steel was transported off-site progressively, and nib walls and concrete columns were demolished using excavators with hydraulic attachments.

• Walk Bridge Demolition: Hawkins installed propping to secure the connected walk bridge before the removal of its external cladding and suspended concrete floor. The steel structure was manually separated from the adjacent building, followed by the mechanical demolition of the concrete columns.

Risk Management

Throughout the project, Henderson Demolition adhered to stringent safety protocols, including dust control using water suppression and dust cannons, continuous monitoring for FOD risks, and careful sequencing of demolition tasks. The team also strictly followed COVID-19 safety measures, ensuring all staff were double vaccinated and operating under established health protocols.

The successful completion of the AIAL East Baggage Hall demolition demonstrated Henderson Demolition’s ability to manage high-risk projects in highly sensitive environments. The team’s focus on safety, precision, and collaboration with multiple contractors ensured the project was completed within the set timeframe, without any disruption to airport operations. This project highlights our commitment to delivering complex demolition projects while maintaining the highest standards of safety and operational excellence.