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7.2.2 Building construction
The building element of this project is the key to successful implementation of the concept abattoir operation.
The building must be an envelope or shell that will provide the environment for the operational and hygienic process to occur on a day by day basis. It must be
cleanable, durable and able to be repaired to maintain that condition. Metal corrosion inhibits repair and cleaning processes. Paint in whatever form is
an unattractive option, and hot dip galvanised items have a limited life. All metal elements in the process area should be stainless steel including nuts and bolts,
pipes, electrical services, drainage and building door frames, etc. Concrete must be of a quality that allows continuous cycles of washing, drying and
cleaning as well as an aggressive atmosphere of blood, fat, detergents and continual moisture.
The building must be designed to have natural ventilation with a roof pitched to a central ridge vent lantern roof and adequate air entry below eave level to create
airflow refer drg. 13. Walls to pedestrian door height need to have a smooth, impervious finish which inhibits mechanical damage and facilitates cleaning and
possible repair. The basic structure of the building will typically be a steel frame that will span the
process areas and free standing interior walls. The plant should be built around the drainage system which must handle the partial walls.
The simplest form of construction is possibly concrete blockwork installed to a local construction code. This will usually require reinforced concrete infill columns and
ring beams to meet construction code requirements. External walls need no treatment, however, internal walls need to be sealed to avoid moisture build-up and
to allow cleaning. Paint finishes have proved inadequate. Glass fibre reinforced GRP wall coatings have been very effective on block work
and do tie the blocks together whilst providing a cleanable waterproof surface that is able to be repaired. Although components are readily available, skilled
installation would be required. These trades are usually associated with truck body or boat building industries. In Australia and New Zealand, such coatings are sold
under the name
“FibreClean”. The more traditional solution is hard, acid resistant, industrial tiles BuchtalMetz
attached to block work with a waterproof swimming pool grade adhesive and grouted with an epoxy grout to ensure a long life and impervious surface. All
products must be non toxic and repairable. Any lost grout must be able to be overcoated.
Jointing at the interface of tiles to other finishes requires an agreed and achievable detail. Joints between tiles and fixed frames such as doorways need to be
completed with a selected polysulphide sealant to avoid water ingress as excess moisture equates to growth of contamination materials. Details of appropriate tile
attachments and joint interfaces have been provided in Drg. 16.
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Condensation of any sort accumulating on structures must be avoided to prevent bacterial growth. This is typically due to insufficient air flow.
All wall to floor joints must be finished with a coved detail to assist cleaning and maintenance of a water impervious joint at that line. Typical examples have been
provided and apply to all wall to floor joints in the building refer drg. 16. Wall to wall joints also require a cove treatment to manage cracking or movement, and aid
cleanability. Similarly and where applicable, coved wall to ceiling joints are required. This is particularly important with flat ceilings of insulated panel
construction. Alternative wall finishes may be provided using concrete precast panels, where
alignment, support and joint details are similar to a tiled finish. Panels are usually supported on the floor line and supported between steel building frame columns. A
typical detail is provided refer drg. 11. Panels manufactured with attention to detail would require no special surface treatment for application to a food
processing facility.
A further alternative is a stainless steel clad plank similar to a precast panel but made in smaller widths and supported by a header steel girt.
This allows ‘on-site’ construction by filling preformed stainless steel trays with fibre reinforced cement.
The stainless steel tray provides a clean and durable working surface and can be made from stainless steel rolled material similar to roof sheeting.
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7.2.3 Drainage
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