The Forge – Te Toki
About the Project
The Forge – Te Toki is an advanced maintenance and repair facility purpose-built for NZDF's next generation of defence engineering. Featuring high-capacity gantry cranes, precision-engineered floor slabs, and secure fabrication zones, the facility enables rapid prototyping, and complex repairs in a single, resilient building.
Delivered on an active defence site with strict security protocols, the project required careful coordination of heavy industrial systems, specialist trades, and operational continuity—all while meeting defence-level security and performance standards.
NZDF
Client
November 2025
Completed
Burnham
Location
The Forge – Te Toki consolidates advanced repair, assembly, and secure operations into a single, future-ready facility. The building includes large-span workshop areas, high-capacity gantry crane infrastructure, specialised fabrication zones, secure equipment handling rooms, and integrated office and collaboration spaces.
The facility's layout ensures efficient material flow and operational separation where required. Its structural grid, services framework, and internal planning were all designed to accommodate evolving technologies, allowing the space to scale and adapt as operational demands change.
Working within a high-security industrial environment required a tailored approach to site management, logistics, and workforce coordination. Leighs implemented robust security protocols, controlled access zones, and strict delivery sequencing to meet operational requirements without disrupting ongoing campus activities.
Collaboration with the client and security teams ensured full alignment on risk, compliance, and safety throughout construction. Given the sensitivity of work carried out within the completed facility, particular attention was given to maintaining confidentiality and ensuring the building's design, construction, and service installations met strict security and reliability standards.
The project demanded high-performance industrial infrastructure with integrated specialist systems. Significant engineering coordination was needed for high-load slab areas, vibration-resistant foundations, and overhead crane infrastructure capable of supporting precision fabrication work.
Heavy mechanical and electrical systems were designed to provide redundancy and support continuous operations. Advanced environmental controls were incorporated to support sensitive repair and fabrication activities. The project also involved integrating bespoke, complex systems from international suppliers to meet specific defence performance and reliability requirements.
The Forge – Te Toki provides a strong platform for expanding defence manufacturing capability in New Zealand. With its adaptable layout, engineered robustness, and secure operating framework, the facility supports innovation, operational efficiency, and long-term asset performance.
It enables faster delivery of complex work programmes and ensures the organisation can respond quickly to new requirements or emerging technologies. High-performing materials, a flexible structural grid, and future-proofed service routes support long-term asset performance.
The project reflects Leighs' expertise in delivering high-specification industrial facilities where precision, security, and operational continuity are essential.
The completed facility stands as a key component of NZDF’s strategic infrastructure, supporting innovation, operational efficiency, and resilience for years to come.
