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Mars Single Serve Plant Upgrade

  • Client: JC Butko for Mars Australia
  • Location: Wodonga, VIC

First Scaff was engaged by JC Butko to design and install scaffold access for the Mars Single Serve Plant Upgrade in Wodonga. The project required specialised scaffolding to provide access to a pipe bridge during installation of new pipework for the plant’s expansion works.

All scaffolds were installed within a live food manufacturing environment, requiring precise design, contamination control and timing to align with the client’s weekend shutdown schedules.

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Technical Scope

Scaffold Type

Hung access scaffold

Height

Multi-level internal access

Compliance

CM3-certified OH&S Management Plan; AS/NZS 1576, AS/NZS 4576, AS/NZS 4994 and AS 1657:2018 standards

Access Method

Suspended from overhead steel structure (no ground supports)

Application

Pipe bridge installation for plant upgrade

Site Type

Live food manufacturing facility (Wodonga)

Key Challenges / Constraints

Minimal clearances, contamination controls, weekend shutdown window

Environmental Control

Clean site procedures to meet food-grade standards

Project Environment

  • Tight tolerances: Scaffold installed with minimal clearances, fitting precisely within existing infrastructure and mechanical systems.
  • Live environment: All works conducted directly above operational production lines, requiring strict contamination controls and coordination with Mars’ hygiene and HSE protocols.
  • Suspended design: Scaffold was fully hung from overhead steel structures, with no ground supports, increasing complexity in both design and installation.
  • Time-critical delivery: All installation and dismantle activities occurred within limited weekend shutdown windows, demanding detailed planning and efficient execution.

Project Outcome

First Scaff successfully delivered a safe, stable and precisely engineered scaffold system that enabled JC Butko to complete pipework installation without disruption to Mars’ live production operations. The project showcased the team’s ability to work safely within high-risk, high-standard environments and reinforced First Scaff’s reputation for precision access solutions under tight scheduling constraints.

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