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4. Building Construction

• Scope
• 4.1 Outcome
• 4.2 General Principles
  • 4.2.1 Construction material approval
  • 4.2.2
  • 4.2.3
  • 4.2.4 Cleanability
    • 4.2.4.1
    • 4.2.4.2
    • 4.2.4.3
  • 4.2.5 Durability
    • 4.2.5.1
    • 4.2.5.2
    • 4.2.5.3
    • 4.2.5.4
    • 4.2.5.5
    • 4.2.5.6
  • 4.2.6 Corrosion resistance
  • 4.2.7 Inertness
  • 4.2.8 Thermal properties
  • 4.2.9 Colour
  • 4.2.10 Resistance to discoloration
  • 4.2.11 Ease of repair and maintenance
• 4.3 Floors
  • 4.3.2 Installation
  • 4.3.3 Grading
  • 4.3.4 Junctions
• 4.4 Interior Walls
• 4.5 Ceilings
• 4.6 Windows
  • 4.6.2 Window sills
  • 4.6.3 Glass
• 4.7 Doors
  • 4.7.2 Self-closing doors
  • 4.7.3 Plastic strips
    • 4.7.3.1
    • 4.7.3.2
    • 4.7.3.3
    • 4.7.3.4
  • 4.7.4 Air curtains
• 4.8 Stairs, Decks and Walkways
  • 4.8.1
• 4.9 Protrusions Within the Hygiene Envelope
  • 4.9.1
  • 4.9.2
• 4.10 Vermin Proofing
  • 4.10.1
  • 4.10.2

4. Building Construction

Scope

This section outlines the requirements for the construction of any food area and food support area in the following categories of premises:

AB, ME, PH, DSP, GIP, GD, PPH, APH, CKP, RSH.

Section 4.7.3: Plastic strips also applies to Section 7: Amenities and Section 13: Stores.

Section 4.10: Vermin Proofing also applies to Section 7: Amenities, Section 13: Stores and Section 16: Byproduct Facilities.

4.1 Outcome

Premises shall be constructed in accordance with good sanitary design principles, using materials that are suitable for the conditions of use, to facilitate the hygienic slaughter and dressing of animals and the processing, packing, storage and transport of food.

4.2 General Principles

4.2.1 Construction material approval

Construction materials complying with the requirements of this section can be used in premises licensed in terms of the Meat Act 1981 and approved premises. In addition, a current list of building materials that have been validated as meeting the requirements of this section and have been approved by MAF RA (M&S) for use in licensed and approved premises can be found in Manual 15: Approvals; "Building Materials and Equipment".

4.2.2	Interior finishes (walls, floors, ceilings, doors, windows and any other associated installation or fitting) shall be selected and installed on the basis of good sanitary design principles and fitness for purpose.
4.2.3	General principles of sanitary design for construction materials are described in the following Sections 4.2.4-4.2.11.

4.2.4 Cleanability

Materials shall be:

4.2.4.1	able to be adequately cleaned by normal procedures (for that area of the premises) without damage to the surface;
4.2.4.2	smooth and non-porous, and free from cracks, crevices, recesses, dead-ends and gaps, so as to eliminate areas where contaminants can collect;
4.2.4.3	readily accessible for inspection except where it can be shown that cleaning procedures eliminate the possibility of contamination.

4.2.5 Durability

Materials shall be:

4.2.5.1	resistant to chipping, flaking or delamination;
4.2.5.2	able to withstand exposure to extremes of moisture that may occur under normal operating conditions;
4.2.5.3	resistant to abrasion;
4.2.5.4	able to withstand machinery vibration;
4.2.5.5	able to withstand regular cleaning and sanitising programmes;
4.2.5.6	resistant to, or protected from, an impact of a magnitude likely to be encountered during normal conditions of use.

4.2.6 Corrosion resistance

Materials shall be corrosion-resistant under the prolonged influence of corrosive agents encountered during the normal conditions of use, including water, water vapour, food ingredients and chemicals.

4.2.7 Inertness

Materials used in exposed product areas shall be inert to the food and cleaning materials encountered during normal conditions of use.

4.2.8 Thermal properties

Materials shall be capable of maintaining their original properties when subjected to temperature extremes that may occur during normal conditions of use. The thermal movement of materials shall be consistent with fixings, jointing systems and backing materials.

4.2.9 Colour

Surface finishes shall be of a colour which does not disguise contaminants.

White or light coloured material has been found to be satisfactory.

4.2.10 Resistance to discoloration

Materials should not stain when splashed with food components handled in the premises, acids or alkaline solutions, or other chemicals normally found in the premises.

4.2.11 Ease of repair and maintenance

Materials shall remain fit for purpose following repair and maintenance.

Materials should be easy to maintain and repair without damage to surface areas or the integrity of the material. Manufacturers’ specifications should be adhered to.

4.3 Floors

4.3.1

Floors shall be constructed to be fit for purpose.

Commonly used acceptable materials are concrete, floor tiles, vinyl and synthetic materials. Concrete or mortar floors which incorporate an approved latex or synthetic resin finish have better than ordinary resistance to meat, fats and acids. As a safety precaution, excessively smooth floors should be avoided in areas subject to wet cleaning.

4.3.2 Installation

Floors shall be installed and maintained to eliminate all cracks, open joints, depressions or other low areas that would accumulate moisture or harbour contamination.

4.3.3 Grading

Floors subject to wet cleaning shall be adequately graded and drained so that liquids do not accumulate.

Floor falls of 1 in 50 have been found to be satisfactory in wet processing areas. Wash areas normally have a 1 in 25 fall.

4.3.4 Junctions

Floor-to-wall junctions shall be constructed to facilitate easy cleaning and, if subject to wet cleaning, shall be coved to provide a smooth junction.

Coving to a radius of 80 mm has been found to be satisfactory in wet cleaning areas.

4.4 Interior Walls

Interior walls shall be constructed to be fit for purpose.

4.5 Ceilings

Ceilings, including false ceilings, shall be constructed to be fit for purpose. Associated installations, equipment and fittings shall be designed and installed to facilitate effective cleaning.

4.6 Windows

4.6.1

Windows shall be constructed to be fit for purpose.

4.6.2 Window sills

Windows should be flush with the inside surface of the wall. However, if the sill has an inside ledge, this shall be sloped downwards at an angle to prevent the build-up of dust and to facilitate effective cleaning.

A window ledge angled to at least 45° has been found to be satisfactory.

4.6.3 Glass

Glass windows shall not be used where glass could contaminate product if the window broke.

The use of safety glass is a satisfactory alternative.

4.7 Doors

4.7.1

Door openings and passageways shall be designed and constructed to ensure that unprotected food does not come into contact with the door jambs or walls.

4.7.2 Self-closing doors

All doors opening from the exterior or byproduct areas directly to food areas or food support areas shall be, as far as practicable, self-closing. Alternatively, an ante room providing two doors between the room and the exterior or byproduct area would be an acceptable substitute for a self-closing door.

4.7.3 Plastic strips

4.7.3.1	Plastic strips used in doorways shall be installed with sufficient overlap to provide contiguous coverage.
4.7.3.2	Plastic strips may be used in doorways as the only door to food areas and food support areas provided they are fit for purpose and do not open directly to the exterior or to byproduct or other non-food areas.
4.7.3.3	Plastic strips may be used in doorways as the only door to amenities and stores provided they do not open directly to the exterior or to byproduct areas.
4.7.3.4	Plastic strips shall be installed so that they can be taken down regularly for cleaning.

4.7.4 Air curtains

Air curtains in doorways are not regarded as doors. Air curtains shall not be used in a way which will introduce contamination to unprotected food. Refer also to IS 2: Section 5.9.

4.8 Stairs, Decks and Walkways

4.8.1

Where stairs, decks, walkways or catch trays are located over exposed food or food contact surfaces, they shall be constructed of impervious material with solid treads and closed risers, and curbed to prevent contamination of food by splash or fallout.

 

Side curbs at least 150 mm high measured at the front edge of the treads have been found to be acceptable.

 

4.8.2	Where the process is fully enclosed and there is no danger of food being contaminated, open grid type stairs, decks and walkways may be used.
4.8.3	All stairs, decks and walkways shall be constructed to prevent the ponding of water and shall be sloped to drain points.

4.9 Protrusions Within the Hygiene Envelope

4.9.1	Where product lines, service lines, ducting and trunking pass through walls, ceilings or floors, they shall be flashed and sealed to eliminate crevices on both the interior and exterior surfaces, to prevent water seepage, harbourage and entry of vermin.
4.9.2	Associated installations, fittings and services that act as protrusions into a room or area shall be constructed to prevent accumulation of contaminants and shall facilitate effective cleaning at the frequency required for the function of the room or area.

4.10 Vermin Proofing

4.10.1

Premises shall be designed and constructed to minimise the entrance and harbourage of vermin.

Opening windows, doorways, drains and other openings that would admit vermin should be equipped with effective vermin exclusion devices.

4.10.2

The location of any vermin control device shall not jeopardise the safety of food.