A Tunnel Boring Machine (TBM) called ‘Blanche’ set a new world record when it reached 1496.48 metres - the longest ever stretch of pipe laid by the Direct Pipe® tunnelling methodology. The TBM is located at Watercare’s Army Bay Wastewater Treatment Plant, Whangaparaoa.

On the afternoon of Friday 13 July, the McConnell Dowell project team were monitoring progress with building excitement as the TBM approached 1495m, the previous record set in Texas in 2017. 

McConnell Dowell Project Manager Chris Powell explained that the record was attained “by achieving the right balance between pipe strength, thrust and the operation of the 34 tonne TBM to maximise its capabilities.”

“This is the first time the Direct Pipe® system has been used in New Zealand. As a consequence we weren’t constrained by traditional applications and were able to used the Direct Pipe system it in ways not explored before. We set some pretty high expectations, we learn’t much and achieved   a real global step-change in how this new tunnelling technology can be used.”

The unique benefits of Herrenknect’s Direct Pipe® system includes the ability to install long pipelines in a single drive, safely with speed, all of which reduce environmental impacts and make it ideal for working in small or sensitive spaces such as the Shakespear Regional Park.

Ben Hayes, Pipeline Expert and Area Sales Manager at Herrenknecht Asia congratulated McConnell Dowell on using the method to achieve a world record.

“The hands-on site team have been particularly impressive in their ability to adapt and overcome hurdles encountered - along with the support of Herrenknecht site personnel with their considerable trenchless technology expertise - to ensure an efficient and safe execution with a technology that was essentially new to them.”

Direct Pipe® is a Herrenknecht trademarked tunnel boring machine (TBM) that combines the best of microtunnelling and Horizontal Direct Drilling (HDD) into one machine. In one step, the borehole can be excavated and a prefabricated pipeline installed. The project team have also developed the system so it can achieve drive speeds of up to 30m a day, which makes it an extremely  efficient tunnelling option. Direct Pipe® is generally used in Europe to install pipelines under rivers and other large bodies of water.

The scope of Watercare’s $31 million project includes constructing 2.9km of new gravity-fed wastewater pipeline -  two kilometres of onshore pipeline installed using the trenchless Direct Pipe™ system, and 900m of marine outfall that will run along the seabed. The project also involves upgrading the existing ultraviolet disinfection facility, electrical controls and standby generators as well as building a new pump station.

Construction upgrading Watercare’s third largest wastewater treatment plant began in August 2017 and is scheduled for completion in early 2019.

The taxiway decks are designed to carry a fully loaded aircraft weighing a massive 700 tons (this is larger than an A380!!!) across live traffic lanes.

Each of the Taxiways, which are identical, consist of:

• 1,900 m3 of concrete (40 MPa)
• 375 tons of reinforcing
• 1720 m2 of fire board attached to the soffit of the decks
• 22,500 no screws to anchor the fire board to the soffit
• 280 tons of falsework

The thickness of the decks varied between 800mm and 1600m, and the reinforcing steel ranging from N24 to N40 at 150mm spacings.

Each individual pour commenced at 0130 on the day of the pour and took approximately 5 hours to complete. The decks were then completed by applying a particular broom texture to the surface of the deck which is specific to aircraft pavements.Thermal controls were also utilised to control cracking of the concrete due to the thickness of the decks and the heat generated during the heat of hydration reaction.

For those wanting more information on the construction of the Dryandra Underpass project, this recent story in Infrastructure Magazine is a compelling read.

Delivered by the McConnell Dowell-HEB JV, the team worked collaboratively with Watercare and CH2M Beca in a culture driven by a key concept of “Together Doing it Better”. This approach enabled enhancements to the programme, effective risk management, and alternate solutions, which maximised construction and long term operational safety.

Greg Wichman, McConnell Dowell’s Project Manager for Mangere BNR, on the key to our success: “Fundamentally, we listened to our customer and worked collaboratively with project partners in a culture based on mutual understanding and respect to produce an excellent outcome for Watercare. We are proud to have delivered a legacy project and world-class infrastructure for the people of Auckland.”

The Mangere BNR Upgrade project also won the Excellence in Building Risk Management Capability at the Risk New Zealand Awards in 2016.

To view the project video click here

The proposal also involves additional marine infrastructure to support the AC36 activities. This includes areas to accommodate vessels competing in associated challenger and regatta, support boats and superyachts associated with the syndicates and their supporters.

Auckland Council, the government and Emirates Team New Zealand agreed to Auckland as the host of America’s Cup in March.   

Resource consent for the proposed America's Cup infrastructure has been lodged and is currently going through the regulatory process. This includes a direct referral to the Environment Court with a decision expected from the Court in October 2018.

The Downer - McConnell Dowell team will be collaborating with the Project Designers Beca and Tonkin & Taylor and working closely with Auckland Council and MBIE under an Alliance model. The Alliance will be led by Project Director Ian Campbell, who has delivered outstanding outcomes on major civil and marine infrastructure projects in New Zealand, Asia, and the Pacific Islands. Most recently he was the Executive General Manager of the SCIRT Alliance which was responsible for rebuilding Christchurch’s earthquake-damaged horizontal infrastructure.

“We will be proud to deliver a legacy project and world-class infrastructure that delivers best value and benefit for ETNZ, Auckland, and our country,” says Ian Campbell

Downer and McConnell Dowell have worked collaboratively to deliver public realm infrastructure for many years, including Christchurch’s SH1 Russley Road Upgrade and Christchurch Southern Motorway Stage 2 and the City Rail Link 2 contract in Auckland. Both companies have vast New Zealand alliancing experience and have collectively delivered 19 Alliance projects in New Zealand.

Downer and McConnell Dowell will be represented on the Project Alliance Board by McConnell Dowell Managing Director Fraser Wyllie and Downer’s John Burden, Executive General Manager Infrastructure Projects.

The consortium will be working to a tight timeframe for a project of this scale - whilst the main AC36 races (Challenger and Cup series) will be held over January to March 2021 for Auckland, the race series starts in December 2020. Some of the syndicates want to be set up a year in advance, which means most of the infrastructure to host the team bases needs to be ready in late 2019.

Between them, Downer and McConnell Dowell have delivered a number of significant public infrastructure projects in Downtown Auckland, including Silo Park and the Wynyard Quarter Innovation Precinct, ASB Waterfront Theatre, Park Hyatt, Viaduct Events Centre, Te Wero Island, Gaunt and Halsey St Upgrades, Westhaven Promenade, the Holcim Depot, and the first two stages of City Rail Link.

About McConnell Dowell

Since 1961, McConnell Dowell’s building and infrastructure construction expertise has grown steadily. Our professional engineering and construction teams in Australia, New Zealand, South East Asia and the Middle East now deliver building, civil, electrical, fabrication, marine, mechanical, pipeline, rail, tunnel and underground construction projects for clients around the world.

With an extensive track record of wharves, jetties, ocean outfalls, breakwaters, causeways and submarine pipelines, McConnell Dowell brings over 50 years of award-winning marine design and construction experience to the America’s Cup infrastructure project. Previous projects include several ocean outfalls around New Zealand, twin 1,200 mm diameter pipelines across Botany Bay in Sydney, a 250 m continuous piled promenade deck and two circular cofferdams for the semi-submerged crystal pavilions as part of the $6.3B Marina Bay Sands Casino development, and the award winning Webb Dock Project at the Port of Melbourne.