Information Pack

Prepared for prepared for James Glastonbury

May 2026

Introduction General

Introduction General

Thank you for the opportunity to present this brief capability statement which details a cross-section of our skills and experience, and showcases a selection of our recent projects.

Port of Melbourne Design and Construct Melbourne, Victoria

Port Capacity Project - Webb Dock

Enhancing and expanding Australia's busiest container port

We received the Australian construction industry's highest accolade for this major wharf redevelopment within Melbourne's main port precinct.

This was a large and complex marine project delivered within Australia's busiest operational container port, and within very tight environmental controls to protect the rich marine life within the surrounding bay.

Fast Facts

  • 900 tubular steel piles up to 1500 mm diameter and 45 m long driven as single length piles.
  • 40,000 m³ of structural concrete.
  • 10,000 tonnes of reinforcing steel.
  • 40,000 m of sheet pile installation.
  • 210,000 tonnes of imported quarry product.
  • 15,000 m³ of rehabilitated concrete deck.
Port Capacity Project - Webb Dock
Port of Melbourne Early Contractor Involvement Melbourne, Victoria

Swanson Dock East Berths 1 & 2 Rehabilitation

Collaborative Approach, Safety Focus, and Minimising Disruptions in Port Rehabilitation Project

Working in collaboration with the Port of Melbourne, we successfully completed four contracts at Swanson Dock between 2017 and 2020.

After completing the award winning Port Capacity Project, we continued our partnership with Port of Melbourne with a series of smaller contracts to rehabilitate the iconic Swanson Dock - the heart of Australia's busiest container terminal.

Fast Facts

  • Multiple projects successfully completed without disrupting port operations
  • 412 piles driven
  • 570 tonnes of reinforcement used
  • 3,600 m2 of new wharf deck laid
Swanson Dock East Berths 1 & 2 Rehabilitation
Port of Melbourne Early Contractor Involvement, leading to lump sum contract Melbourne, Victoria

Swanson Dock West remediation

We recently completed Stage 1 of the Swanson Dock West Remediation, and are now delivering Stage 2. This is our sixth project for Port of Melbourne since 2017.

Swanson Dock West (SDW) is a critical International Container Terminal comprising of a 944 m wharf with three container-handling berths, which were constructed in several stages between the 1960s and 1980s. The existing wharf is of varying forms of construction and some sections are close to or beyond the typical design life of 30 years. As a result, major remediation was needed.

Fast Facts

  • A three-staged wharf remediation project
  • McConnell Dowell's sixth project for this customer since 2017
  • Works programmed around operational wharf
Swanson Dock West remediation
Watercare Services Ltd Design & Construct Warkworth, Auckland, New Zealand

Warkworth to Snells Transfer Pipeline

Enhancing wastewater management for a sustainable future

Drawing on our industry-leading trenchless construction experience, we delivered the Warkworth to Snells Transfer Pipeline for Watercare, continuing our strong relationship with them.

The project was part of Watercare's North-East Wastewater Servicing Scheme, which conveyed wastewater from Warkworth to Snells Beach. The scheme will cater for future growth and enable Watercare to decommission the existing Warkworth Wastewater Treatment Plant, which discharges into the Mahurangi River.

Fast Facts

  • 1.4 km long dual rising main
  • 3.6 km long single gravity sewer
  • 409 steel pipes, each 1219 mm in diameter and weighing 6.85 tonnes
  • Water NZ Project of the Year 2025
Warkworth to Snells Transfer Pipeline
Watercare Services Ltd Design & Construct Warkworth, Auckland

Warkworth Wastewater Pump Station

Improving Watercare's wastewater network

Using an innovative caisson (sunk shaft) construction method, we designed and delivered the Warkworth Pump Station, part of Watercare's broader scheme to improve the wastewater network from Warkworth to Snells Beach.

We built the new 247 litre per second wet-well / dry-well pump station adjacent to an existing pump station in Lucy Moore Memorial Park, implementing construction strategies and approaches to protect the sensitive park and river environment.

Fast Facts

  • 247 litres/sec pump station
  • Above and below-ground structures
  • Part of a broader wastewater scheme delivered by McConnell Dowell
Warkworth Wastewater Pump Station
Watercare Services Ltd Design and Construct Mahurangi East, Auckland

Snells Algies Wastewater Pipe & Outfall

Improving wastewater infrastructure while minimising disruption

Proposing a trenchless solution to minimise disruption, Watercare Services awarded us the Snells Algies wastewater pipe and outfall construction project. It resulted in new world record - a 2021 metre long Direct Pipe® drive delivered using a micro tunnel boring machine.

The project was the first phase of a three-phased scheme to improve water quality in the Mahurangi Harbour and cater for population growth in the Warkworth and Mahurangi East communities north of Auckland.

Fast Facts

  • 2021 m world record Direct Pipe® drive by MTBM
  • 4.3 km of 630 mm diameter HDPE pressure/gravity main installed in open trench
  • 2 km of 1.2 m diameter steel pipe installed using the Direct Pipe® system
  • 230 m outfall pipeline
  • 530 m of 710 mm diameter HDPE pipe using horizontal directional drilling (HDD)
  • 1220 mm OD steel pipe for the Direct Pipe®, 32 mm wall thickness
Snells Algies Wastewater Pipe & Outfall
Watercare Services Ltd Construct Only Auckland, New Zealand

Pukekohe Wastewater Treatment Plant Upgrade

Value-engineered, fast-tracked upgrade

We delivered this state-of-the-art wastewater treatment plant upgrade in Auckland, drawing on our learnings from past projects to value-engineer the design and fast-track the programme. We delivered the project on time and within budget, all while keeping the existing plant fully operational.

We were engaged (in joint venture) by Watercare to upgrade the Pukekohe Wastewater Treatment Plant to support population growth in Franklin, and improve the quality of the water discharged into the Waikato River.

Fast Facts

  • 3,950 m3 of concrete insitu
  • 447 tonnes of steel reinforcing
  • 404 precast concrete panels and beams
  • 4,120 m of underground pipework
  • 7,820 m of stainless-steel pipework above ground
  • 106,680 m of cabling including power, communication and instrument
Pukekohe Wastewater Treatment Plant Upgrade
Watercare Services Ltd type:Construct only Auckland, New Zealand

Māngere Biological Nutrient Removal Facility Upgrade

Expanding wastewater treatment capacity to meet growing demand

In joint venture, we delivered an additional Biological Nutrient Removal (BNR) facility for Watercare, streamlining the programme and providing alternate solutions that reduced the cost of this complex brownfield project. The facilty provides additional secondary treatment capacity for approximately 250,000 people.

The project, which was part of Watercare's expansion of their Māngere Resource Recovery Facility (MRRF) in Auckland, won a IPWEA 'Best Public Works Project' award.

Fast Facts

  • 200 staff
  • 830,000-man hours worked
  • 120,000 m3 earth moved
  • 15,500 m3 of concrete poured, or 750 concrete truckloads
  • 2,400 No. 150 mm steel piles each weighing 500 kg
  • 323 No. precast concrete panels
Māngere Biological Nutrient Removal Facility Upgrade
Watercare Services Ltd Ongoing contract to upgrade and refurbish plant Auckland, New Zealand

Māngere Wastewater Treatment Plant - Asset Renewals

Three to five year asset renewal programme

Our in-house mechanical team delivering these works has extensive experience in asset renewal, planned maintenance, and fabrication. They are using advanced techniques such as LiDAR scanning, 3D modeling, and the creation of digital shop drawings to reduce site work and save time compared with traditional methods.

Regularly recording site conditions using drone-captured photogrammetry data has also enabled better tracking and more accurate progress payment claims.

Fast Facts

  • Three-five year asset renewal programme
  • Refurbishment of major plant and equipment
  • Advance management and maintenance techniques deployed
Māngere Wastewater Treatment Plant - Asset Renewals
 Watercare Services Ltd Type: Design and Construct  Army Bay, Auckland, New Zealand

Army Bay Ocean Outfall

Record Breaking Direct Pipe Drive

Using state-of-the-art Direct Pipe® tunnelling technology for the first time in New Zealand helped us mitigate the significant risks we faced on Watercare's Army Bay Ocean Outfall project.

They engaged us to design and construct a new wastewater outfall, upgrade an existing pump station, and build a new ultraviolet disinfection facility to increase the outfall capacity of their Army Bay Wastewater Treatment Plant at Shakespear Regional Park.

Fast Facts

  • 3 km of gravity system replacement pipeline
  • 1.9 km of trenchless pipeline using the Direct Pipe® system
  • 1,100 mm OD HDPE liner pipe (installed within 1200mm OD steel casing)
  • 900 mm OD HDPE outfall pipeline
  • new UV treatment plant, including electrical controls and standby generator
  • 1929 m world record for the longest Direct Pipe® drive.
Army Bay Ocean Outfall
Water & Wastewater Solutions

Water & Wastewater Solutions

We understand what matters most to our water industry customers - uninterrupted supply, minimal disruption, safety, compliance, and positive community engagement.

We've been entrusted with the design and delivery of major metro desalination and water treatment plants, as well as the construction of dams and large-diameter pipeline and pump station networks.

We've delivered approximately $9 billion in new water assets over the last 15 years, including:


SA Water Construct only Eyre Peninsula, South Australia

Eyre Peninsula Marine Works

We're delivering the Eyre Peninsula Desalination Plant Marine Works for SA Water.

This project plays a key role in supporting a more reliable and climate independent water supply for the Eyre Peninsula, reducing reliance on the Uley South Basin and preparing the region for future growth.

Fast Facts

  • Micro-tunnelled intake and outfall pipelines
  • Minor dredging
  • Installation of intake tower and outfall diffuser
Eyre Peninsula Marine Works
Watercare Services Ltd Design & Construct Auckland, New Zealand

Hūnua 4 Section 11

Improving and expanding Auckland's water infrastructure

We designed and constructed the final section of Auckland's biggest water pipeline project, re-routing the pipeline to minimise impacts, and completing New Zealand's longest ever pipe-jack.

The 32 km long Hūnua 4 project connects Watercare’s reservoirs in Manukau to central city water storage, improving the capacity and the resilience of the city's water network.

Fast Facts

  • 3.5 km watermain tunnel, up to 30 m below ground
  • 1.5 m OD diameter steel liner and 2.5 m OD diameter concrete casing
  • 6 jacking and reception shafts
  • 80% trenchless construction to reduce disruption
  • 3 small sections trenched, only 50 to 75 m of trench open at a time
  • 55 tonne Herrenkenecht TBM used
Hūnua 4 Section 11
Watercare Services Ltd Design and Construct Glen Eden, Auckland, New Zealand

Glen Eden Storage Tank and Branch Sewer

Innovative tank design to reduce disruption

We upgraded Glen Eden's wastewater infrastructure, using innovative construction methods to reduce our footprint and lessen the impact on residents. The network upgrades have reduced the number of overflows that occur following prolonged heavy rains.

The design and construction of a 2 million-litre storage tank under an existing car park in Harold Moody Reserve using a caisson method was a creative solution to space constraints..We also used trenchless tunnelling methods to install the new pipelines, minimising disruption to residents living on Glendale Road.

Fast Facts

  • 2 million litre storage tank, 20 m deep, 13 m dia.
  • 800 m of 375 mm dia. pipework
  • 800 m of 600 mm dia. pipework
  • 10 m deep pipeline construction
Glen Eden Storage Tank and Branch Sewer
Watercare Services Ltd Design & Construct Auckland, New Zealand

Cosseys Dam Upgrade & Remedial Works

Ensuring the long-term integrity of Auckland's third largest dam

We developed some innovative design and construction solutions to upgrade 1950s-built Cosseys Dam, after Watercare detected significant deterioration. Located in the environmentally sensitive Hunua Ranges, the earth fill structure is Auckland's third largest dam and holds 14% of the city’s water storage.

The earthfill dam stands 49 m high and 170 m long at the crest. It has a 230 m long diversion tunnel linking to a valve tower and scour systems.

Fast Facts

  • 49 m high, zoned earthfill dam
  • 36 m deep excavation face
  • 300,000 m3 of fill replaced
  • 0 LTIs
Cosseys Dam Upgrade & Remedial Works
Watercare Services Ltd Design & Construct Auckland, New Zealand

Hobson Bay Tunnel Project

Sewage infrastructure upgrade to accommodate population growth

We introduced new tunnelling techniques and lining systems to New Zealand when we replaced the 90 year old sewage pipe crossing Hobson Bay on Auckland's waterfront. And we delivered it ahead of schedule.

The new tunnel increases sewerage capacity for projected population growth and prevents wastewater overflows into the bay and Waitemata Harbour basin, a popular swimming and boating spot.

Fast Facts

  • 3 km long, 3.8 m dia tunnel driven 30 m below the bay floor
  • Three shafts (23 m, 8 m & 10 m internal dia), approx. 35 m to 40 m deep
  • Mechanical and electrical works
  • Surface reticulation and connection works
  • Demolition of the existing sewer pipeline
  • 17 days ahead of schedule
Hobson Bay Tunnel Project
Victorian & NSW State Governments Design and Construct Echuca, Victoria/NSW border

Echuca Moama Bridge

Providing locals and visitors with safer and easier travels between Echuca and Moama

An innovative bridge solution saw us secure the design and delivery of this important new river crossing for the Victorian and NSW state governments.

Completed four months ahead of schedule, construction of this vital second crossing between Echuca and Moama included new bridges over the Murray and Campaspe rivers, and two new flood relief bridges.

Fast Facts

  • 600 m of elevated structures, including a 115 m in-situ balanced cantilever box girder for main river crossing
  • Eight span 300 m Campaspe Bridge structure completed in 10 months
  • 400,000 tonnes of fill successfully imported through busy border tourist town
  • 125 Super-Tees (each 35 m long) used for bridge approaches
  • 10,000 tonnes of asphalt laid
  • 13.7 ha of habitat improvement works
Echuca Moama Bridge
BCI Minerals Early Contractor Involvement Pilbara, Western Australia

Mardie Salt & Potash Marine Structures

Delivering new marine facilities to grow Australian exports

We designed and constructed the marine structures for BCI Minerals’ Mardie Salt & Potash Project in Western Australia, using our innovative canti-traveller system for speed and low impact delivery.

The 'Mardie' Project is a large-scale, solar evaporation operation on the Pilbara coast. Capacity of the completed facility is estimated to be 5.35 million tonnes per annum of high purity salt and 140,000 tonnes per annum of sulphate of potash, over an operating life of at least 60 years.

Fast Facts

  • 2.4 km long jetty with berthing and mooring dolphins
  • 200 steel piles, up to 30 metres long
  • 100 m of jetty completed every 10 days using innovative canti-traveller system
Mardie Salt & Potash Marine Structures

Contacts

James Glastonbury

James Glastonbury

Chief Engineering & Innovation Officer

LinkedIn