Capability Statement
Prepared for Direct Pipe Projects
May 2026
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.
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
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
Westland Milk Products Ocean Outfall
Delivering an ocean outfall to improve the water quality of Hokitika River
We completed the first-ever ocean outfall on the rugged west coast of New Zealand’s South Island, successfully dealing with extreme weather, avoiding dolphins and penguins, and managing the challenging marine environment. This landmark project has significantly improved water quality in the Hokitika River.
Westland Cooperative Dairy Company Ltd appointed us to design and construct the 844 m long ocean outfall pipeline to stop the discharge of treated wastewater from their facility into the River.
Fast Facts
- 844 m outfall
- 1,219 mm OD 20 mm thick steel carrier pipe
- 844 m Direct Pipe® MTBM drive
- 23 m below the seabed - max depth during tunnelling
- Mass flow excavation used
- Re-use of TBM and pontoon from the Army Bay and Snells Algies projects
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.
