Prepared for Direct Pipe for Herrenknecht
May 2026
New Zealand's 11th outfall and our ninth Tunnel Boring Machine (TBM) ‘marine recovery’ were completed in late 2025, on time, on budget, with zero Lost Time Injuries (LTIs) and no stakeholder complaints - a 'hole in one' by all the project's key metrics.
Watercare's Clarks Beach Wastewater Treatment Plant, which is located within the Clarks Beach Golf Course in Auckland’s southwest, required a new 240 metre-long outfall.
For the first time in New Zealand, a Direct Pipe® micro-Tunnel Boring Machine (mTBM) and traditional pipe jacking methods were used to install Glass Reinforced Plastic (GRP) pipes in a single drive.
We utilised two different tunnelling systems, doubling down on innovation to install a new pipeline for the Queen Street Wastewater Diversion Project in Auckland, New Zealand. On the project, we managed the tunnelling scope for lead contractor Fulton Hogan and client Watercare to construct a 570-metre-long wastewater pipeline in the city centre under Queen Street.
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.
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.
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.
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.
Paul Cooper
Tunnels & Microtunnelling Lead
mobile: +64 21 242 1194
paul.cooper@mcdgroup.com LinkedIn