Capability Statement

Capability Statement

Prepared for For Underground and Tunnelling Clients

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.

Tunnelling & Underground

Tunnelling & Underground

We've delivered over 160 km of tunnels, outfalls, underground stations, hydropower caverns, and underpasses; moving more than five million tonnes of earth and rock in the process.

Our creative construction approach has seen us successfully pioneer new and innovative technologies, and we are renowned for our capacity to provide fully integrated engineering and construction solutions. 

Wellington Water Construct Wellington, New Zealand

Barber Grove to Seaview Wastewater Treatment Plant Pipe Duplication

Future proofing and improving water quality

We used the optimum mix of tunnelling and trenched construction techniques to deliver the Barber Grove to Seaview Wastewater Treatment Plant Pipe Duplication Project for Wellington Water, causing the least impact possible.

The project involved the installation of a new 1.2 km long, 1 m diameter pressurised wastewater pipeline. It services 90% of the residents in Hutt Valley, improving water quality and catering to the region’s growth.

Fast Facts

  • 1.2 km long, 1 m dia. pressurised wastewater pipeline installed up 9 m deep
  • 55% of the alignment installed using micro-tunnelling
  • 4 No. shafts for access tunnel
Barber Grove to Seaview Wastewater Treatment Plant Pipe Duplication
Auckland Council Healthy Waters Construct Henderson, Auckland

Corban Reserve Stormwater Upgrade

Enhancing the Opanuku and Waitaro streams

With a carefully designed tunnelling methodology and construction program to minimise impacts, we successfully delivered the Corban Reserve Stormwater Upgrade in Auckland. The new facilities allow for future growth in the area, while also protecting the local ecology.

This was an environmentally and socially complex project, with homes, schools, native flora and fauna, and parklands intertwined with our worksites.

Fast Facts

  • 713 m stormwater pipeline
  • 2100 mm dia. micro tunnel boring machine (MTBM)
  • 3 No. shafts
  • 240 m long, 450 mm dia. low flow pipeline built by horizontal directional drilling
  • 3 No. footbridges
Corban Reserve Stormwater Upgrade
Auckland Council Healthy Waters Construct only Greville Road, Pinehill, Auckland

Greville Road Stormwater Culvert Upgrade

Mobilising quickly for a flood emergency

We had an experienced tunnelling team ready to go, so we took on emergency work for Auckland Council Healthy Waters after major Auckland floods.

The Corban Reserve Stormwater Upgrade for Healthy Waters was still underway at the time of the flooding. Our team had just finished the 270 m long tunnelling drive at that job, so it was good timing and an easy transfer of skills, experience, materials, and equipment from the worksite out west to Greville Road for the Stormwater Culvert Upgrade.

Fast Facts

  • A new 2100 mm ID stormwater pipeline
  • installed using a slurry micro-tunnel boring machine
  • in two tunnelling drives, 220 m and 50 m
  • the inlet shaft, the main shaft and a receiving pit
  • and decommissioning the existing culvert
Greville Road Stormwater Culvert Upgrade
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

Ports of Auckland Outfall Upgrade

Improving Auckland's stormwater network and overall infrastructure resilience

Ports of Auckland Outfall Upgrade
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 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
Sydney Water Construct Only Western Sydney

Thompsons Creek Stage 1 - South Project

New wastewater infrastructure to support western Sydney’s growth

We’re working with Sydney Water to deliver the Thompsons Creek Stage 1 - South project, part of a program of new wastewater infrastructure to support western Sydney’s rapid growth.

Fast Facts

  • 3.4 km long, 550-650 mm dia. wastewater gravity pipeline
  • Trenchless construction up to 12 m deep
  • 24 shaft excavations
  • 23 permanent maintenance hole structures
Thompsons Creek Stage 1 - South Project

Contacts

Paul Cooper

Paul Cooper

Tunnels & Microtunnelling Lead

mobile: +64 21 242 1194

LinkedIn
Daniel Patten

Daniel Patten

Engineering Manager

mobile: +64 21 737 614

LinkedIn
Charles Sweeney

Charles Sweeney

Engineering Manager

mobile: +64 22 315 0140

LinkedIn