We’re always on the lookout for safer ways of working and our team came up with some ripper solutions on the Warkworth to Snells Transfer Pipeline project in New Zealand.
To keep our workers safe deep underground in a 1.2 m diameter steel tunnel, we engineered a game-changing upgrade to our tunnel service vehicles (TSVs), and reimagined critical slurry pump components—setting new industry standards in the process.
Our custom TSV modifications transformed factory-standard equipment into life-saving assets. We replaced software-based emergency brakes with a mechanical airbag-drop braking system that physically grips the rails. We added accessible emergency stop cords, rebreathers, fire suppressants, and even bump bars with auto-shutoff triggers. These thoughtful upgrades weren’t just theoretical—they were stress-tested, operator-approved, and rolled out across our full fleet. Combined with new training protocols and ergonomic tweaks, our upgrades are now enhancing safety on multiple tunnelling projects across New Zealand.
Meanwhile, our engineers tackled another critical safety and productivity hurdle—slurry pump failures. Working hand-in-hand with tunnelling specialists and Herrenknecht, we trialled and refined new materials and mechanical seal designs that dramatically improved the durability of in-pipe pumps. The result? Inspection intervals have jumped from 400m to 1200m of tunnelling, virtually eliminating the need for underground maintenance and slashing safety risks and downtime.
By thinking beyond off-the-shelf solutions and relentlessly improving with each project, we not only protect our people but elevate safety and performance benchmarks for the entire trenchless tunnelling industry. These breakthroughs—now adopted by global manufacturer Herrenknecht—are testament to our team’s ingenuity and our culture of ‘Home without Harm’.
