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Customer: Auckland International Airport Ltd Location: Auckland, New Zealand
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Fast Facts
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McConnell Dowell has been working with the airport team since January 2019 to maintain critical, complex assets such as the jet fuel pipelines, utility services and carrying out runway pavement renewals.
We have also been working on contracts to enable the planned Transport Hub, removing old buildings, and constructing new secure facilities, roading, pavement works and utilities.
The different scales and capabilities of the projects listed below, demonstrate just how flexible and responsive we are to the client’s needs.
Click on the boxes below to expand and hide them for more information about the projects.
The scope of work for all three stages included:
Civil works:
- Re-routing a new 600m section of the existing DN 450 (18”) buried steel fuel supply pipeline main to enable the construction of a new domestic jet terminal baggage handling building
- Maintenance for 11 existing valve pits
- New pipe work connecting the valve pits
- Maintenance of three fuel hydrant expansion loops
- Replacing eight fuel hydrant pits
- Removal of concrete and asphalt pavements
- Excavation and disposal of material
- Complex lift of the new fuel pipe
- Backfilling
- Lighting upgrades, line marking, and new concrete and asphalt surfaces
Mechanical Works:
- Internal Pipe Coating
- External Pipe Wrapping
- Pipe Spool Fabrication & Welding – Pipe Butt Welds
- Commissioning of Pipeline (Flushing, CCTV, Pressure Test, Nitrogen Preservation)
Located on a live airfield, making the work a complex logistical exercise while ensuring there was no disruption to the critical airport operations.
The complexities and challenges of safely working within a busy airport operational environment meant valuable lessons were learned that can be applied to future projects. Some key examples include:
- Efficient management of airside security processes for sub-contractors
- Upskilling staff to self-perform the ‘clear and bright tests’, minimising resourcing risk from external parties during shutdowns
- Designing and fabricating an innovative magnetic vacuum tool to remove swarf after hot tapping with First Gas Ltd
- Planning and completing complex fuel line ‘shutdowns’ without disrupting fuel flows
- Working to ‘clean build’ standards and achieving a 100% pass rate first time in tests
- Safely excavating around hundreds of existing services without a single strike
- Working with Auckland Airport to become one of the first sites in NZ to trial RAT testing during Covid-19
- Achieving a 100% pass rate on the weld tests, completing a complex lift, and dealing with an unusually wet winter’s impacts on the open trenching
The project scope includes the construction of:
- A new ‘walkway and canopy join the international and domestic terminals,
- An airside security checkpoint and an access road,
- A Transitional waste facility for processing aircraft solid wastes,
- A new Effluent waste facility for processing aircraft liquid wastes,
- Relocation of the Ministry for Primary Industries (MPI) livestock inspection facility and construction of a new single-span shed,
- Diversion of existing utilities and construction of new underground services
- Pavement, barriers, fencing, gates, footpaths and road furniture.
Project Awards:
CCNZ Hirepool Construction Excellence Awards 2023, the project was shortlisted and a finalist for Category 4 - Projects between $20m and $100m.
McConnell Dowell began the demolition of the existing parking areas and the construction of a new trucking route in February 2023.
The scope of work includes:
- Demolition of 4200m2 existing pavement, kerbs and channel, street furniture
- Construction of new underground services including 360m of stormwater, 114m of wastewater and 90m of watermain pipe works, including manholes, cesspits, sumps etc.
- Assessing and protecting the existing three waters services and decommissioning or diverting redundant services networks
- Installation of ducting and pits for misc. utilities – lighting, security
- Construction of 5300m2 flexible and rigid pavement new traffic barriers, islands, fencing, gates, footpaths and road furniture.
