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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 them for more information about the projects.
The scope of works for all the packages included:
- 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
- Civil and mechanical work to refurbish the existing fuel network, valves and pipework, as well as 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 and re-construction of 2000m2 of concrete
- Lighting upgrades, line marking and new asphalt surfaces
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
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.
The Challenge:
The main challenge was maintaining the fuel supply during the upgrade and ensuring it was kept clean throughout the handling and storage process. Containment testing failure was a key risk and mitigating this allowed the fuel to be recycled back into the system. While the new pipework was connected, MCD kept all services live and fully operational as they are critical in the AIAL daily operations.
The Solution:
- The shuts were programmed in two parts as increased detail and micro-planning were required for ‘the shutdown’ itself.
- Shutdowns are planned to the minute as part of that micro-planning, this allows us to accurately track in detail the progress of the shut as works progress.
MCD programmed each fuel shutdown into two parts the setup and prep work, then the shutdown and re-establishment. It was split into two parts as increased detail and micro-planning were required for the shutdown itself.
The shutdown was timed to the minute as part of that micro-planning. This allowed the team to accurately track the progress of the shut as the works progressed. Detailed planning began six months in advance to ensure all contingencies were covered.
The plans were also reviewed in collaborative workshops with the client. Various scenarios and plans to manage each were worked through to ensure all contingencies were addressed. We also followed each shutdown with a ‘lessons learned’ session to ensure the process was completed without fault and refined each time.
The Key to Success:
Extensive forward planning, maintaining high-quality standards and making sure the airport’s strict health and safety rules were followed were key to successful construction.
The project’s success was largely due to a high-performing team who were focused on delivering value and carrying top-quality work to improve Auckland’s International Airport. Commitment to quality, coupled with cooperation and robust health and safety systems resulted in a high-quality project that was delivered with minimal disruption for the client.
The TDP fuel line enabling works began in September 2019 and were completed in August 2020.
