Company Profile
Contents About Us 4 Our Purpose 6 Our Approach 8 Our Service Offering 10 Our Water Solutions 12 Our Mechanical Division 28
From city-shaping new infrastructure to ambitious energy and resource projects in remote locations. Pukekohe Wastewater Treatment Plant Upgrade Auckland, New Zealand
About Us McConnell Dowell was founded over 60 years ago by two entrepreneurial New Zealanders who valued smart engineering and construction. That’s why we’re known as the Creative Construction company. Since that beginning, we’ve built thousands of quality assets and facilities for customers and communities across four continents. Our expertise has grown to be truly multi-disciplinary, spanning building, civil, electrical, fabrication, marine, mechanical, pipelines, rail, tunnel and underground construction. We are owned by Aveng Limited, an international infrastructure and resources company listed on the Johannesburg Stock Exchange. Working with us is a collaboration not a transaction, and we hold ourselves accountable for delivering what we promise. This, along with our focus on safety, quality, sustainability and the community, has earned us the trust and loyalty of our customers. We are a Purpose and Values driven organisation; delivering projects that connect, support and sustain communities, and living our values of Safety & Care, Honest & Integrity, Customer Focus, Performance Excellence and Working Together. Scan here to learn more about our values
McConnell Dowell is Creative Construction. We successfully deliver complex infrastructure with our customers and the community. 5
Providing a better life Our Purpose
Safety & Care Honesty & Integrity Customer Focus Working Together Performance Excellence Our Values
Mordialloc Freeway VIC, Australia Creative Construction at McConnell Dowell is the inspired engineering behind the complex infrastructure we deliver. It’s the technical problems and challenges solved behind the scenes, by people empowered to think creatively and work collaboratively to deliver more value for our customers and communities. It might not always be evident when you look at the end product, but it’s there inside every project. Our Approach Creative Construction As a modern engineering company we understand that construction today is as much about sustainability and community, as it is about concrete and steel. That’s why we focus on both smart engineering and care for people and the environment. Wynyard Edge Auckland, New Zealand Scan here to learn more about Creative Construction
We take a holistic approach to doing business, embracing environment, social and governance objectives aligned with our values and purpose of Providing a Better Life. Environment Social Governance Carbon & Our Environment Our Community & People Conduct & Compliance Environmental, Social & Governance Reducing carbon Acting on climate change Minimising waste and pollution Embracing the circular economy Keeping everyone safe Nurturing and developing our people Working with and for the community Embracing diversity and inclusion Being open, honest and transparent Managing risk Being compliant Delivering what we promise 9 Scan here to learn more about
We offer services across the complete project lifecycle to suit our customers’ objectives and preferred project delivery and asset management approach. Opportunity, Pre-feasibility & Feasibility Studies Conceptual Design Value Engineering Technical Solution Development Contract Administration Purchasing Expediting Material Management Logistics Preliminary & Detailed Engineering Construction Management Subcontractor Management Self-perform Commissioning Operations & Maintenance Operations Engineering, Support Sustaining Capital Works Decommissioning Design optimisation & pre-construction planning Early collaboration & concept development Mobilisation & construction execution Completion, commissioning & ongoing care Our Service Offering
We use a wide range of Digital Engineering (DE) systems and technologies to improve service and performance across the project lifecycle, including: • Optimising designs and pre-construction decision-making and communication, through a single source of immersive and interactive data. • Aligning data models with procurement to improve information accuracy and supply-chain engagement and responsiveness. • Enhancing site decision-making, productivity, and reporting through data capture and analysis. • Improving operations and management through integrated sensors and enhanced Asset Information Models. Digital Engineering 11 Scan here to learn more about Digital Engineering
Our Water Solutions Our portfolio of services and solutions is broad, comprehensive and truly multidisciplined Māngere Wastewater Treatment Plant Auckland, New Zealand
Where We Operate 13
St Marys Bay Water Quality Improvement Project Auckland, New Zealand Māngere Wastewater Treatment Plant Auckland, New Zealand Government Infrastructure Customer (Australia) from MCD’s 2021 customer perceptions survey run by TKP Market Research If you want something specialist or technically demanding, you go to McConnell Dowell. 14
Our expertise covers drinking, waste and stormwater, with successful projects in capture, storage, treatment, distribution and disposal. We’ve designed and delivered some of the largest, most modern and complex wastewater treatment plants in New Zealand. In Australia we have designed and built some of the world’s largest and most efficient desalination plants. We have upgraded plants and pump stations to ensure water security and wastewater treatment for urban and rural communities. Partnering with suppliers for innovative treatment technologies. We are experts in large diameter pipeline construction and have delivered water pipelines up to 1800 mm (70”) in diameter. Our in-house specialist skills and plant enable execution of HDD, micro-tunnelling, Direct Pipe® and other complex trenchless solutions. Water & Wastewater Solutions Army Bay Ocean Outfall New Zealand Gisborne WWTP Upgrade – Stages 2 New Zealand St Marys Bay Ocean Outfall New Zealand Warkworth to Snells Pump Station & Transfer Pipeline New Zealand Barber Grove to Seaview WWTP Pipe Duplication New Zealand Māngere WWTP BNR Upgrade New Zealand Wellington Sludge Minimisation New Zealand Snells Algies WWTP & Ocean Outfall New Zealand Daldy Street Outfall New Zealand Pukekohe WWTP Upgrade New Zealand Ports of Auckland Outfall Upgrade New Zealand Projects include: Shotover WWTP Upgrade New Zealand Scan here to learn more about our Water & Wastewater Solutions
Watercare engaged McConnell Dowell and our design partner, McMillen Jacobs in March 2017 to install a new wastewater outfall, upgrade the existing pump station and build a new ultraviolet disinfection facility to increase the outfall capacity for its Army Bay Wastewater Treatment Plant at Shakespear Regional Park on the Whangaparāoa Peninsula. Shakespear Regional Park (SRP) is a pest-free conservation area, home to a variety of native wildlife including Kiwi, Little Blue Penguins and skinks, so choosing a construction methodology that minimised impacts on the area was important. Direct Pipe®, a methodology new to New Zealand, was ideal for this project as it enables small diameter pipelines to be installed over large distances more accurately than traditional trenchless tunnelling techniques. In delivering the project, McConnell Dowell achieved a world-record for the longest Direct Pipe® drive. Awards • 2019 Winner, CCNZ Hirepool Construction Excellence Awards • 2019 Winner, CCNZ Hynds Construction Awards (Auckland) • 2019 Winner Water New Zealand Pipeline and Civil Project Award • 2019 Winner International Society for Trenchless Technology New Project Award • 2019 ASTT Trenchless award fro New Technology: Machine, Tool, Material System or Technique Army Bay Outfall Auckland, New Zealand
McConnell Dowell was awarded by Wellington Water to deliver the Barber Grove to Seaview Wastewater Treatment Plant Pipe Duplication Project This project located in Wellington, New Zealand’s North Island, involves the installation of a new 1.2km long of one metre diameter pressurised wastewater pipeline from Barber Grove Pump Station to the Seaview Wastewater Treatment Plant. This new pipeline will service 90 percent of the residents in Hutt Valley, improve water quality to cater to the region’s growth and provide a robust solution in the event of earthquakes. • Re-engineering a live connection at the pump station has de-risked the construction works and protected the capacity of the existing network. This was achieved by collaboratively working with Wellington Water’s Operations Team. • Reduced impact on the 15,000 vehicles a day that use Randwick Road by switching to a trenchless solution • Programme savings achieved by changing the pipe material from concrete lined steel to PE • Risk of service strike and costs reduced by altering the alignment at the Seaview end. This will also provide better future connections. Barber Grove to Seaview WWTP Pipe Duplication Wellington, New Zealand
Just 12 months after the arrival of 510 metres of large diameter HDPE pipework from Thailand, the Daldy Street Outfall has been handed over to Auckland Council’s Healthy Waters. Wynyard Edge Alliance (WEA) consisting of McConnell Dowell, Downer, Beca, Tonkin & Taylor and Auckland Council carried out the work. Relocation of the existing outfall within Wynyard Basin was required to improve water quality within the basin after the breakwaters had been installed that provided tranquility for the forthcoming 36th Americas Cup. The new extension runs along the entire length of Wynyard Point, an area formed nearly 100 years ago by reclamation from the Waitemata Harbour. A basalt breakwater was formed around its perimeter and infilled with hydraulic fill and excavated arisings from the CBD development. Historically, the area had been used for heavy industry – gas works, fuel storage and was heavily contaminated. The design of the new pipeline determined the pipe to be 3 metres in diameter for its upstream half, expanding to 3.5 metres diameter for the downstream half. HDPE pipe, in 15 metre lengths was ordered from Uponor in Thailand and delivered onto Wynyard Wharf last September. Daldy Street Outfall Auckland, New Zealand
Constructing quality infrastructure on a constricted, sandy site In Gisborne, on the East Coast of New Zealand’s North Island McConnell Dowell is upgrading a wastewater plant to double its existing capacity to treat domestic effluent. The budget for the project was tight and so the team had a value engineering challenge to meet before construction could start. Working with the Gisborne District Council the team rescoped and redesigned the method reducing the cost by 30 per cent and future-proofing the plant so for further upgrades. The project has been carried out in two stages. First, the ground conditions needed to be stabilised and made suitable for construction and initial civil work completed in Stage One. In Stage Two currently underway the additional infrastructure to increase the processing capacity of the plant is being constructed and installed. Gisborne WWTP Upgrade – Stages 2 Gisborne, New Zealand
McConnell Dowell, in joint venture, delivered an additional Biological Nutrient Removal (BNR) facility for Watercare as part of its expansion of processing facilities at Māngere Resource Recovery Facility (MRRF). The scope of work involved the construction of two reactors, two clarifiers, a blower building, splitter boxes (including for future duplication of reactors in 10 years), secondary effluent (SEF) pipeline, sludge storage tanks and interconnecting SEF pipework to provide additional secondary treatment capacity of approximately 250,000 people. We successfully installed the twin SEF pipes using a pipejacking method, which required precision in execution due to a gas main, 33 kV cable, and the main fuel main from the Marsden Point Refinery to Auckland and the airport running along the alignment. Māngere WWTP BNR Upgrade Auckland, New Zealand
Delivering another state-of-the-art wastewater treatment plant upgrade to Auckland Watercare engaged McConnell Dowell (in joint venture) to upgrade the Pukekohe Wastewater Treatment Plant (WWTP) to support population growth in Franklin and improve the quality of the water discharge into the Waikato River. The upgrade of the Pukekohe WWTP was completed on time and within budget while keeping the existing WWTP fully functioning. This new WWTP is one of the most advanced plants of its kind in the country, and has more than double the capacity of the plant, enabling it to cater for up to 60,000 people. We converted the current reactors that clean the water into activated sludge reactors and constructed a third reactor, increasing the plant’s previous capacity. We also constructed a new Ultra-Violet disinfection system, which greatly improved the water quality being released into the Parker Lane stream and Waikato River. Pukekohe WWTP Upgrade Auckland, New Zealand
The St Marys Bay Area Water Quality Improvement Project was driven by Auckland Council’s Healthy Waters department and funded by the Water Quality Targeted Rate. The new pipeline will reduce wastewater overflows to St Marys Bay and Masefield Beach by 95 per cent. The high flows after rain events will be stored in the new larger capacity pipeline and pumped back into the sewer network when there is capacity. As well as reducing overflows, once complete the new marine outfall will discharge to an outfall far away from places where people swim. The most significant challenge the project faces is the location of the new stormwater pipeline under some of the oldest, narrowest and most densely populated streets in Auckland. The alignment runs beneath Point Erin and alongside the large Pohutakawa trees that grow on the cliff face from the park up to London Street and beneath a residential neighbourhood. The tunnelling itself did not create noise or vibration levels that disturbed the neighbours and keeping noise and vibration impacts from the piling to a minimum was important. Using a slurry TBM and locating the separation plant in Point Erin Park as far away from stakeholders as possible also meant the team also managed slurry lines up to 1100m long. Protecting the nearby marine life while dredging and installing the marine section of the pipeline was also important to the success of the project. St Marys Bay Ocean Outfall Auckland, New Zealand
McConnell Dowell awarded by Wellington City Council, the Wellington Sludge Minimisation Project McConnell Dowell and joint venture partner HEB have been awarded the Early Contractor Involvement (ECI) contract for the Wellington Sludge Minimisation Project by Wellington City Council. “We are excited to working on such an innovative project. The new facility will generate power from the waste treatment process, and we think this sustainable approach is the way of the future. We’re proud to be working with the Council to deliver this project and help make life better for ”Wellingtonians”, says Fraser Wyllie, Managing Director - New Zealand & Pacific at McConnell Dowell. This new facility will use Thermal Hydrolysis - heating and drying under pressure - to sterilise and reduce the volume of the sludge and make it more biodegradable. The biogas produced during will be captured and used to power the facility. The sustainability benefits of the design include minimising the amount of waste going to landfill, improving the quality of the material that does and substantially reducing carbon emissions. Construction work has commenced in mid-2023 and will be completed in 2026. Wellington Sludge Minimisation Wellington, New Zealand
The Ports of Auckland Outfall Upgrade Project, funded by the Auckland Unitary Plan, has been in Auckland Council’s pipeline for a number of years. And we are pleased to be constructing this important infrastructure for downtown Auckland. The proposed design is an inverted siphon (U-bend shaped pipe). The horizontal section is 2.5m in diameter and approximately 270m long, installed within bedrock to avoid risks associated with construction within reclaimed land. This horizontal section connects two shafts, the inlet shaft south of Quay Street and the outlet shaft in the Ports of Auckland site that connects to a marine outfall. Once complete, the new outfall will increase the stormwater network’s capacity and improve the resilience of downtown Auckland’s infrastructure. The improved network will also mitigate flood risk for properties in the downtown area, including Britomart train station. This stormwater outfall upgrade draws on McConnell Dowell’s extensive track record in marine outfall construction using trenchless methodologies. Ports of Auckland Outfall Upgrade Project Auckland, New Zealand
McConnell Dowell (MCD) was awarded the design and construct contract for the Warkworth to Snells Transfer Pipeline by Watercare in September 2022 The project is a component of the North-East Wastewater Servicing Scheme to convey 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. The scope of works includes construction of a five kilometre wastewater pipeline from the upgraded pump station in Lucy Moore Memorial Park transferring the wastewater to a new modern treatment plant at Snells Beach. The new wastewater transfer pipeline comprises the following: • a dual rising main approximately 1.4 km long from the Warkworth Pump Station to a new break chamber, and; • a single gravity sewer approximately 3.6 km long from the break chamber to the Snells Beach Wastewater Treatment Plant. Warkworth to Snells Pump Station & Transfer Pipeline Auckland, New Zealand
Outfall pipeline creates opportunity to set new tunnelling world record The Snells Algies wastewater pipe and outfall construction project was the first phase of a three-stage scheme to supply the Warkworth and Mahurangi East communities north of Auckland, New Zealand, with reliable wastewater services to cater for population growth. The scheme will improve water quality in the Mahurangi Harbour and deliver an upgraded wastewater system. McConnell Dowell was awarded the design and construct contract by Watercare in March 2019. It continues to build on McConnell Dowell’s extensive track record in the construction of major marine outfall pipelines in New Zealand. Our solution featured the use of the Direct Pipe® system to install a trenchless pipeline to minimise disruption to the farmland and local environment. The project involved the following elements of construction: • Constructing 4.3 kilometres of 630mm diameter HDPE pressure/gravity main by open trench methods following the public road alignment. • Installing 2.02 kilometres of 1.2 diameter steel pipe using the Herrenknecht Direct Pipe® system under private farmland out to a marine recovery trench 550 metres off the coast. • Laying a 230m marine outfall pipeline with 80m diffuser section on the seabed for disposal of highquality treated effluent into the Hauraki Channel. • An extension to the contract to install 530m of 710mm diameter HDPE pipe from the WWTP to connect to an existing pipe using horizontal directional drilling (HDD) across the Te Whau Creek. Snells Algies WWTP & Ocean Outfall Auckland, New Zealand
McConnell Dowell signed the official contract to complete Stage Three of the Shotover Wastewater Treatment Plant Upgrade in early July 2023 The project is the third and final stage of Queenstown Lakes District Council’s 20-year-long programme to transition the plant from the traditional Biological and Aerated Pond Treatment processes to the ‘Activated Sludge Treatment’ method. The new clarifier, reactor tank and other improvements will future-proof the plant and double its current capacity. The new process is more efficient than the traditional effluent treating effluent to a higher standard. Our approach to planning the project has been focused on finding simple, sustainable ways to upgrade the plant while minimising disruption to the existing plant and impacts on the environment. Shotover WWTP Upgrade Queenstown, New Zealand
Our Mechanical Division Experienced local team with a proven track record McConnell Dowell’s Mechanical Division has been operating in New Zealand for more than 30 years. The Division was born out of our focus on delivering complex projects requiring significant mechanical capability. We have delivered some of New Zealand’s most significant mechanical projects in recent years such as the SH1/16 Waterview Connection, the largest geothermal power station at Te Mihi, and the largest wastewater treatment plant upgrades at the Māngere WWTP and Pukekohe WWTP. In all cases, we have achieved industry leading results in safety performance, quality, and client satisfaction. We have a loyal, local and highly experienced workforce that is available to undertake this complex mechanical work. TBM assembly and disassembly McConnell Dowell has a strong track record in the delivery of tunnelling projects, as the only in-country contractor to have direct experience of assembling and dismantling large tunnel boring machines. In addition, we enjoy a strong relationship with Herrenknecht due to our other ongoing tunnelling projects across New Zealand. Temporary works We have an in-house Engineering Team that led the SH1/16 Waterview Connection temporary works. The team also undertakes the temporary works design for all our projects and provides support to the Mechanical Division for larger packages of work. The Mechanical Division also fabricated, assembled and installed all form work for the ‘cut and cover’ trench works on City Rail Link C2. Steel fabrication We have a wide range of steel fabrication services from structural steelwork, fuel, water, and wastewater tanks, conveyors, high pressure pipework, stainless steel, and custom lifting devices. In this brochure, we highlight our multidisciplinary capabilities and a small selection of case studies that demonstrates our experience delivering mechanical projects relevant to Project Electron. We would be pleased to provide further details on request. SH1/16 Waterview Connection New Zealand Hunua 4 Section 11 New Zealand Core services highlighted in this brochure: • Temporary Works • Equipment Refurbishment • Maintenance & Shut-down Support • Pipe Spooling Projects include: Scan here to learn more about our Mechanical Division
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Overview The Mechanical Division have built up an impressive track record based on winning repeat business and building long-term relationships. We take pride in our ability to supply products and labour to our clients within New Zealand and the Pacific. Our workforce has the full support of engineers, draftsmen, planners, as well as quality, safety and environmental advisors. We handle the tough jobs, without compromise. Our core services include on-site and off-site: • Steel Fabrication • Temporary Works • Maintenance and Shut-down Support • Equipment Refurbishment • Pipe Spooling We have the ability to provide a mobile welding service with a fully equipped custom built truck and qualified welding specialists. 30 Māngere Wastewater Treatment Plant Auckland, New Zealand
The Mechanical Division has a unique ability to apply their steel fabrication knowledge and skills to the temporary works fabrications required for construction projects. This unique ability comes from working closely with our construction projects and in-house temporary works design team to understand the needs of the project team. The Mechanical Division have performed both simple and complex temporary works design including: • Standard Scaffold • Formwork (less than 1.2 m to over 3 m high) • Hoarding and fencing (less l.2 m high to 3 m high) Old Māngere Bridge Client: Waka Kotahi NZ Transport Agency The Mechanical Division have preformed the temporary works on the old Māngere Bridge Replacement project. The temporary staging forms two arcs. A smaller arc on the north side and a larger arc from the south. These arcs overlap slightly. The temporary platforms have a combined length of 315 m which comprise 150 tonnes of head stock and bracing, 555 tonnes of steel for piles and vertical support and 370 tonnes of staging beams and horizontal support. City Rail Link Contract 2 (CRL C2) Client: City Rail Link Ltd CRL C2 involves the construction of 350 m of twin rail tunnels in an 18 m deep ‘cut and cover’ trench operation extending through Custom and Albert Streets in Auckland CBD. The Mechanical Division fabricated, assembled and installed all form work for the ‘cut and cover’ trench works. Once the concrete tunnels were completed the team disassembled all temporary steel work and assisted with the removal of steel struts. • Simple propping schemes • Falsework • Working platforms for cranes and piling rigs • Ground support schemes • Trenchless construction • Complex structural steelwork and precast concrete erection schemes • Cofferdams • Bridge erection schemes Temporary Works
Before After The Mechanical Division has the capability to refurbish equipment. Equipment refurbishment works can include the rebuilt of worn or corroded structures. We provide this service internally on McConnell Dowell’s plant including Tunnelling Boring Machines (TBM) and Microtunnelling Boring Machines (MTBM). The Mechanical Diversion refurbished the cutter head of Amiria our Hunua 4 Section 11 project MTBM. We repaired the cutter head after it came out of the ground, replacing cutter teeth and cutter wheels, along with rehardfacing the cutting surfaces. Hunua 4 MTBM break through Hunua 4 Section 11 - Amiria cutter head refurbishment completed by the Mechanical Division Equipment Refurbishment
Maintenance on the steel plant’s caster and run out table machinery We deliver complex multi-disciplined construction projects and provide maintenance support for mechanical, electrical and civil components including: • Manufacturing plant preventative maintenance and repairs • Co-generation power plant maintenance • Mobile plant preventative maintenance and repairs • Mechanical installation • Electrical installations, repair and servicing • Working at height • Confined spaces • Rigging and scaffolding solutions • Project scoping, planning, drafting and problem solving The Mechanical Division has a high quality proven track record of providing value-for-money crane and hoist maintenance and repairs. Our crane and hoist maintenance capabilities include: • Gearbox overhauls • Trunnion overhauls • Fall block rebuilds • Hoist re-roping • Chain hoist rebuilds • Electrical control upgrades and modifications The Mechanical Division also has the ability to supply on-demand and planned maintenance personnel. Team members are widely skilled and can provide fabrication and welding services on-site, as well as, mechanical fitting services including pipework, valve and pump replacements. Maintenance & Shut-down Support
McConnell Dowell has a long history and vast experience in running pipe spooling projects for a wide range of applications ranging from water, fire deluge, natural gas and Jet-A1. The site spooling work is complemented by the teams ability to pre-spool and coat piping, which is then transported and tied in on site. Waterview Tunnel Fire Deluge Terminal Development Plan Fuel Diversion - Fuel Network Compliance Stages 2 and 3 Client: Waka Kotahi NZ Transport Agency The Mechanical Division was awarded the contract to design, procure, fabricate and install the fire deluge works in the two 14 m diameter Waterview Tunnels. The Fire Deluge provides the means to fight potential fires in the tunnels once they are opened to traffic. The works include coordinating with external specialists to finalise an achievable design. The kilometres of piping was spooled up in the Mechanical Division’s fabrication workshop, coated and delivered to site for installation. Client: Auckland International Airport Limited The Mechanical Division, has re-routed a new 600 m section of the existing DN 450 (18”) buried steel pipeline fuel supply. This involved excavations, civil repairs, mechanical repairs, and reinstatement of various maintenance items on the airside Jet A1 fuel supply network. The new networks consist of 68 m steel fuel pipeline and the replacement of approximately 1,800 m2 of concrete apron. “The Airport fuel shutdown was commenced and completed on time with fuel returned at 5am this morning. All tasks were completed and signed off. Thanks to everyone who assisted.” - Colin Fromont, PMC TDP Fuel Diversion Senior Project Manager, Worley Pipe Spooling
Entrance to the MTBM Welding Project Hunua 4 Section 11 Hunua 4 is a 31 km long watermain running from Watercare’s reservoirs in Manukau to reservoirs in the Auckland CBD and has been designed to improve the capacity and resilience of Auckland’s water network. Using predominantly microtunnelling methods, we are constructing the new watermain using a micro tunnel boring machine (MTBM) to drive and install 2500 mm ID jacking pipes between six shafts, before lining the tunnel with a 1575 mm OD steel pipe. Once complete, two of the three pipe jacks will be the longest ever completed in New Zealand.
The Mechanical Division have been involved in designing the pipe installation method. They have pipe welders on-site to install the pipe which was spooled at the McConnell Dowell mechanical yard. The concrete pipe is lined with a steel pipe fitting which is welded to the inside. The Mechanical team have fabricated service brackets in the tunnel, which are used during the MTBM operation to hold all services inside the tunnel. The services brackets are specifically designed to keep services off the tunnel floor and are specially fabricated for every tunnel. They have also fabricated all the slurry pipes to transport slurry from the cutter head of the MTBM to the separation plant. Hunua 4 Section 11 (continued) Inside the tunnel showing the service brackets Lowering of the MTBM Amiria into a shaft
Project SH1/16 Waterview Connection Temporary Works Temporary structures included a platform to support a 650 tonne crane weighting 1,200 tonne that was positioned on top of a deep-piled excavation. The platform required deeper and longer piles than any of the permanent structures and included 400 multi-strand ground anchors. Our team built all the temporary works required for the crane to set-up and TBM (named Alice) set-up to construct the tunnels. Pictured below are steel temporary works.
Maintenance During the tunnelling process the Mechanical Division were involved with repairing and maintaining the running gear and seals while the machine was in motion. When the TBM got to the end of the first tunnel it was turned around before the second drive. At the turnaround, the TBM needed to be received from the tunnel onto a purpose-built cradle fabricated by the Mechanical Division, lowered 6 m, moved sideways by 12 m and turned 180 degrees. To do this, the TBM and back-up gantries had to be pulled apart. The biggest section turned in one piece was 2,500 tonne. The Mechanical Division have gained unique TBM experience for the turning of Alice the 10th largest TBM in the world and largest to have operated in New Zealand. The Mechanical Division performed the permanent works for four cross passages between the two tunnels, supplied and installed all form work and poured the concrete. The cross passages provide a safe exit point if an incident occurred. Alice the TBM was assembled in the Southern Approach Trench (SAT) and commenced boring in late October 2013. All 127 pieces were transported to site over a seven day period. The assembly and commissioning of the TBM took only three months, with three teams of 8 to 10 people working 24/7. A 65 tonne crane with a super heavy counterweight and a 550 tonne assist crane were used to assembled the TBM in the SAT. Assembling the TBM involved steel structures and the “Cans” Cutter Head, as illustrated below. Assembly SH1/16 Waterview Connection (continued)
On completion of the final drive, the TBM and its complex electrical components were dismantled, cleaned, and transported to the Port of Auckland, where it was shipped back to Herrenknecht. The site team, in conjunction with Herrenknecht, planned the transfer and removal of the TBM components from site using a special 600 tonne crane with a super heavy counterweight and a 550 tonne assist crane. The team removed oil and cleaned the sections as they were removed from the TBM / tunnel before cradling and packaging them for shipping. The TBM was dismantled into 127 pieces and placed into 100 containers. Disassembly
mcconnelldowell.com AUG2024
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