BNR Treatment Plant

BNR Treatment Plant:

Drainage - Services - Roading

CB Civil were engaged as key subcontractor to McConnell Dowell HEB JV on the significant $105M WWTP BNR Upgrade design and build project in Auckland. CB Civil was responsible for and self-performed large-scale earthworks, large diameter pipe installation, roading work, and coordination of complicated utility services on the site.

The site was located close to the coastline of the Manukau Harbour, in a tidal environment, and controlling ground water and advanced planning was key to achieving good earthworks productivity.

Our scope of work for the project included:

• Installation of 3km of pipeline from 150Ø to 1400Ø using open trench methods
• 30,000m3 bulk earthworks
• Construction of 1km of road and associated works such as kerb and channels, footpaths and berms
• Services relocation
• Coordination with the master programme to ensure performance to time

As the site was within Watercare’s Mangere WWTP, the team were installing drainage within a network of critical services including process lines, fibre optic cables and underground HV lines. There was also the added complexity of being within private property boundaries, so the team were coming across unknown services as there were no accurate service location plans for the site.

CB Civil’s strong safety culture came into play with safe work methodologies for service identification and marking out service locations, as any interruption in service would have a significant effect on the wastewater treatment capacity for Auckland. This required significant coordination and planning around programme, and initiated a visual programme to manage the interfaces of different divisions and teams within the project.

Through close communication with the McConnell Dowell HEB JV and a flexible approach to incorporating change (e.g. unknown site services), we were able to overcome any obstacles that arose during the works.

All testing and quality assurance was completed in accordance with the ITPs developed to the JV’s management systems. We successfully delivered the project on budget with zero LTIs or MTIs, despite working within a high-hazard environment.