New Zealand’s first low carbon concrete jacking pipe is currently being installed in Albany as part of the Greville Road Stormwater Culvert Upgrade.
The project was identified as an emergency works project by Auckland Council’s Healthy Waters after the major Auckland floods in January 2023.
The existing Greville Road culvert consists of a 1950mm diameter corrugated steel pipe that conveys flow from an inlet located within a basin north of Greville Road.
The pipe stretches across a key arterial road (Greville Road), that connects to the Northern Motorway and Albany Expressway, and under Rosedale Landfill where it connects into a 1950mm concrete pipe. The culvert had failed at the inlet on the northern side of Greville Road.
Although the initial scope was to excavate and remove the collapsed culvert and replace it with a temporary shaft, a collaborative decision was made by Auckland Council and McConnell Dowell to design and construct the shaft to accommodate the permanent inlet at the same time.
The reason for this solution was to avoid any reworking later in the project, saving time in the construction program.
Healthy Waters, McConnell Dowell and Hynds Pipe Systems collaborated in a joint workshop on low carbon pipe options, jacking pipe requirements and procurement timelines.
Ultimately, it was decided to proceed with HyndsLC (Low Carbon) 2100mm diameter Hyforce® Butt Joint Concrete Jacking Pipes with a fixed stainless steel jacking band.
Karun Kumar, Tunnels Project Engineer for McConnell Dowell, said the early engagement with all parties ensured a smooth process and procurement was able to be fast tracked given the urgency of the project.
“We made the decision to incorporate low carbon concrete in the design of the pipes. It was important that the design of the jacking pipes allowed for the push of 1400 tonnes which also coincides with the maximum thrust force of our jacking frame,” Kumar said.
“We were able to deliver the lowest carbon option that met the project requirements for the material strength, program and cost. The 92 Hynds pipes will save approximately 62 tonnes of CO2 emissions which is a 16 per cent reduction in the standard pipe range.”
The first phase of the project to unblock the culvert began last March. At the beginning of this year, the project team mobilised the landfill site which accommodates the launch shaft for the Micro-Tunnel Boring Machine (mTBM).
The mTBM will install a 2100 mm ID stormwater pipeline in two tunnelling drives. The first will complete 220m in the first drive and 50 m in the second drive.
Hynds was able to deliver the HyndsLC pipes in the same timeframe and meeting the same engineering specifications as the standard offering, making life easy for the project team on-site.
By conforming to the same engineering specifications, the low carbon pipes have the same durability and design life as the standard options, meeting Healthy Waters’ long-term sustainability goals.
Sustainability commitment
Gerhard Van Rooyen, Project Manager for Healthy Waters, emphasised Auckland Council’s commitment to sustainability.
“We are actively seeking opportunities to incorporate low carbon products into our projects. By closely collaborating with our supply chain and project teams, we can ensure these outcomes are realised, allowing us to deliver sustainable stormwater infrastructure that enhances Auckland’s resilience,” Van Rooyen said.
Todd Randell, Trenchless and Pipelines Specialist for Hynds Pipe Systems, said being able to offer a bespoke solution was a game changer for the project.
“The jacking pipe used in this project is actually a lower carbon than we would normally produce. To meet the specifications, we substituted raw materials – concrete, cement and steel – and chose from our diverse supply chain the lowest carbon producers that we work with,” he said.
“Without compromising the quality or durability we have been able to adopt a sustainable outcome for the future.”
The HyndsLC range is manufactured at the company’s state-of-the-art facility at Pōkeno which embraces new technology and production processes, all underpinned by leading edge sustainability practices.
Jackson MacFarlane, Group Sustainability Manager at Hynds, said the company is committed to lowering the carbon footprint of all its product ranges as well as across operations nationally.
“We are expanding our low carbon concrete product range across the country and working with our customers to develop products that meet their sustainability needs.
“As part of this commitment, we are also engaging with our key supply partners to bring them on the journey and offer the best solutions possible,” he said.
“Delivering effective and sustainable infrastructure products is all part of our goal to improve the resilience of communities across New Zealand.”
This collaborative approach with the client, consultants and designers has already made a positive impact on the overall program and provided a cost-effective solution.
The project is expected to be completed by mid-2025.
For more information, visit hynds.co.nz
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