Judges comments on the Winners and Highly Commended entrants in the CCNZ Hirepool Construction Excellence Awards 2022 categories 1-6.

Celebrating construction excellence

– judges comments

We thank the awards judges: Categories 1, 2, 3 and 6, Dave Macdonald and Tim Ford Categories 4 and 5, Steve Hart, Alan Powell and John Bryant. Their comments on the winning entries are summarised below.

CATEGORY 1 WINNER

Abseil Access, Specularite Gully Bridge Build (Hugo Bridge)

PROJECTS WITH A VALUE OF UP TO $2M

Abseil Access was appointed from a design and build tender process and took just four months to develop the concept through to completing construction.

This 86-metre long suspension bridge forms part of the Lake Dunstan trail and spans a deep schist rock gully with specularite inclusions. The site is remote with access predominately by helicopter across the lake.

The project involved sourcing all the materials, prechecking the construction at a staging area remote from the final location before helicoptering in all the plant and the structure and installing it on site. The 11 metre timber towers were installed with temporary stays prior to the suspension cables being installed over them. The main suspension cables and wind cables were drilled, grout anchored into the schist rock and tested. The suspension cables had vertical support cables connected to them off site prior to being draped into position.

The materials used for the bridge blend into the environment through the timber being dark stained and steel components are Corten weathering steel.

The extremes of the local climate required the design to withstand large snow loads and wind loading. The site was challenging due to its remoteness, and the project required meticulous planning to minimise the helicopter operations and use, working at heights, exposure to the climate, providing a helicopter lifted site hut, and rock drilling and environmental controls around material entering the lake.

The social outcomes of this work as part of the Dunstan trail have enabled a whole new cycling industry to establish in the area with further support to the existing hospitality and accommodation businesses.

The cost of the bridge at $240,000 in the opinion of the judges is real value for money.

CATEGORY 1 HIGHLY COMMENDED Universal Underground, City Rail Link – Major Wastewater Diversion to Basque Park

PROJECTS WITH A VALUE OF UP TO $2M

Universal Underground subcontracted to the City Rail Link Alliance to install a drilled 330 metre wastewater high density polyethylene pipe diversion of a Watercare asset away from the twin rail tunnels.

The contractor's early involvement in the design resulted in a drilled curved alignment that eliminated a deep access shaft and a pump station. This provided an approximate $1m cost saving. This also enabled the route to be under public land which eliminated the need for a resource consent as the diversion was originally proposed to go under private property.

The area of the works was in an urban environment with inherent risks such as adjoining apartments, public access, traffic, noise, existing services, ground water and drilling fluid management and a very restricted working space.

A multi drill process including a pilot hole though to final hole were drilled in soil conditions that varied from alluvial to sandstone/siltstone rock and solid basalt.

Due to the pipe depth (up to 26 metres) this required the assistance of a specialist steering subcontractor based in Australia.

With a Covid border closure the pilot hole was steered remotely from Melbourne in real time. The pipe route coordinates were provided on completion and CCTV confirmed no reverse grades.

The pull though of the pipe in the confined working area required seven joints in the pipe when normally there would be two. Each joint installation and testing took around four hours prior to restarting pulling and increased the risk of pipe lock when restarting the pull.

A very successful use of the latest horizontal drilling technology and full credit to Universal Underground for the risk profile they managed in successfully installing an alternative that saved the client both time and money.

CATEGORY 1 HIGHLY COMMENDED Geovert, Waikato River Bridge to Peacocke Soil Nails

PROJECTS WITH A VALUE OF UP TO $2M

Geovert, as sub-contractors to HEB, developed a unique stabilising solution for the embankment adjacent to the abutments of a new major Waikato river crossing connecting to the existing SH 1 and enabling the rapidly developing major residential area in the south of Hamilton.

The work was carried out immediately adjacent to the Waikato River and for a height of around 35 metres above the river.

A custom designed platform was used to support a crawler rig for the 150 mm soil nail drilling. This enabled a safer work environment, a more cost effective and reduced timing for installing the soil nails and assisted greatly in protecting the Waikato River from pollution.

A special silt fence was constructed to provide protection at the river edge. This was regularly cleaned of debris that fell from the site.

A great team culture was developed and an excellent working relationship developed between HEB and Geovert. This has led to further opportunities for Geovert to work with HEB around the country.

CATEGORY 2 WINNER HEB Construction, Interislander Rail Ferry Terminal (RFT) 3 Linkspan Project

PROJECTS WITH A VALUE OF BETWEEN $5M AND $20M

The benefit of an established working relationship between KiwiRail and HEB was called on when critical wharf works were required to accommodate the UK Ferry Valentine brought in to replace the main Cook Strait Ferry Kaiarahi due to gear box failure.

The Valentine has a much wider and heavier stern door for loading traffic, requiring the ports hydraulic linkspan be upgraded otherwise the Valentine would have nowhere to berth upon its arrival in Wellington.

With no time to go to market, KiwiRail engaged the services of HEB on a design and build basis based on their track record of completing other works on site at Wellington and proven relationships with the client.

In addition to the construction of the new linkspan there was a requirement to maintain the existing Interislander ferry services for the port owner CentrePort making the project even more challenging.

With a non-negotiable programme deadline the team at HEB took on the challenge of planning, designing, and building the new structure to accommodate the arrival of the Valentine from the UK. Whilst the challenges continued daily, the project outcome was successfully delivered without compromising safety, quality, or environment testament to the team’s innovation and collaborative approach.

This was truly a great outcome for the client KiwiRail, Port owner CentrePort and the constructor HEB with the new linkspan operable as planned on 24 of December 2021 just in time for the busy summer holiday period.

CATEGORY 2 HIGHLY COMMENDED E Carson & Sons, Jervois Quay Emergency Stormwater Upgrade 2021

PROJECTS WITH A VALUE OF BETWEEN $5M AND $20M

The Jervois Quay Stormwater Upgrade Project was initiated due to the potential risk of a major road collapse on one of the main thoroughfares through the Wellington CBD.

Wellington Water engaged the services of E Carson & Sons to undertake this project under emergency works to construct a replacement 750 mm Reinforced Concrete stormwater main 2.5 metres deep in a tidal environment across Jervois Quay.

Careful planning and a detailed methodology was undertaken for this full lane closure, requiring the collaboration of a number of suppliers to achieve a successful outcome.

Coordination of several construction teams was necessary to complete the physical works with this project requiring a 24-hour commitment over a fourday working envelope.

Temporary traffic management played an integral part of the project with 17 separate sites required to manage the various closures 24/7.

The new pipe was installed in close proximity to a number of critical underground services including 33KVA & 11 KVA power cables, the main city link fibre optic cable as well as an 800mm diameter bulk water main feeding the east side of the city.

Despite all the challenges and risks the project was delivered ahead of time, constructed to a very high standard with both clients WWL & WCC very happy with the project outcome.

CATEGORY 2 HIGHLY COMMENDED Rock Control, SR10 Rockfall Canopy

PROJECTS WITH A VALUE OF BETWEEN $5M AND $20M

SR 10 is an exposed section of the Kaikoura coastline bounded by a 110m vertical rockface with State Highway 1 running directly below the site.

Rock Control were awarded the project to construct the client designed canopy structure and attenuator following an invitation to tender for this work, having previously advised on options for the site.

The physical works comprised of drilling of anchor works incorporating TECCO mesh that was installed in four locations. Most of this work was undertaken with operators suspended via harnesses and to make things even more challenging completed at night whilst the state highway was closed allowing the road to open during the day.

Another section of the works including a 30m x 6.5 m high anchored shotcrete wall incorporated to provide support in a location where milling work was undertaken to widen the road.

A 100m long self-cleaning canopy made up of 87 steel wire ropes and 14 support posts were then erected to protect the newly widened road below, this section required precise engineering detail to construct due to the variability of the rock wall geometry.

During the construction of the canopy, 2100 m2 of Geobrugg Rocco and Geobrugg TECCO mesh was installed on the canopy structure to provide a low maintenance rockfall protection solution.

Collaboration and Innovation contributed significantly to this successful one-of-a-kind project with the benefit of early contactor involvement de-risking the project for a very happy client, the North Canterbury Transport Infrastructure Recovery Alliance.

CATEGORY 3 WINNER Brian Perry Civil, Bluff Town Wharf Upgrade

PROJECTS WITH A VALUE OF BETWEEN $20M AND $100M

Bidding for this work first occurred in 2018 when all tenders were declined as they were well over the budget and the tender process cancelled.

This led Brian Perry Civil to look at alternatives that could better meet the client’s requirements. Their key to a solution was to use the staging works to become the permanent solution and this increased the load capacity for future use of the wharf than was originally proposed.

In 2019 South Port were made aware of Brian Perry Civil's alternative and entered into an early contractor involvement process to develop a buildable and cost effective solution. The new construction proposed impacted on tanker operational issues at the wharf for South Port and these were worked through to a satisfactory conclusion.

The design and construction process was very collaborative with all issues being openly discussed and resolved.

Risk management was developed jointly and risk apportioned to the party best able to manage these with targets set and agreed with benefits to both parties on achieving these.

On site work was managed in a completely transparent way with a very open approach in communications and resolving upcoming concerns well before they eventuated.

With the impact of the frequent tanker use of the wharf closing the construction site Brian Perry Civil on site staff were relocated to do other works for South Port.

A very strong team culture was developed for the works which had the benefit of a great cohesiveness and willingness to help each other in completing the works. The outcome from developing this very strong working relationship between South Port and Brian Perry Civil is a more robust solution than originally intended that provides South Port with an outcome that met their initial needs and also provided an investment that could support future opportunities.

It is worth noting that only a few months after completion South Port are having initial discussions with a third party that has the potential to utilise the completed work further. This option would not be available if the initial design in 2018 had been constructed. Very much a win/win outcome.

CATEGORY 3 HIGHLY COMMENDED McConnell Dowell Constructors, Westland Milk Products Ocean Outfall

PROJECTS WITH A VALUE OF BETWEEN $20M AND $100M

McConnell Dowell designed and constructed this ocean outfall 844 metres out into the sea which is a first on the West Coast of the South Island. The completion of the job meets the local objective of improving the quality of the Hokitika River.

The work involved the construction of a temporary 60 m long and 7.5 metre deep sheet piled launching trench with continuous dewatering, a micro tunneling boring machine (MTBM) drive at up to 12.5 m below sea level, installing the 1.2 m diameter HDPE pipe, recovering the MTBM from 4 m below sea level installing a diffuser beneath the sea bed and connected to the outfall pipe, connecting the pipe to the on shore works and removing all the temporary works.

The project had some very high risks including working in the extremes of the West Coast weather, access over the Greymouth bar for work at the pipe end, removal of the MTBM from below the sea bed, use of a mass flow excavator to access the MTBM and install the diffuser.

McConnell Dowell utilised its experience and knowledge of managing these risks from other outfall projects it has recently completed.

Environmental concerns for the area focused on the interface with the local flora and the presence of the Little Blue Penguin and Hectors Dolphin. These aspects were well planned for and managed during the works to minimise any negative impacts.

The team worked closely with the client and designers to complete the works under very challenging conditions and to meet the resource consent requirement timing for the new outfall to be operative.

CATEGORY 4 WINNER CB Civil, Peacocke Northern Transfer Mains Project

PROJECTS WITH A VALUE OF BETWEEN $20M AND $100M

Hamilton City Council's Peacocke Northern Transfer Mains Project is part of a wider programme of works to provide infrastructure for over 8,000 new homes over the next 30 years to accommodate expansion of Hamilton City.

The project provides two pressure mains of 630mm and 355mm diameter for about 5.5km along the busy Wairere Drive with associated tie-ins to existing operational infrastructure. Pipe depths vary up to 6m and include a mix of trenched and trenchless solutions, with traffic management, protection, relocation and replacement of existing underground and overhead services required.

The judges were most impressed by the collaboration and innovation shown by the contractor in initially providing a tender under budget for this lump sum contract and to also establish with the client an agreed set of project values, targets and objectives to define “what good looks like” for the project. Having done this, the contractor proposed and the client accepted, further value engineering proposals to bring the price down to a point where an additional $5M of work was able to be included within the original project budget while also providing better margin to the Contractor.

Other impressive achievements were: - 200,000 manhours worked without incident - Use of a cloud based business system providing current information to participants - Proposal and acceptance of recycling opportunities to use available site materials and cheaper alternatives to those specified - Adoption of Alliance type attitudes to achieve an exceptional outcome on a lump sum project - Completion of the project almost a year earlier than tendered, offering a significant administration benefit to the client - Client so impressed with the project outcome they engaged an external consultant to assess modification to procurement process and delivery to achieve similar results

The judges congratulate CB Civil and their client Hamilton City Council for winning the Category 4 Hirepool Construction Excellence Award by collaborating to achieve a project outcome ahead of time, below budget and without incident - a rare and almost unheard of outcome, in this current resource constrained environment.

CATEGORY 5 WINNER Joint Venture Downer NZ & Soletanche Bachy, City Rail Link Contract 1 Britomart

PROJECTS WITH A VALUE OF GREATER THAN $100 MILLION

The City Rail Link Contract 1 Britomart required the construction of two rail tunnels starting in the Britomart Station and extending under the old Central Post Office and adjacent public space. The project had significant construction challenges and equally significant risks. These included underpinning and temporarily supporting a 14,000 tonne heritage building; constructing 20m deep concrete walls with only 7m headroom whilst working around the temporary building supports and working in and around Auckland’s busiest commuter rail station.

The early contractor involvement contract form provided the Downer-Soletranche Bachy joint venture team the opportunity to work collaboratively with the client, City Rail Link and designers, Aurecon during the design development, which they took full advantage of. In addition, consultation was required with rail operators, heritage organisations, iwi and the public throughout the project duration. The judges were impressed with the attention to detail and planning of the temporary and permanent works construction methodologies. This included developing safe construction practises and realtime digital monitoring of building and ground movements. The use of a fully integrated 3D BIM model was critical in avoiding temporary / permanent works clashes and the successful installation of an extensive network of services. The one year spent in the planning phase produced outstanding results for the project.

Numerous heritage features inside the CPO buildings required removal or demolition during the construction works. The use of detailed point cloud scanning and photographic records lead to the successful restoration of the heritage building’s visual features.

Equally impressive was the completion of 2.5 million hours of work with zero harm, a feature seen at many of the projects visited this year by the judges, an outstanding trend for the construction industry.

The project also achieved excellent outcomes in sustainability and environmental.

The judges congratulate Downer NZ and Soletanche Bachy joint venture on the successful delivery of this highly complex project and winning the Category 5 Hirepool Construction Excellence Award.

CATEGORY 6 WINNER CORDE, Contract 19/43 District Road & Drainage Maintenance 2020 – 2023

MAINTENANCE & MANAGEMENT OF ASSETS

CORDE has held the Waimakariri Road Maintenance Contract for the past 27 years and has built up a local loyal team to service this contract consistently over this period.

The company values of CORDE based around family, trust and teamwork are evident and this is the way they manage and deliver their contract with Waimakariri District Council.

The use of modern systems coupled with field knowledge have allowed CORDE the opportunity to develop and maintain a sensible approach to asset management based on the 80:20 rule. Experience has shown that 20 per cent of the district's roads carry most of the vehicles with the other 80 per cent carrying less traffic. This helps determine the funding option where most of the allocation is directed towards the busier roads. Supplementing this asset strategy is the practical Deming model of “Plan, Do, Check, Act” that allows continuous improvement in everyday dealings and longterm planning. To ensure the network condition is maintained to the contract standard and specification rigorous audits are caried out, any non-conformances are recorded and closed out in accordance with the contract quality plan.

Training and development in CORDE is also a key to the ongoing relationship with Waimakariri District Council ensuring the staff working on their network are suitably skilled, CORDE has a policy of investing 2 per cent of its salary and wage spend on training.

Innovation also plays a key part to the successful delivery of the contract in particular the investment in information technology allowing council access real time data throughout the network. CORDE also has a fledgling programme to identify areas that it can work on to reduce its carbon footprint as part of its sustainability strategy.

Underpinning all the aspects associated with the successful delivery of this contract is the collaborative framework in which the contract is managed/ administered resulting in a win/win relationship for both the contractor CORDE and the client.

CATEGORY 6 HIGHLY COMMENDED SouthRoads, Southlnd Network Outcomes Contract

MAINTENANCE & MANAGEMENT OF ASSETS

SouthRoads is an Invercargill based family construction and contracting business contracted to Waka Kotahi NZ Transport Agency for the maintenance and management of the Southland State Highway NOC (Network Outcomes Contract).

Throughout New Zealand there are 21 NOC contracts delivering this service, SouthRoads are the only tier 2 company contracted to Waka Kotahi with the balance delivered by tier 1 contractors.

Since the award of this contract in 2016 SouthRoads have continued on a journey of continual improvement culminating in them being the number 1 NOC in the country achieving a perfect KRA score of 4 at the end of June 2021.

Contributing factors to this result include working in and embracing a very strong collaborative environment across all levels of the business where issues are worked through professionally.

The team is also challenged to continually improve their performance including the development and incorporation of innovation to place them ahead of the competition.

Customer satisfaction ratings have increased from 52 per cent at the commencement of the contract in 2016/2017 through to 81 per cent for the 2020/2021 financial year, indicating a strong community engagement on issues. It is evident that SouthRoads have fully embraced the NOC contract philosophy/ delivery and deservedly achieved the KRA score of number 1 throughout the country.