The Tasmanian Department of State Growth has awarded McConnell Dowell the contract to design and construct the New Bridgewater Bridge in Hobart - Tasmania's largest ever transport infrastructure project, and the longest road bridge over water in Australia.

The new one kilometre long bridge will replace the existing lift-span bridge built in the 1940s, providing a new modern crossing of the River Derwent. The new bridge will cut travel times for the 22,000 people that use the route each day. It will also improve freight routes around the state capital.

Our winning design features a new, four lane bridge constructed downstream of the existing one. Works also include enhanced interchanges at Granton and Bridgewater, and a dedicated shared pathway for cyclists and pedestrians.

The McConnell Dowell team includes design partners Jacobs; Tony Gee and Partners; Tonkin and Taylor; Wood Marsh; and Pitt and Sherry. McConnell Dowell's main construction partner is bridge specialist VSL.

With a strong focus on local involvement, the team has also engaged local constructors Batchelor, BridgePro, Hazel Brothers and VEC to maximise economic value for Tasmania.

The final design and construct contract was signed in July 2022 and major construction is due to start later the same year.

For more information visit www.bridgewaterbridge.tas.gov.au.

McConnell Dowell has been engaged by Major Road Projects Victoria (MRPV) to upgrade Epping Road in Melbourne's booming northern growth corridor.

This is the fifth major project we'll deliver for MRPV, after the successful completion of the Mordialloc Freeway and Echuca Moama Bridge projects, and the current Narre Warren-Cranbourne Road and Healesville-Koo Wee Rup Road upgrades.

The Epping Road upgrade will improve traffic flow and travel times by providing better north-south road connectivity. It will also increase livability and commercial development opportunities, and make it easier and safer to walk and cycle around the local area. Most importantly, it will lower the risk and severity of crashes through safety upgrades.

Our workscope includes:

• adding extra lanes in each direction between Craigieburn Road East and Memorial Avenue
• installing new traffic lights at Park Street
• upgrading existing intersections in the area
• upgrading the pedestrian traffic lights at Taggerty Grove
• building a new shared walking and cycling path
• adding on-road bicycle lanes
• installing safety barriers along the road.

McConnell Dowell, in partnership with John Holland, is constructing the Kidston Pumped Storage Hydro Project in Far North Queensland - an innovative project that involves the world-first conversion of a disused gold mine into a pumped storage hydroelectric power generation facility.

This first-of-its-kind natural battery storage facility has the potential to generate up to 250 MW of rapid response (less than 30 seconds), flexible power to Australia’s National Electricity Market.

The project will create 800 jobs and will be a gamechanger for the clean energy industry in Australia and worldwide as it is an entirely new approach to large-scale energy storage. The project is an important step in the move towards a more sustainable energy future.

The project is being led by Genex Power and involves the conversion of two existing mine pits into reservoirs. The technical feasibility and collaborative design development process took approximately four years. The construction involves significant underground infrastructure, including a large powerhouse cavern, and waterway shafts and tunnels to allow the transfer of water between the upper and lower reservoirs.

Once completed, the facility will generate power during peak demand periods and return water back to the upper reservoir during off peak periods. The facility will generate enough electricity to power 143,000 homes for eight hours.

The project continues to build McConnell Dowell’s presence throughout Australia in the successful delivery of major infrastructure projects in the resources, energy and transport sectors.

The Project received funding from ARENA (Australian Renewable Energy Agency) as part of their Advancing Renewables Program. Below is a short explanitory video of the project produced by ARENA.

McConnell Dowell is delivering the Archer River Crossing project for Department of Transport and Main Roads (TMR) in Far North Queensland.

The Archer River Crossing is the latest project in a program of upgrades as part of the Cape York Region Package (CYRP) Stage 2, which is jointly funded by the Australian and Queensland governments under the Roads of Strategic Importance program.

Every wet season, the crossing is closed for long periods due to flooding. When complete, the new crossing will reduce the average annual time of closure to less than two days, improving access for road users and improving connectivity for some of Queensland’s most remote communities.

Our scope of work includes:

• a new 230 metre long (11x 21 metre spans), 10.4 metre wide deck bridge over Archer River
• vertical alignment modification to improve resilience to flooding
• bitumen surfacing
• earthworks and drainage
• guardrails, signs, and pavement marking.

The new bridge will be located around 20 metres downstream of the existing crossing, with abutments and piers supported by three 1200 millimetre diameter columns.

Drawing upon our extensive remote road and bridge construction knowledge, we have developed a methodology that will deliver the project at a faster than normal pace.

We have also developed a project-specific procurement strategy that will maximise the use of local and regional businesses and deliver greater benefits to the region, beyond the infrastructure itself.

What started out initially as a plant hire contract in July 2016 has successfully been converted into a BCM contract from August 2017.

Moolmans is responsible for assisting the client, Nordgold plc, with the current mining operation, which encompasses loading and hauling over 600 000 in-situ cubic metres a month.

The mine is located around 700km north east of the capital, Conakry. It is a typical modern open cut operation with three major mining areas and several smaller, higher-grade satellite pits.

Siguiri is a multi-pit oxide gold mine covering a concession area of 1,500 square kilometres in the relatively remote district of Siguiri which lies 850 km north of Conakry, the nation’s capital. AngloGold Ashanti owns 85% of the mine with the Guinean government owning the balance.

The first shipment of bullion left Siguiri in April 1998 with production expected to continue until 2018.

Moolmans was awarded the mining contract in January 1997. Further extensions were since awarded which saw the contract run up until April 2014. Moolmans was contracted to render the following services to the client – Production drilling and blasting, load and haul of waste and ore, re-handling of ore at the crusher in a blend of saprolites and laterites, and dewatering of the pits.

The site personnel consisted of more than 630 employees with less than 4% being expatriates. Moolmans purchasing and logistics department managed the import of spares and equipment for this mine that operated on a continual basis 365 days a year.

In November 2008, Moolmans was awarded a five-year contract to carry out the mining at AngloGold Ashanti’s Iduapriem Gold Mine in the western region of Ghana, some 10km south of Tarkwa. The Iduapriem Mine consists of the Teberebie and Iduapriem properties in a 1 000km2 concession area.

Moolmans operated with a fleet that comprised of Caterpillar 785 rigid dump trucks, Liebherr R9350 excavators, Sandvik D25KS drill rigs, as well as the usual ancillary support equipment of dozers, graders and water carts.

Moolmans’ responsibilities at Iduapriem included short-term mine planning, overburden clearing and topsoil stripping, drilling, blasting and the loading, hauling and dumping of ore and waste.

The Langer Heinrich Uranium Mine is located to the west of central Namibia. It lies 85km east of Swakopmund with seaport access at nearby Walvis Bay.

Langer Heinrich Uranium (Pty) Ltd is a Namibian-registered company which is wholly owned by Australian-based Paladin Energy Limited, a company that is listed on both the Australian and Toronto Stock Exchanges.

Moolmans was responsible for the entire mining operation, including drilling, blasting, loading and hauling of waste and ore. Some 19 million tonnes of ore and waste were mined annually. Grade control is supplemented electronically by means of the loaded trucks passing under an ore discriminator for radiometric examination.

Moolmans employed 315 Namibian people during the contract period.

Moolmans’ history at Sishen Iron Ore dates back to 2006 and spans numerous commodity cycles. The current 60-month waste removal contract at Sishen was re-secured in 2017. At peak production, Moolmans was mining in excess of 60 million tonnes per annum. In addition to the load and haul contract, Moolmans is also constructing haul roads and undertaking dump rehabilitation activities on behalf of the client. The current annual volume is around 9.0 million BCMs.

Moolmans has established a full training centre with two simulators for training operators and apprentices that is used not only by the Sishen mine, but also by the industry at large.

Moolmans was awarded the open cut contract by Tshipi é Ntle in October 2011. The initial five-year contract was a greenfields opportunity, with Moolmans establishing the entire open cut operation to provide a full mining service for overburden and manganese ore. Due to a downturn in the manganese price in 2016, the contract was reduced to 50 000 BCMs per month. The market has since recovered and Moolmans is once again providing a full mining service, which includes bush clearing, top soil stripping, drilling and blasting, loading and haul of ore and waste.

A contract extension for an additional 60 months was negotiated before the end of term of the initial contract, taking mining well into 2020. Moolmans is currently mining in excess of 12 million BCMs per annum, supporting South Africa’s biggest exporter of manganese.

The initial North Pit scope of work from the client, Black Mountain Mining, included the establishment of a fleet of mining equipment, workshops, offices, stores and related support facilities on site, the formation of access ramps, as well as mining of ore and waste material. Additional work includes drilling, blasting, presplit as well as trimming of final pit walls, forming and maintaining dumps and ore stockpiles, construction of haul roads and implementing dust control measures. A total of 51 million BCMs of waste and ore will be mined over the initial 44-month contract period: 48 million of waste and 3 million of ore. The current annual production of 17,2 million BCMs is expected to increase year-on-year over the remaining contract period, peaking at 19,6 million BCMs in year four. Post the initial contract award, the scope of work was increased to include crusher feed and ore re-handle. Subsequently, the South Pit mining contract, which includes drill, blast, load and haul of waste and ore, was awarded. A total of 9.1 million BCMs of waste and ore will be mined over a 20-month contract period: 7.8 million of waste and 1.3 million of ore.

Klipspruit colliery is a single dragline, multi-seam, open cut mine that is combined with truck and shovel mining in the mini pits.

The scope of work under this contract from the client South 32 Coal Holdings, encompasses the pre-stripping works, loading and hauling of overburden and mid-burden materials, totalling approximately 9 million in-situ cubic metres per annum, and additional pit services associated with the remainder of the main pits at Klipspruit. The fleet employed on this contract includes Moolmans’ largest-sized, hydraulic face shovels together with Caterpillar’s 200-ton haulers assisting the client with moving safe cubic metres to plan.

McConnell Dowell is upgrading the Queen Sālote International Wharf for the Tonga Ports Authority. The port is the country’s main international port and a lifeline for the people of Tonga. An estimated 98% of Tonga’s imports arrive by sea.

This critical infrastructure upgrade will achieve a number of objectives including modernizing and climate-proofing the facility, increasing container capacity, and improving overall port operations.

The main features of the project include an extension to Wharf 2 to better accommodate larger vessels, construction of a new dolphin between Wharf 1 and 2, construction of new dolphins on the eastern side of Wharf 1, reconstruction of Wharf 1, and general improvements such as reorganisation, new paving, drainage, smart lighting, waste management, and firefighting.

To ensure that the port remains operational with minimal disruption during construction, the works will be completed in three phases, with a mix of marine and onshore work.

The works will be predominantly self-delivered by McConnell Dowell, supported by carefully selected specialist subcontractors who offer expertise and efficiency in delivering works in the Pacific region.

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.

Work on this project includes:

• Service relocation works
• Piling works for both the outlet and inlet shafts
• Excavation works for both shafts
• Tunnelling under Quay Street to a maximum depth of 20 metres
• Chamber and outfall construction
• Culvert strengthening

This project is expected to be completed in late 2023.

Eastland Port in Gisborne, New Zealand awarded McConnell Dowell the design and construct contract to rebuild Wharf 7 in late March 2022 after a very successful six-month value engineering exercise. Construction is expected to take about 18 months to complete.

The contract is part of Stage One of the $60 million Twin Berth Project which will enable two handymax (180-200m long) ships to load and unload at the port safely, simultaneously.

The new wharf will be strong enough to accommodate three new mobile harbour cranes and will be capable of withstanding a one-in-2500-year earthquake event providing significant regional resilience in the event of a natural disaster.

Marty Bayley, Eastland Port’s infrastructure manager, overseeing the project said the wharf design had been significantly refined.

“We’ve taken the time to work closely with McConnell Dowell to refine and modify our original concepts and come up with some innovative solutions.”

Following a six-month value engineering process collaborating with the Port McConnell Dowell’s in house engineering team refined the design and used digital engineering and animation capabilities to refine the staging:

• To maximise value and sustainability
• Remove the need for 49,500 tonnes of hardfill
• 3,300 fewer truck movements through the city are needed
• Minimise disruption to port activities
• A drill and drive method will mitigate noise and vibration during piling
• The design and construction also minimises the impact of the project on the marine environment, (Rua Koura (crayfish puerulus)) local ecology and seabed.

We are also planning to use a range of sub-contractors from Tairāwhiti throughout the rebuild. See infographic below.

Managing demolition and construction around the port operations is the key to successfully rebuilding the wharf. Coordinating sub-contractors and maintaining a Covid-19 safe environment while working around the operational wharf will be a challenge but one that the team have experience overcoming.

For more information visit the Eastland port website https://www.eastland.nz/eastland-port/twin-berth-project/

McConnell Dowell (MCD) was awarded this design and construct contract by Watercare and the project is a component of the Warkworth to Snells Transfer Pipeline scheme, which conveys wastewater from Warkworth to Snells Beach.

The North East Wastewater Servicing Scheme will cater for future growth and enable Watercare to decommission the existing Warkworth Wastewater Treatment Plant which discharges into the Mahurangi River. The overall scheme comprises of a pump station, associated rising mains and a final gravity sewer that terminates at the proposed site for the new Snells Beach WWTP.

The scope of works includes construction of a new 247 l/s Wastewater Pump Station located adjacent to the existing Lilburn Street Pump Station in Lucy Moore Memorial Park. The pump station is designed to be a wet well / dry well facility and includes:

• an above ground structure approximately 4.4 m high, 9.2 m long and 4m wide
• belowground structures including inlet chamber, gantry crane, drywell, wet well and emergency storage to a depth of approximately 12 m.
• an overflow pipe from the pump station to the existing stormwater pond
• ancillary above ground structures, including odour control (biofilter), standby generator, transformer, flowmeter chamber and welfare facilities; and
• an access road and carpark

The challenge

The Warkworth pump station site is located within Lucy Moore Memorial Park, adjacent to the Mahurangi River. The park is an open green space which contains a number of walking tracks, a skate ramp and flying fox. The park is a popular community amenity and provides a thoroughfare to the town centre.

Lucy Moore Memorial Park is named after Warkworth’s own botanical legacy, Lucy Moore who was often referred to as the ‘mother of New Zealand botany’, gaining both national and international recognition for her achievements.

The park and the river link to the historic Portland Cement Works further downstream. The cement works was closed down some years ago and the ruins remain on the banks of the river behind what has become a marina.

The solution

The pump station and storage tank will be constructed using an innovative caisson (sunk shaft) construction method which provides the following benefits:

• Reduced construction footprint due to a reduction in the working space
• Less noise and vibration impact because there is no significant backfilling required
• Minimised time required on-site, which further reduces overall community impact
• Enhanced safety to site workers and park users

The key to success

The construction methodology was developed with input from specialists and experts to comply with statutory, contractual and consent requirements. This includes the development of environmental controls to protect the sensitive park and river environment, engaging an arborist to identify and protect trees and vegetation, iwi consultation, and a strategy for effective stakeholder management of impacted residents and the invested community.

Construction started in September 2021 and is scheduled for completion in November 2023.

Vale SA awarded McConnell Dowell (Malaysia) Sdn Bhd, in joint venture with BAM Malaysia and SYS Sdn Bhd, the design and construct contract for the berthing facilities at Vale Malaysia Manufacturing Project (VMMP) in Malaysia.

The berthing facilities cater for the world’s largest bulk carriers, the 400,000 DWT VLOC (also known as ValeMax. Approx. Length 360 m x Width 65 m, Draft: 24 m).

The VMMP project is an iron ore distribution centre located in Teluk Rubiah, Perak State, Malaysia near the Malacca Strait. It comprises a pelletizing plant, stockpiles and a jetty for import and export of iron ore with sufficient depth to accommodate ships of 400,000 DWT.

The berths are located 2 km offshore and constructed in 25 m of water. The access trestle measures 2,200 m long and the operational jetty head is 800 m long.

In the initial phase, the jetty will be capable of handling up to 30 million metric tonnes of iron ore annually, with an option to expand facilities to 90 million metric tonnes per year in the future. This project is facilitating the distribution of Brazilian iron ore to the world, strategically located to facilitate markets in the Asian region, simultaneously boosting the local economy of Malaysia.

Project was successfully completed and handed over on schedule.

McConnell Dowell was awarded the Engineering, Procurement and Construction (EPC) contract for the New Bang Phra Raw Water Line Project Pump Station Package in Thailand. The new pump station and raw water pipeline provides over 4,000 m3/h of raw water and replaces the existing system, which is insufficient due to its low capacity pumps, pipe leakage and corrosion due to sediment.

The multidisciplinary nature of the project, which included the construction of a temporary cofferdam (20m x 20m and approximately 10m deep), allowed MCD to differentiate from our competitors by bringing together knowledge and experience from across the Group.

The project is located at Bang Phra Reservoir, Chonburi, Thailand, which is approximately 16 km from the Thai Oil Public Company Limited (TOP) Refinery in Sriracha. There, our team successfully completed the IDEA Project last year. That project involved the construction of 4 km of 36” HDPE pipeline.

This was an important win for MCD in Thailand, with the marine and civil works associated with the pier and cofferdam, providing the opportunity for MCD's local team to further build our in-country capability and capacity.

Resorts World at Sentosa have developed an integrated resort which includes six hotels, casino and a Universal Theme Park on Sentosa Island. The world-class and pioneering resort project is set on 49 hectares and opened in the first quarter of 2010. They awarded McConnell Dowell a design and construction contract for a new vehicular bridge from Singapore to Sentosa Island.

The bridge provides additional traffic capacity for the anticipated 15 million visitors to the new resort. The 710m long, three-lane bridge was built parallel to the current Sentosa bridge (four lanes).

McConnell Dowell's scope of work included:

• Design and construction of a new 710 m long, three-lane vehicle bridge.
• A 400 m long balanced cantilever bridge and 310 m long causeway.
• A 50 m long pedestrian underpass and a 400 m long steel utilities bridge were also included in contract.
• Relocation of three piers of an existing light-rail line bridge was required to make way for the new structure.

McConnell Dowell (Malaysia) Sdn Bhd was awarded an EPCC contract by Petronas PRPC Utilities and Facilities Sdn Bhd for Package 12B. This encompassed the Engineering, Procurement, Construction and Commissioning (EPCC) of the Solid Product Jetty and associated Handling Facilities (SPJ) at Tanjung Setapa, as part of the RAPID project in Malaysia.

The package included:

• A Solid Handling Jetty comprising of a 1300 m long trestle, 710 m long jetty head, 2 container berths and a sulphur loading berth
• Onshore Civil Works comprising of a container stacking yard, truck and trailer parks, a workshop area along with distributor roads and utilities
• Industrial Buildings comprising of a 450m long Sulphur stockpile warehouse, at terminal operation building, an administration building, workshop, substations and other ancillary buildings
• A topside and landside material handling system for sulphur with loaders and unloaders including all mechanical and electrical works
• The project duration was 30 months, including an extensive 6 months of engineering design.