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Hynds low carbon jacking pipe is being installed in a significant infrastructure project on Auckland’s North Shore, delivering a first in performance and sustainability.

Following the major Auckland floods in January 2023, the Greville Road Stormwater Culvert Upgrade project in Albany was identified as an emergency works project by Auckland Council’s Healthy Waters.

The existing Greville Road culvert consists of a 1,950 mm 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 1,950 mm 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, the decision was made by Auckland Council and McConnell Dowell to design and construct the shaft to accommodate the permanent inlet at the same time. This was to avoid any reworking later in the project, saving time in the construction programme.

After a joint workshop between Hynds, Healthy Waters and McConnell Dowell, it was decided to proceed with HyndsLC® 2100mm diameter Hyforce® Butt Joint Concrete Jacking Pipes with a fixed stainless steel jacking band.

Karun Kumar, Tunnels Project Engineer for McConnell Dowell, says it was important that the design of the jacking pipes allowed for the push of 1,400 tonnes which also coincides with the maximum thrust force of the jacking frame.

 

“We were able to deliver the lowest carbon option that met the project requirements for the material strength, programme and cost. The 92 Hynds pipes will save approximately 62 tonnes of CO2 emissions which is a 16% 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 220 m 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 Innovative low carbon jacking pipe to the rescue Projects 25 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.

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 deliver sustainable stormwater infrastructure that enhances Auckland’s resilience,” says Gerhard.

Todd Randell, Trenchless and Pipelines Specialist for Hynds Pipe Systems, says 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 worked with the lowest carbon producers to get the right outcome, without compromising quality or durability,” says Todd.

This collaborative approach with the client, consultants and designers has already made a positive impact on the overall programme and provided a cost-effective solution. The project is expected to be completed by mid-2025.

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