This project, performed by Brian Perry Civil, was for the design and construction of a 5km, 1600mm diameter sewer pipeline on farmland and reserves to the east of Auckland's International Airport.

The installation of 2km's of concrete pipe using a microtunnelling and pipe jack method - a first for New Zealand was required. For this task, an Iseki Poly-Tech 1.8m-diameter Crunching-mole microtunnelling machine was used.  This remote control machine was laser guided and was programmed to bore up to 15m per day at up to 800 tonnes jacking pressure.  Soil conditions consisted mainly of sands, silts and sensitive clays with a high water table.  Up to 330m of pipe was jacked in one operation.

Slurry from the mole was pumped to sediment ponds with pond effluent recycled to the tunnel face.  The balance of the pipeline comprised 1.3km of trenching up to 7.7m deep requiring benching and some sheet piling, 1.2km of concrete rubber ring jointed pipe installed within an embankment and 0.5km of concrete lined steel pipe installed in bridges over tidal estuaries.  The largest bridge was a curved truss with a single span of 65m.

The construction required careful planning for Airport Operations, environmental protection and work within areas of sensitivity to local iwi.

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