Bridge deck panels have landed!

September 2024 - Project Update

Tena koe and welcome to our third construction update for 2024.

Overnight on Sunday 8 September, the project ticked off a magic milestone when a 450-tonne crane landed six 32-tonne pre-cast concrete deck panels onto the purpose built extension to Berry Bridge.

This moment was long anticipated with the crew working at the Berry Bridge location since November 2023 to prepare for the milestone.

Brett, the Structures Team Leader (4th from right below) said “The work has been tricky with the existing bridge needing to be strengthened so the extension could be constructed – the whole team has worked so hard to get this right in a tight site with challenging conditions and I am very proud of what we have achieved here.”

It takes a whole team! The Structures Team (below) when they got together to celebrate completing all the piling works at Berry Bridge on 1 May 2024.

Construction update; what’s news with the crews?

It has been a big winter with our crews working behind metal barriers on the northern side of the state highway during the day, and across to the southern side during the night. A huge thank you to our neighbours as this disruptive work is set to continue, and a reminder to fresh air enthusiasts that the road remains very narrow. Please avoid walking or cycling through the construction site.

We also want to thank the Rodney Local Board for their continued support. And to our daily commuters – top marks for continuing to make the 60kph speed restriction a priority.

In early September there was a slight change in the road layout when we widened the highway by Kumeu No.2 Bridge - near Coopers Creek Vineyard. Traffic was shifted to the north to allow us to begin bridge widening work on the south side.

However, the biggest noticeable change is set to start shortly. The team is gearing up for what we’re calling the ‘Southern Switch’.  As work on the northern side of the state highway comes to an end, the team need to shift the area where they’re working to the southern side. To complete the Southern Switch, the metal barriers currently in place need to be progressively shifted to the southern side of the state highway.

The first phase of the Southern Switch, from Trigg Road to Matua Road, is due to happen in November.  The second phase will happen in either December or early 2025 and is from Matua Road to Factory Road.

When the safety upgrade is complete, there will be no right turns into or out of Matua Road, however left-hand turn access will remain in place permanently.

Please see the webpage and contact details below if you would like to read more or receive construction updates.

Keeping safe

While the road is being upgraded there are 3 things to remember to keep you safe when travelling through our site:

• Please avoid walking or cycling through the site during construction
• Please don't get distracted by moving machinery - especially the diggers working on the roadside
• Please drive carefully and always keep to the 60 km/h speed limit

Meet the Phase B Team; Megs, Vaibhav, Nichola, Liam, Brett and Sean

Phase B Team

The Phase B Team are responsible for planning and carrying out all the work from Trigg Road to Matua Road.

Megs whose site duties can include day shifts and night shifts is a Graduate Engineer who trained at Auckland University and joined Fulton Hogan in 2023. She coaches basketball in her spare time and says she doesn’t mind the freezing nights because her early years were spent growing up in the UK.

Vaibhav has been a site engineer for a year and joined us in November. Part of his responsibility is making sure the Variable Message Signs (VMS) are kept updated as we move forward. His off-duty fun includes “reading and studying for my Masters’ degree!”.

Nichola is the Phase B Construction Manager with 15 years on the job and a passion for tramping. Site Engineer Liam is a local `with my roots in good Huapai soil’ he enjoys football and grew up playing for the West Coast Rangers.

Brett is the Site Foreman and was with Fulton Hogan for 9 years before heading off for a stint in the UK. Now he is back in wine country, and his Croatian heritage makes him feel right at home.

Sean is a recent addition to the project. He is a Graduate Engineer with a passion for golf and cars, and he is looking forward to finishing his qualification and getting an engineering chartership.

Here's what we've achieved since the last update in June

Structures

• Concrete abutment beams and pier walls were completed at Berry Bridge in July.
• Precast Berry Bridge deck panels were installed in early September.
• Crew set up at Kumeu No.2 Bridge in September.

Services 

• Drilled road crossings have been completed ready for ducting to carry the new power cables where overhead services are being removed.
• We’ve transferred both 33KV and 11KV (domestic supply) electrical lines from overhead to underground connections in Phase B.
• Property connection works are progressing at night.
• The common services trench for utility ducting is now 90% installed on the northern side of the state highway.
• New streetlights are being installed throughout the site.

Drainage

• Work on the northwestern half of the project (Phase A) is 90% complete and 100% completed on the northeastern side (Phase B).

Earthworks

• As pavement works are completed, the final stages of earthworks on the northern side involve finishing the batters, i.e. the earth shaped into a slope on the side of the highway.
• Topsoiling, mulching and grassing works are now underway on the northern side.

Pavement

• Road widening construction for the new shoulder continues, creating a solid subbase for the road pavement to sit on.
• Subsoil drainage is being installed.
• Road widening construction is underway between Factory Road and Joyce Adams Place. The team has built as much as they can in this section and now wait for the existing overhead services to be redirected underground.

More than 1.5kms of new concrete V-shaped kerb and channel has been installed including 7 ‘apron’ areas that surround drainage catch-pits. See the picture below. Underground beams are constructed to support new metal guard rails and protect underground utility services running below.

For the boffins - the kerb and channel was machine laid at 150-250m per 8-hour shift, with the aprons being hand formed in concrete on site. The concrete is usually dry after a day but requires 7-28 days curing for the optimum 25Mpa strength to be met.

Kerb and channel! The kerb forms the higher outer edge of the road while the channel directs rain water to drainage catch-pits to keep the road from getting too wet.

Looking ahead; what’s the focus for the next couple of months - September /October/November?

Looking ahead, we’ll progress widening work at the Kumeu No.2 Bridge and our teams will continue with day and night works across the site. In November the `Southern Switch’ will see the metal barriers progressively move from the northern to the southern side of the state highway.

Structures

• Piling works will continue at Kumeu No.2 Bridge in September.
• The 6 x Berry Bridge precast panels will be ‘stitched’ together with concrete to form a solid deck.

Services

• Properties throughout the site will have their power cut-over (transferred) into the newly laid underground network.
• Chorus copper and gas diversions will begin.

Drainage

• Day and night works to complete drainage will continue throughout the site.
• Drainage will be completed on the eastern side of Berry Bridge in October following completion of the new Berry Bridge deck structure.

Earthworks

• Prior to switching to the other side of the road, final earthworks are being completed along the northern side of the site and planting will take place in 2025.

Pavement

• Further road widening construction for the new shoulder will be carried out including creating a solid subbase for the road pavement to sit on and installing subsoil drainage.
• Pavement widening works will begin on the northern side of the state highway between Joyce Adams Place and Matua Road.

Project information

We are keen to provide you with regular updates, so you always know what to expect.  These can be via e-text direct to your phone or email to your inbox and can be stopped at any time.

Please contact Nettie Bird, Fulton Hogan Communications and Engagement Manager by emailing nettie.bird@fultonhogan.com or phoning 0800 287 667.

If you would like to see more construction photos or get more information on the SH16 Brigham Creek to Waimauku project, please visit nzta.govt.nz/projects/sh16-brigham-creek-and-waimauku or email us sh16safetyimprove@nzta.govt.nz