Greenlane Project
A number of businesses from across the Stevenson Group are supplying expertise and materials to a major new motorway project – the 4th lane extension from Market Road to Greenlane – for main contractor Downer.
Project name: 4th Lane Extension: Market Road to Greenlane
Project value: $18 millionClient: NZ Transport
AgencyContractor: Downer
Project Manager: Craig Fletcher, Downer
This project continues Stevenson’s ongoing contribution to the development of Auckland’s infrastructure for nearly a century. ‘This is a complex project with many logistical issues,’ says Downer Project Manager Craig Fletcher. ‘The depth of experience and expertise across the Stevenson Group has assisted us in meeting challenges that have ranged from stringent site access and safety requirements to technical solutions which respond to the unique site and operating environment.’ ‘Our ability to work collaboratively across our business to meet the requirements of Downer has been reinforced on this project,’ says Stevenson Resources Business Development Manager Barry Larsen.
Construction on the new 1.7km southbound lane between the Market Road off-ramp and the Greenlane Interchange began in October last year. This new 4th southbound lane will increase capacity and help to reduce congestion across the central motorway system. The project is scheduled to be completed in February 2011.
Good communication is the key
Stevenson Resources has been supplying aggregates to this high profile project since November last year. Products include a range of drainage metals, base course and cement-treated TNZ40, which is produced through the Drury quarry’s pug mill. Downer Project Manager Craig Fletcher commented that he is particularly pleased with the application of Stevenson’s cement-treated product. ‘Our capacity and flexibility has enabled us to provide night-time deliveries to Downer, which is vital for taking advantage of the off-peak traffic to gain more safe and efficient motorway access,’ says Stevenson Resources Transport Manager Leigh Turner. ‘The key to managing the logistics and timing of deliveries to meet the day-to-day project requirements has been maintaining clear and open communication with Downer,’ she says. ‘Our dispatchers are in constant contact with Downer about where the trucks are in transit so that a traffic control vehicle is positioned ready to lead our truck off the motorway and safely onto the site.’
Safety and access logistics a priority
Downer is responsible for managing access on and off site for suppliers. Access to the site is restricted to enable the company to meet stringent Auckland Motorway Alliance requirements. Getting trucks off a free-flowing motorway and onto the site to unload materials is potentially hazardous. Mobile crash barriers are used to allow trucks to safely exit into one of five access gates and unload materials.
Visual, noise and safety barriers
A key aspect of the project has been to ensure that visual and noise impacts will be reduced for residents and a consistent vista is provided for motorists. Using Stevenson Concrete’s readymix, Stevenson Precast has almost completed the supply of 150 standard safety barriers to the project. Precast is also manufacturing 83 fascia panels, a large number of L-shaped retaining wall units and 212 noise wall panels. ‘Initially the L-shaped units were designed to be produced in situ, but site constraints meant this just wasn’t practical and we are now making them in our factory,’ says Precast Project Manager Jared Dickson. ‘We have worked closely with GHD, the design engineers on the project, to develop a bespoke product – this has been one of the biggest challenges.’ The fascia panels have also thrown up challenges. ‘They are extremely difficult to make. Each panel has an exposed aggregate finish on one side and angled rebates on the reverse side to absorb sound. We have developed a system in-house for obtaining the desired even spread of aggregate. ‘This is a very exciting and demanding project, one of the biggest Precast has ever undertaken in terms of complexity and product diversity.’
Special high durability concrete ‘Stevenson Concrete is delighted to be involved on this significant infrastructure project,’ says General Manager David Lowe. ‘We have been supplying a range of concrete mixes to the project, with strict requirements on the concrete specification and testing. High durability mixes have been specifically designed for the project. ‘Constant communication and a close working relationship are essential on a project of this nature. We have enjoyed working with Downer as part of the team to ensure that all of NZTA requirements are met in full.’
