United Civil Construction was a key project partner in the delivery of a new processing facility at Refining NZ’s Marsden Point oil refinery. Using continuous catalytic reactor technology, this $365 million investment increases the refinery’s process capacity by 3 million barrels per annum while significantly reducing operating costs, maintenance costs and CO2 emissions.
After a rigorous selection process United Civil Construction was appointed the civil works contractor for the project in early 2013.
With the works undertaken in the high risk environment of an operating oil refinery, and often within live process areas, stringent safety controls were in place at all times with the hazards of both the plant and the construction activities themselves taken into account.
The successfully delivery of Te Mahi Hou was contingent on the development of an integrated and highly collaborative team. United Civil Construction’s Senior Civil Works Manager was seconded into the Project’s Construction Management Group and worked closely with managers from the instrumentation and electrical, heavy lift, mechanical and rotating equipment disciplines.
Working on multiple fronts and concurrently with other trades on what was a very busy site, the United Civil Construction team of around 100 skilled tradespeople and engineers completed over 2,300 separately scheduled civil works activities to a very high standard, without any Lost Time Injury and ahead of schedule.
United Civil Construction provided the following works and services for the Te Mahi Hou project;
- As part of an early contractor engagement approach, key members of the United Civil management team were relocated to the project’s design office in the United States to assist in the review and optimisation of the detailed design and further development of the detailed construction schedule
- All earthworks required to bring the site to grade and construct foundations, including dewatering and conditioning of excavated spoil
- Significant temporary works including shoring, scaffolding, construction of laydown yards and other temporary pavements
- The construction of over 10,000m3 of heavily reinforced concrete foundations, plinths, supports and frames, including the placement of over 3,000 hold down bolts all with a positional accuracy of +/- 3mm
- The construction of what is believed to be one of the largest off-site batched continuous concrete pours ever undertaken in New Zealand, being a heavily reinforced foundation up to 2m thick, some 2,750m3 in volume and completed over a period of 16 hours
- Construction of 16m high heavily reinforced frame structure using self-compacting concrete which in turn supported processing units rising nearly 90m above grade
- All site drainage including the Accidentally Oil Contaminated and Continuously Oil Contaminated systems
- Both exsitu and insitu fireproofing (with reinforced concrete) of structural steel members
- Constructing of fire mains, access roads and site paving
- Providing survey and site out for the entire Te Mahi Hou project, including verticality checks and settlement monitoring
In late 2015 the Te Mahi Hou project was commissioned, producing on-specification fuel ahead of schedule and within budget.