With a fast-growing population, Horowhenua District Council embarked on an ambitious multi-year $110m wastewater upgrade. They are facing the challenge of 300 to 400 new houses being built each year in and around Levin and the serious strain this population growth is putting on the existing water network. CCL were engaged to execute phase one of the wastewater upgrade and the Council, impressed with our work and the result, have engaged CCL for phase two.

The wastewater treatment plant is now more than 70 years old and is sorely in need of repair. The main inlet pipe is cracked and franly can;t be trusted to hold in a bog earthquake. We know if this pipe were to fail, the consequences would be severe.

– Bernie Wanden, Mayor, Horowhenua District Council

The biggest challenge during the project was protecting the old pipe during construction. The pipe sits precariously above ground on a stop bank, and already showed cracks from age and past earthquakes. It was clear to the CCL team that even a small impact could cause a break and significant environmental damage.

CCL’s detailed planning included a robust contingency plan, including an emergency overpumping system to keep wastewater contained, should the old pipe rupture. With careful excavation of the trench for the new pipe, we were able to successfully install 620 metres of one-metre-diameter pipe without disturbing the original pipe. The project kicked off during winter, with access requiring crossing farmlands. Boggy ground and a rising water table created additional challenges and required extensive groundwater pumping. Knowing how critical this phase was, CCL were determined to deliver on time and increased their crew to 24 to get the project delivered.

CCL carefully installed over 600 metres of one metre diameter polyethylene pipe beside the existing fragile 70-year-old pipe, without any damage. Despite access and weather challenges, the CCL team delivered on time and on budget, fulfilling the Council’s needs while simultaneously preventing an environmental incident.

The project created some great team bonding time. We drove up in a convoy from Wellington each day, with team leaders handling the driving so the guys could relax, chat, or even grab some shuteye. The team were all eager to be part of such a big project and worked hard together to get it done.

– Dan Burns, Operations Manager, CCL

CCL were proud to deliver the first phase of the project on time and on budget, and set the council off to a strong start on this critical upgrade. However, what matters most to us is our clients’ satisfaction. We were delighted to hear the Council were happy with the work done on stage one of the project. And our hard work has paid off. Having now been awarded the second stage of the project, the CCL team have continued throughout this year to deliver the second stage with the same commitment to quality and collaboration.