The replacement involved lifting out the 120-tonne existing bridge in seven sections and installing two 38-tonne prefabricated steel-concrete deck units, stitched on site using a 400T mobile crane. The high early-strength concrete stitch pour achieved 30MPa within 24 hours, enabling reopening inside the closure window. All works were completed within a tight 500m² site, with single-sided access.
We led intensive pre-closure planning, conducted risk workshops with BECA, NZTA, and key subcontractors to test programme assumptions and contingency plans. Temporary pedestrian access was maintained throughout construction via a standalone bridge and escorted school crossing windows.
Environmental controls included asbestos management, full work area encapsulation, and crane pad design around a lizard habitat to avoid triggering additional consents.
The project was delivered with no incidents, positive feedback from NZTA and BECA, and a final cost under NZTA’s budget.
