18 | McConnell Dowell: Eastland Wharf T T Richard Loader Wharf rebuild boosts port capacity The new wharf will play a pivotal role in accommodating larger vessels and future proofing the port. “We wanted to share the story of how the ECI contract structure enabled the Port, MCD and the Port’s designer, Worley, to develop the wharf design and achieve significant carbon emission savings.” REGIONAL DEVELOPMENT Early contractor involvement (ECI), collaboration and building a trusting relationship between constructor, client, and designer were key themes in McConnell Dowell’s (MCD) successful completion of Eastland Port’s (EPL) recently completed Wharf 7 Rebuild. EPL is an important regional facility with over 25% / $626m of the Tairāwhiti/Gisborne economy directly dependent on the Port to get its export products to the world. The replacement of Wharf 7 at Eastland Port is the first stage of the Twin Berths Project designed to increase port capacity and enable container trade. “The new wharf will play a pivotal role in accommodating larger vessels and enable us to accommodate the projected volumes of wood products, the growing horticulture sector, cruise ships and enable containerisation,” says Marty Bayley, EPL GM Infrastructure & Development. Mr Bayley says that from the outset of the ECI process MCD engaged to understand beyond the written specifications what outcomes were important to the Port, its customers and community. “By bringing a committed, professional team to the project, MCD gained a thorough understanding of the desired project outcomes and explored items openly and honestly. They built trust and a very good working relationship with our team, so that when an alternative solution was proposed, we were open to the idea. We are both committed to the Road to Zero Carbon and MCD’s proposal supported that.” Working in partnership with EPL and Worley, MCD identified a cost-effective and sustainable solution to redesign the wharf structure from an initial Quay Wall specimen design, which required 85,000 tonnes of backfill, to a reinforced concrete deck on steel pile structure. “Taking the time to collaborate ensured minimal issues and resulted in all the positive outcomes that were important to us,” says Mr Bayley. MCD’s Project Manager Mike Bonnette says that collaboration during the ECI process significantly minimised costs, reduced schedule duration, realised sustainability benefits and helped the team actively manage project risk. “The second stage of the ECI and design was completed in a very short timeframe. Traditionally ECIs are seen as taking a lot of time but in this instance the timeframe from the drawings Issued For Construction (IFC) and construction starting was short.” The revised Deck on Pile Design resulted in 9748 tonnes of Co2e (Carbon dioxide equivalent) being saved - the same as driving 40,216,660 km or around the world 1004 times. The design also resulted in 50% less piles, 70% less steel, 85,000 tonnes hardfill avoided (including the 600km round trip for delivery), and 3695t steel saved including 245t of new steel purchased. 4000t of old concrete was reused, 4250t of old wharf deck was stored for reuse in Twin Berth Stage Two. “On top of the emission savings from the redesign, thought was given to how materials could be utilised elsewhere. With thorough planning, most materials taken off site have been reused or stockpiled for use in the future. Sustainability doesn’t necessarily have to cost money, it can save money,” said Mr Bayley. EPL required the port remain 100% operational while construction was being undertaken. MCD not only achieved this they also developed a plan to move the ships moorings mid-project which cut twelve months from the overall project schedule. “The move meant work planned as two separate stages could be carried out simultaneously. This allowed for two ships to berth much earlier than planned saving money for the client and its customers,” said Mr Bonnette. A showcase of collaboration and the benefits of an ECI project, MCD submitted the project into the 2023 Construction Sector Beacon Awards, winning the Innovation category. “We wanted to share the story of how the ECI contract structure enabled the Port, MCD and the Port’s designer, Worley, to develop the wharf design and achieve significant carbon emission savings. “The trust established within the ECI, coupled with an open-book approach, facilitated the project’s redesign. Investing additional time in the design stage can realise better longer-term outcomes for projects and the planet. “Finishing the project on time, within budget and achieving the carbon footprint reductions was a great feeling. Winning the Beacon award was the icing on the cake for the team. It’s always rewarding to have hard work recognised by the industry and our peers.” The wharf structure was redesigned from an initial Quay Wall specimen design, which required 85,000 tonnes of backfill, to a reinforced concrete deck on steel pile structure.
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