Project: Te Rapa Bypass,  a 7.3 km section of the Waikato Expressway

Client: NZ Transport Agency

Contractor/Delivery method: The Te Rapa Alliance.  Alliance contracting is an innovative approach to contracting in which the owner (NZ Transport Agency), the designer (Opus) and the contractor (Fulton Hogan) join forces to form a single united team that works from design through to completion of construction. The alliance approach creates the opportunity for designers and constructors to work together collaboratively to achieve the most cost effective or ‘best for project’ solution for all stakeholders.

Project Value: $194 million

Duration:  Commenced late 2010, completed December 2012, seven months ahead of schedule

Alliance Project Manager: Tony Dickens

Aggregates Supplied : Over 550,000 tonnes of aggregate supplied by the Stevenson Quarry (25 different products)  –  Including TNZ M/4 basecourse,  cement treated basecourse (CTB) for bridge abutments, TRA65 (a ‘made to order’ subbasecourse specified by the Alliance), sealing chip (from the Stevenson Quarry), sub-grade improvement, drainage metal and filter materials, gabion rock,  rip rap and hardfill.

Stevenson technical experts worked collaboratively with pavement designers and project managers from Fulton Hogan and the Alliance to ensure we could produce aggregates to meet their pavement design

Client Feedback:

“Once you’ve got consistency with your aggregates you can have consistency with your methodology. We get consistent grading results from our aggregates because Stevenson put it through their pugmill, and with accurate blending create the aggregate we specified for the job.”

– Tony Dickens, Project Manager, Te Rapa Alliance

” The Stevenson aggregate is very consistent and well graded which makes it easier to compact and reduces our compaction costs. We have consistently exceeded our pavement production targets on the Te Rapa Bypass project using this aggregate.”

– Ross Inglis, Pavement and Surfacing manager, Te Rapa Alliance

We acknowledge NZ Contractor Magazine, NZTA and the Te Rapa Alliance  for some of the content in this project case study. Download the full  article from Contractor Magazine here (pdf)

Laying sub-base, Te Rapa bypass


Pavement and bridge construction, Te Rapa Bypass