Stage Two Update
The second stage of the development works progressed across October and November. This period included the completion of contaminated soil excavation and the installation of over 3,500m³ of engineered aggregate delivered by Fulton Hogan to form the sub-base for the post-tensioned concrete pavement.
Once compacted, the upper 300 mm of the aggregate layer was stabilised with cement to create the foundation surface and drainage profile for the new hardstand. Fulton Hogan completed the sub-base works at the end of October, after which Conset Construction took over to construct the post-tensioned pavement.
During early November, Conset installed plastic membrane and a complex network of post-tensioning wires across half of the new hardstand.
Two record-breaking concrete pours were undertaken in mid-November, followed by another two pours on 4–5 December. Across these four pours, over 2,000m³ of concrete was delivered via more than 380 truckloads, with one truck arriving approximately every eight minutes. Achieving this required support from multiple concrete fleets, including vehicles from Christchurch.
To sustain continuous batching across the 11-hour pours, Golden Bay Cement deployed both Nelson- and Christchurch-based transporters to operate two round trips per hour between Port Nelson and Firth Richmond. Aggregate deliveries were also doubled, with quarry trucks supplying the plant twice per hour over the same period.
Following each pour, post-tensioning tendons were stressed, cut, and grouted. The completed pavement is now undergoing a 90-day curing period. The commissioning of the Cimolai Mobile Boat Hoist is scheduled for late March, aligned with the arrival of a Cimolai technician and a required test load of at least 688 tonnes.
The next phase begins in early 2026 with the installation of services around the perimeter of the heavy pavement. While some service conduits were installed beneath the slab, the majority, more than 95%, will be positioned externally to ensure future accessibility and ease of maintenance.
Upcoming works include:
Wastewater and stormwater networks
Electrical, data, and air lines
Recycled water supply connections
CCTV and access control infrastructure
Fencing and gate access
The next edition of Calwell News will provide a detailed overview of these services and introduce the advanced wastewater treatment system being installed for the new yard.
