Combining a rich engineering legacy with refined trenchless techniques, McConnell Dowell continues to advance project delivery in the water sector.
Since its inception in 1961, McConnell Dowell has had a hunger for technically complex work – it is part of its DNA. This mindset has taken the ‘Creative Construction’ company across Australia, Southeast Asia and beyond, establishing it as a leader in the water sector.
Water infrastructure remains integral to McConnell Dowell’s long-term strategy. With water security and water quality among the world’s most pressing challenges, the company is committed to delivering smarter, more sustainable solutions across the water and wastewater cycle. As industry demands evolve, so too does McConnell Dowell’s approach.
Dr James Glastonbury, chief engineering and innovation officer at the company, highlights how regulatory shifts and technological advancements are shaping McConnell Dowell’s work.
“We’re increasingly seeing positive regulatory changes in various jurisdictions setting improved wastewater discharge requirements and firmer environmental protections,” says Glastonbury. “Technology is a major lever in our response to this evolving landscape. We are continuously assessing and integrating new advancements to improve water sector outcomes.”
Balancing innovation with experience, McConnell Dowell draws on decades of expertise while embracing new thinking where it adds value – whether through smarter, more efficient, safer or higher-quality solutions. Trenchless technology is a prime example, particularly in densely populated or environmentally sensitive areas.
“In many cases, traditional construction methods can cause significant disruption to roads, community assets and parklands,” says Glastonbury. “While conventional methods remain an option in urban settings, technology-enabled solutions can help reduce that community impact.”
Related stories:
- Innovation anchors McConnell Dowell’s success in marine sector
- Mario Russo leads McConnell Dowell’s vision for growth
- McConnell Dowell welcomes Mick Slocombe to leadership team
McConnell Dowell’s expertise in trenchless methods is particularly evident in New Zealand, where the company has built a strong reputation in complex water transmission and treatment projects.
Daniel Patten, McConnell Dowell’s GM engineering – New Zealand and Pacific, notes that tightening environmental regulations have driven changes, particularly around seabed and foreshore excavation.
“Where we once relied on staged excavations with large temporary works, we have transitioned to trenchless crossings,” says Patten. “As the technology has advanced, we have embraced deeper and longer crossings to meet evolving requirements.”
Patten has been involved in many of these New Zealand water projects over his 22 years with the company. One standout example is the Army Bay Ocean Outfall project in Auckland. Engaged by Watercare Services, McConnell Dowell designed and constructed a new wastewater outfall, upgraded an existing pump station and built a new ultraviolet disinfection facility – all while working within a conservation area.
With most construction occurring within a pest-free conservation zone and the need to avoid disrupting plant operations, the project team introduced Direct Pipe. This method, combining micro-tunnelling and horizontal directional drilling, allowed for long pipe installations in a single drive well below the surface, minimising environmental impact. The team not only pioneered its use within the company but also set a new Direct Pipe tunnelling world record, reaching 1,985 metres for the land section of the pipeline.
Building on this success, McConnell Dowell has since worked with Watercare to complete the Snells Algies wastewater pipe and outfall project, further extending the tunnel length and establishing a new world record of 2,021 metres.
More recently, the company completed Watercare’s Warkworth to Snells Transfer Pipeline, where trenchless technology provided a more efficient and less disruptive alternative to a conventional dig-and-lay approach along a challenging route.
“This project was more of a cross-country tunnelling effort. The original plan involved a pipeline installation along a difficult, winding road – the only viable access route to Snells and Algies Beach. The road presented geotechnical challenges, including a high risk of slips,” says Patten.
“Instead, we proposed a cross-country tunnelling solution that eliminated almost all disruption, minimised the impact on landowners and delivered significant cost savings. Not only did this reduce construction costs, but it also lowered operational expenses by eliminating one of three pump stations and deferring another.”
As trenchless technologies in the water and wastewater sector continue to advance, McConnell Dowell is not just an early adopter but often a first adopter, setting new industry benchmarks.
“Implicit in the projects we have delivered in the water sector is a powerful cycle of learning, refinement and optimisation. I think of it as a flywheel of continuous improvement,” says Glastonbury.
“Just like in sport, where teams analyse games to refine their performance, we take lessons from each project and apply them to the next. That level of precision is visible onsite – it is tangible, and it is what makes this work exciting.”
For the company, three key drivers shape its approach to innovation. Safety remains paramount, influencing both design and construction processes.
Sustainability is another focus, with efforts to improve efficiency – such as exploring ways to directly install product pipes rather than using carrier pipes, reducing tunnel size and material duplication.
Constructability is the third driver. While McConnell Dowell is not a consultancy, it often provides constructability input to clients tackling complex challenges.
“A stormwater catchment prone to flooding in a highly urbanised area may require an innovative solution to efficiently redirect water,” says Patten. “As new technologies emerge, addressing these challenges becomes more feasible. These three factors – safety, sustainability and constructability – are the key forces driving us to innovate.”
While technical expertise plays a crucial role, McConnell Dowell’s ability to self-perform has also strengthened its position in the market.
“We own or lease our tunnelling machines and deliver projects with our own engineers, technicians and labour,” says Patten. “This hands-on approach has allowed us to refine our capabilities and push the boundaries of trenchless technology.”
That expertise is now informing projects beyond New Zealand. As similar opportunities arise in Australia, McConnell Dowell’s New Zealand operations are sharing their knowledge across the business, fostering strong collaboration between teams in both countries.
“The expertise in New Zealand is helping our Australian colleagues tackle similar opportunities, where that experience, technology and key partnerships can be applied to the local market,” says Glastonbury.
“Knowledge-sharing requires constant nurturing, but we are adept at connecting the right experts with the right teams – both internally and with our clients – across our business footprint.”
Trenchless methods have gained traction in New Zealand due to environmental and water control legislation, and a similar shift is now underway in Australia.
“In some of Australia’s most urbanised areas, there is limited community support for disruptive construction methods such as digging up roads, parklands or national parks – for good reason,” says Glastonbury.
“Trenchless technology offers a viable alternative, and we are actively engaging with water agencies to explore its potential – particularly for urban areas where much of the major water conveyance infrastructure is reaching the end of its service life.
“There are opportunities for asset renewals and the replacement of key water infrastructure using trenchless methods. Shore crossing projects are another area where we see potential in the Australian market. Overall, there is growing relevance and increasing interest in these technologies.”
With urbanisation on the rise and greater demand for efficient water and wastewater infrastructure in Australia, McConnell Dowell is well positioned to drive the next wave of innovation – delivering solutions that balance technical excellence with environmental and community considerations.