Projects

Summary of works

Manukau Quarry LP required an engineered solution to restore a breach within an existing quarry wall that was impacting water retention within the quarry. Traditional civil construction methods would have required significant mobilisation, access preparation and extended installation durations, creating programme and cost challenges for the asset owner.

Vault Subsea developed a bespoke multi-layer fabric formwork barrier designed specifically for the site's geometry and varying water depths. The solution incorporated an integrated levelling layer, foundation layer and vertical retaining wall that could be deployed in confined conditions and filled in situ with micro-concrete material to create a durable hydraulic barrier. The custom-engineered system was designed to conform to the existing quarry profile while providing long-term structural stability and water retention performance.

Vault's scope included site-specific engineering, detailed design, fabrication of the custom formwork system, preparation of installation methodologies and construction drawings, international logistics and air freight to New Zealand, and technical support for installation and grout placement. The completed solution provided a rapid, cost-effective and durable alternative to conventional civil reconstruction methods, enabling the quarry wall breach to be reinstated with minimal site disruption and a significantly reduced construction footprint.