Lyttleton Port Company – Precast Outfall Chamber

Marine Outfall Construction — Tidal Environment Works

Client

LPC / Fulton Hogan

Scope

Outfall Works

Environment

Marine / Tidal

Structure

PE Pipe System

Installation

Precast Solution

Project Overview

Moore Construction delivered construction works for the LPC stormwater outfall, including installation of structural pipework, retaining elements, and marine interface works within a challenging tidal environment.

The project required precise coordination of plant, materials, and sequencing to safely execute works within narrow tidal windows and difficult ground conditions.

Engineering Solution

The solution integrated piled support structures, precast concrete elements, and a polyethylene (PE) outfall pipeline system designed to operate in a marine environment.

Piling & Structural Works

The works included the installation of driven UC steel piles to support the outfall structure, delivered using crane-mounted drop hammer techniques.

  • Installation of UC steel piles up to 12m length
  • Driven using drop hammer in reclaimed fill conditions
  • Pile cap fabrication and on-site welding
  • Integration with structural pipe support system

Construction Methodology

A staged construction methodology was developed to align with tidal conditions and site access constraints.

  • Formation of crane and piling platforms above high-water level
  • Excavation and removal of existing rock revetment
  • Terraced working approach to maintain safe access
  • Installation of trenching systems for pipe connection works

Precast Pipe Encasement Solution

A key innovation on the project was the use of a precast concrete encasement system for the outfall pipeline. Due to the size and weight of the fully encased pipe, the system was split into top and bottom sections to enable safe lifting and installation.

Project Challenges

  • Working within tidal windows and marine conditions
  • Heavy lifting and constrained access
  • Installation in reclaimed and variable fill
  • Coordination of multiple work fronts

Outcome

The successful completion of the LPC outfall works provided a durable and high-performance marine discharge solution, designed to operate reliably under tidal and environmental loading.

This project demonstrates Moore Construction’s expertise in delivering complex civil works at the interface of land and marine environments.

    Project Gallery

Key Capabilities Demonstrated

  • Marine and tidal construction works
  • Driven piling and structural support systems
  • Precast concrete design and installation
  • Heavy lifting and logistics coordination
  • Trenching and pipeline installation
  • Full in-house civil and structural delivery