Eastern Busway Alliance Honored for Rā Hihi Innovation

The Eastern Busway Alliance (EBA) has been awarded the excellence in onsite/management innovation award at the 2025 Civil Contractors New Zealand (CCNZ) prize-giving ceremony. This recognition highlights the alliance’s significant contributions to the construction of the Rā Hihi flyover, showcasing their innovative practices and collaborative efforts.

The award serves as a testament to the alliance’s commitment to delivering world-class infrastructure. It emphasizes the successful partnership between various stakeholders, including Auckland Transport, Fletcher Construction, ACCIONA, AECOM, and Jacobs, along with the involvement of mana whenua. This collaboration has been crucial in advancing the Eastern Busway project.

The EBA implemented a range of innovative strategies that combined advanced temporary works, bespoke formwork design, and real-time concrete monitoring. These methods not only addressed construction challenges effectively but also led to the completion of the Rā Hihi project five months ahead of schedule, resulting in a cost saving of $2 million for Auckland Transport.

Innovative Techniques Drive Success

The project featured several unique aspects. Among them was the design and construction of custom heavy-duty steel formwork for Rā Hihi’s 16 flared architectural piers. The alliance developed a uniquely engineered removable wedge panel, which allowed for the easy removal of formwork from hardened concrete, a significant improvement over traditional methods.

Additionally, the EBA worked with suppliers to create a low-heat, low-carbon concrete mix that replaced up to 70 percent of cement with slag and fly ash. This initiative not only supports environmental sustainability but also enhances the overall quality of the construction.

The use of wireless concrete sensors to monitor temperature and strength gain in real time marked another first for the EBA. This intelligent sensor system proved invaluable in guiding formwork removal, showcasing the alliance’s commitment to leveraging technology for improved construction practices.

Revolutionizing Bridge Construction

In a bold move to optimize temporary works, the EBA employed a method that involved lifting and relocating entire steel falsework towers using two cranes, rather than dismantling and rebuilding support towers for each span. This innovative approach reduced the diaphragm cycle duration from three and a half weeks to just two weeks.

The Rā Hihi flyover was constructed on three-metre diameter mono piles featuring plunged cages, which were delivered to high standards. This method saved four months compared to traditional smaller pile and pile cap solutions.

The Eastern Busway Alliance celebrated this recognition as a reflection of the hard work and dedication of everyone involved in the Rā Hihi project. As they continue to set new standards in project excellence and partnership, the EBA demonstrates how innovation can lead to successful outcomes in large-scale infrastructure projects.