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Connell delivered a key upgrade to the Kawerau substation as part of wider energy resilience upgrades around Kawerau and the surrounding areas.
The capable Waikato civil contractors Connell completed substation civil works alongside energised assets while protecting generation and network operations.
A full scope of works included:
Works commenced in earnest in February 2025 following early interface planning with clients Eastland Generation, Transpower and Northpower, and Connell began by preparing the switchyard extension to house the T10 transformer.
Connell ran parallel work fronts to meet outage windows and commissioning milestones, managing multiple teams concurrently to ensure the timeline was adhered to.
Key to the project was the extensive civil construction and demolition works of the original T11 transformer foundation, construction of the new transformer foundation, and extension of the switchyard — all completed within a live operational environment and without significantly impacting energy generation and network operations.
The team modified the existing building to function as a 33kV switchroom and completed cable basement works, as well as extensive trenchworks. Crews installed new cable routes and completed oil containment systems. The oil containment system was constructed and implemented, including an oil containment tank laid approximately five metres below the surface.
Opportunities to improve efficiency and reduce risk on site included completing trenchworks in stages to avoid trenches being left open, and excavations around services inside of the trench being done by hand to ensure accuracy and precision.
The worksite sat within a constrained footprint beside a state highway and near energised high-voltage assets. Identifying and working within fixed outage windows was a key element of the project, and the programme allowed limited time for critical works.
Connell managed multiple parties working on or around the site, which required daily coordination and disciplined access control. The brownfields environment added uncertainty around underground services and existing structures, while design information continued to develop during delivery. Connell managed deep excavations, material handling and environmental controls under strict operational constraints.
Project Manager Matt Dean said the project was a great opportunity for the Connell team to showcase their range of internal capabilities.
“The team were pleased deliver a high quality of work to the client in quite a complex working environment.”
He said developing infrastructure in the area was an important part of growing the region’s energy resilience, as well as ingratiating themselves into the local community.
“Areas like Kawerau benefit from a higher standard of energy resilience and independence. Being able to work within local communities like Kawerau and help deliver projects that directly benefit them is such a core aspect of what we do at Connell.”
The team used inspection and test plans with staged hold points for verification. Specialist lift planning and temporary works enabled safe installation of large precast firewall panels weighing more than 24 tonnes each, under overhead line constraints. This required an exceptional level of coordination and a focus on safety. Connell coordinated closely with the client to plan an outage and temporary relocation of a transmission line, utilising a 300-tonne crane for installation.
The team completed construction and reinstatement in September 2025, with operational continuity maintained throughout.
The project finished with no injuries recorded and no major environmental incidents, and the Connell team was proud to deliver the project on time and within budget, with most works being achieved utilising the skillsets of our in-house team.
