Case Studies
Aratiatia Surge Chamber
Client
MB Century
Date of Completion
25th February 2025
Location
Aratiatia Power Station
Project Overview
Euro Scaffolds was engaged by MB Century to build scaffolds that would provide access to the Gate Slots in the Surge Chamber for maintenance.
After consultation, it was decided that scaffold towers would be pre-built in exclusion zones in the car park above the Surge Chamber and then craned down. The primary objective was to ensure safe and efficient access into the Surge Chamber and Penstock.
The project involved multiple scaffolding structures: a 20m access scaffold with stairs built in 4m modules, a 10m access scaffold into the Penstock built in two modules, an 8m platform scaffold for painting and blasting slots, and handrails with shrink-wrap tents covering three slots.
The work supported painters, water blasters, mechanical fitters, engineers, and crane drivers.
Challenges
One of the biggest challenges was discovering an underwater plinth after draining the Surge Chamber, which obstructed planned access and had to be avoided.
The site presented further hazards, as work took place on the side of a 20m cliff, requiring strategic access solutions.
Additional challenges such as ensuring everyone’s safety when craning pre-built towers into the chamber. To address safety risks, Euro Scaffolds developed a Site Safety Specific Plan (SSSP) tailored to the project’s needs.
Solution
The project began with a detailed scope assessment by Euro Scaffolds Operations Manager Lance Clark and Leading Hand Karl Alker, using original plans to gain accurate measurements.
Scaffolding towers were pre-built in the car park exclusion zone and craned into the pit using McLeod’s Cranes, minimizing work at height. Dina bolts were used to tie scaffold towers to the walls, ensuring stability.
Daily toolbox talks were conducted with both the Euro Scaffolds team and MB Century crew. These discussions covered previous hazards, safety improvements, and risk mitigation for isolated work areas.
Exclusion zones were also barriered off to prevent falling object hazards. Pre-planning with Mercury and MB Century ensured seamless coordination and trust between all parties.
Results
The project was completed on time and within budget. The scaffolding was essential to the overall success, providing the necessary access for all contractors to meet their deadlines. Without it, the work could not have been completed.
A total of four scaffolders were on-site daily, and approximately 8 tons of scaffolding were used throughout the project. The team’s ability to adapt and efficiently execute the plan contributed to the smooth completion of the work.
Team Insights
The team found the experience of working 45 meters down in the pit both challenging and rewarding. They learned valuable lessons, such as using cranes more frequently to move gear, conducting more off-site builds when possible, and recognizing the benefits of crane usage in reducing height risks, lowering dropped object hazards, and simplifying planning.
A standout moment involved adjusting the angle when craning sections together to ensure smoother landings. By changing the angle so one section landed before the other, instead of both simultaneously, the team significantly improved efficiency and sped up the job. This adaptability showcased the team’s problem-solving skills and ability to refine processes in real time.
