When the Te Ara Pekapeka project, which claimed Supreme Winner and Over $3 Million Project of the Year at the SCNZ Excellence in Steel Awards, it was a proud moment for Culham Engineering and Eastbridge Ltd.
This achievement was not just an industry award; it was a celebration of engineering ability, collaboration, and environmental responsibility on a complex infrastructure project and reinforces the valuable contribution that SCNZ provides to our sector with advocacy, technical resources, training, and networking to strengthen New Zealand’s structural steel industry and promote excellence.
The bridge is a centrepiece of Hamilton City Council’s largest-ever transport investment, connecting the city’s southern growth area across the Waikato River. At 215 metres long, Te Ara Pekapeka is a critical link for future urban development and a showcase of what can be achieved when innovation meets precision.
The Te Ara Pekapeka bridge features two striking lattice-shaped piers and a steel superstructure that demanded exceptional skill from the teams involved. While the architectural decision to use weathering steel set the tone for durability, it introduced significant fabrication challenges.
HEB Construction entrusted Culham Engineering with fabricating and installing the piers, which are both a visually striking and technically challenging element of the project. Eastbridge delivered the superstructure, representing another major engineering challenge, including four lines of box-tube girders with complex angles and a composite deck that had to interface perfectly with the lattice piers. Both elements required pinpoint accuracy to achieve seamless integration, structural integrity, and visual harmony.
Fabricating these massive lattice structures was anything but straightforward. Individual plates, ranging from 30 mm to 50 mm thick, were transformed into 2.2 m x 0.82 m box sections, requiring thousands of metres of welding and totalling more than 1.4 kilometres. To ensure absolute dimensional accuracy, a purpose‑built jig was designed to assemble each component with millimetre‑level tolerances. This meticulous approach reduced risk during onsite installation and ensured that once transported, each lattice could be welded into its final form without the need for adjustments. Every step reflected Culham’s commitment to delivering precision and quality under demanding conditions.
Transporting the colossal lattice frames was another challenge. Culham developed a bespoke logistics plan, using specialised equipment to optimise the number of trips required, each carefully sequenced to minimise disruption and ensure safety while aligning with sustainability goals.
Once on-site, strict welding controls were implemented, including purpose‑built habitats around weld points to protect workers and maintain controlled conditions to achieve the quality expectations set for the project. The habitats also served an environmental purpose: they were designed to be “bat-proof,” and omit low-level lighting during night operations, safeguarding the critically threatened pekapeka-tou-roa (long-tailed bat) that inhabits the Waikato region. This project reflected Culham’s commitment to environmental stewardship alongside engineering achievement.
Heavy lifting added yet another layer of complexity. The lattice frames, 228 tonnes for the southern pier and 241 tonnes for the northern, were installed using one of New Zealand’s largest crawler cranes in superlift mode. This operation earned the project recognition at the Crane Association Awards for Lift of the Year, further cementing its reputation for technical excellence.
Behind the steel was a dedicated team of fabricators, welders, engineers, and project leaders, who worked tirelessly to meet demanding timelines and technical standards. Culham’s ability to integrate cutting-edge technology with hands-on craftsmanship was key to delivering a structure that met and exceeded expectations.
The SCNZ judges were unequivocal in their praise: “This visually stunning bridge makes clever use of weathering steel to enable elegant, durable construction, with clean lines, cultural detailing and impressive structural engineering.”
For Culham Engineering, the Supreme Award is a testament to the team’s skill, dedication, and ingenuity. This achievement highlights Culham’s capability to tackle New Zealand’s most demanding steel fabrication challenges.
The Te Ara Pekapeka project stands as a benchmark for integrated engineering, balancing cultural meaning, technical precision, ecological respect and urban needs. For the teams at Culham Engineering, Eastbridge Ltd, HEB Construction, Hamilton City Council and numerous specialist contractors, the awards are a celebration of years of planning, problem-solving and craftsmanship.
Steel bridging specialists Eastbridge were pleased to contribute to the success of the Te Ara Pekapeka bridge alongside Culham Engineering for our client, HEB Construction, and the Principal, Hamilton City Council.
“The bridge is an awesome outcome of engineering and architectural form,” says Eastbridge general manager Jayden Mellsop. “The fabrication and installation of the box tub girders was a great project for Eastbridge, and we were suitably impressed by the workmanship on the pier frames fabricated by Culham’s.”
Beyond its functional role, the bridge represents a milestone in New Zealand’s infrastructure, showcasing how innovation and collaboration can deliver enduring benefits for communities and the environment.
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